Bobcat 331 331e 334 Repair Manual [Excavator] (234313000-…)

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Description

Revised Factory [6903830] Workshop Repair Service Manual For Bobcat 331 331E 334 (G Series). Detailed Step by Step Instructions, diagrams, illustrations make easy any repair, Overhaul, Disassembly and Assembly, Testing, Adjustment, Replacement and Change, Inspection and Adjustment, etc.

= Printable,
= Zoom able,
= Clickable index,
= Bookmarks,
= Searchable Text

MODELS Covered

Bobcat Excavator (G Series)

Bobcat 331 – Serial Number 234313000 & Above
Bobcat 331E – Serial Number 234412000 & Above
Bobcat 334 – Serial Number 234513000 & Above

SECTIONS covered

* SAFETY AND MAINTENANCE

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AIR CLEANER SERVICE
Daily Check
Replacing The Filters
ENGINE COOLING SYSTEM
Checking Coolant Level
Cleaning The Cooling System
Replacing The Coolant
ENGINE ACCESSORY DRIVE BELT
Belt Adjustment
Belt Tension
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Oil Chart
Replacing Oil And Filter
FUEL SYSTEM
Draining The Fuel Tank
Filling The Fuel Tank
Fuel Filter
Fuel ifications
Removing Air From The Fuel System
Removing Water From The Fuel Filter
HEATER AIR FILTER (WITH CAB OPTION ONLY)
Removal And Installation
HYDRAULIC SYSTEM
Checking And Adding Hydraulic Fluid
Diagnostic Couplers
Replacing The Case Drain Filter
Replacing The Hydraulic Filter
Replacing The Hydraulic Fluid
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
LIFTING THE EXCAVATOR
Procedure
LUBRICATION OF THE HYDRAULIC EXCAVATOR
Procedure
OPERATOR CAB (ROPS/TOPS)
Cab Door
Emergency Exit
Front Window
Right Side Windows
RIGHT SIDE COVER
Opening And Closing The Right Side Cover
SEAT BELT
Intion And Maintenance
SERVICE SCHEDULE
Chart
SPARK ARRESTOR MUFFLER
TAILGATE
Adjusting The Bumper
Adjusting The Latch
Opening And Closing The Tailgate
TRANSPORTING THE EXCAVATOR
TRAVEL MOTOR
Checking Oil Level
Draining The Travel Motor
UPPERSTRUCTURE SLEW LOCK
Operation (Early Models)
Operation (Later Models)
HYDRAULIC SYSTEM
ARM CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BLADE CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BOOM CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BOOM SWING CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BOOM SWING LOCK VALVE
Assembly
Disassembly
Parts Identification
Removal And Installation
BUCKET CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation (Extendible Arm)
Removal And Installation (Standard And Long Arm)
Testing
CASE DRAIN FILTER
Removal And Installation
CONTROL PATTERN SELECTOR VALVE
Assembly
Disassembly
Parts Identification
Removal And Installation
CROSSPORT RELIEF VALVES
Testing And Adjusting The Crossport Relief Valves
DIRECT TO TANK VALVE
Disassembly And Assembly
Parts Identification
Removal And Installation
EXTENDIBLE ARM CYLINDER
Parts Identification
Removal And Installation
HYDRAULIC CONTROL VALVE
Arm Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Boom Swing Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Description
Disassembly
First Auxiliary Valve Section Disassembly And Assembly
Inlet Section Disassembly And Assembly
Left Travel Valve Section Disassembly And Assembly
Parts Identification
Removal And Installation
Right Travel Valve Section Disassembly And Assembly
Second Auxiliary Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
HYDRAULIC CONTROL VALVE
Arm Valve Section Disassembly And Assembly
Assembly
Auxiliary Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Boom Swing Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Description
Disassembly
Inlet Section Disassembly And Assembly
Left Travel Valve Section Disassembly And Assembly
Parts Identification
Removal And Installation
Right Travel Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
HYDRAULIC FILTER MOUNT
Removal And Installation
HYDRAULIC PUMP
Assembly
Coupler Removal And Installation
Description
Disassembly
Parts Identification
Removal And Installation
Testing Auxiliary Hydraulic Flow
Testing The Piston Pump
Torque Adjustment
HYDRAULIC RESERVOIR
Removal And Installation
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators
Troubleshooting The Cylinder Circuit
Troubleshooting The Hydraulic Circuit
Troubleshooting The Swing (Upperstructure Slew) Circuit
Troubleshooting The Travel Circuit
HYDRAULIC XCHANGE VALVE
Assembly
Disassembly
Parts Identification
Removal And Installation
LEFT CONTROL LEVER (JOYSTICK)
Assembly
Disassembly
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Testing
MAIN RELIEF VALVE
Testing And Adjusting The Main Relief Valve
MANIFOLD ASSEMBLY/ ACCUMULATOR
Description
Disassembly And Assembly
Parts Identification
Removal And Installation
OIL COOLER
Removal And Installation
PORT RELIEF VALVES
Testing And Adjusting Port Relief Valve Pressure
PRESSURE REDUCING VALVE
Testing And Adjusting The Pressure Reducing Valve
RIGHT CONTROL LEVER (JOYSTICK)
Assembly
Disassembly
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Testing
SWING MOTOR
Assembly
Disassembly
Parts Identification
Removal And Installation
SWING MOTOR DRIVE CARRIER
Assembly
Disassembly
Parts Identification
Removal And Installation
SWIVEL JOINT
Assembly
Description
Disassembly
Parts Identification
Removal And Installation
TRAVEL CONTROL VALVE
Disassembly And Assembly
Parts Identification
Removal and Installation
TRAVEL MOTOR
Assembly
Disassembly
Parts Identification
Removal And Installation

* HYDRAULIC SYSTEM

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HYDRAULIC SYSTEM
ARM CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BLADE CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BOOM CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BOOM SWING CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation
Testing
BOOM SWING LOCK VALVE
Assembly
Disassembly
Parts Identification
Removal And Installation
BUCKET CYLINDER
Assembly
Disassembly
Parts Identification
Removal And Installation (Extendible Arm)
Removal And Installation (Standard And Long Arm)
Testing
CASE DRAIN FILTER
Removal And Installation
CONTROL PATTERN SELECTOR VALVE
Assembly
Disassembly
Parts Identification
Removal And Installation
CROSSPORT RELIEF VALVES
Testing And Adjusting The Crossport Relief Valves
DIRECT TO TANK VALVE
Disassembly And Assembly
Parts Identification
Removal And Installation
EXTENDIBLE ARM CYLINDER
Parts Identification
Removal And Installation
HYDRAULIC CONTROL VALVE
Arm Valve Section Disassembly And Assembly
Assembly
Blade Valve Section Disassembly And Assembly
Boom Swing Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Description
Disassembly
First Auxiliary Valve Section Disassembly And Assembly
Inlet Section Disassembly And Assembly
Left Travel Valve Section Disassembly And Assembly
Parts Identification
Removal And Installation
Right Travel Valve Section Disassembly And Assembly
Second Auxiliary Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
HYDRAULIC CONTROL VALVE
Arm Valve Section Disassembly And Assembly
Assembly
Auxiliary Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Boom Swing Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Description
Disassembly
Inlet Section Disassembly And Assembly
Left Travel Valve Section Disassembly And Assembly
Parts Identification
Removal And Installation
Right Travel Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
HYDRAULIC FILTER MOUNT
Removal And Installation
HYDRAULIC PUMP
Assembly
Coupler Removal And Installation
Description
Disassembly
Parts Identification
Removal And Installation
Testing Auxiliary Hydraulic Flow
Testing The Piston Pump
Torque Adjustment
HYDRAULIC RESERVOIR
Removal And Installation
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators
Troubleshooting The Cylinder Circuit
Troubleshooting The Hydraulic Circuit
Troubleshooting The Swing (Upperstructure Slew) Circuit
Troubleshooting The Travel Circuit
HYDRAULIC XCHANGE VALVE
Assembly
Disassembly
Parts Identification
Removal And Installation
LEFT CONTROL LEVER (JOYSTICK)
Assembly
Disassembly
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Testing
MAIN RELIEF VALVE
Testing And Adjusting The Main Relief Valve
MANIFOLD ASSEMBLY/ ACCUMULATOR
Description
Disassembly And Assembly
Parts Identification
Removal And Installation
OIL COOLER
Removal And Installation
PORT RELIEF VALVES
Testing And Adjusting Port Relief Valve Pressure
PRESSURE REDUCING VALVE
Testing And Adjusting The Pressure Reducing Valve
RIGHT CONTROL LEVER (JOYSTICK)
Assembly
Disassembly
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Testing
SWING MOTOR
Assembly
Disassembly
Parts Identification
Removal And Installation
SWING MOTOR DRIVE CARRIER
Assembly
Disassembly
Parts Identification
Removal And Installation
SWIVEL JOINT
Assembly
Description
Disassembly
Parts Identification
Removal And Installation
TRAVEL CONTROL VALVE
Disassembly And Assembly
Parts Identification
Removal and Installation
TRAVEL MOTOR
Assembly
Disassembly
Parts Identification
Removal And Installation

* UNDERCARRIAGE

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BLADE
Removal And Installation
SWING CIRCLE GEAR
Swing Bearing Installation
Swing Bearing Removal
TRACK DAMAGE IDENTIFICATION
Abrasion Of Embedded Metals
Abrasion Of The Track Roller Side
Cracks And Cuts On The Lug Side Rubber
Cracks On The Lug Side Rubber Due To Fatigue
Cuts On The Edges Of Track Roller Side
Cuts On The Lug Side Rubber
Cutting Of Steel Cords
Lug Abrasion
Separation Of Embedded Metals
Separation Of Embedded Metals Due To Corrosion
TRACK FRAME
Disassembly And Assembly
Recoil Spring Cylinder
TRACK IDLER
Assembly
Disassembly
Parts Identification
TRACK ROLLER
Assembly
Disassembly
Parts Identification
TRACKS
Adjustment
Rubber Track Removal And Installation
Steel Track Removal And Installation
Track Lug Height

* UPPERSTRUCTURE & SWING SECTION

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BLADE CONTROL
Lever Removal And Installation
Linkage Bar Removal And Installation
Linkage Removal And Installation
Lower Linkage Removal And Installation
BOOM
Removal And Installation
BUCKET
Bucket Side Cutting Edge Removal And Installation
Bucket Teeth Removal And Installation
CAB
Door Removal And Installation
Front Window Removal And Installation
Glass Installation
Glass Removal
Right Side Front And Rear Sliding Window Weather Strip Removal And
Installation
Right Side Front And Rear Sliding Window Wiper Strip Removal And
Installation
Right Side Front Sliding Window Removal And Installation
Right Side Rear Sliding Window Removal And Installation
Removal And Installation
ENGINE SPEED CONTROL
Adjustment (Later Models)
Removal And Installation
EXTENDIBLE ARM
Disassembly And Assembly
Removal And Installation
FLOOR MAT AND FLOOR PLATE
Removal And Installation (Cab Equipped Excavators)
Removal And Installation (Canopy Equipped Excavators)
FUEL TANK
Removal And Installation
HORN
Removal And Installation (Early Models)
Removal And Installation (Later Models)
LEFT CONSOLE
Compression Spring Disassembly And Assembly
Compression Spring Removal And Installation
Console Base Removal And Installation
Console Removal And Installation
Disassembly And Assembly
Lock Lever Removal And Installation
Lower Console Cover Removal And Installation
Upper Console Cover Removal And Installation
RIGHT CONSOLE
Console Base Removal And Installation
Console Cover Removal And Installation
RIGHT PEDAL AND LINKAGE
Linkage Removal And Installation
Pedal Disassembly And Assembly
Pedal Removal And Installation
RIGHT SIDE COVER
Removal And Installation
ROPS CANOPY
Removal And Installation
SEAT AND SEAT MOUNT
Removal And Installation
STANDARD AND LONG ARM
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)
Removal And Installation
SWING FRAME
Boom Swing Frame Hose Routing
Bushing Installation
Bushing Removal
Removal And Installation
TAILGATE
Latch Removal And Installation
Removal And Installation
TRAVEL CONTROLS
Adjustment
Control Linkage Removal And Installation
Disassembly And Assembly
Removal And Installation
UPPERSTRUCTURE
Installation
Removal
UPPERSTRUCTURE SLEW LOCK
Disassembly And Assembly (Later Models)
Removal And Installation (Early Models)
Removal And Installation (Later Models)
XCHANGE™
Assembly
Check Proper Latch Engagement
Disassembly
Removal And Installation
XCHANGE (HYDRAULIC)
Assembly
Disassembly
Parts Identification
Removal And Installation

* ELECTRICAL SYSTEM AND ANALYSIS

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ALTERNATOR
Alternator Identification
Alternator Regulator Test
Alternator Voltage Test
Assembly
Charging System Check
Disassembly
Engine Accessory Drive Belt
High Voltage Test
Low Voltage Test
Parts Identification
Rectifier Continuity (Diode) Test
Removal And Installation
Rotor Continuity Test
Rotor Ground Test
Stator Continuity Test
Stator Ground Test
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
DELUXE INSTRUMENT PANEL SETUP
Changing The Owner Or Operator Password
Job Clock
Password Entry (For Starting and Operating the Machine)
Password Lockout Feature
Passwords
RPM
DIAGNOSTICS SERVICE CODE
Number Codes List
ELECTRICAL SYSTEM INFORMATION
Description
Fuse And Relay Location
Troubleshooting Chart
FUEL LEVEL SENDER
Removal And Installation
Testing
LIGHTS
Boom Light Bulb Replacement (Later Models)
Boom Light Disassembly And Assembly (Early Models)
Boom Light Removal And Installation (Early Models)
Boom Light Removal And Installation (Later Models)
Removal And Installation
MAGNETIC LOCKOUT SENSOR
Removal And Installation
STARTER
Assembly
Disassembly
Intion And Repair
Parts Identification
Removal And Installation
TWO SPEED SWITCH
Removal And Installation

* ENGINE SERVICE

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AIR CLEANER
Removal And Installation
ENGINE
Removal And Installation
ENGINE COMPONENTS AND TESTING
Checking The Glow Plug
Engine Compression Checking
Fuel Injector Nozzle Check
Fuel Injector Nozzles Removal And Installation
Fuel Injection Pump Check
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Timing
Fuel Shutoff Solenoid Removal And Installation
Glow Plugs Removal And Installation
Valve Clearance Adjustment
ENGINE FLYWHEEL (EARLY MODELS)
Flywheel Removal And Installation
Flywheel Ring Gear
Hydraulic Pump Coupler
ENGINE FLYWHEEL (LATER MODELS)
Flywheel Removal And Installation
Flywheel Ring Gear
Hydraulic Pump Coupler
RADIATOR
Removal And Installation
RECONDITIONING THE ENGINE
Camshaft Servicing
Checking Engine Oil Pressure
Connecting Rod Alignment
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings Servicing
Crankshaft Gear Removal And Installation
Cylinder Bore Checking
Cylinder Head Disassembly And Assembly
Cylinder Head Removal And Installation
Cylinder Head Servicing
Cylinder Head Top Clearance
Fan Removal And Installation
Fuel Camshaft Governor
Fuel Camshaft Removal And Installation
Idler Gear And Camshaft Removal And Installation
Idler Gear And Shaft Servicing
Oil Pump Removal And Installation
Oil Pump Service
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Servicing
Reconditioning The Valve And Valve Seat
Rocker Arm And Shaft Checking
Timing Gearcase Cover Removal And Installation
Timing Gears Checking Backlash
Valve Guide Checking
Valve Spring
Valve Tappets
Water Pump Disassembly And Assembly
Water Pump Removal And Installation
SPARK ARRESTOR MUFFLER
Removal And Installation
TROUBLESHOOTING
Chart

* HEATING, VENTILATION, AIR CONDITIONING

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AIR CONDITIONING SERVICE
Chart
AIR CONDITIONING SYSTEM FLOW
Chart
Principals
BASIC TROUBLESHOOTING (EARLY MODELS)
Checking The Electrical System
Cleaning The A/C Evaporator Coil & Heater Coil
Engine Accessory Drive Belt Intion
Engine Coolant ByPassing The Heater Valve
Poor A/C Performance
BASIC TROUBLESHOOTING (LATER MODELS)
Checking The Electrical System
Cleaning The A/C Evaporator Coil & Heater Coil
Engine Accessory Drive Belt Intion
Engine Coolant ByPassing The Heater Valve
Poor A/C Performance
BLOWER FAN (EARLY MODELS)
Disassembly And Assembly
Removal And Installation
BLOWER FAN (LATER MODELS)
Disassembly And Assembly
Removal And Installation
Resistor Removal And Installation
COMPONENTS
Identification
COMPRESSOR
Compressor Clutch Disassembly And Assembly
Removal And Installation
CONDENSER
Removal And Installation
EVAPORATOR (EARLY MODELS)
Removal And Installation
EVAPORATOR (LATER MODELS)
Removal And Installation
EVAPORATOR/HEATER UNIT (EARLY MODELS)
Disassembly And Assembly
Removal And Installation
EVAPORATOR/HEATER UNIT (LATER MODELS)
Disassembly And Assembly
Removal And Installation
EXPANSION VALVE (EARLY MODELS)
Removal And Installation
EVAPORATOR VALVE (LATER MODELS)
Removal And Installation
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Component Replacement And Refrigeration Leaks
Compressor Oil
Compressor Oil Check
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
HEATER VALVE (EARLY MODELS)
Removal And Installation
HEATER VALVE (LATER MODELS)
Removal And Installation
PRESSURE RELIEF VALVE
Removal And Installation
PRESSURE SWITCH
Removal And Installation
RECEIVER/DRIER
Removal And Installation
REGULAR MAINTENANCE
Cleaning The Condenser
Engine Accessory Drive Belt Intion
Heater Air Filter
SAFETY
Safety Equipment
SYSTEM CHARGING AND RECLAMATION
Charging Procedure With A Manifold Gauge Set
Reclamation Procedure
SYSTEM TROUBLESHOOTING CHART
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Gauge Pressure Related Troubleshooting
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Operates Improperly Or Not At All
TEMPERATURE/PRESSURE Chart
THERMOSTAT (EARLY MODELS)
Removal And Installation
THERMOSTAT (LATER MODELS)
Removal And Installation

* SPECIFICATIONS

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CONVERSIONS
Decimal And Millimeter Equivalents
US To Metric Conversion
ENGINE IFICATIONS
Camshaft
Connecting Rods
Crankshaft
Crankshaft ReGrind Data
Cylinders
Cylinder Head
Engine Bolt Torque
Fuel Injection Nozzles
Fuel Injection Pump
Oil Pump
Piston Rings
Pistons
Rocker Arms
Tappet
Thermostat
Timing Gear
Valves
Valve Springs
Valve Timing
FUEL, COOLANT AND LUBRICANTS
Chart
HYDRAULIC CONNECTION IFICATIONS
Flare Fitting
ORing Face Seal Connection
ORing Flare Fitting
Port Seal Fitting
Straight Thread ORing Fitting
Tubelines And Hoses
HYDRAULIC FLUID SPECIFICATIONS
SPECIFICATIONS
Excavator Machine Dimensions
Excavator Machine Dimensions
Controls
Drive System
Electrical
Engine
Hydraulic Cycle Times
Hydraulic Cylinders
Hydraulic System
Performance
Track
Undercarriage
TORQUE IFICATIONS
Torque For General Metric Bolts
Torque For General SAE Bolts