Bobcat Excavators 331 334 6901139 Service Manual 2 06-21416B320078.pdf -Bookmark created by https://wimanual.com MAINTENANCE SAFETY ALPHABETICAL INDEX CONTENTS FOREWORD SAFETY INSTRUCTIONS Fire Prevention SERIAL NUMBER LOCATIONS Bobcat Excavator Serial Number Engine Serial Number DELIVERY REPORT BOBCAT EXCAVATOR IDENTIFICATION SAFETY AND MAINTENANCE LIFTING AND BLOCKING THE EXCAVATOR Procedure SWING LOCK Operation LIFTING THE EXCAVATOR Procedure OPERATOR CAB (ROPS Emergency Exit Cab Door Front Window TRANSPORTING THE EXCAVATOR Procedure TAILGATE Opening And Closing The Tailgate (Early Models) Adjusting The Bumper Adjusting The Tailgate Latch (Early Models) Opening And Closing The Tailgate (Later Models) Adjusting The Tailgate Latch (Later Models) SERVICE SCHEDULE Chart AIR CLEANER SERVICE Daily Check Replacing The Filters HEATER AIR FILTERS (WITH CAB OPTION ONLY) Recirculation Filter Fresh Air Filter ENGINE COOLING SYSTEM Cleaning The Cooling System Checking The Coolant Level Replacing The Coolant FUEL SYSTEM Fuel Specification Filling The Fuel Tank Removing Water From The Fuel Filter Replacing The Fuel Filter Removing Air From The Fuel System Draining The Fuel Tank ENGINE LUBRICATION SYSTEM Checking Engine Oil Replacing Oil And Filter HYDRAULIC SYSTEM Checking And Adding Fluid Replacing The Hydraulic Filter Replacing The Case Drain Filter Replacing The Hydraulic Fluid Diagnostic Couplers LUBRICATING THE EXCAVATOR Procedure TRAVEL MOTOR Checking Oil Level Draining The Travel Motor SPARK ARRESTOR MUFFLER Cleaning The Spark Arrestor Muffler Continued On Next Page Continued On Next Page Continued On Next Page Continued On Next Page Continued On Next Page HYDRAULIC SYSTEM HYDRAULIC HYDRAULIC SYSTEM INFORMATION Glossary Of Hydraulic Troubleshooting The Hydraulic Circuit Troubleshooting The Cylinder Circuit Troubleshooting The Swing (Slew) Circuit Troubleshooting The Travel Circuit BOOM CYLINDER Checking The Boom Cylinder Removal And Installation Parts Identification Disassembly Assembly ARM CYLINDER Checking The Arm Cylinder Removal And Installation Parts Identification Disassembly Assembly BOOM OFFSET CYLINDER Checking The Boom Offset Cylinder Removal And Installation Parts Identification Disassembly Assembly BUCKET CYLINDER Checking The Bucket Cylinder Removal And Installation (Standard And Long Arm) Removal And Installation (Extendible Arm) Parts Identification Disassembly Assembly BLADE CYLINDER Checking The Blade Cylinder Removal And Installation Parts Identification Disassembly Assembly EXTENDIBLE ARM CYLINDER Removal And Installation Parts Identification MAIN RELIEF VALVES Testing And Adjusting The Main Relief Valves (S System Pressures At Gauge Port Specifications (S Testing And Adjusting The Main Relief Valves (S System Pressures At Gauge Port Specifications (S PORT RELIEF VALVES Testing And Adjusting Port Relief Valve Pressure (S Testing And Adjusting Port Relief Valve Pressure (S CROSSPORT RELIEF VALVES Testing The Crossport Relief Valves System Pressures At Gauge Port Specifications PRESSURE REDUCING VALVE Testing And Adjusting The Pressure Reducing Valve (S Testing And Adjusting The Pressure Reducing Valve (S HYDRAULIC CONTROL VALVE (S Description Removal And Installation Control Valve Identification Disassembly Right Travel Valve Section Disassembly And Assembly Boom Offset Valve Section Disassembly And Assembly Boom Valve Section Disassembly And Assembly Left Travel Valve Section Disassembly And Assembly Arm Valve Section Disassembly And Assembly Bucket Valve Section Disassembly And Assembly Auxiliary Valve Section Disassembly And Assembly Boost Valve Section Disassembly And Assembly Blade Valve Section Disassembly And Assembly Swing Valve Section Disassembly And Assembly Assembly HYDRAULIC CONTROL VALVE (S Description Removal And Installation Control Valve Identification Disassembly Right Travel Valve Section Disassembly And Assembly Boom Offset Valve Section Disassembly And Assembly Boom Valve Section Disassembly And Assembly Left Travel Valve Section Disassembly And Assembly Arm Valve Section Disassembly And Assembly Bucket Valve Section Disassembly And Assembly Auxiliary Valve Section Disassembly And Assembly Boost Valve Section Disassembly And Assembly Blade Valve Section Disassembly And Assembly Swing Valve Section Disassembly And Assembly Assembly HYDRAULIC PUMP Description Torque Adjustment Testing The Piston Pump Testing The Gear Pump Testing Auxiliary Hydraulic Flow Removal And Installation Coupler Removal And Installation Parts Identification Piston Pump Parts Identification Disassembly Gear Pump Disassembly Gear Pump Assembly Piston Pump Disassembly Piston Pump Assembly Assembly MANIFOLD ASSEMBLY Manifold Description Removal And Installation MANIFOLD ASSEMBLY (S Parts Identification Disassembly Assembly MANIFOLD ASSEMBLY Manifold Description Removal And Installation MANIFOLD ASSEMBLY (S Parts Identification Disassembly Assembly TRAVEL MOTOR Removal And Installation Parts Identification Disassembly Assembly SWIVEL JOINT Removal And Installation Parts Identification Description Disassembly Assembly SWING MOTOR Removal And Installation Parts Identification Disassembly Assembly Cross Port Relief Valve Parts Identification Cross Port Relief Valve Disassembly Cross Port Relief Valve 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) (S Testing Handle Removal And Installation Joystick Assembly, Removal And Installation Parts Identification Disassembly LEFT CONTROL LEVER (JOYSTICK) (S Testing Handle Removal And Installation Joystick Assembly, Removal And Installation Parts Identification Disassembly And Assembly LEFT CONTROL LEVER (JOYSTICK) (S Testing Handle Removal And Installation Joystick Assembly, Removal And Installation Parts Identification Disassembly Assembly RIGHT CONTROL LEVER (JOYSTICK) (S Testing Handle Removal And Installation Joystick Assembly Removal And Installation Parts Identification Disassembly Assembly HYDRAULIC FILTER Removal And Installation HYDRAULIC RESERVOIR Removal And Installation OIL COOLER Removal And Installation DIRECT TO TANK VALVE Removal And Installation Disassembly And Assembly BUILD UP VALVE Description Removal And Installation Disassembly And Assembly CASE DRAIN FILTER Removal And Installation Continued On Next Page 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 Disassembly And Assembly TRACK DAMAGE IDENTIFICATIONS 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 (S Disassembly (S Assembly (S Parts Identification (S Disassembly (S Assembly (S TRACK ROLLER Parts Identification (S Disassembly (S Assembly (S Parts Identification (S Disassembly (S Assembly (S SWING CIRCLE GEAR Removal And Installation Swing Bearing Removal Swing Bearing Installation Alignment Pins (Not Threaded) Continued On Next Page Continued On Next Page UPPERSTRUCTURE & SWING SECTION UPPERSTRUCTURE Removal And Installation Swing Bearing Removal Swing Bearing Installation Alignment Pins (Not Threaded) ROPS CANOPY Removal And Installation CAB Removal And Installation Door Removal And Installation Front Window Removal And Installation Lower Front Window Removal And Installation Right Side Rear Sliding Window Removal And Installation Right Side Front Sliding Window Removal And Installation Right Side Panel And Window Assembly Removal And Installation Door, Left Side, Rear And Upper Front Window Removal And Installation SEAT AND 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 Lock Lever Removal And Installation Upper Console Removal And Installation Console Switch Removal And Installation Disassembly And Assembly Console Base Removal And Installation ENGINE SPEED CONTROL Removal And Installation 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 Right Pedal Disassembly And Assembly TRAVEL CONTROLS Removal And Installation Disassembly And Assembly FLOOR MAT AND FLOOR PANELS Removal And Installation FUEL TANK Removal And Installation HORN Removal And Installation SWING FRAME Boom Swing Bracket Removal And Installation Boom Swing Bracket Hose Installation Bushing Removal Bushing Installation BOOM Removal And Installation Boom Bushing Removal And Installation ARM Removal And Installation Arm To Boom Bushing Removal And Installation Arm To Bucket And Bucket Link Bushing Removal And Installation EXTENDIBLE ARM Removal And Installation Disassembly And Assembly BUCKET Bucket Teeth Removal And Installation Bucket Side Cutting Edge Removal And Installation TAILGATE Removal And Installation Release Rod Removal And Installation (Early Models) Latch Removal And Installation (Early Models) Latch Removal And Installation (Later Models) X-CHANGE� Removal And Installation Disassembly Assembly RIGHT SIDE COVER Removal And Installation ELECTRICAL SYSTEM AND ANALYSIS ELECTRICAL SCHEMATICS ELECTRICAL SYSTEM INFORMATION Troubleshooting Chart Description Fuse Location BATTERY Servicing Removal And Installation Using A Booster Battery (Jump Starting) ALTERNATOR Adjusting The Alternator 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 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 Disassembly And Assembly FUEL LEVEL SENDER Removal And Installation Testing DIAGNOSTICS SERVICE CODE Number Codes List Continued On Next Page ENGINE SERVICE TROUBLESHOOTING Chart SPARK ARRESTOR MUFFLER Removal And Installation AIR CLEANER Removal And Installation RADIATOR Removal And Installation ENGINE COMPONENTS AND TESTING Valve Clearance Adjustment Engine Compression Checking Fuel Shutoff Solenoid Adjustment Fuel Shutoff Solenoid Removal And Installation Fuel Injection Pump Check Fuel Injection Pump Removal And Installation Fuel Injection Pump Timing Fuel Injector Nozzles Fuel Injector Nozzles Removal And Installation Fuel Injector Nozzles Check ENGINE Removal And Installation ENGINE 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 Oil Pump Relief Valve 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 Continued On Next Page HEATING, VENTILATION, AIR CONDITIONING HEATER COIL Removal And Installation With A Removal And Installation Without A HEATER Removal And Installation Disassembly And Assembly Resistor Removal and Installation Wire Connector Removal and Installation HEATER VALVE Removal and Installation AIR CONDITIONING SYSTEM FLOW Principals Chart COMPONENTS Identification SAFETY Safety Equipment REGULAR MAINTENANCE Filter Elements Removal And Installation Compressor Drive Belt Inspection Cleaning The Condenser BASIC TROUBLESHOOTING Poor A Cleaning The A Compressor 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 Does Not Operate At All, Or Operates Improperly Gauge Pressure Related Troubleshooting TEMPERATURE Chart AIR CONDITIONING SERVICE Chart SYSTEM CHARGING AND RECLAMATION Reclamation Procedure Charging Procedure With A Manifold Gauge Set Charging Procedure COMPRESSOR Removal And Installation Compressor Clutch Disassembly CONDENSER Removal And Installation RECEIVER Removal And Installation PRESSURE RELIEF VALVE Removal And Installation PRESSURE SWITCH Removal And Installation EVAPORATOR Removal And Installation Disassembly And Assembly THERMOSTAT Removal And Installation EXPANSION VALVE Removal And Installation EVAPORATOR Removal And Installation Continued On Next Page SPECIFICATIONS HYDRAULIC EXCAVATOR SPECIFICATIONS Machine Dimensions (Standard Arm) Machine Dimensions (331E Extendible Arm) Machine Dimensions (334 Long Arm) Lifting Capacity Specifications Weights Controls Engine Electrical Hydraulic System Cylinder Cycle Time Swing System Hydraulic Cylinders Drive System Brakes Undercarriage STD Track Shoes Refill Capacities Digging Force 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 FUEL, COOLANT AND LUBRICANTS (CONT�D) CONVERSIONS Decimal And Millimeter Equivalents U.S. To Metric Conversion SMR 331 331 331 . 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