Bobcat 331, 331E, 334 D-Series Excavator Repair Service Manual - 6901139

(S/N: 232511001 & Above - S/N: 232711001 & Above - S/N: 232611001 & Above) - (D Series) 
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This workshop repair service manual PDF download for the 331 / 331E / 334 Bobcat Mini Hydraulic Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat 331 / 331E / 334
S/N: 232511001 & Above
S/N: 232711001 & Above
S/N: 232611001 & Above
(D Series)


TABLE OF CONTENTS :

SAFETY INSTRUCTIONS 
FOREWORD
SERIAL NUMBER LOCATIONS 
DELIVERY REPORT
BOBCAT EXCAVATOR IDENTIFICATION 
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM 
UNDERCARRIAGE
UPPERSTRUCTURE & SWING SECTION 
ELECTRICAL SYSTEM AND ANALYSIS 
ENGINE SERVICE 
HEATING, VENTILATION, AIR CONDITIONING 
SPECIFICATIONS
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6901139 (2-06)
Total Pages : 865


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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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/TOPS) (IF EQUIPPED)
        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/HYDROSTATIC SCHEMATICS
    HYDRAULIC SYSTEM INFORMATION
        Glossary Of Hydraulic/Hydrostatic Symbols For Excavators
        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/N 232512782 & Below, 232711433 & Below And 232612157 & Below)
        System Pressures At Gauge Port Specifications (S/N 232512782 & Below, 232711433 & Below And 232612157 & Below)
        Testing And Adjusting The Main Relief Valves (S/N 232512783 & Above, 232711434 & Above And 232612158 & Above)
        System Pressures At Gauge Port Specifications (S/N 232512783 & Above, 232711434 & Above And 232612158 & Above)
    PORT RELIEF VALVES
        Testing And Adjusting Port Relief Valve Pressure (S/ N 232512782 & Below, 232711433 & Below And 232612157 & Below)
        Testing And Adjusting Port Relief Valve Pressure (S/ N 232512783 & Above, 232711434 & Above And 232612158 & Above)
    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/N 232512782 & Below, 232711433 & Below And 232612157 & Below)
        Testing And Adjusting The Pressure Reducing Valve (S/N 232512783 & Above, 232711434 & Above And 232612158 & Above)
    HYDRAULIC CONTROL VALVE (S/N 232512782 & BELOW, 232711433 & BELOW AND 232612157 & BELOW)
        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/N 232512783 & ABOVE, 232711434 & ABOVE AND 232612158 & ABOVE)
        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/ACCUMULATOR (S/N 232512162 & BELOW, 232611711 & BELOW AND 232711316 & BELOW)
        Manifold Description
        Removal And Installation
    MANIFOLD ASSEMBLY (S/N 232512162 & BELOW, 232611711 & BELOW AND 232711316 & BELOW)
        Parts Identification
        Disassembly
        Assembly
    MANIFOLD ASSEMBLY/ ACCUMULATOR (S/N 232512163 & ABOVE, 232611712 & ABOVE AND 232711317 & ABOVE)
        Manifold Description
        Removal And Installation
    MANIFOLD ASSEMBLY (S/N 232512163 & ABOVE, 232611712 & ABOVE AND 232711317 & ABOVE)
        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/N 232512782 & BELOW, 232711433 & BELOW AND 232612157 & BELOW)
        Testing
        Handle Removal And Installation
        Joystick Assembly, Removal And Installation
        Parts Identification
        Disassembly
    LEFT CONTROL LEVER (JOYSTICK) (S/N 232512782 & BELOW, 232711433 & BELOW AND 232612157 & BELOW)
        Testing
        Handle Removal And Installation
        Joystick Assembly, Removal And Installation
        Parts Identification
        Disassembly And Assembly
    LEFT CONTROL LEVER (JOYSTICK) (S/N 232512783 & ABOVE, 232711434 & ABOVE AND 232612518 & ABOVE)
        Testing
        Handle Removal And Installation
        Joystick Assembly, Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    RIGHT CONTROL LEVER (JOYSTICK) (S/N 232512783 & ABOVE, 2327114334 & ABOVE AND 232612518 & ABOVE)
        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/N 232511877 & Below, 23271165 & Below And 232611488 & Below)
        Disassembly (S/N 232511877 & Below, 232711165 & Below And 232611488 & Below)
        Assembly (S/N 232511877 & Below, 232711165 & Below And 232611488 & Below)
        Parts Identification (S/N 232511878 & Above, 23271166 & Above And 232611489 & Above)
        Disassembly (S/N 232511878 & Above, 232711166 & Above And 232611489 & Above)
        Assembly (S/N 232511878 & Above, 232711166 & Above And 232611489 & Above)
    TRACK ROLLER
        Parts Identification (S/N 232511877 & Below, 232711165 & Below And 232611488 & Below)
        Disassembly (S/N 232511877 & Below, 23271165 & Below And 232611488 & Below)
        Assembly (S/N 232511877 & Below, 23271165 & Below And 232611488 & Below)
        Parts Identification (S/N 232511878 & Above, 232711166 & Above And 232611489 & Above)
        Disassembly (S/N 232511878 & Above, 23271166 & Above And 232611489 & Above)
        Assembly (S/N 232511878 & Above, 23271166 & Above And 232611489 & Above)
    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/C
        Removal And Installation Without A/C
    HEATER/AC FAN
        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/C Performance
        Cleaning The A/C Evaporator Coil & Heater Coil
        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/PRESSURE
        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/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
        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
        
SERVICE MANUAL REVISION
    331/331E/334-1
    331/331E/334-2
    331/331E/334-3
    
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