Bobcat X331 Excavator Repair Service Manual - 6724222

(S/N: 512911001 – 512912999) 
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This workshop repair service manual PDF download for the X-331 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 Excavator X 331 
S/N: 512911001 – 512912999


TABLE OF CONTENTS :

SAFETY INSTRUCTIONS 
SERIAL NUMBER LOCATIONS 
DELIVERY REPORT 
HYDRAULIC EXCAVATOR IDENTIFICATION 
PREVENTIVE MAINTENANCE 
HYDRAULIC SYSTEM 
DRIVE SYSTEM 
UPPER WORKS & SWING SECTION 
MAIN FRAME & TRACKS 
ELECTRICAL SYSTEM 
ENGINE SERVICE 
SPECIFICATIONS 
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6724222 (2–96)
Total Pages : 525


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
    SERIAL NUMBER LOCATIONS
    HYDRAULIC EXCAVATOR SERIAL NUMBER
    ENGINE SERIAL NUMBER
    DELIVERY REPORT
    HYDRAULIC EXCAVATOR IDENTIFICATION
    MACHINE SIGNS TRANSLATIONS (DECALS)
    
PREVENTIVE MAINTENANCE
    SERVICE SCHEDULE (S/N 11001–11999)
    SERVICE SCHEDULE (S/N 12001 & Above)
    PREVENTIVE MAINTENANCE
    LIFTING AND BLOCKING THE EXCAVATOR
        Procedure
    TRANSPORTING THE EXCAVATOR
        Procedure
    ENGINE COVER
        Opening the Cover
    AIR CLEANER
        Servicing the Air Cleaner (S/N 11001–11999)
        Servicing the Air Cleaner (S/N 12001–12999)
        Servicing the Air Cleaner (S/N 13001 & Above)
    FUEL SYSTEM
        Fuel Specification
        Filling the Fuel Tank
        Fuel System Service
        Fuel Filter
        Removing Air from the Fuel System
    ENGINE LUBRICATION SYSTEM
        Checking Engine Oil
        Replacing Oil and Filter
    COOLING SYSTEM
        Coolant Level
        Ethylene Glycol
        Propylene Glycol
        Coolant Replacement
    HYDRAULIC SYSTEM
        Checking and Adding Fluid
        Replacing the Hydraulic Filter (S/N 11001–11999)
        Replacing the Hydraulic Filter (S/N 12001 & Above)
        Return Line Filter Service (S/N 12240 & Above)
        Hydraulic Reservoir
        Diagnostic Couplers
    USING A BOOSTER BATTERY (Jump Starting)
        Procedure (S/N 11001–11999)
        Procedure (S/N 12001 & Above)
    SPARK ARRESTOR MUFFLER
        Cleaning Spark Arrestor Muffler (S/N 11001–11999)
        Cleaning Spark Arrestor Muffler (S/N 12001 & Above)
    LUBRICATION OF THE EXCAVATOR
        Procedure (S/N 11001 – 11999)
        Procedure (S/N 12001 & Above)
    FINAL DRIVE CASE
        Checking Oil Level
        Draining Final Drive Case
    HEATER AIR FILTER SERVICE
    
HYDRAULIC SECTION
    HYDRAULIC SCHEMATICS
    HYDRAULIC SYSTEM TROUBLESHOOTING
    HYDRAULIC SERVICE INFORMATION (S/N11001–12999)
        Description
    MAIN RELIEF VALVES (S/N 11001–12999)
        Description
        Checking Dual Pressure Relief Valves
        Checking Single Pressure Relief Valve
        Dual Pressure Relief Valve Adjustment (6–Spool Valve)
        Single Pressure Relief Valve Adjustment (3–Spool Valve)
    HYDRAULIC SERVICE INFORMATION (S/N 13001 &Above)
        Description
    MAIN RELIEF VALVE (Adjustable) (S/N 13001 & Above)
        Checking the Main Relief Valves
        Testing the Blade, Boom Swing, Arm and Boost Circuit Relief Valves
        Testing the 4050 PSI (27925 kPa) Circuit Relief
        Testing the Auxiliary and Bucket Circuit Relief Valve
        Testing the Left Hand Travel Circuit Relief Valve
        Testing the Right Hand Travel Circuit Relief Valve
        Testing the Boom Circuit Relief Valve
    HYDRAULIC PUMP
        Checking the Hydraulic Pump
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
    HYDRAULIC CONTROL VALVE (6–Spool) (S/N 12999 & Below)
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
        Right Hand Travel Section Disassembly and Assembly
        Boom, Bucket and Arm Section Disassembly and Assembly
        Auxiliary Section Disassembly and Assembly
        Left Hand Travel Section Disassembly and Assembly
        End Cover Disassembly and Assembly
    HYDRAULIC CONTROL VALVE (3–Spool) (S/N 12999 & Below)
        Description
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
        Housing Swing Section Disassembly and Assembly
        Blade and Boom Swing Section Disassembly and Assembly
        End Cover Disassembly and Assembly
    HYDRAULIC CONTROL VALVE (5–Spool) HUSCO VALVE (S/N 13001 & Above)
        Left Travel, Right Travel, Boom, Bucket and Auxiliary
        Removal and Installation
        Parts Identification
        Disassembly
        Outlet Sections Disassembly
        Outlet Sections Assembly
        Mid Inlet Section Disassembly
        Mid Inlet Section Assembly
        Left Travel, Right Travel and Auxiliary Disassembly
        Left Travel, Right Travel and Auxiliary Assembly
        Boom and Bucket Disassembly
        Boom and Bucket Assembly
        Assembly
    PORT RELIEF VALVES AND MAIN RELIEF VALVES (S/N 13001 & Above)
        Parts Identification
        Port Relief Valve Pressure Setting
        Disassembly
        Assembly
    MAIN RELIEF VALVES (Adjustable) (S/N 13001 & Above)
        Parts Identification
        Assembly
        Disassembly
        Assembly
        Adjusting the Main Relief Valves
    HYDRAULIC CONTROL VALVE (5–Spool) HUSCO VALVE (S/N 13001 & Above)
        Boost, Arm, Boom Swing, Blade and Swing Section
        Description
        Removal and Installation
        Parts Identification
        Disassembly
        Inlet Section
        Arm, Boost and Swing Motor Disassembly
        Arm, Boost and Swing Motor Assembly
        Boom Swing Disassembly
        Boom Swing Assembly
        Blade Disassembly
        Blade Assembly
        Assembly
    ACCUMULATOR (S/N 12999 & Below)
        Adjustment
        Pressure Reducing Valve
        Testing
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
        Setting the Safety Relief Valve
        Charging
    ACCUMULATOR (S/N 13001 & Above)
        Removal and Installation
        Parts Identification
    AUXILIARY SELECTOR VALVE
        Removal and Installation (S/N 12999 & Below)
        Removal and Installation (S/N 13001 & Above)
        Disassembly and Assembly
    TWO SPEED VALVE (S/N 12999 & Below)
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
    TWO SPEED SWITCH (S/N 13001 & Above)
        Removal and Installation
    PORT BLOCK
        Removal and Installation (S/N 12999 & Below)
        Removal and Installation (S/N 13001 & Above)
    OIL COOLER
        Removal and Installation (S/N 11001 – 11999)
        Removal and Installation (S/N 12001 & Above)
    HYDRAULIC RESERVOIR AND FUEL RESERVOIR
        Removal and Installation
    HYDRAULIC FILTER ASSEMBLY
        Removal and Installation (S/N 11001–11999)
        Removal and Installation (S/N 12001 & Above)
    BOOM CYLINDER
        Removal and Installation (S/N 11001–11999)
        Removal and Installation (S/N 12001 & Above)
        Parts Identification
    ARM CYLINDER
        Removal and Installation (S/N 11001–11999)
        Removal and Installation (S/N 12001 & Above)
        Parts Identification
    BUCKET CYLINDER
        Removal and Installation (S/N 11001–11999)
        Removal and Installation (S/N 12001 & Above)
        Parts Identification
    BLADE CYLINDER
        Removal and Installation
        Parts Identification
    BOOM SWING CYLINDER
        Removal and Installation
        Parts Identification
    HYDRAULIC CYLINDER
        Disassembly
        Assembly
    JOYSTICK CONTROL CHANGE
        ISO to STANDARD Control Pattern (S/N 12999 & Below)
        STANDARD to ISO Control Pattern (S/N 12999 & Below)
        ISO to STANDARD Control Pattern (S/N 13001 & Above)
        STANDARD to ISO Control Pattern (S/N 13001 & Above)
        
DRIVE SECTION
    LEFT CONSOLE (S/N 12999 & Below)
        Lockout Valve Removal and Installation
        Cylinder Removal and Installation
        Removal and Installation
    LEFT CONSOLE (S/N 13001 & Above)
        Control Lock Micro–Switch Removal and Installation
        Cylinder Removal and Installation
        Removal and Installation
    LEFT CONSOLE RELEASE HANDLE (S/N 13001 & Above)
        Removal and Installation
        Adjustment
    JOYSTICK (S/N 12999 & Below)
        Removal and Installation
        Parts Identification
        Disassembly and Assembly
    JOYSTICK (S/N 13001 & Above)
        Removal and Installation
    JOYSTICK (S/N 13001 & Above)
        Parts Identification
        Disassembly
        Assembly
        Troubleshooting
    RIGHT CONSOLE
        Removal and Installation (S/N 12999 & Below)
        Removal and Installation (S/N 13001 & Above)
    RIGHT CONSOLE COVER
        Removal and Installation
    SPEED CONTROL LEVER
        Low Idle Adjustment
        High Idle Adjustment
        Removal and Installation
    BLADE CONTROL LEVER AND CABLE
        Removal and Installation
    STEERING LEVERS AND PEDALS
        Removal and Installation
        Adjusting Linkage Rods
        
UPPER WORKS AND SWING SECTION
    ENGINE COVER
        Removal and Installation (S/N 11001–11999)
        Removal and Installation (S/N 12001 & Above)
    SEAT AND SEAT MOUNT
        Removal and Installation
    FLOORMAT AND FLOOR PLATE
        Removal and Installation
    REAR FLOOR PLATE
        Removal and Installation
    SWING MOTOR COVER
        Removal and Installation
    INSPECTION COVER (S/N 11001–11999)
        Removal and Installation
    TOOL BOX
        Removal and Installation (S/N 11001–11999)
        Removal and Installation (S/N 12001 & Above)
    LEFT HAND SIDE COVER
        Removal and Installation (S/N 11001–11999)
        Removal & Installation (S/N 12001 & Above)
    RIGHT HAND SIDE COVER
        Removal and Installation (S/N 11001–11999)
        Removal and Installation (S/N 12001 & Above)
    RIGHT HAND CORNER POST
        Removal and Installation
    LEFT HAND CORNER POST
        Removal and Installation
    COUNTERWEIGHTS
        Removal and Installation
    FRONT ENGINE COVER
        Removal and Installation
    BUCKET
        Removal and Installation
    BUCKET TEETH
        Removal and Installation
    ARM
        Removal and Installation (S/N 11001–11999)
        Removal and Installation (S/N 12001 & Above)
    BOOM
        Removal and Installation
    BOOM SWING BRACKET
        Removal and Installation
        Hose Installation
    SWING BRACKET BUSHING
        Bushing Removal
        Bushing Installation
    BOOM PIVOT BUSHING
        Bushing Removal
        Bushing Installation
    SWING MOTOR
        Removal and Installation (S/N 11001–11056)
        Removal and Installation (S/N 11057–12999)
        Disassembly (S/N 11001–12999)
        Assembly (S/N 11001–12999)
    CROSS PORT RELIEF VALVE (S/N 11001–11056 S/N 13001 &  Above)
        Disassembly
        Assembly
        Description
        Testing
    COUNTERBALANCE VALVE (S/N 11057–12999)
        Description
        Removal and Installation
        Disassembly
        Assembly
    SWING GEAR BOX
        Parts Identification (S/N 11001–12999)
        Disassembly (S/N 11001–12999)
        Assembly (S/N 11001–12999)
    SWING MOTOR
        Removal and Installation (S/N 13001 & Above)
    SWING MOTOR DRIVE CARRIER (S/N 13001 & Above)
        Removal and Installation
        Parts Identification
        Disassembly
        Assembly
    UPPERSTRUCTURE AND SWING CIRCLE GEAR
        Removal and Installation
        Swing Bearing Removal
        Swing Bearing Installation
        Alignment Pins (Not Threaded)
    CENTER SWIVEL JOINT
        Removal and Installation (S/N 12999 & Below)
        Removal and Installation (S/N 13001 & Above)
        Parts Identification
        Disassembly
        Assembly
    ROPS CANOPY
        Removal and Installation
    CAB
        Removal and Installation
        Front Window Removal and Installation
        Front Lower Window Removal and Installation
        Front Upper Window Removal and Installation
        Door Removal and Installation
        Door Window Removal and Installation
        Left Hand Side Window Removal and Installation
        Right Hand Side Window Removal and Installation
        Right Hand Window Assembly Removal and Installation
        Rear Window Removal and Installation
    CAB/CANOPY REAR COVER
        Removal
        Installation
        
MAIN FRAME AND TRACKS
    BLADE
        Removal and Installation
    TRACK
        Track Lug Height
        Track Tension Adjustment
        Rubber Track Clearance
        Steel Track Clearance
        Adjustment (S/N 512912999 & Below)
        Adjustment (S/N 512913001 & Above)
        Rubber Track Removal and Installation
        Steel Track Removal and Installation
    TRACK FRAME
        Disassembly and Assembly (S/N 512912999 & Below)
        Disassembly and Assembly (S/N 512913001 & Above)
    TRAVEL MOTOR
        Testing
        Removal and Installation
        (S/N 512911001–512913404)
            Parts Identification
            Disassembly
            Assembly
        (S/N 512913405 & Above)
            Parts Identification
            Disassembly
            Assembly
    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 Of 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
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    TROUBLESHOOTING
    ELECTRICAL SYSTEM
        Description
        Fuses
        Fuse Arrangement
        Electrical System Service
    BATTERY
        Check the Battery
        Removal and Installation (S/N 11001–11999)
        Removal & Installation (S/N 12001 & Above)
    ALTERNATOR
        Belt Adjustment
        Removal and Installation
        Parts Identification
        Disassembly and Inspection
        Stator Continuity Test
        Stator Ground Test
        Rotor Continuity Test
        Rotor Ground Test
        Rectifier Continuity (Diode) Test
        Assembly
    STARTER
        Removal and Installation
        Disassembly and Assembly
        Cleaning and Inspection
        Part Identification
    FUEL LEVEL SENDER
        Removal and Installation
        Checking
    INSTRUMENT PANEL
        Removal and Installation
    GAUGES
        Removal and Installation
    GAUGE LIGHTS
        Removal and Installation
    CAB ELECTRICAL
        Cab Option
        
ENGINE SERVICE
    TROUBLESHOOTING
        Chart
    VALVE CLEARANCE
        Adjustment
    ENGINE COMPRESSION
        Checking
    GLOW PLUGS
        Removal and Installation
        Checking the Glow Plug
    FUEL SHUT–OFF SOLENOID
        Adjustment
        Removal and Installation
        Timer Module Removal and Installation
    FUEL INJECTION PUMP
        Checking the Injection Pump
        Removal and Installation
        Timing the Injection Pump
    FUEL INJECTOR NOZZLES
        Removal and Installation
        Checking the Injector Nozzle
    FAN GUARD
        Removal and Installation (S/N 11001–11999)
        Removal and Installation (S/N 12001 & Above)
    RADIATOR
        Removal and Installation (S/N 11001 – 11999)
        Removal and Installation (12001 & Above)
    MUFFLER
        Removal and Installation (S/N 11001–11999)
        Removal and Installation (S/N 12001 & Above)
    AIR CLEANER
        Removal and Installation (S/N 11001–11999)
        Removal and Installation (S/N 12001–12999)
        Removal and Installation (S/N 13001 & Above) 
    ENGINE
        Removal and Installation
    ENGINE FLYWHEEL
        Removal and Installation
        Flywheel Ring Gear
    CYLINDER HEAD
        Removal and Installation
        Disassembly and Assembly
        Servicing the Cylinder Head
        Top Clearance
    VALVE, VALVE SEAT AND GUIDE
        Checking the Valve Guide
        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
        Servicing the Camshaft
        Servicing the Idler Gear and Shaft
    TIMING GEARS
        Checking Backlash
    FUEL CAMSHAFT
        Removal and Installation
        Governor
    CRANKSHAFT GEAR
        Removal and Installation
    OIL PUMP
        Removal and Installation
        Oil Pump Service
    ENGINE COMPRESSION
        Checking Engine Oil Pressure
        Relief Valve
    PISTON AND CONNECTING ROD
        Removal and Installation
        Servicing the Piston and Connecting Rod
        Connecting Rod Alignment
    CRANKSHAFT AND BEARINGS
        Removal and Installation
        Servicing the Crankshaft and Bearings
    CYLINDER BORE
        Checking the Cylinder Bore
    WATER PUMP
        Removal and Installation
        Disassembly and Assembly
        
SPECIFICATIONS
    EXCAVATOR SPECIFICATIONS
        Machine Dimensions (S/N 11001–11999)
        Machine Dimensions (S/N 12001 & Above)
        Lifting Capacity
        OPERATIONS & PERFORMANCE
        ENGINE
        HYDRAULIC SYSTEM
        SWING SYSTEM
        HYDRAULIC CYLINDERS
        DRIVE SYSTEM
        BRAKES
        UNDERCARRIAGE
        STD TRACK SHOES
        REFILL CAPACITIES
        DIGGING FORCE
        Machine Dimensions (S/N 13001 & Above)
        Lifting Capacity
        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
        Piston Rings
        Pistons
        Connecting Rod
        Oil Pump
        Crankshaft
        Timing Gear
        Thermostat
        Engine Bolt Torque
        Crankshaft Re–Grind Data
        Torque For General Metric Bolts
        FUEL, COOLANT AND LUBRICANTS
    ENGINE OIL SPECIFICATIONS
        Description
        Ethylene Glycol
        Propylene Glycol
    DECIMAL AND MILLIMETER EQUIVALENTS
    U.S. TO METRIC CONVERSION
    
SERVICE MANUAL REVISION
    331-1
    331-2
    331-3
    331-4
    331-5
    
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