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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