Bobcat 331 compact excavator service repair manual (sn 511920001 & above)

X 331 Excavator Service Manual (S/N 511920001 & Above)

6722918 (5–94)

Printed in U.S.A.

© Melroe Company 1994

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

B-10731a

Never service the Hydraulic Excavator instructions.

Bobcat without

CORRECT

CORRECT

B-14148

Use the correct procedure to lift and support the excavator.

Always lift the blade fully before installing jackstands.

B-14142

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-14147

B-14141

B-14145

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Vent exhaust to outside when engine must be run for service.

Exhaust system must be tightly sealed. Exhaust Fumes can kill without warning.

Always lower the bucket and blade to the ground before doing any maintenance.

Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

WRONG

WRONG

B-14146

B-14143 B-16102

B-6589 B-16102

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust machine with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Never fill fuel tank with engine running, while smoking or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used.

Use eye protection approved for type of welding.

Keep rear door closed except for service. Close and latch door before operating the excavator.

Lead-acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact.

Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer.

MSW20-0805

CONTENTS SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii HYDRAULIC EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . iii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 DRIVE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 UPPER WORKS & SWING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME & TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

PREVENTIVE MAINTENANCE

HYDRAULIC SECTION

DRIVE SECTION

UPPER WORKS & SWING SECTION

MAIN FRAME & TRACKS

ELECTRICAL SYSTEM

ENGINE SERVICE

TECHNICAL DATA

–3

331 Hydraulic Excavator (S/N 20001) Service Manual

FOREWORD This manual is for the Bobcat hydraulic excavator mechanic. It provides necessary servicing and adjustment procedures for the hydraulic excavator and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

A general inspection of the following items must be made after the hydraulic excavator has had service or repair: 1. Check that the ROPS/TOPS/ FOGS is in good condition and is not modified.

9. Safety treads must in good condition.

2. Check that ROPS/TOPS mounting hardware is tightened and is Melroe approved.

10. Check for correct function of indicator lamps.

3. The seat belt must be correctly installed, functional and in good condition.

11. Check hydraulic fluid level, engine oil level and fuel supply.

4. Inspect for loose or broken parts or connections.

12. Inspect for fuel, oil or hydraulic fluid leaks.

5. Machine signs must be legible and in the correct location.

13. Lubricate excavator.

6. Steering levers, control levers and foot pedals must return to neutral. Check that foot pedals lock and control lever locks are in working condition.

14. Check the condition of the battery and cables.

7. Inspect the air cleaner for damage or leaks. Check the condition of the element.

Recommend to the owner that all necessary corrections be made before the machine is returned to service.

the

hydraulic

8. Check the electrical charging system.

–1

331 Hydraulic Excavator (S/N 20001) Service Manual

SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–0797

The following publications provide information on the safe use and maintenance of the loader and attachments:

• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.

• The Operation & Maintenance Manual delivered with the excavator gives operating information as well as routine maintenance and service procedures. It is a part of the excavator and must stay with the machine when it is sold.

• The excavator has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat Excavator dealer.

• The CIMA Safety Manual delivered with the excavator gives information for safe operating and standard signals.

• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and repair work.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

W–2044–1285

This notice identifies procedures which must be followed to avoid damage to the machine.

I–2019–0284

Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this symbol follow the safety message to avoid personal injury or death.

• Wear tight fitting clothing and any other required safety apparel when operating or servicing the excavator.

• Wear safety glasses when maintaining or servicing the excavator.

• Exhaust gases can kill, vent engine exhaust outdoors.

• Know where fire extinguishers and first aid kits are located and how to use them.

• Do not run the excavator where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check

for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

• Do not use ether or starting fluids on an engine that has glow plugs. These starting aids can explode and injure you.

• Clean the excavator before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the excavator when welding.

• Have good ventilation when welding or grinding painted parts. Wear a dust mask when grinding painted parts. Toxic dust or gas can be produced.

• Stop the engine and let it cool before adding fuel. No smoking!

• Use the procedure in this manual for installing, connecting and jump starting batteries. i

331 Hydraulic Excavator (S/N 20001) Service Manual

SERIAL NUMBER LOCATIONS

A

Always use the serial number of the machine when requesting service information or when ordering parts.

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

HYDRAULIC EXCAVATOR SERIAL NUMBER The excavator serial number is on the front of the machine frame, to the left of the boom [A].

P–2932

ENGINE SERIAL NUMBER

B

The engine serial number is located on the engine block, near the fuel injection pump [B].

P–2880

C DELIVERY REPORT All Delivery Report items must be explained to the owner/operator by the dealer. The dealer is to fill out the form and the owner/operator signs the form to indicate his understanding [C].

ii

331 Hydraulic Excavator (S/N 20001) Service Manual

HYDRAULIC EXCAVATOR IDENTIFICATION CONTROL LEVERS (JOYSTICK) OPERATOR SEAT

BOOM

BOOM CYLINDER BUCKET CYLINDER SEAT BELT BUCKET LINK BLADE CYLINDER

BUCKET

CANOPY (ROPS) ARM CYLINDER

ENGINE COVER ARM

UPPERSTRUCTURE

BLADE TRACK FRAME TRACK

CD–13291 CD–13292

iii

331 Hydraulic Excavator (S/N 20001) Service Manual

MACHINE SIGNS TRANSLATIONS (DECALS) Follow the instructions on all the Machine Signs (Decals) that are on the excavator. Replace any damaged machine signs and be sure they are in the correct locations. Machine signs are available from your Bobcat Hydraulic Excavator dealer.

6539688 6537588 ISO 6537457 STANDARD

6588730

6537634

6587587 ISO 6537456 STANDARD 6587247

6587139

6533901

6589059 6539812 6577754

6534217

6588921

6534739 6539813

6588382 6539811

iv

PI–13291

331 Hydraulic Excavator (S/N 20001) Service Manual

MACHINE SIGNS TRANSLATIONS (DECALS) (Cont’d)

6577754

6588380 6643356 6588716

6561379

6565990

6643355 6534739

6588715

PI–13292

v

331 Hydraulic Excavator (S/N 20001) Service Manual

PREVENTIVE MAINTENANCE Page Number

PREVENTIVE MAINTENANCE

AIR CLEANER SERVICE Replacing the Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 COOLING SYSTEM Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 ENGINE COVER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 ENGINE LUBRICATION SYSTEM Checking the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 Engine Oil and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 FUEL SYSTEM Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–5 1–4 1–4 1–5

FINAL DRIVE CASE Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 Draining Final Drive Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 HYDRAULIC SYSTEM Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of the Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–8 1–9 1–9 1–8

LUBRICATION OF THE HYDRAULIC EXCAVATOR Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 USING A BOOSTER BATTERY (JUMP STARTING) Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10

–1––1–

331 Hydraulic Excavator (S/N 20001) Service Manual

SERVICE SCHEDULE Maintenance work must be done at regular intervals.

Failure to do so may result in excessive and early failures.

The Service Schedule is a guide for correct maintenance of the Hydraulic Excavator.

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–0797

SERVICE SCHEDULE ITEM Engine Air Cleaner

Engine Oil Engine Coolant System Indicator Lights Operator Cab Seat Belt Safety Signs (Decals) Tracks Hydraulic Reservoir All Machinery Pivot Points Fuel Tank/Fuel Filter Swing Circle Swing Pinion Engine Oil & Filter Alternator Belt Final Drive Case Hydraulic Filter Fuel Filters Battery Air Cleaner Cooling System Alternator & Starter Engine Valve Clearance Port Block Screen Filter Cooling System Hydraulic Tank Final Drive Case

HOURS 8–10 50

SERVICE REQUIRED

100 250 500 1000

Empty the just cap. Replace the filter element only when the red ring shows in the indicator window. Check for leaks and damaged components.

Check the oil level & add oil as needed.

Check coolant level in recovery bottle.

Check for correct operation.

Check the fastening bolts, nuts & condition of cab.

Check the condition & that fasteners are tight.

Check for damaged signs (decals), replace as needed.

Check & adjust tension & clean.

Check fluid level.

Lubricate 25 grease fittings.

Drain water and sediment from fuel tank/filter.

Lubricate two grease fittings.

Lubricate one grease fitting.

Replace oil & filter element.

Check & adjust tension.

Check fluid level & add oil as needed.

Replace filter element.

Replace filter elements.

Check & clean cable ends & check electrolyte level.

Replace the filter element.

Clean the radiator fins.

Check the condition.

Check & adjust valve clearance.

Clean the screen with solvent.

Drain, flush & add new coolant to the cooling system.

Change the fluid, clean fill neck strainer.

Change the oil.

After the first 50 hours of machine operation do the following: • Replace hydraulic fluid filter • Check condition of fan belt.

After the first 250 hours of machine operation do the following procedures: • Change oil in final drive case.

• Check and adjust engine valve clearance.

–1–1–

331 Hydraulic Excavator (S/N 20001) Service Manual

ENGINE COVER

A

Procedure

AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual.

W–2012–0497 P–02885

Keep the engine cover closed when operating the machine.

W–2141–0189

B

Open the engine cover to service the engine. Pull on the latch and lift the engine cover up until it is fully open [A].

AIR CLEANER SERVICE Replacing the Filter Element See the Service Schedule (Page 1–1) for the correct service interval.

Replace the filter element when the red ring shows in the window of the condition indicator (Item 1) [B].

P–02896

NOTE: Push the button on the condition indicator and start the engine. If the red ring does not show, do not replace the filter element.

C

Service the air cleaner as follows: 1. Loosen the clamp on the dust cup and remove the dust cup [C].

P–02895

2. Remove the rubber cup to clean the dust cup [D].

D

P–02892

–1–2–

331 Hydraulic Excavator (S/N 20001) Service Manual

AIR CLEANER SERVICE (Cont’d)

A

Replacing the Filter Element (Cont’d) 3. Remove the wing nut (Item 1) [A].

1

P–02897

4. Remove the filter element [B].

B

5. Check the air cleaner housing for damage.

6. Wiper the canister and the seal surface with a clean cloth. Do Not use compressed air.

7. Install a new filter element. Install and tighten the wing nut.

8. Install the dust cup so the arrow points up.

9. Check that all the air cleaner 10. Push the button on the condition indicator so the red ring does not show.

P–02898

–1–3–

331 Hydraulic Excavator (S/N 20001) Service Manual

FUEL SYSTEM

A

Use Number 2 diesel fuel in the engine. During very cold temperatures, Number 1 fuel can be used. (See Fuel, Coolant and Lubricants Chart, Page 8–8).

2

1 Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can cause an explosion or fire.

P–02921

W–2063–0887

B

Fuel System Service The fuel level in the tank is indicated by the fuel gauge (Item 1) when the engine is running [A].

NOTE: When the fuel level reaches the 2.5 gals. (9,3 L) fuel setting, the low fuel light (Item 2) will come “ON” to alert the operator of this condition.

Use the key to unlock the fuel fill door [B].

P–02920

Turn the fill cap to remove it [C].

C

Use a clean, approved safety container to add fuel to the tank.

Add fuel only in an area that has a free movement of air and no open flames or sparks. NO SMOKING! After the tank is full, install and tighten the fuel fill cap.

Close and lock the fuel door.

P–02917

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

–1–4–

331 Hydraulic Excavator (S/N 20001) Service Manual

FUEL SYSTEM (Cont’d)

A

To remove the water and sediment from the fuel tank, turn the upperstructure until the fuel tank is centered between the rear tracks. (If time allows, let machine sit overnight so water and sediment will settle to the bottom of the tank.)

Open the drain valve (Item 1) at the bottom of the fuel tank [A].

1

Drain all water and sediment into a container.

P–03012

Fuel Filters

B

See the Service Schedule (Page 1–1) for the correct service interval.

2 4

To remove the water from the filter element, open the drain valve (Item 1) at the bottom of the fuel filter [B].

Drain the water into a container. When fuel, free of water emerges from the drain valve, close the drain valve.

3

See the Service Schedule (Page 1–1) for the correct service interval for fuel filter element replacement.

1

Remove the hose (Item 2) from the filter housing and plug the hose [B], or firmly squeeze the hose, to eliminate the fuel from siphoning out of the tank when the element is removed.

P–02891

C

Remove the fuel filter element (Item 3) [B]. Clean the area around the filter housing. Put oil on the seal of the new filter element. Install the new fuel filter element and hand tighten only.

1

Removing Air From the Fuel System The fuel system uses an electric fuel pump (Item 1) [C].

Turn the ignition key to the ‘‘ON’’ position (do not start the engine).

Loosen the filter bleed screw (Item 4) on the filter housing [B].

When fuel, free of air bubbles emerges from the filter, tighten the bleed screw (Item 4) [B].

P–02640

Leave the key in the ‘‘ON’’ position for a short period, or until all air is removed from the fuel system.

–1–5–

331 Hydraulic Excavator (S/N 20001) Service Manual

ENGINE LUBRICATION SYSTEM

A

Checking The Engine Oil Check the engine oil every day.

Stop the engine. Open the engine cover.

Remove the dipstick [A].

Keep the oil between the marks on the dipstick.

Use a good quality motor oil that meets API Service Classification of CE (See Fuel, Coolant and Lubrication Chart, Page 8–8).

P–02888

B

1 Engine Oil and Filter Replacement

P–02954

See the Service Schedule (Page 1–1) for the correct service interval.

C

Use the following procedure to change the oil and filter: 1. Run the engine until it is at operating temperature.

2. Turn the upperstructure so the engine oil drain plug is located between the tracks. Stop the engine.

3. Remove the drain plug (Item 1) [B]. Drain the oil into a container.

1

4. Remove the oil filter (Item 1), using a filter wrench [C].

P–02882

5. Clean the filter housing surface. Put clean oil on the filter gasket. Install the new filter and hand tighten only.

D

1

6. Install and tighten the oil drain plug.

7. Remove the oil fill cap (Item 1) [D]. Put 9.0 quarts (8,5 L) of oil into the engine (See Fuel, Coolant and Lubricants Chart, Page 8–8).

8. Start the engine and let it run for several minutes.

Stop the engine. Check for leaks at the oil filter and the drain plug.

9. Check the oil level and add oil as needed to bring it to the “top” mark on the dipstick.

P–02884

–1–6–

331 Hydraulic Excavator (S/N 20001) Service Manual

COOLING SYSTEM

A

Coolant Level

1

When the engine is cool, the coolant level in the recovery tank (Item 1) must be half full [A].

If the coolant level is low, add premixed coolant (50% water and 50% ethylene glycol) to the recovery tank.

Coolant Replacement

P–02879

Do not remove radiator cap when the engine is hot. You can be seriously burned.

B

W–2070–1285

1. Turn the upperstructure so there is access to the engine and radiator from between the tracks. Stop the engine.

2. Loosen and remove the radiator cap [B].

P–02886

C

3. Open the radiator drain valve (Item 1) [C].

4. Drain all the coolant from the system.

NOTE: Also remove all coolant from the coolant recovery tank (Item 1) [A].

1

5. When all the coolant is removed, close the drain valve.

6. Premix 50% water and 50% ethylene glycol in separate container. Fill the radiator with the premixed coolant until it is full. Add coolant to the recovery tank until it is half full.

P–03077

7. Run the engine at idle speed for about 5–10 minutes to remove the air from the cooling system (leave the radiator cap off during this operation).

8. Stop the engine. Check the coolant level and add as needed to bring it up to the radiator filler neck. Install the radiator cap and tighten.

–1–7–

331 Hydraulic Excavator (S/N 20001) Service Manual

HYDRAULIC SYSTEM

A

Checking and Adding Fluid To check and add hydraulic fluid to the reservoir, use the following procedure: 1. Put the machine on a flat level surface.

1

2. Retract the arm and bucket cylinders, put the bucket on the ground and raise the blade. Stop the engine.

3. Check the hydraulic fluid level, it must be visible in the sight gauge (Item 1) located on the side of the hydraulic reservoir [A].

P–02916

4. If fluid level is not correct, open the hydraulic tank access door [B].

B

5. Remove the oil fill cap (Item 1) [B].

1

P–02917

6. Check the condition of the fill strainer [C]. The screen must be installed in the fill neck when adding oil.

C

7. Add the correct fluid to the reservoir until it is visible in the sight gauge (See Fuel, Coolant and Lubricants Chart, Page 8–8).

8. Install the reservoir cap and close and lock the access door.

Replacement of the Hydraulic Filter

P–02919

See the Service Schedule (Page 1–1) for the correct service interval.

D

1. Open the engine cover.

2. Use a filter wrench and remove the filter element (Item 1) [D].

3. Clean the housing where the filter gasket makes contact.

4. Put clean hydraulic oil on the gasket. Install the new filter element and hand tighten only.

1

5. Start the engine. Run the machine through the hydraulic functions. Stop the engine. Check the fluid level at the reservoir and add as needed. Check around the filter for leaks.

P–02950

–1–8–

331 Hydraulic Excavator (S/N 20001) Service Manual

HYDRAULIC SYSTEM (Cont’d)

A

Hydraulic Reservoir See the Service Schedule (Page 1–1) for the correct service interval).

1

1. Move the upperstructure so there is clearance for the reservoir drain between the tracks.

2. Retract the arm and bucket cylinders, lower the bucket to the ground. Stop the engine.

3. Remove and replace the hydraulic filter (See Page 1–8).

P–03014

4. Remove the drain plug (Item 1) from the bottom of the reservoir [A].

B

5. Drain the fluid into a container.

6. Install the drain plug.

1

7. Add approximately 10.6 gals. (40 L.) of fluid to the reservoir (See Fuel, Coolant and Lubricants Chart, Page 8–8).

8. Run the machine through the hydraulic functions.

Check the fluid level and add as needed.

P–03075

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

Diagnostic Couplers The diagnostic couplers (Item 1) located on each hydraulic pump are used to check circuit pressures [B].

–1–9–

331 Hydraulic Excavator (S/N 20001) Service Manual

USING A BOOSTER BATTERY (JUMP STARTING)

A

Procedure

If jump starting the excavator from a second machine: When jump starting the excavator from a battery installed in a second machine. Make sure that the second machine is NOT running while using the glow plugs. High voltage spikes from a running machine can burn out the glow plugs.

1 P–02952

I–2060–0195

B

If it is necessary to use a booster battery to start the engine, BE CAREFUL! Make sure the swing locking lever is in the engaged position.

1

The key switch must be in the “OFF” position.

The booster battery must be 12 volt.

Open the engine cover.

Remove the two (2) bolts (Item 1) from the inside of the rear engine cover [A].

Remove the two (2) bolts (Item 1) from the side cover [B].

Remove the side cover.

P–02942

Connect the end of the first cable to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the positive (+) terminal (Item 1) of the machine battery [C].

C 1

Connect the end of the second cable to the negative (–) terminal of the booster battery. Connect the other end of the same cable to the machine frame (Item 2) [C].

2 (+)

NOTE: Also see “Cold Temperature Starting Condition”, on Page 10 of the Operation &Maintenance Manual.

(–)

Start the engine. After the engine is running, remove the cable (Item 2) connected to the frame first. Disconnect the cable from the machine battery (Item 1) [C]. (+) (–)

Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.

P–02951

Damage to the alternator can occur if:

Do not jump start or charge a frozen or damaged battery. Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

Never lean over battery while boosting, testing or charging.

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a •

Battery gas can explode and cause serious injury.

fast charger or when welding on the loader.

(Remove both cables from the battery.)

Extra battery cables (booster cables) are connected wrong.

I–2023–1285

W–2066–1296

–1–10–

331 Hydraulic Excavator (S/N 20001) Service Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR

A

Procedure

1

Lubricate the Hydraulic Excavator as specified in the Service Schedule (Page 1–1) for the best performance of the machine.

2

Always use a good quality lithium based multi–purpose grease when lubricating the machine. Apply the lubricant until extra grease shows.

3

Ref. Description (Number of Fittings) 1. Blade Cylinder Rod End, every 8–10 hours (1) [A].

2. Blade Pivots, every 8–10 hours (2) [A].

3. Blade Cylinder Base End, every 8–10 hours (1) [A].

P–02908

B

4. Boom Swing Bracket Pivot, top L.H., every 8–10 hours (2) [B].

5. Boom Swing Bracket Pivot, bottom L.H., every 8–10 hours (1) [B].

6. Boom Base Pivot, every 8–10 hours (1) [B].

6

1

5 P–02905

7. Boom Swing Bracket Pivot, top R.H., every 8–10 hours (1) [C].

8. Boom Swing Bracket Pivot, bottom R.H., every 8–10 hours (2) [C].

9. Swing Circle Pinion, every 50 hours (1) [C].

Install 4 pumps of grease from a grease gun into the grease fitting. Rotate the upperstructure 180° and install 4 more pumps of grease into the grease fitting.

10. Boom Swing Cylinder Rod End, every 8–10 hours (1) [C].

11. Boom Cylinder Base End, every 8–10 hours (1) [C].

C 7 10 11 9

8

P–02904

D

12. Boom Cylinder Rod End, every 8–10 hours (1) [D].

13. Arm Cylinder Base End, every 8–10 hours (1) [D].

13

12 P–02906

–1–11–

331 Hydraulic Excavator (S/N 20001) Service Manual

LUBRICATION OF THE HYDRAULIC EXCAVATOR (Cont’d)

A

Procedure (Cont’d)

14

Ref. Description (Number of Fittings)

15

14. Arm Cylinder Rod End, every 8–10 hours (1) [A].

15. Arm, Base Pivot, every 8–10 hours (1) [A].

16. Bucket Cylinder Base End, every 8–10 hours (1) [A].

16 P–02903

17. Bucket Cylinder Rod End, every 8–10 hours (1) [B].

18. Bucket Link Pivots, every 8–10 hours (2) [B].

19. Bucket Pivots, every 8–10 hours (3) [B].

B

18

19 17

P–02909

20. Swing Circle Ball Bearings, every 50 hours (2) [C].

C

NOTE: Do not over–grease the swing circle or damage to the seals could result. Install 4 to 5 pumps of grease from a grease gun into each of the 2 grease fittings. Rotate the upperstructure 90° and install 4 to 5 pumps of grease into each of the 2 grease fittings.

20

P–02910

D

21. Boom Swing Cylinder Base End, every 8–10 hours (1) [D].

(Under the right side of upperstructure)

21 P–03011

–1–12–

331 Hydraulic Excavator (S/N 20001) Service Manual

FINAL DRIVE CASE

A

Checking Oil Level 1. Put the machine on a flat surface with the plugs positioned as shown in figure [A].

1

2. Remove the top plug (Item 1) [A]. The oil level should be at the bottom edge of the plug hole.

2

3. Add gear lube 90W through the hole if the oil level is below the hole (See Fuel, Coolant and Lubricant Chart, Page 8–8).

4. Install and tighten the plug.

P–02955

5. Repeat the procedure for the other side.

Draining Final Drive Case See the Service Schedule (Page 1–1) for the correct service interval.

1. Put the machine on flat level surface with the plugs positioned as shown in figure [A].

2. Remove the bottom plug (Item 2) and top plug (Item 1) [A].

3. After all the oil is removed, install and tighten the bottom plug (Item 2) [A].

4. Add .55 quarts (0,5 L) of gear lube 90W to the top plug hole (or until gear lube level is at the bottom edge of the plug hole). Install the plug.

5. Repeat the procedure for the other side.

–1–13–

331 Hydraulic Excavator (S/N 20001) Service Manual

HYDRAULIC SERVICE INFORMATION

A

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

I–2003–0888

1

P–03075

Description There are three (3) main relief valves, five (5) port relief valves, one (1) joystick relief valve and one (1) unloading relief valve in the hydraulic system.

See hydraulic schematic for relief valve locations.

MAIN RELIEF VALVES The hydraulic system has three (3) main relief valves protecting the hydraulic components from high pressure.

The six (6) spool hydraulic valve uses two (2), dual pressure relief valves. These relief valves operate at 2450–2500 PSI (16896–17241 kPa) for the boom, arm, bucket and auxiliary functions. When the drive motors are activated, a shuttle valve is used to activate the high pressure side of the two (2) relief valves which increases their pressure setting to 2950–3000 PSI (20344–20689 kPa). As soon as the drive motor levers are returned to neutral, the relief valves return to the standard pressure setting at 2450–2500 PSI (16896–17241 kPa).

The three spool hydraulic valve uses a single stage relief valve with a constant pressure setting of 2450–2500 PSI (16896–17241 kPa).

The hydraulic pump has three (3) diagnostic couplers (Item 1) for checking each pump section’s hydraulic pressure [A].

The following tools will be needed for the diagnostic coupler check: MEL–1355 – Test Kit MEL–1355–3 – 5000 PSI Gauge MEL–1355–12 – Coupler MEL–1355–4 – Hose Connect the coupler and the gauge to the hose.

–2–1–

331 Hydraulic Excavator (S/N 20001) Service Manual

MAIN RELIEF VALVE (Cont’d)

A

Checking the Dual Pressure Relief Valves at Diagnostic Couplers Remove the floormat, the floorboards and the rear floorcover (See Pages 4–3).

To check the high pressure setting on the dual pressure relief valves, the four (4) hoses that go to the left and right hand travel sections must be removed [A]. Mark the hoses for ease of assembly.

NOTE: For safety purposes, when doing any testing and/or adjusting of the dual pressure relief valves, make sure that the four (4) travel section hoses are removed from the valve. Plug the hoses and cap the tee fittings with steel caps. This will prevent the excavator from accidently being moved during the pressure tests.

PI–13212

Install steel caps onto the tees and plug the hoses [B].

B

NOTE: Make sure the swing locking lever is in the engaged (locked) position.

With the engine off, connect the gauge assembly onto the diagnostic coupler on the pump [C].

NOTE: Pump Section 1 (closest to the engine) supplies fluid to the right hand side (P1 inlet port) of the 6–spool valve.

Pump Section 2 (middle section) supplies fluid to the left hand side (P2 inlet port) of the 6–spool valve.

Pump Section 3 (outer section) supplies fluid to the (P1 inlet port) 3–spool valve.

Steel Caps

Start the engine.

Run the engine at high idle and warm the hydraulic fluid to 140°F (60 °C).

PI–13213

For Pump Section 1 (closest to the engine): Raise the boom. Curl the bucket until the bucket cylinder is fully extended and continue to apply hydraulic pressure until the relief valve opens. Record the pressure gauge reading. Repeat this five (5) times to get the average pressure reading (this is the right hand side, low pressure setting of the dual pressure relief valve).

C

Low pressure setting: 2450–2500 PSI (16896–17241 kPa) Move the RIGHT HAND travel lever forward and hold in the forward position until the relief valve opens. Record the pressure gauge reading. Repeat this five (5) times to get the average pressure reading (this is the right hand side, high pressure setting of the dual pressure relief valve).

High Pressure Setting: 2950–3000 PSI (20344–20689 kPa) Stop the engine.

For Pump Section 2 (center pump section) P–03226

Move the coupler/pressure gauge assembly onto the diagnostic coupler at the center pump section (Item 2) [D].

D

Start the engine.

Raise the boom. Move the arm towards the excavator until the arm cylinder is fully extended and the relief valve opens. Record the pressure gauge reading. Repeat this five (5) times to get the average pressure reading (this is the left hand side, low pressure setting, of the dual pressure relief valve).

Low Pressure Setting: 2450–2500 PSI (16896–17241 kPa) Lower the boom to the ground.

Move the LEFT HAND travel lever forward and hold in the forward position until the pressure relief valve opens. Record the pressure gauge reading. Repeat this five (5) times to get the average pressure reading (this is the left hand side, high pressure setting, of the dual pressure relief valve).

P–03222

High Pressure Setting: 2950–3000 PSI (20344–20689 kPa).

–2–2–

331 Hydraulic Excavator (S/N 20001) Service Manual

MAIN RELIEF VALVES (Cont’d)

A

Check the Single Pressure Relief Valve (3 Spool Valve) For Pump Section 3 (farthest from engine).

Move the coupler/pressure gauge assembly onto the diagnostic coupler at the end of the pump (farthest from the engine) [A].

Start the engine.

Raise the blade up until the blade cylinder is fully retracted and the relief valve opens. Record the pressure gauge reading. Repeat this five (5) times to get the average pressure reading.

P–03225

Pressure Setting: 2450–2500 PSI (16896–17241 kPa) Lower the blade to the ground.

Stop the engine.

For Relief Valve Adjustment procedure (See Pages 2–4 & 2–5).

–2–3–

331 Hydraulic Excavator (S/N 20001) Service Manual

MAIN RELIEF VALVES (Cont’d)

A

6 Spool Dual Pressure Relief Valve Adjustment Procedure: Remove the tube(s) from the relief valve(s) [A].

Plug the tube(s).

NOTE: Adjust the high pressure relief valve(s) first (if needed) and then adjust the low pressure relief valve(s).

High Pressure Adjustment Procedure (6 Spool Only): Remove the outer portion of the relief valve body and the spring [B].

NOTE: Make sure that no shims are stuck to the end of the spring when it is removed from the relief valve. If shims are attached, remove them and install them back onto the relief valve poppet.

PI–13202

B

Add shims to increase the pressure or remove shims to decrease the pressure setting from the relief valve poppet [C].

Spring Outer Body

The following list is the approximate pressure change per shim thickness: B–13843

Shim .010” (0,25 mm) thick (896265) = 75 PSI (517 kPa) Shim .020” (0,50 mm) thick (896264) = 200 PSI (1379 kPa) Shim .040” (1,01 mm) thick (896263) = 300 PSI (2069 kPa) Check the outer relief body O–ring for damage, replace the O–ring (79K–10) if necessary.

Install the spring and outer portion of the relief valve [D].

PI–13214

Tighten the outer portion of the relief valve to 20 ft.–lbs.

(27 Nm) torque.

C

DO NOT overtighten.

Install the tubes onto the adapters.

Poppet Shims

Install the coupler/pressure gauges onto the pump section closest to the engine for checking the right hand relief valve and onto the center pump section for checking the left hand relief valve (See Page 2–2).

Start the engine and warm the hydraulic fluid to 140°F (60°C).

B–13844

With the engine running at high idle, retest the high pressure relief settings by pushing the right hand or the left hand travel levers forward and record the pressure gauge readings when the relief valves open. Repeat the check five (5) times to get the average relief valve pressure settings.

PI–13215

If the settings are correct (2950–3000 PSI [20344–20689 kPa]), the low pressure settings of the relief valve can now be set. If the pressure settings are not correct, repeat the steps needed to add or remove shims as necessary until pressure settings are correct.

D

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

I–2003–0888

PI–13214

–2–4–

331 Hydraulic Excavator (S/N 20001) Service Manual

MAIN RELIEF VALVES (Cont’d)

A

6 Spool Dual Pressure Relief Valve Adjustment Procedure (Cont’d) Low Pressure Adjustment Procedure (6 Spool Only): NOTE: Make sure the high pressure setting(s) are correct before adjusting the low pressure setting(s).

NOTE: If high pressure adjustment was done prior to adjusting low pressure setting, retest pressure setting and then adjust the relief valves.

Remove the tube(s) from the relief valve adapter(s) [A].

Plug the tube(s).

PI–13202

Install the coupler/pressure gauge onto the pump section (Item 1) closest to the engine for checking the right hand relief valve and/or the center (Item 2) pump section for checking the left hand relief valve [B].

B

Start the engine and warm the hydraulic fluid to 140°F (60°C).

Raise the boom.

Run the engine at high idle.

If testing the right hand relief valve, curl the bucket and extend the cylinder until the low pressure relief valve opens and record the pressure reading. Repeat this five (5) times to get the average pressure reading.

P–03226

If testing the left hand relief valve, extend the arm cylinder until the low pressure relief valve opens and record the pressure reading. Repeat this five (5) times to get the average pressure reading.

C

Lower the boom to the ground.

Stop the engine.

If relief valve adjustment is required, loosen the relief valve jam nut [C].

Turn the adjusting screw clockwise to increase the pressure or turn the adjusting screw counterclockwise to decrease the pressure [D].

NOTE: Turning the adjusting screw one (1) turn (360° will change the pressure setting approximately 700 PSI (4827 kPa).

PI–13216

Readjust and retest the low pressure relief valves until pressure settings are correct 2450–2500 PSI (16896–17241 kPa).

D

Tighten the jam nut while holding the adjusting screw from turning [C].

Install the tube(s) [A].

Install the four (4) hoses onto the control valve.

After all the relief valves have been tested and/or adjusted, install the rear floor cover, the rear floorboards and the floormat.

Check the hydraulic fluid reservoir and add fluid as necessary (See Page 1–8 for the correct procedure).

PI–13217

–2–5–

331 Hydraulic Excavator (S/N 20001) Service Manual

MAIN RELIEF VALVES (Cont’d)

A

3 Spool Single Pressure Relief Valve Adjustment Procedure To adjust the 3 spool valve, main relief valve, loosen the relief valve plug (Item 1) [A] & [B].

PI–12308

B

Remove the plug (Item 1) and the spring (Item 2) [B].

Make sure no shims are stuck to the end of the spring.

Add shims (Item 3) to increase pressure or remove shims (Item 3) to decrease the pressure setting [B].

3 2

The following list is the approximate pressure change per shim thickness:

1

Shim .010” (0,25 mm) thick (896265) = 75 PSI (517 kPa) Shim .020” (0,50 mm) thick (896264) = 200 PSI (1379 kPa) Shim .040” (1,01 mm) thick (896263) = 300 PSI (2069 kPa)

PI–13273

Check the outer relief body O–ring for damage, replace the O–ring (79K–10) if necessary.

Reinstall the plug. Retest the relief valves to make sure that the pressure settings are correct 2450–2500 PSI (16896–17241 kPa).

After all the relief valves have been tested and/or adjusted, install the rear floor cover, the floorboards and the floormat.

Check the hydraulic fluid reservoir and add fluid as necessary (See Page 1–8 for the correct procedure).

–2–6–

331 Hydraulic Excavator (S/N 20001) Service Manual

HYDRAULIC PUMP

A

Checking the Hydraulic Pump The hydraulic pump flow should be 9.1 GPM (34.5 L/min.) on a new pump at 2500 RPM. The following tools will be needed for the hydraulic pump test: MEL–10003–Hydraulic Tester Stop the engine.

Raise the engine cover [A].

Remove the outlet hose from the hydraulic pump section being tested [B].

P–02885

Connect the hose removed from the pump to the outlet of the tester [B].

B

Connect the inlet hose of the tester to the pump outlet fitting [B].

NOTE: The tester connections will be the same for each pump section.

NOTE: Open the flow control knob (Item 1) fully to prevent pump damage [C].

Start the engine and run at low RPM. Make sure the tester is connected correctly. If no flow is indicated at the tester, the hoses are connected wrong.

Increase the engine speed to full RPM. Warm the hydraulic fluid to 140°F (60°C) by turning the restrictor valve until the gauge reads about 1000 PSI (6895 kPa).

Do not exceed system pressure.

P–02956

C

After the temperature is correct, open the restrictor valve fully.

Record the pump free flow GPM (L/min).

NOTE: The flow should be 9.1 GPM (34,5 L/min.) at 2500 RPM on a new pump, with the flow restrictor open fully.

Close the flow control knob (Item 1) slowly to 100 PSI below the relief valve setting 2450–2500 PSI (16896–17241 kPa).

1

Record the pump high pressure flow GPM (L/min).

P–03228

NOTE: The high pressure flow must be at lease 80% of free flow.

HIGH PRESSURE FLOW (GPM) X 100 FREE FLOW (GPM) If the high pressure flow is less than 80% of free flow, remove the hydraulic pump for repair or replacement. %

Repeat the testing procedure for each pump section.

–2–7–

331 Hydraulic Excavator (S/N 20001) Service Manual

HYDRAULIC PUMP (Cont’d)

A

Removal and Installation

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

P–03141

I–2003–0888

B

NOTE: Mark the hoses for ease of assembly.

1

Drain the hydraulic fluid (See Page 1–9).

Remove the left hand side cover (See Page 4–6).

Remove the two (2) inlet hose clamps [A].

Remove the two (2) inlet hoses from the pump.

Remove the inner fitting (Item 1) from the pump [B].

P–03142

Remove the three (3) pressure hoses from the pump [C].

C

P–02956

Remove the inner diagnostic coupler (Item 1), the adapter (Item 2) and the tee (Item 3) from the pump [D].

D

1 2 3

P–03143

–2–8–

331 Hydraulic Excavator (S/N 20001) Service Manual

HYDRAULIC PUMP (Cont’d)

A

Removal and Installation (Cont’d)

1

Remove the two bolts (Item 1) [A] holding the pump to the housing.

1

P–03146

B

Slide the pump away from the engine and remove [B].

P–03151

Parts Identification TRIPLE GEAR PUMP 1.

2.

3.

4.

5.

6.

7.

8.

End Cover Shaft Seal Seals Bearings Housing Gears Plate Housing

1 3

2

4 3 5

3

3

4

6

3 4 5

3

3 7

6 4 3

4

3

3 7 8

3 6 4 3

1 B–013917

–2–9–

331 Hydraulic Excavator (S/N 20001) Service Manual

HYDRAULIC PUMP (Cont’d)

A

Disassembly

1

6

4

2

5

3

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

7

CD–00190

I–2003–0888

B

Using a center punch, mark both sides of each separation point (Items 1–6) on the inlet side of the pump, as shown, with the corresponding separation point number [A].

Tape the shaft splines (Item 7) [A] to ensure that the splines will not damage the oil seal when the shaft is removed [A].

No Inlet Port–Section 3

Put the pump, mounting flange down, in a protective jaw vise. Remove the four assembly bolts [B].

NOTE: The pump has only two inlet ports. The pump section without the inlet port is located in section 3 (end cap section).

CD–00193

Remove the end cap (or separating plate) and two dowel pins (Item 1) [C].

C 1

CD–00194

Remove the gear housing and two dowel pins (Item 1) [D].

D

Remove the O–ring from each side of the housing.

NOTE: Early pumps used four dowel pins (two on each side of the separating plate). Later pumps use two dowel pins that extend through the separating plate and into the gear housing on either side of the separating plate.

Remove the O–ring from each end of the gear housing.

1

Revised June 98

–2–10–

CD–00195

331 Hydraulic Excavator (S/N 20001) Service Manual

HYDRAULIC PUMP (Cont’d)

A

Disassembly (Cont’d)

Back–Up Ring (White) E–Seal (Black)

Remove the upper bearing [A].

Remove the back–up ring and E–seal from the bearing.

CD–00196

B

Remove the drive and idler gears [B].

CD–00197

C

Remove the lower bearing [C].

Remove the back–up ring and E–seal from the bearing.

CD–00198

D

Remove the coupling [D].

Repeat Page 2–10, step [C] through Page 2–11), step [D] to disassemble each of the remaining pump sections.

Keep the parts from each section separate from other sections.

NOTE: The gear housing, two (2) bearings, drive gear and idler gear in each pump section are not serviced separately. These parts are matched sets which are run in at the factory.

If any part is damaged, the entire section must be replaced.

CD–00199

–2–11–

331 Hydraulic Excavator (S/N 20001) Service Manual

HYDRAULIC PUMP (Cont’d)

A

Disassembly (Cont’d) Remove the retaining ring (Item 1) from the mounting flange. Using a seal puller, remove the oil seal [A].

Use the correct size driver and install a new oil seal (seal lips to inside of pump) into the mounting flange. Install the retaining ring (Item 1) [A].

1

Apply a light coating of grease to the seal lips.

Assembly All parts must be clean before assembly. Clean all parts in clean solvent. Use air pressure to dry.

CD–00209

Apply a light coating of grease in the E–seal groove of each bearing. Install a new E–seal (Item 1) stepped side up, into each E–seal groove. Push each E–seal down into the groove [B].

B 2

Apply a light coating of grease to each back–up ring (Item 2). Install the back–up ring into the groove made by the E–seal and bearing. Push the back–up ring down flush with the E–seal [B].

3

NOTE: There is a notch (Items 3 & 4) in the center of the back–up ring and E–seal. When installing the back–up ring, make sure that these notches are aligned. If the back–up ring or E–seal is not installed correctly the back–up ring will not sit flush with the E–seal [B].

4 1 CD–00192

Put the mounting flange, oil seal side down, in a protected jaw vise [C].

C

Install two (2) dowel pins (Item 1) into the mounting flange (or separating plate) [C].

Install the lower bearing, seal side down, on the mounting flange (or separating plate). The open side of the E–seal must point toward the inlet port side (marked side) of the pump [C].

The open side of the E–Seal must face the inlet ports on the housing.

1 1

CD–00201

D

Tape the splined end (Item 1) of the drive gear to ensure that the splines will not damage the oil seal during installation [D].

Apply oil to the drive gear and idler gear and to the side faces of the gears. Install the gears into the lower bearing [D].

1

CD–00202

–2–12–

331 Hydraulic Excavator (S/N 20001) Service Manual

HYDRAULIC PUMP (Cont’d)

A

Assembly (Cont’d) Install the upper bearing, seal side up, on the drive and idler gears. The open side of the E–seal must point toward the inlet port side (marked side) of the pump [A].

The open end of the E–seal must face the inlet ports on the housing.

CD–00203

B

Apply a light coating of grease to the O–rings and install a new O–ring on each end of the gear housing.

The bearing must be slightly lower O–ring than the housing face.

Align the marks made during disassembly on the gear housing and mounting flange (or separating plate).

Carefully install the gear housing over the bearings and gears [B].

1

1

NOTE: The upper bearing must be slightly lower than the gear housing. If the bearing is higher than the housing, disassemble the pump section to verify that the E–seal, back–up ring, or O–ring have not moved out of position.

Install two (2) dowel pins (Item 1) into the gear housing [B].

CD–00204

C

Apply oil to the coupling. Install the coupling into the drive gear [C].

CD–00205

D

Align the marks made during disassembly on the separating plate and gear housing. Install the separating plate [D].

CD–00206

–2–13–

331 Hydraulic Excavator (S/N 20001) Service Manual

HYDRAULIC PUMP (Cont’d)

A

Assembly (Cont’d)

Inlet Passage

3

Repeat Page 2–12 step [B] through Page 2–13 step [D] to assemble pump section 2.

Repeat Page 2–12 step [B] through Page 2–13 step [B] to assemble pump section 3.

1

NOTE: When installing pump sections 2 and 3, make sure that the inlet passage is aligned from the section 2 gear housing (Item 2) through the separating plate (Item 1) to the section 3 gear housing (Item 3). Section 3 has no external inlet port and must receive oil flow from the section 2 inlet port [A].

Inlet Passage

2 CD–00208

Align the marks made during disassembly on the end cap and gear housing. Install the end cap [B].

B

CD–00194

C

Install the four (4) assembly bolts [C].

Evenly tighten the bolts to a final torque of 50–55 ft.–lbs.

(68–75 Nm).

Rotate the inlet shaft periodically while tightening the bolts to make sure the pump is assembled correctly.

Using a locking plier, rotate the pump shaft to be sure there is no binding.

CD–00221

–2–14–

331 Hydraulic Excavator (S/N 20001) Service Manual

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