Bobcat 335 Compact Excavator Service Manual – 6904775

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(S/N: A16U11001 & Above)

This service manual PDF download for the Bobcat 335 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 335 Excavator
S/N: A16U11001 & Above

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6904775 (10-09)
Total Pages : 1014

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
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Excavator Serial Number
Engine Serial Number
DELIVERY REPORT
EXCAVATOR IDENTIFICATION
SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
UPPERSTRUCTURE SLEW LOCK
Operation
LIFTING THE EXCAVATOR
Procedure
OPERATOR CAB (ROPS / TOPS)
Description
Cab Door
Front Window
Front Wiper
Window Washer Reservoir
Right Side Window
Heating, Ventilation And Air Conditioning Duct
Heating, Ventilation And Air Conditioning Duct (Cont’d)
TRANSPORTING THE EXCAVATOR ON A TRAILER
Loading And Unloading
Fastening
TAILGATE
Opening And Closing
Adjusting The Bumper
Adjusting The Latch
RIGHT SIDE COVER
Opening And Closing
Adjusting The Bumper
Adjusting The Latch
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Daily Check
Replacing Filter Elements
HEATER AIR FILTER (WITH CAB OPTION ONLY)
Removal And Installation
ENGINE COOLING SYSTEM
Cleaning
Checking Level
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
Draining The Fuel Tank
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC SYSTEM
Checking And Adding Fluid
Removing And Replacing Hydraulic Filter
Removing And Replacing Hydraulic Case Drain Filter
Removing And Replacing Hydraulic Fluid.
LUBRICATING THE EXCAVATOR
Lubrication Locations
TRAVEL MOTOR
Checking And Adding Oil
Removing And Replacing Oil
SPARK ARRESTOR MUFFLER
Cleaning Procedure
ACCESSORY DRIVE BELT
Belt Adjustment
Belt Replacement
SEAT BELT
Inspection And Maintenance
PIVOT PINS
Inspection And Maintenance
EXCAVATOR STORAGE AND RETURN TO SERVICE
Storage
Return to Service
STOPPING THE ENGINE AND LEAVING THE EXCAVATOR
Procedure
Emergency Exits
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 (Upperstructure Slew) Circuit
Troubleshooting The Travel Circuit
BOOM CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
ARM CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
BOOM SWING CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
BUCKET CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
BLADE CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
EXTENDIBLE ARM CYLINDER
Removal And Installation
Parts Identification
ANGLE BLADE CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CLAMP CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Testing And Adjusting The Main Relief Valve
PORT RELIEF VALVES
Testing And Adjusting The Port Relief Valve Pressure
CROSSPORT RELIEF VALVES
Testing And Adjusting The Crossport Relief Valve
PRESSURE REDUCING VALVE
Testing And Adjusting The Pressure Reducing Valve
HYDRAULIC CONTROL VALVE
Description
Removal And Installation
Identification Chart
Disassembly
Right Travel Valve Section Disassembly And Assembly
Left Travel Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Arm Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Boom Swing Valve Section Disassembly And Assembly
Auxiliary Valve Section Disassembly And Assembly
Inlet Section Disassembly And Assembly
Assembly
HYDRAULIC PUMP
Piston Pump Work Sheet
Description
Testing The Piston Pump
Test Fitting Installation
Torque Limiter Adjustment
Testing Auxiliary Hydraulic Flow
Removal And Installation
Coupler Removal And Installation
Hydraulic Pump Start Up
Parts Identification (Torque Limiter Valve)
Torque Limiter Valve Removal
Torque Limiter Valve Disassembly
Torque Limiter Valve Assembly
Initial Torque Limiter Valve Setting
Torque Limiter Valve Installation
Parts Identification (Pump Control)
Pump Control Removal And Installation
Pump Control Disassembly And Assembly
Parts Identification (Piston Pump)
Piston Pump Disassembly
Piston Pump Assembly
MANIFOLD ASSEMBLY/ ACCUMULATOR
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
TRAVEL MOTOR (S/N A16U11001 THROUGH A16U11490)
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
TRAVEL MOTOR (S/N A16U11491 & Above)
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
SWIVEL JOINT
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
SWING MOTOR
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
SWING MOTOR DRIVE CARRIER
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
CONTROL PATTERN SELECTOR VALVE
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
RIGHT CONTROL LEVER (JOYSTICK)
Description
Testing
Handle Removal And Installation
Removal And Installation
Parts Identification
Disassembly
Assembly
LEFT CONTROL LEVER (JOYSTICK)
Description
Testing
Handle Removal And Installation
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC FILTER
Description
Housing Removal And Installation
CASE DRAIN FILTER
Description
Housing Removal And Installation
HYDRAULIC RESERVOIR
Description
Removal And Installation
OIL COOLER
Description
Removal And Installation
DIRECT TO TANK VALVE
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC X-CHANGE VALVE
Removal And Installation
Parts Identification
Disassembly
Assembly
BOOM SWING LOCK VALVE
Removal And Installation
Parts Identification
Disassembly
Assembly
TRAVEL CONTROL VALVE
Removal and Installation
Parts Identification
Disassembly And Assembly
ANGLE BLADE VALVE
Description
Testing And Adjusting Port Relief Valves
Testing And Adjusting Sequence Valve
Removal And Installation
Parts Identification
Disassembly
Assembly
UNDERCARRIAGE
BLADE
Description
Blade Removal And Installation
ANGLE BLADE ASSEMBLY
Removal And Installation
ANGLE BLADE
Removal And Installation
ANGLE BLADE CUTTING EDGE
Removal And Installation
TRACK FRAME COMPONENTS
Description
Track Lug Height
Checking Tension
Adjusting Tension
Rubber Track Removal And Installation
Steel Track Removal And Installation
Idler (Front) Removal And Installation
Idler (Front) Parts Identification
Idler (Front) Disassembly
Idler (Front) Assembly
Recoil Spring Assembly And Cylinder Removal And Installation
Recoil Spring Assembly And Cylinder Disassembly And Assembly (Without Replaceable Shaft)
Recoil Spring Cylinder Parts Identification (With Replaceable Shaft)
Recoil Spring Assembly And Cylinder Disassembly And Assembly (With Replaceable Shaft)
Roller Removal And Installation
Upper Roller Parts Identification
Upper Roller Disassembly
Upper Roller Assembly
Lower Roller Parts Identification
Lower Roller Disassembly
Lower Roller Assembly
Track Guide Removal And Installation
Sprocket Removal And Installation
Track Damage Identification
SWING CIRCLE GEAR
Removal
Installation
UPPERSTRUCTURE & SWING SECTION
UPPERSTRUCTURE
Description
Removal
Installation
CANOPY
Removal And Installation
CAB
Removal And Installation
Door Removal And Installation
Front Window Removal And Installation
Right Side Rear Sliding Window Removal And Installation
Right Side Front Sliding Window Removal And Installation
Glass Removal
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation
Glass Installation
SEAT AND SEAT MOUNT
Seat Mount Removal And Installation
Seat Removal And Installation
RIGHT CONSOLE
Description
Console Cover Removal And Installation
Console Frame Removal And Installation
Console Frame Disassembly And Assembly
LEFT CONSOLE
Description
Joystick Console Cover (Bottom) Removal And Installation
Joystick Console Cover (Top) Removal And Installation
Left Rear Console Cover Removal And Installation
Compression Spring Removal And Installation
Compression Spring Disassembly And Assembly
Lever Removal And Installation
Joystick Console Frame Removal And Installation
Joystick Console Frame Disassembly And Assembly
Left Console Frame Removal And Installation
BLADE CONTROL
Removal And Installation
Linkage Removal And Installation
Linkage Disassembly And Assembly
UPPERSTRUCTURE SLEW LOCK
Removal And Installation
Disassembly And Assembly
Disassembly And Assembly (Cont’d)
FLOOR MAT & FLOOR PANEL
Description
Removal And Installation (Canopy Equipped)
Removal And Installation (Cab Equipped)
BOOM SWING PEDAL
Description
Removal And Installation
Disassembly And Assembly
Linkage Removal And Installation
TRAVEL LEVER/PEDALS
Description
Removal And Installation
Disassembly And Assembly
Adjustment
Linkage Removal And Installation
FUEL TANK
Removal And Installation
HORN
Removal And Installation (Early Models)
Removal And Installation (Later Models)
SWING FRAME
Description
Removal And Installation
Hose Routing
Bushing Removal And Installation
Swing Frame Bushing Removal And Installation
BOOM
Description
Removal And Installation
Boom Bushing Removal And Installation
ARM
Description
Removal And Installation
Arm To Boom Bushing Removal And Installation
Arm To Bucket & Bucket Link Bushing Removal And Installation
BUCKET
Removal And Installation (Pin-On X-Change)
Removal And Installation (Bolt-On X-Change)
Removal And Installation (Hydraulic X-Change)
Bucket Teeth Removal And Installation
Bucket Side Cutting Edge Removal And Installation
CLAMP
Removal And Installation
TAILGATE
Removal And Installation
Latch Removal And Installation
X-CHANGE
Pin-On Removal And Installation
Pin-On Disassembly and Assembly
X-CHANGE (HYDRAULIC)
Removal And Installation
Parts Identification
Disassembly
Assembly
RIGHT SIDE COVER
Removal And Installation
Latch Removal And Installation
ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Harness Connectors
Troubleshooting
Description
Fuse And Relay Locations/Identification
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR
Belt Adjustment
Charging System Inspection
Alternator Voltage Testing
Low Voltage Testing
High Voltage Testing
Removal And Installation
Parts Identification
STARTER
Testing
Removal And Installation
Part Identification
LIGHTS
Upperstructure Light Removal And Installation
Upperstructure Light Disassembly And Assembly
Boom Light Removal And Installation (Early Models)
Boom Light Disassembly And Assembly (Early Models)
Boom Light Removal And Installation (Later Models)
Boom Light Bulb Replacement (Later Models)
MAGNETIC LOCKOUT SENSOR
Testing Left Console Magnetic Lockout Sensor
Left Console Magnetic Lockout Sensor Removal And Installation
FUEL LEVEL SENDER
Removal And Installation
Testing
DIAGNOSTIC SERVICE CODES
Description
Service Codes List
DELUXE INSTRUMENT PANEL SETUP
Passwords
Password Entry (For Starting and Operating the Machine)
Changing The Owner Or Operator Password
Password Lockout Feature
Job Clock
RPM
ENGINE SERVICE
ENGINE INFORMATION
Description
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 Values
Troubleshooting
Engine Removal And Installation
Engine Mount Replacement
Compression – Checking
ENGINE SPEED CONTROL
Removal And Installation
Adjustment (Later Models)
SPARK ARRESTOR MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
ENGINE COOLING SYSTEM
Radiator Removal And Installation
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
Thermostat Housing Removal And Installation
Testing The Thermostat
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor Disassembly And Assembly
Fuel ShutOff Solenoid – Checking
Fuel Shutoff Solenoid Removal And Installation
Fuel Injection Pump Removal And Installation
Injection Pump – Timing
Fuel Injector Removal And Installation
Fuel Injector Nozzle Pressure – Checking
Nozzle Spray Condition
Valve Seat Tightness
ENGINE FLYWHEEL (LATER MODELS)
Flywheel Removal And Installation
Hydraulic Pump Coupler
Flywheel Ring Gear
CYLINDER HEAD
Glow Plug – Testing
Glow Plug Removal And Installation
Valve Clearance Adjustment
Valve Timing – Checking
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
Valve Tappets
Rocker Arm And Shaft – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore – Checking
Connecting Rod – Alignment
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings – Servicing
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash – Checking
Idler Gear And Shaft Removal And Installation
Camshaft – Servicing
Idler Gear And Shaft – Servicing
FLYWHEEL AND HOUSING
Flywheel Housing Removal And Installation
Hydraulic Pump Coupler Removal And Installation
Flywheel Removal And Installation
FAN
Removal And Installation
HEATING, VENTILATION, AIR CONDITIONING
HEATER COIL (EARLY MODELS)
Removal And Installation With A/C
Removal And Installation Without A/C
HEATER COIL (LATER MODELS)
Removal And Installation With A/C
Removal And Installation Without A/C
BLOWER FAN (EARLY MODELS)
Removal And Installation
Connector Identification
Disassembly And Assembly
BLOWER FAN (LATER MODELS)
Removal And Installation
Disassembly And Assembly
Resistor Removal And Installation
HEATER VALVE
Removal And Installation
AIR CONDITIONING SYSTEM FLOW
Principals
Chart
COMPONENTS
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Heater Air Filter
Engine Accessory Drive Belt
Cleaning The Condenser
BASIC TROUBLESHOOTING (EARLY MODELS)
Poor A/C Performance
Cleaning The A/C Evaporator Coil & Heater Coil
Engine Accessory Drive Belt Inspection
Checking The Electrical System
Engine Coolant By-Passing The Heater Valve
Heater Valve Not Opening Or Closing
BASIC TROUBLESHOOTING (LATER MODELS)
Poor A/C Performance
Cleaning The A/C Evaporator Coil & Heater Coil
Engine Accessory Drive Belt
Electrical System
Engine Coolant By-Passing The Heater Valve
Heater Valve Not Opening Or Closing
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING CHART
Blower Motor Does Not Operate
Gauge Pressure Related Troubleshooting
TEMPERATURE/PRESSURE
Chart
AIR CONDITIONING SERVICE
Chart
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Charging With A Manifold Gauge Set
COMPRESSOR
Removal And Installation
Clutch Disassembly And Assembly
CONDENSER
Removal And Installation
RECEIVER/DRIER
Receiver/Drier Removal And Installation
PRESSURE RELIEF VALVE
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR/HEATER UNIT (EARLY MODELS)
Removal And Installation
Disassembly And Assembly
EVAPORATOR/HEATER UNIT (LATER MODELS)
Removal And Installation
Disassembly And Assembly
THERMOSTAT (EARLY MODELS)
Removal And Installation
THERMOSTAT (LATER MODELS)
Removal And Installation
EXPANSION VALVE (EARLY MODELS)
Removal And Installation
EXPANSION VALVE (LATER MODELS)
Removal And Installation
EVAPORATOR COIL (EARLY MODELS)
Removal And Installation
EVAPORATOR (LATER MODELS)
Removal And Installation
SPECIFICATIONS
EXCAVATOR SPECIFICATIONS
Dimensions
Performance
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Electrical
Drive System
Slew System
Undercarriage
Capacities
Tracks
Ground Pressure
TORQUE SPECIFICATIONS FOR BOLTS
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
Port Seal Fitting
HYDRAULIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion Chart
SERVICE MANUAL REVISION
Revision No: 335 – 1
Revision No: 335 – 2
Revision No: 335 – 3
Revision No: 335 – 4
Revision No: 335 – 5
Revision No: 335 – 6

 

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Bobcat 335 Compact Excavator Service Manual – 6904775.pdf

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