Bobcat 335 Compact Excavator Repair Service Manual - 6986949

(S/N: AAD111001 & Above - S/N: A9KA11001 & Above) 
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This workshop repair service manual PDF download for the 335 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 335 
S/N: AAD111001 & Above
S/N: A9KA11001 & 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
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6986949 (5-10)
Total Pages : 952


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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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
        Biodiesel Blend Fuel
        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
    MOTION ALARM SYSTEM (IF EQUIPPED)
        Description
        Inspecting
        Adjusting Switch Position
        
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
    CLAMP CYLINDER
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    ANGLE BLADE 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
        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
    SLEW LOCK VALVE
        Description
        Removal And Installation
        Parts Identification
        Disassembly And 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 (S/N A9KA11100 & Below And AAD114409 & Below)
        Recoil Spring Cylinder Parts Identification (S/N A9KA11101 & Above And AAD114410 & Above)
        Recoil Spring Assembly And Cylinder Disassembly And Assembly (S/N A9KA11101 & Above And AAD114410 & Above)
        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
    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
    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
    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
        Boom Light Bulb Replacement
    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
    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
    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
        Flywheel Ring Gear
    FAN
        Removal And Installation
        
HEATING, VENTILATION, AIR CONDITIONING
    HEATER COIL
        Removal And Installation With A/C
        Removal And Installation Without A/C
    BLOWER FAN
        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
        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
        Removal And Installation
        Disassembly And Assembly
    THERMOSTAT
        Removal And Installation
    EXPANSION VALVE
        Removal And Installation
    EVAPORATOR
        Removal And Installation
        
SPECIFICATIONS
    335 Excavator SPECIFICATIONS
        Dimensions
        Excavator With Optional Angle Blade Dimensions
        Performance
        Controls
        Engine
        Hydraulic System
        Hydraulic Cylinders
        Hydraulic Cycle Times
        Electrical
        Drive System
        Slew System
        Undercarriage
        Capacities
        Tracks
        Ground Pressure
    ENGINE SPECIFICATIONS
        Fuel Injection Nozzles
        Fuel Injection Pump
        Cylinder Head
        Valves
        Valve Springs
        Valve Timing
        Rocker Arms
        Camshaft
        Tappet
        Cylinders
        Piston Rings
        Pistons
        Connecting Rods
        Oil Pump
        Crankshaft
        Timing Gear
        Thermostat
        Engine Bolt Torque
        Crankshaft Re-Grind Data
    TORQUE SPECIFICATIONS
        Torque For General SAE Bolts
        Torque For General Metric Bolts
    HYDRAULIC CONNECTION SPECIFICATIONS
        O-Ring Face Seal Connection
        Straight Thread O-Ring Fitting
        Tubelines And Hoses
        Flare Fitting
        Port Seal Fitting
    HYDRAULIC FLUID SPECIFICATIONS
        Specifications
    FUEL, COOLANT AND LUBRICANTS
        Chart
    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
    
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