Bobcat Excavators 335 6986949 Service Manual 2 08-21416B320086.pdf -Bookmark created by https://wimanual.com 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 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 HYDRAULIC SYSTEM INFORMATION Glossary Of Hydraulic 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 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 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 Coil Spring Assembly And Cylinder Removal And Installation Coil Spring Assembly And Cylinder Disassembly And Assembly 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 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 EXTENDIBLE ARM Removal And Installation Disassembly And Assembly 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 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 Removal And Installation Without A 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 Cleaning The A 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 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 Receiver PRESSURE RELIEF VALVE Removal And Installation PRESSURE SWITCH Removal And Installation EVAPORATOR 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 Instrumentation Drive System Slew System Undercarriage Crawler Track Design Capacities Fuel Tank Tracks Type 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 . 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