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Bobcat 430 Compact Excavator Repair Service Manual - 6986955


(S/N: AA8711001 & Above - S/N: AA8811001 & Above - S/N: AACF11001 & Above - S/N: AACG11001 & Above)
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This service manual PDF download for the 430 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 Compact Excavator 430
S/N: AA8711001 & Above
S/N: AA8811001 & Above
S/N: AACF11001 & Above
S/N: AACG11001 & Above


TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT EXCAVATOR IDENTIFICATION
SAFETY & MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
UNDERCARRIAGE
UPPERSTRUCTURE & SWING SECTION
ELECTRICAL SYSTEM & 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 : 6986955 (9-09)
Total Pages : 1168


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
BOBCAT EXCAVATOR IDENTIFICATION
SAFETY & 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
TRANSPORTING THE EXCAVATOR ON A TRAILER
Loading And Unloading
Fastening
TAILGATE
Opening And Closing The Tailgate
Adjusting The Latch
RIGHT SIDE COVER
Opening And Closing The Right Side Cover
SERVICE SCHEDULE
Chart
AIR CLEANER
Daily Check
Replacing The Elements
HEATER AIR FILTER (WITH CAB OPTION ONLY)
Removal And Installation
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking Coolant Level
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Removing Water
Replacing Element
Draining The Fuel Tank
Inline Fuel Filter
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
Hydraulic Fluid Chart
Removing And Replacing The Hydraulic Fluid
Removing And Replacing The Hydraulic Filter
Removing And Replacing The Case Drain Filter
Removing And Replacing The Fan Filter
Diagnostic Couplers
LUBRICATNG THE EXCAVATOR
Lubrication Locations
TRAVEL MOTOR
Checking And Adding Oil
Removing And Replacing Oil
SPARK ARRESTOR MUFFLER
Cleaning Procedure
ALTERNATOR BELT
Belt Tension
Belt Adjustment
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
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
EXTENDIBLE ARM CYLINDER
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVES
Testing And Adjusting The Main Relief Valves (S/N AACF11001 & Above And AA8711001 & Above)
System Pressures At Gauge Port Specifications
Testing And Adjusting The Main Relief Valves (S/N AACG11001 & Above And AA8811001 & Above)
System Pressures At Gauge Port Specifications
PORT RELIEF VALVES
Testing And Adjusting Port Relief Valve Pressure
CROSSPORT RELIEF VALVES
Testing And Adjusting The Crossport Relief Valves (S/N AACF11001 & Above And AA8711001 & Above)
Testing And Adjusting The Crossport Relief Valves (S/N AACG11001 & Above And AA8811001 & Above)
PRESSURE REDUCING VALVE
Description
ANGLE BLADE VALVE
Description
Testing And Adjusting Port Relief Valves
Testing And Adjusting Sequence Valve
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC CONTROL VALVE (S/N AACF11001 & Above And AA8711001 & Above)
Description
Removal And Installation
Parts Identification
Disassembly
Right Travel Valve Section Disassembly And Assembly
Left Travel Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
Auxiliary 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
Inlet Section Disassembly And Assembly
Assembly
HYDRAULIC CONTROL VALVE (S/N AACG11001 & Above And AA8811001 & Above)
Description
Removal And Installation
Parts Identification
Disassembly
Blade Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
Auxiliary 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
Inlet Section Disassembly And Assembly
Assembly
HYDRAULIC PUMP
Description
Torque Adjustment
Testing The Piston Pump
Testing The Gear Pump
Testing Auxiliary Flow
Removal And Installation
Coupler Removal And Installation
Hydraulic Pump Start Up
Gear Pump Parts Identification
Piston Pump Parts Identification
Disassembly
Gear Pump Disassembly
Gear Pump Assembly
Piston Pump Disassembly
Piston Pump Assembly
Assembly
MANIFOLD ASSEMBLY/ACCUMULATOR (S/N AACG11001 & Above And AA8811001 & Above)
Description
Testing Pilot Pressure
Removal And Installation
Parts Identification
Disassembly
Assembly
MANIFOLD ASSEMBLY/ACCUMULATOR (S/N AACF11001 & Above And AA8711001 & Above)
Description
Testing Pilot Pressure
Removal And Installation
Parts Identification
Disassembly
Assembly
TRAVEL MOTOR (S/N AACG11001 & Above And AA8811001)
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
TRAVEL MOTOR (S/N AACF11001 & Above And AA8711001 & Above)
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
SWIVEL JOINT
Removal And Installation
Parts Identification
Description
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
Joystick Assembly Removal And Installation
Parts Identification
Disassembly
Assembly
LEFT CONTROL LEVER (JOYSTICK)
Description
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly
Assembly
TRAVEL CONTROL VALVE (S/N AACG11001 & ABOVE AND AA8811001 & ABOVE)
Removal and Installation
Parts Identification
Disassembly And Assembly
TRAVEL CONTROL VALVE (S/N AACF11001 & ABOVE AND AA8711001 & Above)
Removal and Installation
Parts Identification
Disassembly And Assembly
HOSES
Hose Guide Location
Left Control Lever (Joystick) (S/N AACF11001 & Above AND AA8711001 & Above)
Left Control Lever (Joystick) (S/N AACG11001 AND AA8811001 & Above)
Right Control Lever (Joystick) (S/N AACF11001 And Above AA8711001 & Above)
Right Control Lever (Joystick) (S/N AACG11001 & Above And AA8811001 & Above)
Travel Control Valve (S/N AACF11001 & Above And AA8711001 & Above)
Travel Control Valve (S/N AACG11001 & Above And AA8811001 & Above)
Manifold Assembly / Accumulator (S/N AACF11001 & Above And AA8711001 & Above)
Manifold Assembly / Accumulator (S/N AACG11001 & Above And AA8811001 & Above)
HYDRAULIC FILTER
Description
Housing Removal And Installation
CASE DRAIN FILTER
Removal And Installation
HYDRAULIC RESERVOIR
Description
Removal And Installation
OIL COOLER
Description
Removal And Installation
DIRECT TO TANK VALVE (IF EQUIPPED)
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
BUILD UP VALVE
COOLING FAN
Description
Testing
Removal And Installation
Parts Identification
Disassembly And Assembly
BOOM SWING LOCK VALVE
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC X-CHANGE VALVE
Removal And Installation
Parts Identification
Disassembly
Assembly
SLEW LOCK VALVE
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Relief/Replenishing Valve Function
Relief/Replenishing Valve Location
Relief/Replenishing Valve Removal And Installation
Charge Pressure Relief Valve Location
Charge Pressure Relief Valve Removal And Installation
TRAVEL PILOT PRESSURE
Description
Testing
HYDROSTATIC PUMP
Removal And Installation
Parts Identification (Front) (S/N AACG11001 & Above And AA8811001 & Above)
Disassembly
Inspection
Assembly
Hydrostatic Pump Start-Up
Mechanical Neutral Adjustment
DRIVE BELT SHIELD
Removal And Installation
DRIVE BELT
Adjustment
Removal And Installation
UNDERCARRIAGE
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 (S/N AACF11246 & Below, AACG11102 & Below, AA8711102 & Below And AA8811101 & Below)
Coil Spring Cylinder Parts Identification (S/N AACF11247 & Above, AACG11103 & Above, AA8711103 & Above And AA8811102 & Above)
Coil Spring Cylinder Disassembly And Assembly (S/ N AACF11247 & Above, AACG11103 & Above, AA8711103 & Above And AA8811102 & Above)
Roller Removal And Installation
Roller Parts Identification
Roller Disassembly
Roller Assembly
Track Damage Identification
Abrasion Of Embedded Metals
SWING CIRCLE GEAR
Swing Bearing Removal
Swing Bearing 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
Glass Installation (Cont’d)
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
LEFT CONSOLE
Description
Joystick Console Cover (Bottom) Removal And Installation
Joystick Console Cover (Top) 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 Rear Console Cover Removal And Installation
Left Rear Console Frame Removal And Installation
BLADE CONTROL
Removal And Installation
Linkage Removal And Installation
Linkage Disassembly And Assembly
Control Cable Removal And Installation
UPPERSTRUCTURE SLEW LOCK
Removal And Installation
Disassembly And Assembly
FLOOR MAT AND FLOOR PLATES
Description
Removal And Installation
BOOM SWING PEDAL
Description
Pedal Removal And Installation
Pedal Disassembly And Assembly
Control Cable Removal And Installation
TRAVEL LEVERS/PEDALS
Description
Adjustment
Removal And Installation
Disassembly And Assembly
Control Linkage Assembly Removal And Installation
FUEL TANK
Removal And Installation
HORN
Removal And Installation
SWING FRAME
Description
Removal And Installation
Hose Routing
Bushing Removal
Bushing Installation
BOOM
Description
Removal And Installation
ARM
Description
Removal And Installation
Arm To Boom Bushing Removal And Installation
Arm To Bucket And Bucket Link Bushing Removal And Installation
BUCKET
Removal And Installation (Pin-On X-Change)
Removal And Installation (Bolt-On X-Change)
Removal And Installation (Pin-On Attachment)
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
X-CHANGE™
Removal And Installation
Parts Identification
Disassembly
Assembly
Check Proper Latch Engagement
X-CHANGE (HYDRAULIC)
Removal And Installation
Parts Identification
Disassembly
Assembly
RIGHT SIDE COVER
Removal And Installation
COUNTERWEIGHT
Removal And Installation
ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuse And Relay Location
BATTERY
Removing And Installing The Battery
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR
Belt Adjustment
Belt Replacement
Charging System Inspection
Alternator Description
High Voltage Test
Rectifier Continuity (Diode) Test
Alternator Voltage Test
Low Voltage Test
Alternator Regulator Test
Parts Identification
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Assembly
Removal And Installation
STARTER
Testing
Removal And Installation
Parts Identification
Disassembly
Inspection And Repair
Assembly
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
Console Switch Removal And Installation
FUEL LEVEL SENDER
Removal And Installation
Testing
DIAGNOSTICS SERVICE CODES
Description
Number 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
TWO SPEED SWITCH
Removal And Installation
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
Torque Values
Troubleshooting Chart
Removal And Installation
Compression Checking
ENGINE SPEED CONTROL
Removal And Installation
Disassembly And Assembly
Adjustment (S/N AA8711001 & Above And AA8811001 & Above)
SPARK ARRESTOR MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
ENGINE COOLING SYSTEM
Radiator Removal And Installation
Testing The Thermostat
Thermostat Housing Removal And Installation
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
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 Shut-off 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)
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
Connecting Rod Alignment
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings Servicing
Cylinder Bore, Checking
CRANKSHAFT 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
ENGINE FLYWHEEL
Hydraulic Pump Coupler Removal And Installation
Flywheel Removal And Installation
Flywheel Ring Gear
HEATING, VENTILATION, AIR CONDITIONING
HEATER SYSTEM
Description
Components
REGULAR MAINTENANCE
Filter Element Removal And Installation
Engine Accessory Drive Belt
Cleaning The Condenser
Cleaning The A/C Evaporator Coil & Heater Coil
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operators Normally, But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Does Not Operate At All, Or Operates Improperly
Gauge Pressure Related Troubleshooting
Electrical System
Engine Coolant By-Passing The Heater Valve
Poor A/C Performance
EVAPORATOR/HEATER UNIT
Removal And Installation
Disassembly And Assembly
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 SERVICE
Safety Equipment
Chart
Reclamation Procedure
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
Temperature/Pressure Chart
Charging Procedure With A Manifold Gauge Set
COMPRESSOR
Removal And Installation
Compressor Clutch Disassembly And Assembly
CONDENSER
Removal And Installation
RECEIVER/DRIER
Removal And Installation
PRESSURE RELIEF VALVE
Removal And Installation
PRESSURE SWITCH
Removal And Installation
THERMOSTAT
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR
Removal And Installation
SPECIFICATIONS
EXCAVATOR SPECIFICATIONS
Excavator Dimensions With Standard Arm, Long Arm Option and Extendable Arm Kit
Excavator Standard Arm Machine Dimensions
Excavator Long Arm Machine Dimensions
Excavator Extendable Arm Machine Dimensions
Excavator With Optional Angle Blade Dimensions
Performance - Conventional (S/N AACF11001 & Above And AA8711001 & Above)
Performance - FastTrack (S/N AACG11001 & Above And AA8811001 & Above)
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Electrical
Undercarriage
Capacities
Fuel Tank
Tracks
Type
Drive System- Conventional (S/N AACF11001 & Above, AA8711001 & Above)
Drive System - FastTrack (S/N AACG11001 & Above, AA8811001 & Above)
Slew System
Ground Pressure - Conventional
Ground Pressure - FastTrack
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
O-Ring 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: 430 - 1
Revision No: 430 - 2
Revision No: 430 - 3

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