Complete repair service manual with Electrical Wiring Diagrams for Bobcat 430, 435 Excavators, with technical information to maintain, diagnose, and repair like professional mechanics.

Bobcat Excavators 430, 435 workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6902316 (10-10) - 430 Compact Excavator Operation & Maintenance Manual.pdf
6902318 (07-14) - 430 Service Manual.pdf
6902318 (10-09) - 430 Service Manual.pdf
6902330 (8-06) - 435 Compact Excavator Operation & Maintenance Manual.pdf
6902331 (4-08) - 435 Service Manual.pdf
6986748 (10-09) - 435 Compact Excavator Operation & Maintenance Manual.pdf
6986749 (5-10) - 435 Compact Excavator Service Manual.pdf
6986749 (7-11) - 435 Compact Excavator Service Manual.pdf
6986954 (2-08) - 430 Compact Excavator Operation & Maintenance Manual.pdf
6986955 (07-12) - 430 Compact Excavator Service Manual.pdf
6986955 (9-09) - 430 Compact Excavator Service Manual.pdf

Total Pages: 3,021 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)

TABLE OF CONTENTS
6902316 (10-10) - 430 Compact Excavator Operation & Maintenance Manual...1
  OPERATOR SAFETY WARNING...3
  CONTENTS...5
  FOREWORD...7
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...9
    REGULAR MAINTENANCE ITEMS...9
    SERIAL NUMBER LOCATIONS...11
      Excavator Serial Number...11
      Engine Serial Number...11
    DELIVERY REPORT...11
    EXCAVATOR IDENTIFICATION...12
    FEATURES, ACCESSORIES AND ATTACHMENTS...13
      Standard Items...13
      Options and Accessories...13
      Attachments...13
      Buckets Available...13
    FALLING OBJECT GUARDS (FOGS)...14
      Falling Object Guards (FOGS)...14
      Special Applications Kit...14
      Special Applications Kit Inspection And Maintenance...14
  SAFETY & TRAINING RESOURCES...15
    SAFETY INSTRUCTIONS...17
      Before Operation...17
      Safe Operation Is The Operator’s Responsibility...18
      Safe Operation Needs A Qualified Operator...18
      Avoid Silica Dust...19
    FIRE PREVENTION...19
      Maintenance...19
      Operation...19
      Electrical...19
      Hydraulic System...20
      Fueling...20
      Starting...20
      Spark Arrestor Exhaust System...20
      Welding And Grinding...20
      Fire Extinguishers...20
    MACHINE SIGNS (DECALS)...21
    PUBLICATIONS AND TRAINING RESOURCES...23
  OPERATING INSTRUCTIONS...25
    INSTRUMENTS AND CONSOLES...29
      Cab Interior Light (If Equipped)...29
      Left Console...29
      Right Console...30
      Function Icons...31
      STD/ISO Selector Valve...32
      Upperstructure Slew Lock...32
      Raising And Lowering The Console...32
      Two-Speed Travel...33
    OPERATOR CANOPY (ROPS / TOPS)...34
      Description...34
    OPERATOR CAB (ROPS / TOPS)...34
      Description...34
      Cab Door...35
      Front Window...36
      Front Wiper...37
      Window Washer Reservoir...37
      Right Side Window (Early Models)...38
      Right Side Window (Later Models)...39
      Heating, Ventilation, and Air Conditioning Duct...40
    TRAVEL CONTROLS...41
      Description...41
      Forward And Reverse...41
      Turning...41
    HYDRAULIC CONTROLS...43
      Description...43
      Standard Control Pattern...43
      ISO Control Pattern...44
      Quick Couplers...45
      Auxiliary Hydraulics...46
      Relieving Hydraulic Pressure (Excavator And Attachment)...46
      Return To Tank Valve (If Equipped)...46
    BLADE CONTROL LEVER...47
      Raising And Lowering The Blade...47
      Angling Blade...47
    BOOM SWING PEDAL...48
      Operation...48
    DAILY INSPECTION...49
      Daily Inspection And Maintenance...50
    PRE-STARTING PROCEDURE...51
      Operation & Maintenance Manual And Operator’s Handbook Locations...51
      Entering The Excavator...51
      Seat Adjustment...52
      Seat Belt Adjustment...52
      Control Console...52
    STARTING THE ENGINE...53
      Key Switch...53
      Keyless...54
      Cold Temperature Starting...55
      Warming The Hydraulic System...56
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...57
      Procedure...57
      Emergency Exits...58
    ATTACHMENTS...59
      Installing And Removing The Attachment (Hydraulic X-Change)...59
      Installing And Removing The Attachment (Pin-On X- Change)...63
      Installing And Removing The Attachment (Bolt-On X- Change)...69
      Installing And Removing The Attachment (Pin-On Attachment)...75
    OPERATING PROCEDURE...76
      Inspect The Work Area...76
      Lowering The Work Equipment (Engine STOPPED)...76
      Operating On Public Roads...76
      Horsepower Control System (S/N 562511001 & Above, 562711001 & Above and 563011001 & Above)...77
      Lifting A Load...78
      Excavating...79
      Boom Swing...81
      Backfilling...82
      Driving The Excavator...82
      Operating On Slopes...83
      Operating In Water...85
      Avoiding Track Damage...85
      Extending The Arm (Extendable Arm Option Only)...85
    TOWING THE EXCAVATOR...86
      Procedure...86
    LIFTING THE EXCAVATOR...87
      Procedure...87
    TRANSPORTING THE EXCAVATOR ON A TRAILER...88
      Loading And Unloading...88
      Fastening...88
  PREVENTIVE MAINTENANCE...89
    MAINTENANCE SAFETY...91
    SERVICE SCHEDULE...93
      Chart...93
    CONTROL CONSOLE LOCKOUTS...94
      Inspection And Maintenance...94
    SEAT BELT...95
      Inspection And Maintenance...95
    TAILGATE...96
      Opening And Closing...96
      Adjusting The Latch...96
    RIGHT SIDE COVER...97
      Opening And Closing...97
    CAB FILTERS...98
      Cleaning And Maintenance...98
    AIR CLEANER SERVICE...100
      Daily Check...100
      Replacing Filter Elements...100
    FUEL SYSTEM...102
      Fuel Specifications...102
      Filling The Fuel Tank...102
      Fuel Filters...103
      Draining The Fuel Tank...103
      Removing Air From The Fuel System...103
    ENGINE LUBRICATION SYSTEM...104
      Checking And Adding Engine Oil...104
      Engine Oil Chart...104
      Removing And Replacing Oil Filter...105
    ENGINE COOLING SYSTEM...106
      Cleaning...106
      Checking Level...107
      Removing And Replacing Coolant...108
    ELECTRICAL SYSTEM...109
      Description...109
      Fuse And Relay Location/Identification...109
      Battery Maintenance...110
      Using A Booster Battery (Jump Starting)...111
      Removing And Installing Battery...112
    HYDRAULIC SYSTEM...113
      Checking And Adding Fluid...113
      Hydraulic Fluid Chart...113
      Removing And Replacing The Hydraulic Filter...114
      Removing And Replacing The Case Drain Filter...114
      Removing And Replacing The Fan Filter...115
      Removing And Replacing The Hydraulic Fluid...116
    SPARK ARRESTOR MUFFLER...117
      Cleaning Procedure...117
    TRACK TENSION...118
      Adjusting...118
    TRAVEL MOTOR...120
      Checking And Adding Oil...120
      Removing And Replacing Oil...120
    ENGINE ACCESSORY DRIVE BELT...121
      Belt Adjustment...121
      Belt Replacement...121
    DRIVE BELT...122
      Belt Adjustment...122
    X-CHANGE...124
      Inspection And Maintenance...124
    TRACK ROLLER AND IDLER LUBRICATION...124
      Procedure...124
    BUCKET...125
      Bucket Teeth Removal And Installation...125
    CUTTING EDGE (ANGLE BLADE ONLY)...126
      Removal And Installation...126
    LUBRICATING THE EXCAVATOR...127
      Lubrication Locations...127
    PIVOT PINS...130
      Inspection And Maintenance...130
    EXCAVATOR STORAGE AND RETURN TO SERVICE...131
      Storage...131
      Return to Service...131
  SYSTEM SETUP AND ANALYSIS...133
    DIAGNOSTIC SERVICE CODES...135
      Service Codes List...135
    DISPLAY CONTROLLER PANEL SETUP...136
      Passwords...136
      Password Entry (For Starting and Operating the Machine)...136
      Changing The Operator Password...136
      Password Lockout Feature...137
      Job Clock...137
      RPM...137
      Viewing Service Codes (Key Switch)...138
      Viewing Service Codes (Keyless)...138
  MACHINE SIGN TRANSLATIONS...139
    WARNING (6808185)...141
    LIFT CHART...142
      430 STANDARD ARM (S/N 562511001 & ABOVE AND 562711001-562711773) (6815023)...142
      430 LONG ARM (S/N 562511001 & ABOVE AND 562711001-562711773) (6818043)...145
      430 Extendable ARM (S/N 562511001 & ABOVE AND 562711001-562711773) (7102028)...148
      430 STANDARD ARM (S/N 562711774, ABOVE & 562911001 & Above And 563011001 & Above) (7107910)...151
      430 LONG ARM (S/N 562711774 & ABOVE, 562911001 & above and 563011001 & Above) (7107911)...154
      430 Extendable ARM (S/N 562711774 & ABOVE, 562911001 & ABOVE and 563011001 & above) (7107912)...157
    SERVICE SCHEDULE (7130456)...160
    WARNING (6807776)...163
    WARNING (6804114, 6817225, 6804233)...166
    WARNING (6817815)...167
      WARNING (6808474)...167
    EMERGENCY EXIT (6815984)...168
      (Early Models Only)...168
    WARNING (6576048)...169
    WARNING (6815915)...170
    USING THE X-CHANGE SYSTEM (6817816)...171
    USING THE X-CHANGE SYSTEM (7102651)...174
    USING THE X-CHANGE SYSTEM (7134587)...177
    WARNING (6809829)...180
    JOYSTICK CONTROL PATTERN SELECTOR LEVER (6815957)...181
  SPECIFICATIONS...183
    EXCAVATOR SPECIFICATIONS...185
      Excavator Dimensions With Standard Arm, Long Arm Option and Extendable Arm Kit...185
      Excavator Standard Arm Machine Dimensions...186
      Excavator Long Arm Machine Dimensions...187
      Excavator Extendable Arm Machine Dimensions...188
      Excavator With Optional Angle Blade Dimensions...189
      Performance (S/N 56251101 & Above And 562711001 & Above)...190
      Performance (S/N 562911001 & Above)...190
      Performance (S/N 563011001 & Above)...190
      Controls...190
      Engine...191
      Hydraulic System...192
      Hydraulic Cylinders (S/N 562511001 & Above And S/N 562711001 & Above)...193
      Hydraulic Cylinders (S/N 562911001 & Above And S/N 563011001 & Above)...193
      Hydraulic Cycle Times...193
      Electrical...193
      Undercarriage...194
      Capacities...194
      Fuel Tank...194
      Tracks...194
      Type...194
      Drive System (S/N 562511001 & Above, 562711001 & Above And 563011001 & Above)...195
      Drive System (S/N 562911001 & Above)...195
      Slew System...195
      Ground Pressure (S/N 562511001 & Above)...195
      Ground Pressure (S/N 562711001 & Above, 562911001 & Above And 563011001 & Above)...195
  WARRANTY...197
    WARRANTY...199
  ALPHABETICAL INDEX...201
6902318 (07-14) - 430 Service Manual...203
  MAINTENANCE SAFETY...205
  CONTENTS...207
  FOREWORD...209
    FOREWORD...211
    SAFETY INSTRUCTIONS...213
    FIRE PREVENTION...215
      Maintenance...215
      Operation...215
      Electrical...215
      Hydraulic System...215
      Fueling...215
      Starting...215
      Spark Arrester Exhaust System...215
      Welding And Grinding...216
      Fire Extinguishers...216
    SERIAL NUMBER LOCATIONS...217
      Excavator Serial Number...217
      Engine Serial Number...217
    DELIVERY REPORT...218
    EXCAVATOR IDENTIFICATION...219
  SAFETY & MAINTENANCE...221
    LIFTING AND BLOCKING THE EXCAVATOR...225
      Procedure...225
    UPPERSTRUCTURE SLEW LOCK...227
      Operation...227
    LIFTING THE EXCAVATOR...229
      Procedure...229
    OPERATOR CAB (ROPS / TOPS)...231
      Description...231
      Cab Door...231
      Front Window...232
      Front Window...233
      Right Side Window (Early Models)...234
      Right Side Window (Later Models)...235
      Heating, Ventilation, and Air Conditioning Duct...236
    TRANSPORTING THE EXCAVATOR ON A TRAILER...237
      Loading And Unloading...237
      Fastening...237
    TAILGATE...239
      Opening And Closing The Tailgate...239
      Adjusting The Latch...239
    RIGHT SIDE COVER...241
      Opening And Closing...241
    SERVICE SCHEDULE...243
      Chart...243
    AIR CLEANER SERVICE...245
      Daily Check...245
      Replacing The Filters...245
    HEATER AIR FILTER (WITH CAB OPTION ONLY)...247
      Removal And Installation...247
    ENGINE COOLING SYSTEM...249
      Cleaning...249
      Checking Level...250
      Removing And Replacing Coolant...251
    FUEL SYSTEM...253
      Fuel Specifications...253
      Biodiesel Blend Fuel...253
      Filling The Fuel Tank...254
      Removing Water...254
      Replacing Element...254
      Draining The Fuel Tank...255
      Inline Fuel Filter...255
      Removing Air From The Fuel System...255
    ENGINE LUBRICATION SYSTEM...257
      Checking And Adding Engine Oil...257
      Engine Oil Chart...257
      Removing And Replacing Oil Filter...258
    HYDRAULIC SYSTEM...259
      Checking And Adding Fluid...259
      Hydraulic Fluid Chart...259
      Removing And Replacing The Hydraulic Fluid...260
      Removing And Replacing The Hydraulic Filter...261
      Removing And Replacing The Case Drain Filter...261
      Removing And Replacing The Fan Filter...262
      Diagnostic Couplers...262
    LUBRICATING THE EXCAVATOR...263
      Lubrication Locations...263
    TRAVEL MOTOR...267
      Checking And Adding Oil Level...267
      Removing And Replacing Oil...267
    SPARK ARRESTOR MUFFLER...269
      Cleaning Procedure...269
    ENGINE ACCESSORY DRIVE BELT...271
      Belt Tension...271
      Belt Adjustment...271
    SEAT BELT...273
      Inspection And Maintenance...273
    PIVOT PINS...275
      Inspection And Maintenance...275
    EXCAVATOR STORAGE AND RETURN TO SERVICE...277
      Storage...277
      Return To Service...277
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...279
      Procedure...279
      Emergency Exits...280
    MOTION ALARM SYSTEM (IF EQUIPPED)...281
      Description...281
      Inspecting...281
      Adjusting Switch Position...281
  HYDRAULIC SYSTEM...283
    HYDRAULIC/HYDROSTATIC SCHEMATICS...291
    HYDRAULIC SYSTEM INFORMATION...303
      Glossary Of Hydraulic / Hydrostatic Symbols...303
      Troubleshooting The Hydraulic Circuit...307
      Troubleshooting The Cylinder Circuit...307
      Troubleshooting The Upperstructure Slew Circuit...308
    BOOM CYLINDER...309
      Testing...309
      Removal And Installation...312
      Parts Identification...315
      Disassembly...316
      Assembly...318
    ARM CYLINDER...321
      Testing...321
      Removal And Installation...323
      Parts Identification...325
      Disassembly...326
      Assembly...328
    BOOM SWING CYLINDER...331
      Testing...331
      Removal And Installation...332
      Parts Identification...334
      Disassembly...335
      Assembly...337
    BUCKET CYLINDER...341
      Testing...341
      Removal And Installation...343
      Parts Identification...345
      Disassembly...346
      Assembly...348
    BLADE CYLINDER...353
      Testing...353
      Removal And Installation...354
      Parts Identification...355
      Disassembly...356
      Assembly...358
    CLAMP CYLINDER...361
      Testing...361
      Removal And Installation...362
      Parts Identification...363
      Disassembly...364
      Assembly...367
    ANGLE BLADE CYLINDER...371
      Testing...371
      Removal And Installation...372
      Parts Identification...374
      Disassembly...375
      Assembly...377
    MAIN RELIEF VALVES...381
      Testing And Adjusting The Main Relief Valves (S/N 562511001 & Above)...381
      System Pressures At Gauge Port Specifications...381
      Testing And Adjusting The Main Relief Valves (S/N 562711001 & Above)...385
      System Pressures At Gauge Port Specifications...385
      Testing And Adjusting The Main Relief Valves (S/N 562911001 & Above)...389
      System Pressures At Gauge Port Specifications...389
      Testing And Adjusting The Main Relief Valves (S/N 563011001 Above)...392
      System Pressures At Gauge Port Specifications...392
    PORT RELIEF VALVES...395
      Testing And Adjusting Port Relief Valve Pressure...395
    CROSSPORT RELIEF VALVES...401
      Testing And Adjusting The Crossport Relief Valves (S/N 562511001 & Above)...401
      Testing And Adjusting The Crossport Relief Valves (S/N 562711001 & Above)...403
      Testing And Adjusting The Crossport Relief Valves (S/N 562911001 & Above)...405
      Testing And Adjusting The Crossport Relief Valves (S/N 563011001 & Above)...407
    PRESSURE REDUCING VALVE...409
      Description...409
    ANGLE BLADE VALVE...411
      Description...411
      Testing And Adjusting Port Relief Valves...411
      Testing And Adjusting Sequence Valve...413
      Removal And Installation...415
      Parts Identification...418
      Disassembly...419
      Assembly...432
    HYDRAULIC CONTROL VALVE (S/N 562511001 & ABOVE AND 562711001 & ABOVE)...445
      Removal And Installation...445
      Parts Identification...446
      Disassembly And Assembly...447
      Slew Valve Section Disassembly And Assembly...450
      Blade Valve Section Disassembly And Assembly...453
      Boost Valve Section Disassembly And Assembly...458
      Auxiliary Valve Section Disassembly And Assembly...461
      Bucket Valve Section Disassembly And Assembly...464
      Arm Valve Section Disassembly And Assembly...466
      Mid-Inlet Valve Section Disassembly And Assembly...468
      Boom Valve Section Disassembly And Assembly...470
    HYDRAULIC CONTROL VALVE (S/N 562911001 - 562912778)...479
      Description...479
      Removal And Installation...480
      Parts Identification...483
      Disassembly...484
      Right Travel Valve Section Disassembly And Assembly...485
      Left Travel Valve Section Disassembly And Assembly...489
      Blade Valve Section Disassembly And Assembly...493
      Slew Valve Section Disassembly And Assembly...501
      Second Auxiliary Valve Section Disassembly And Assembly...506
      Bucket Valve Section Disassembly And Assembly...510
      Arm Valve Section Disassembly And Assembly...514
      Boom Valve Section Disassembly And Assembly...519
      Boom Swing Valve Section Disassembly And Assembly...523
      First Auxiliary Valve Section Disassembly And Assembly...528
      Inlet Section Disassembly And Assembly...533
      Assembly...538
    HYDRAULIC CONTROL VALVE (S/N 562912779 & Above)...545
      Description...545
      Removal And Installation...546
      Parts Identification...552
      Disassembly...553
      Right Travel Valve Section Disassembly And Assembly...554
      Left Travel Valve Section Disassembly And Assembly...558
      Blade Valve Section Disassembly And Assembly...562
      Slew Valve Section Disassembly And Assembly...570
      Auxiliary Valve Section Disassembly And Assembly...575
      Bucket Valve Section Disassembly And Assembly...579
      Arm Valve Section Disassembly And Assembly...584
      Boom Valve Section Disassembly And Assembly...588
      Boom Swing Valve Section Disassembly And Assembly...593
      Inlet Section Disassembly And Assembly...598
      Assembly...603
    HYDRAULIC CONTROL VALVE (S/N 563011001 - 563012775)...609
      Description...609
      Removal And Installation...609
      Parts Identification...610
      Disassembly...611
      Blade Valve Section Disassembly And Assembly...612
      Slew Valve Section Disassembly And Assembly...620
      Second Auxiliary Valve Section Disassembly And Assembly...625
      Bucket Valve Section Disassembly And Assembly...629
      Arm Valve Section Disassembly And Assembly...633
      Boom Valve Section Disassembly And Assembly...638
      Boom Swing Valve Section Disassembly And Assembly...642
      First Auxiliary Valve Section Disassembly And Assembly...647
      Inlet Section Disassembly And Assembly...652
      Assembly...657
    HYDRAULIC CONTROL VALVE (S/N 563012776 & ABOVE)...663
      Description...663
      Removal And Installation...664
      Parts Identification...667
      Disassembly...668
      Blade Valve Section Disassembly And Assembly...669
      Slew Valve Section Disassembly And Assembly...677
      Auxiliary Valve Section Disassembly And Assembly...682
      Bucket Valve Section Disassembly And Assembly...686
      Arm Valve Section Disassembly And Assembly...691
      Boom Valve Section Disassembly And Assembly...695
      Boom Swing Valve Section Disassembly And Assembly...700
      Inlet Section Disassembly And Assembly...705
      Assembly...710
    HYDRAULIC PUMP (S/N 562511001 & ABOVE AND 562711001 & ABOVE)...715
      Description...715
      Torque Adjustment...716
      Testing The Piston Pump...717
      Testing The Gear Pump...719
      Testing Auxiliary Flow...721
      Removal And Installation...722
      Coupler Removal And Installation...723
      Hydraulic Pump Start Up...724
      Gear Pump Parts Identification...725
      Piston Pump Parts Identification...726
      Disassembly...727
      Gear Pump Disassembly...729
      Gear Pump Assembly...732
      Piston Pump Disassembly...735
      Piston Pump Assembly...743
      Assembly...751
    HYDRAULIC PUMP (S/N 562911001 & ABOVE AND 563011001 & ABOVE)...753
      Description...753
      Torque Adjustment...754
      Testing The Piston Pump...755
      Testing The Gear Pump...757
      Testing Auxiliary Flow...759
      Removal And Installation...760
      Coupler Removal And Installation...761
      Hydraulic Pump Start Up...762
      Gear Pump Parts Identification...763
      Piston Pump Parts Identification...764
      Disassembly...765
      Gear Pump Disassembly...766
      Gear Pump Assembly...769
      Piston Pump Disassembly...772
      Piston Pump Assembly...778
      Assembly...785
    MANIFOLD ASSEMBLY / ACCUMULATOR (S/N 562511001 & ABOVE, 562711001 & ABOVE AND 563011001 & ABOVE)...787
      Description...787
      Testing Pilot Pressure...788
      Removal And Installation...789
      Parts Identification...791
      Disassembly...792
      Assembly...803
    MANIFOLD ASSEMBLY / ACCUMULATOR (S/N 562911001 & ABOVE)...815
      Description...815
      Testing Pilot Pressure...816
      Removal And Installation...817
      Parts Identification...819
      Disassembly...820
      Assembly...829
    TRAVEL MOTOR (S/N 562511001 & ABOVE, 562711001 & ABOVE AND 563011001 & ABOVE)...839
      Removal And Installation...839
      Parts Identification...841
      Disassembly...842
      Assembly...856
    TRAVEL MOTOR (S/N 562911001 THROUGH 562912751)...873
      Removal And Installation...873
      Parts Identification...875
      Disassembly...876
      Assembly...890
    TRAVEL MOTOR (S/N 562912752 & Above)...905
      Description...905
      Removal And Installation...905
      Parts Identification...906
      Disassembly...907
      Assembly...917
    SWIVEL JOINT...929
      Removal And Installation...929
      Parts Identification...931
      Description...932
      Disassembly...932
      Assembly...935
    SWING MOTOR...939
      Removal And Installation...939
      Parts Identification...941
      Disassembly...942
      Assembly...947
    SWING MOTOR DRIVE CARRIER...953
      Removal And Installation...953
      Parts Identification...954
      Disassembly...955
      Assembly...957
    CONTROL PATTERN SELECTOR VALVE...959
      Removal And Installation...959
      Parts Identification...960
      Disassembly...961
      Assembly...962
    RIGHT CONTROL LEVER (JOYSTICK)...963
      Testing...963
      Handle Removal And Installation...964
      Joystick Assembly Removal And Installation...968
      Parts Identification...971
      Disassembly...972
      Assembly...976
    LEFT CONTROL LEVER (JOYSTICK)...981
      Testing...981
      Handle Removal And Installation...983
      Joystick Assembly Removal And Installation...986
      Parts Identification...988
      Disassembly...989
      Assembly...994
    TRAVEL CONTROL VALVE (S/N 562511001 & ABOVE, 562711001 & ABOVE AND 563011001 & ABOVE)...999
      Removal and Installation...999
      Parts Identification...1000
      Disassembly And Assembly...1001
    TRAVEL CONTROL VALVE (S/N 562911001 & ABOVE)...1007
      Removal And Installation...1007
      Parts Identification...1008
      Disassembly And Assembly...1009
    HOSES...1013
      Hose Guide Location...1013
      Left Control Lever (Joystick) (S/N 562911001 & Above) (Later Models)...1014
      Left Control Lever (Joystick) (S/N 563011001 & Above) (Later Models)...1015
      Right Control Lever (Joystick) (S/N562911001 And Above) (Later Models)...1016
      Right Control Lever (Joystick) (S/N 563011001 & Above) (Later Models)...1017
      Travel Control Valve (S/N 562911001 & Above) (Later Models)...1018
      Travel Control Valve (S/N A563011001 & Above) (Later Models)...1019
      Manifold Assembly / Accumulator (S/N 562911001 & Above) (Later Models)...1020
      Manifold Assembly / Accumulator (S/N 563011001 & Above) (Later Models)...1021
    HYDRAULIC FILTER MOUNT...1023
      Removal And Installation...1023
    HYDRAULIC RESERVOIR...1025
      Removal And Installation...1025
    OIL COOLER...1027
      Removal And Installation...1027
    DIRECT TO TANK VALVE (IF EQUIPPED)...1031
      Removal And Installation...1031
      Parts Identification...1032
      Disassembly And Assembly...1033
    BUILD UP VALVE...1035
    CASE DRAIN FILTER...1037
      Removal And Installation...1037
    COOLING FAN...1039
      Description...1039
      Testing...1039
      Removal And Installation...1040
      Parts Identification...1042
      Disassembly And Assembly...1043
    BOOM SWING LOCK VALVE...1051
      Description...1051
      Removal And Installation...1051
      Parts Identification...1052
      Disassembly...1053
      Assembly...1056
    HYDRAULIC X-CHANGE™ VALVE...1061
      Removal And Installation...1061
      Parts Identification...1064
      Disassembly...1065
      Assembly...1072
  HYDROSTATIC SYSTEM...1079
    HYDROSTATIC SYSTEM INFORMATION...1081
      Troubleshooting Chart...1081
      Relief / Replenishing Valve Function...1082
      Relief / Replenishing Valve Location...1083
      Relief / Replenishing Valve Removal And Installation...1083
      Charge Pressure Relief Valve Removal And Installation...1084
    TRAVEL PILOT PRESSURE...1085
      Description...1085
      Testing...1085
    HYDROSTATIC PUMP...1087
      Removal And Installation...1087
      Fan / Charge Pump Parts Identification...1090
      Fan / Charge Pump Disassembly And Assembly (S/N 562511001 & Above And 562711001 & Above)...1091
      Parts Identification (Front) (S/N 562511001 & Above, 562711001 & Above And 563111001 & Above)...1096
      Parts Identification (Rear) (S/N 562511001 & Above And 562711001 & Above)...1097
      Parts Identification (Rear) (S/N 563011001 & Above)...1098
      Disassembly...1099
      Inspection...1110
      Assembly...1112
      Hydrostatic Pump StartUp...1124
    FAN / CHARGE PUMP...1125
      Description (S/N 562511001 & Above And 562711001 & Above)...1125
      Testing...1125
    DRIVE BELT SHIELD...1127
      Removal And Installation...1127
    DRIVE BELT...1129
      Adjustment...1129
      Removal And Installation...1131
  UNDERCARRIAGE...1133
    BLADE...1135
      Removal And Installation...1135
    ANGLE BLADE ASSEMBLY...1137
      Removal And Installation...1137
    ANGLE BLADE...1139
      Removal And Installation...1139
    ANGLE BLADE CUTTING EDGE...1141
      Removal And Installation...1141
    TRACKS...1143
      Track Lug Height...1143
      Rubber Track Clearance...1144
      Steel Track Clearance...1145
      Adjustment...1145
      Rubber Track Removal And Installation...1146
      Steel Track Removal And Installation...1149
    TRACK FRAME...1153
      Disassembly And Assembly...1153
      Recoil Spring Cylinder Disassembly And Assembly (W / O Replaceable Shaft)...1154
      Recoil Spring Cylinder Parts Identification (With Replaceable Shaft)...1157
      Recoil Spring Cylinder Disassembly And Assembly (With Replaceable Shaft)...1158
    TRACK DAMAGE IDENTIFICATION...1161
      Cutting Of Steel Cords...1161
      Abrasion Of Embedded Metals...1162
      Separation Of Embedded Metals...1163
      Separation Of Embedded Metals Due To Corrosion...1164
      Cuts On The Lug Side Rubber...1165
      Cracks On The Lug Side Rubber Due To Fatigue...1166
      Lug Abrasion...1167
      Cracks And Cuts On The Lug Side Rubber...1168
      Abrasion Of The Track Roller Side...1169
      Cuts On The Edges Of Track Roller Side...1170
    TRACK IDLER...1173
      Parts Identification...1173
      Disassembly...1174
      Assembly...1176
    UPPER TRACK ROLLER...1179
      Parts Identification...1179
      Disassembly...1180
      Assembly...1182
    LOWER TRACK ROLLER...1185
      Parts Identification...1185
      Disassembly...1186
      Assembly...1188
    SWING CIRCLE GEAR...1191
      Swing Bearing Removal...1191
      Swing Bearing Installation...1192
  UPPERSTRUCTURE & SWING SECTION...1193
    UPPERSTRUCTURE...1197
      Removal...1197
      Installation...1199
    ROPS CANOPY...1201
      Removal And Installation...1201
    CAB...1205
      Removal And Installation...1205
      Front Window Removal And Installation...1210
      Right Side Rear Sliding Window Removal And Installation...1213
      Right Side Front Sliding Window Removal And Installation...1213
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...1214
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...1214
      Glass Removal...1215
      Glass Installation...1216
    SEAT AND SEAT MOUNT...1219
      Removal And Installation...1219
    RIGHT CONSOLE...1221
      Console Cover Removal And Installation...1221
      Console Base Removal And Installation...1222
    LEFT CONSOLE...1225
      Lower Console Cover Removal And Installation...1225
      Upper Console Cover Removal And Installation...1226
      Compression Spring Removal And Installation...1227
      Compression Spring Disassembly And Assembly...1228
      Lock Lever Removal And Installation...1229
      Console Removal And Installation...1230
      Disassembly And Assembly...1234
      Console Switch Removal And Installation...1237
      Console Base Removal And Installation...1238
    ENGINE SPEED CONTROL...1239
      Removal And Installation...1239
      Disassembly And Assembly...1240
      Adjustment (Later Models)...1241
    BLADE CONTROL...1243
      Lever Removal And Installation...1243
      Linkage Removal And Installation...1244
      Linkage Disassembly And Assembly...1244
      Control Cable Removal And Installation...1246
    RIGHT PEDAL AND LINKAGE...1247
      Pedal Removal And Installation...1247
      Pedal Disassembly And Assembly...1248
      Control Cable Removal And Installation...1250
    TRAVEL CONTROLS...1251
      Removal And Installation...1251
      Disassembly And Assembly...1254
      Adjustment...1256
    CONTROL LINKAGE ASSEMBLY...1259
      Removal And Installation...1259
    FLOOR MAT AND FLOOR PLATES...1261
      Removal And Installation...1261
    FUEL TANK...1263
      Removal And Installation...1263
    HORN...1265
      Removal And Installation (Earlier Models)...1265
      Removal And Installation (Later Models)...1265
    SWING FRAME...1267
      Boom Swing Bracket Removal And Installation...1267
      Boom Swing Bracket Hose Installation...1270
      Bushing Removal...1271
      Bushing Installation...1272
    BOOM...1273
      Removal And Installation...1273
    ARM...1275
      Removal And Installation...1275
      Arm To Boom Bushing Removal And Installation...1276
      Arm To Bucket And Bucket Link Bushing Removal And Installation...1277
    BUCKET...1279
      Bucket Teeth Removal And Installation...1279
      Bucket Side Cutting Edge Removal And Installation...1280
    CLAMP...1281
      Removal And Installation...1281
    TAILGATE...1283
      Removal And Installation...1283
    X-CHANGE™...1285
      Removal And Installation...1285
      Parts Identification...1287
      Disassembly...1288
      Assembly...1293
      Check Proper Latch Engagement...1299
    X-CHANGE™ (HYDRAULIC)...1303
      Removal And Installation...1303
      Parts Identification...1305
      Disassembly...1306
      Assembly...1311
    UPPERSTRUCTURE SLEW LOCK...1319
      Removal And Installation...1319
      Disassembly And Assembly...1320
    RIGHT SIDE COVER...1323
      Removal And Installation...1323
    COUNTERWEIGHT...1325
      Removal And Installation...1325
  ELECTRICAL SYSTEM & ANALYSIS...1327
    ELECTRICAL SCHEMATICS...1329
    ELECTRICAL SYSTEM INFORMATION...1332
      Troubleshooting Chart...1332
      Description...1333
      Fuse And Relay Location...1333
    BATTERY...1334
      Servicing...1334
      Removing And Installing The Battery...1335
      Using A Booster Battery (Jump Starting)...1336
    ALTERNATOR...1338
      Engine Accessory Drive Belt...1338
      Removal And Installation...1339
      Alternator Identification...1340
      Charging System Check...1340
      Alternator Voltage Test...1342
      Low Voltage Test...1342
      High Voltage Test...1343
      Rectifier Continuity (Diode) Test...1343
      Alternator Regulator Test...1344
      Parts Identification...1345
      Disassembly...1345
      Stator Continuity Test...1345
      Stator Ground Test...1346
      Rotor Continuity Test...1346
      Rotor Ground Test...1347
      Assembly...1347
    STARTER...1348
      Removal And Installation...1348
      Parts Identification...1349
      Disassembly...1350
      Inspection And Repair...1355
      Assembly...1358
    LIGHTS...1364
      Removal And Installation...1364
      Boom Light Removal and Installation (Earlier Models)...1365
      Boom Light Removal and Installation (Later Models)...1366
      Boom Light Bulb Replacement (Later Models)...1366
    TWO SPEED SWITCH...1368
      Removal And Installation...1368
    FUEL LEVEL SENDER...1370
      Removal And Installation...1370
      Testing...1370
    DIAGNOSTIC SERVICE CODES...1372
      Service Codes List...1372
    DELUXE INSTRUMENT PANEL SETUP...1374
      Passwords...1374
      Password Entry (For Starting and Operating the Machine)...1374
      Changing The Owner or Operator Password...1374
      Password Lockout Feature...1375
      Job Clock...1375
      RPM...1375
  ENGINE SERVICE...1376
    TROUBLESHOOTING...1378
      Chart...1378
    MUFFLER...1380
      Removal And Installation...1380
    AIR CLEANER...1382
      Removal And Installation...1382
    RADIATOR...1384
      Removal And Installation...1384
    ENGINE COMPONENTS AND TESTING...1390
      Engine Compression Checking...1390
      Glow Plug Removal And Installation...1391
      Checking The Glow Plug...1391
      Fuel Shut-off Solenoid Removal And Installation...1392
      Fuel Injection Pump Check...1394
      Fuel Injection Pump Removal And Installation...1395
      Fuel Injection Pump Timing...1397
      Fuel Injector Nozzles Removal And Installation...1399
      Fuel Injector Nozzle Check...1402
      Valve Clearance Adjustment...1403
    ENGINE...1404
      Removal And Installation...1404
    ENGINE FLYWHEEL (EARLY MODELS)...1412
      Removal And Installation...1412
      Removal And Installation...1413
      Flywheel Ring Gear...1413
    ENGINE FLYWHEEL (LATER MODELS)...1414
      Removal And Installation...1414
      Hydraulic Pump Coupler...1415
      Flywheel Ring Gear...1415
    RECONDITIONING THE ENGINE...1416
      Cylinder Head Removal And Installation...1416
      Cylinder Head Disassembly And Assembly...1419
      Cylinder Head Servicing...1420
      Cylinder Head Top Clearance...1420
      Valve Guide Checking...1421
      Reconditioning The Valve And Valve Seat...1423
      Valve Spring...1424
      Rocker Arm And Shaft Checking...1425
      Timing Gearcase Cover Removal And Installation...1426
      Idler Gear And Camshaft Removal And Installation...1429
      Camshaft Servicing...1430
      Idler Gear And Shaft Servicing...1431
      Timing Gears Checking Backlash...1432
      Fuel Camshaft Removal And Installation...1432
      Fuel Camshaft Governor...1433
      Crankshaft Gear Removal And Installation...1433
      Oil Pump Removal And Installation...1434
      Oil Pump Service...1434
      Checking Engine Oil Pressure...1436
      Valve Tappets...1436
      Piston And Connecting Rod Removal And Installation...1437
      Piston And Connecting Rod Servicing...1439
      Connecting Rod Alignment...1441
      Crankshaft And Bearings Removal And Installation...1442
      Crankshaft And Bearings, Servicing...1444
      Cylinder Bore, Checking...1447
      Water Pump Removal And Installation...1448
      Water Pump Disassembly And Assembly...1448
  HEATING, VENTILATION, AIR CONDITIONING...1450
    HEATER COIL (EARLY MODELS)...1454
      Removal And Installation With A/C...1454
      Removal And Installation Without A/C...1454
    HEATER COIL (LATER MODELS)...1456
      Removal And Installation With A/C...1456
      Removal And Installation Without A/C...1456
    BLOWER FAN (EARLY MODELS)...1458
      Removal And Installation...1458
      Disassembly And Assembly...1458
    BLOWER FAN (LATER MODELS)...1460
      Removal And Installation...1460
      Disassembly And Assembly...1461
      Resistor Removal And Installation...1462
    HEATER VALVE...1464
      Removal And Installation...1464
    AIR CONDITIONING SYSTEM FLOW...1466
      Principals...1466
      Chart...1467
    COMPONENTS...1468
      Identification...1468
    SAFETY...1472
      Safety Equipment...1472
    REGULAR MAINTENANCE...1474
      Heater Air Filter...1474
      Engine Accessory Drive Belt...1474
      Cleaning The Condenser...1474
    BASIC TROUBLESHOOTING (EARLY MODELS)...1476
      Poor A/C Performance...1476
      Cleaning The A/C Evaporator Coil And Heater Coil...1477
      Engine Accessory Drive Belt...1478
      Checking The Electrical System...1479
      Engine Coolant By-Passing The Heater Valve...1489
    BASIC TROUBLESHOOTING (LATER MODELS)...1490
      Poor A/C Performance...1490
      Cleaning The A/C Evaporator Coil And Heater Coil...1491
      Engine Accessory Drive Belt...1492
      Checking The Electrical System...1493
      Engine Coolant By-Passing The Heater Valve...1503
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...1504
      Compressor Oil...1504
      Compressor Oil Check...1504
      Component Replacement And Refrigeration Leaks...1506
    SYSTEM TROUBLESHOOTING CHART...1508
      Blower Motor Does Not Operate...1508
      Gauge Pressure Related Troubleshooting...1509
    TEMPERATURE / PRESSURE...1512
      Chart...1512
    AIR CONDITIONING SERVICE...1514
      Chart...1514
    SYSTEM CHARGING AND RECLAMATION...1516
      Reclamation Procedure...1516
      Charging Procedure With A Manifold Gauge Set...1519
    COMPRESSOR...1522
      Removal And Installation...1522
      Compressor Clutch Disassembly And Assembly...1523
    CONDENSER...1526
      Removal And Installation...1526
    RECEIVER / DRIER...1528
      Removal And Installation...1528
    PRESSURE RELIEF VALVE...1530
      Removal And Installation...1530
    PRESSURE SWITCH...1532
      Removal And Installation...1532
    EVAPORATOR / HEATER UNIT (EARLY MODELS)...1534
      Removal And Installation...1534
      Disassembly And Assembly...1535
    EVAPORATOR/HEATER UNIT (LATER MODELS)...1536
      Removal And Installation...1536
      Disassembly And Assembly...1537
    THERMOSTAT (EARLY MODELS)...1538
      Removal And Installation...1538
    THERMOSTAT (LATER MODELS)...1540
      Removal And Installation...1540
    EXPANSION VALVE (EARLY MODELS)...1542
      Removal And Installation...1542
    EXPANSION VALVE (LATER MODELS)...1544
      Removal And Installation...1544
    EVAPORATOR (EARLY MODELS)...1546
      Removal And Installation...1546
    EVAPORATOR (LATER MODELS)...1548
      Removal And Installation...1548
  SPECIFICATIONS...1550
    EXCAVATOR SPECIFICATIONS...1552
      Excavator Dimensions With Standard Arm, Long Arm Option and Extendable Arm Kit...1552
      Excavator Standard Arm Machine Dimensions...1553
      Excavator Long Arm Machine Dimensions...1554
      Excavator Extendable Arm Machine Dimensions...1555
      Excavator With Optional Angle Blade Dimensions...1556
      Performance (S/N 56251101 & Above And 562711001 & Above)...1557
      Performance (S/N 562911001 & Above)...1557
      Performance (S/N 563011001 & Above)...1557
      Controls...1557
      Engine...1558
      Hydraulic System...1559
      Hydraulic Cylinders (S/N 562511001 & Above And S/N 562711001 & Above)...1560
      Hydraulic Cylinders (S/N 562911001 & Above And S/N 563011001 & Above)...1560
      Hydraulic Cycle Times...1560
      Electrical...1560
      Undercarriage...1561
      Capacities...1561
      Fuel Tank...1561
      Tracks...1561
      Type...1561
      Drive System (S/N 562511001 & Above, 562711001 & Above And 563011001 & Above)...1562
      Drive System (S/N 562911001 & Above)...1562
      Slew System...1562
      Ground Pressure (S/N 562511001 & Above)...1562
      Ground Pressure (S/N 562711001 & Above, 562911001 & Above And 563011001 & Above)...1562
    ENGINE SPECIFICATIONS...1564
      Specifications...1564
      Crankshaft Re-Grind Data...1570
    TORQUE SPECIFICATIONS...1572
      Torque for General SAE Bolts...1572
      Torque For General Metric Bolts...1573
    HYDRAULIC CONNECTION SPECIFICATIONS...1574
      O-ring Face Seal Connection...1574
      Straight Thread O-ring Fitting...1574
      Tubelines And Hoses...1574
      Flare Fitting...1575
      O-ring Flare Fitting...1576
      Port Seal Fitting...1578
    HYDRAULIC FLUID SPECIFICATIONS...1580
      Specifications...1580
    FUEL, COOLANT AND LUBRICANTS...1582
      Chart...1582
    CONVERSIONS...1584
      Decimal And Millimeter Equivalents Chart...1584
      U.S. To Metric Conversion Chart...1584
    SERVICE TOOLS REQUIRED...1586
      Remote Start Tools...1586
      Hydraulic Tools...1587
      Engine Tools...1589
      HVAC Tools...1591
  ALPHABETICAL INDEX...1592
6902318 (10-09) - 430 Service Manual...1596
  MAINTENANCE SAFETY...1598
  ALPHABETICAL INDEX...1600
  CONTENTS...1602
    FOREWORD...1603
    SAFETY INSTRUCTIONS...1605
    FIRE PREVENTION...1607
      Maintenance...1607
      Operation...1607
      Electrical...1607
      Hydraulic System...1607
      Fueling...1607
      Starting...1607
      Spark Arrestor Exhaust System...1607
      Welding And Grinding...1608
      Fire Extinguishers...1608
    SERIAL NUMBER LOCATIONS...1609
      Excavator Serial Number...1609
      Engine Serial Number...1609
    DELIVERY REPORT...1610
    BOBCAT EXCAVATOR IDENTIFICATION...1611
  SAFETY AND MAINTENANCE...1612
    LIFTING AND BLOCKING THE EXCAVATOR...1614
      Procedure...1614
    UPPERSTRUCTURE SLEW LOCK...1616
      Operation...1616
    LIFTING THE EXCAVATOR...1618
    OPERATOR CAB (ROPS/TOPS)...1620
      Emergency Exit (Early Models)...1620
      Emergency Exit (Later Models)...1621
      Cab Door...1622
      Front Window...1622
      Right Side Windows (Early Models)...1624
      Right Side Windows (Later Models)...1625
    TRANSPORTING THE EXCAVATOR...1628
      Procedure...1628
    TAILGATE...1630
      Opening And Closing The Tailgate...1630
      Adjusting The Latch...1630
    RIGHT SIDE COVER...1632
      Opening And Closing The Right Side Cover...1632
    SERVICE SCHEDULE...1634
      Chart...1634
    AIR CLEANER...1636
      Daily Check...1636
      Replacing The Filters...1636
    HEATER AIR FILTER (WITH CAB OPTION ONLY)...1638
      Removal And Installation...1638
    COOLING SYSTEM...1640
      Cleaning The Cooling System...1640
      Checking Coolant Level...1640
      Replacing The Coolant...1641
    FUEL SYSTEM...1644
      Fuel Specifications...1644
      Filling The Fuel Tank...1644
      Removing Water From The Fuel Filter...1645
      Draining The Fuel Tank...1645
      Spin On Fuel Filter...1646
      Inline Fuel Filter...1646
    ENGINE LUBRICATION SYSTEM...1648
      Checking Engine Oil...1648
      Replacing Oil And Filter...1648
    HYDRAULIC SYSTEM...1650
      Checking And Adding Hydraulic Oil...1650
      Replacing The Hydraulic Oil...1651
      Replacing The Hydraulic Filter...1652
      Replacing The Case Drain Filter...1652
      Replacing The Fan Filter...1653
      Diagnostic Couplers...1653
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...1654
    TRAVEL MOTOR...1658
      Checking Oil Level...1658
      Draining The Travel Motor...1658
    SPARK ARRESTOR MUFFLER...1660
    ENGINE ACCESSORY DRIVE BELT...1662
      Belt Tension...1662
      Belt Adjustment...1662
  HYDRAULIC SYSTEM...1664
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1674
    HYDRAULIC SYSTEM INFORMATION...1686
      Glossary Of Hydraulic / Hydrostatic Symbols...1686
      Troubleshooting The Hydraulic Circuit...1690
      Troubleshooting The Cylinder Circuit...1690
      Troubleshooting The Upperstructure Slew Circuit...1691
    BOOM CYLINDER...1692
      Testing...1692
      Removal And Installation...1695
      Parts Identification...1698
      Disassembly...1699
      Assembly...1701
    ARM CYLINDER...1704
      Testing...1704
      Removal And Installation...1706
      Parts Identification...1708
      Disassembly...1709
      Assembly...1711
    BOOM SWING CYLINDER...1714
      Testing...1714
      Removal And Installation...1715
      Parts Identification...1717
      Disassembly...1718
      Assembly...1720
    BUCKET CYLINDER...1724
      Testing...1724
      Removal And Installation...1726
      Parts Identification...1728
      Disassembly...1729
      Assembly...1731
    BLADE CYLINDER...1736
      Testing...1736
      Removal And Installation...1737
      Parts Identification...1738
      Disassembly...1739
      Assembly...1741
    CLAMP CYLINDER...1744
      Testing...1744
      Removal And Installation...1745
      Parts Identification...1746
      Disassembly...1747
      Assembly...1750
    ANGLE BLADE CYLINDER...1756
      Testing...1756
      Removal And Installation...1757
      Parts Identification...1759
      Disassembly...1760
      Assembly...1762
    MAIN RELIEF VALVES...1766
      Testing And Adjusting The Main Relief Valves (S/N 562511001 & Above)...1766
      System Pressures At Gauge Port Specifications...1766
      Testing And Adjusting The Main Relief Valves (S/N 562711001 & Above)...1770
      System Pressures At Gauge Port Specifications...1770
      Testing And Adjusting The Main Relief Valves (S/N 562911001 Above)...1774
      System Pressures At Gauge Port Specifications...1774
      Testing And Adjusting The Main Relief Valves (S/N 563011001 Above)...1777
      System Pressures At Gauge Port Specifications...1777
    PORT RELIEF VALVES...1780
      Testing And Adjusting Port Relief Valve Pressure...1780
    CROSSPORT RELIEF VALVES...1786
      Testing And Adjusting The Crossport Relief Valves (S/N 562511001 & Above)...1786
      Testing And Adjusting The Crossport Relief Valves (S/N 562711001 & Above)...1788
      Testing And Adjusting The Crossport Relief Valves (S/N 562911001 & Above)...1790
      Testing And Adjusting The Crossport Relief Valves (S/N 563011001 & Above)...1792
    PRESSURE REDUCING VALVE...1794
      Description...1794
    ANGLE BLADE VALVE...1796
      Description...1796
      Testing And Adjusting Port Relief Valves...1796
      Testing And Adjusting Sequence Valve...1798
      Removal And Installation...1800
      Parts Identification...1803
      Disassembly...1804
      Assembly...1817
    HYDRAULIC CONTROL VALVE (S/N 562511001 & ABOVE AND 562711001 & ABOVE)...1830
      Removal And Installation...1830
      Parts Identification...1831
      Disassembly And Assembly...1832
      Slew Valve Section Disassembly And Assembly...1835
      Blade Valve Section Disassembly And Assembly...1838
      Boost Valve Section Disassembly And Assembly...1843
      Auxiliary Valve Section Disassembly And Assembly...1846
      Bucket Valve Section Disassembly And Assembly...1849
      Arm Valve Section Disassembly And Assembly...1851
      Mid-Inlet Valve Section Disassembly And Assembly...1853
      Boom Valve Section Disassembly And Assembly...1855
    HYDRAULIC CONTROL VALVE (S/N 562911001 - 562912778)...1864
      Description...1864
      Removal And Installation...1865
      Parts Identification...1868
      Disassembly...1869
      Right Travel Valve Section Disassembly And Assembly...1871
      Left Travel Valve Section Disassembly And Assembly...1875
      Blade Valve Section Disassembly And Assembly...1879
      Slew Valve Section Disassembly And Assembly...1888
      Second Auxiliary Valve Section Disassembly And Assembly...1893
      Bucket Valve Section Disassembly And Assembly...1897
      Arm Valve Section Disassembly And Assembly...1902
      Boom Valve Section Disassembly And Assembly...1907
      Boom Swing Valve Section Disassembly And Assembly...1912
      First Auxiliary Valve Section Disassembly And Assembly...1917
      Inlet Section Disassembly And Assembly...1922
      Assembly...1927
    HYDRAULIC CONTROL VALVE (S/N 562912779 & Above)...1934
      Description...1934
      Removal And Installation...1935
      Parts Identification...1941
      Disassembly...1942
      Right Travel Valve Section Disassembly And Assembly...1944
      Left Travel Valve Section Disassembly And Assembly...1948
      Blade Valve Section Disassembly And Assembly...1952
      Slew Valve Section Disassembly And Assembly...1961
      Auxiliary Valve Section Disassembly And Assembly...1966
      Bucket Valve Section Disassembly And Assembly...1971
      Arm Valve Section Disassembly And Assembly...1976
      Boom Valve Section Disassembly And Assembly...1981
      Boom Swing Valve Section Disassembly And Assembly...1986
      Inlet Section Disassembly And Assembly...1991
      Assembly...1996
    HYDRAULIC CONTROL VALVE (S/N 563011001 - 563012775)...2002
      Description...2002
      Removal And Installation...2002
      Parts Identification...2003
      Disassembly...2004
      Blade Valve Section Disassembly And Assembly...2005
      Slew Valve Section Disassembly And Assembly...2014
      Second Auxiliary Valve Section Disassembly And Assembly...2019
      Bucket Valve Section Disassembly And Assembly...2023
      Arm Valve Section Disassembly And Assembly...2028
      Boom Valve Section Disassembly And Assembly...2033
      Boom Swing Valve Section Disassembly And Assembly...2038
      First Auxiliary Valve Section Disassembly And Assembly...2043
      Inlet Section Disassembly And Assembly...2048
      Assembly...2053
    HYDRAULIC CONTROL VALVE (S/N 563012776 & ABOVE)...2060
      Description...2060
      Removal And Installation...2061
      Parts Identification...2064
      Disassembly...2065
      Blade Valve Section Disassembly And Assembly...2066
      Slew Valve Section Disassembly And Assembly...2075
      Auxiliary Valve Section Disassembly And Assembly...2080
      Bucket Valve Section Disassembly And Assembly...2085
      Arm Valve Section Disassembly And Assembly...2090
      Boom Valve Section Disassembly And Assembly...2095
      Boom Swing Valve Section Disassembly And Assembly...2100
      Inlet Section Disassembly And Assembly...2105
      Assembly...2110
    HYDRAULIC PUMP (S/N 562511001 & ABOVE AND 562711001 & ABOVE)...2116
      Description...2116
      Torque Adjustment...2117
      Testing The Piston Pump...2118
      Testing The Gear Pump...2120
      Testing Auxiliary Flow...2122
      Removal And Installation...2123
      Coupler Removal And Installation...2124
      Hydraulic Pump Start Up...2125
      Gear Pump Parts Identification...2126
      Piston Pump Parts Identification...2127
      Disassembly...2128
      Gear Pump Disassembly...2130
      Gear Pump Assembly...2133
      Piston Pump Disassembly...2136
      Piston Pump Assembly...2144
      Assembly...2152
    HYDRAULIC PUMP (S/N 562911001 & ABOVE AND 563011001 & ABOVE)...2154
      Description...2154
      Torque Adjustment...2155
      Testing The Piston Pump...2156
      Testing The Gear Pump...2158
      Testing Auxiliary Flow...2160
      Removal And Installation...2161
      Coupler Removal And Installation...2162
      Hydraulic Pump Start Up...2163
      Gear Pump Parts Identification...2164
      Piston Pump Parts Identification...2165
      Disassembly...2166
      Gear Pump Disassembly...2168
      Gear Pump Assembly...2171
      Piston Pump Disassembly...2174
      Piston Pump Assembly...2181
      Assembly...2188
    MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 562511001 & ABOVE, 562711001 & ABOVE AND 563011001 & ABOVE)...2190
      Description...2190
      Testing Pilot Pressure...2191
      Removal And Installation...2192
      Parts Identification...2194
      Disassembly...2195
      Assembly...2207
    MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 562911001 & ABOVE)...2220
      Description...2220
      Testing Pilot Pressure...2221
      Removal And Installation...2222
      Parts Identification...2224
      Disassembly...2225
      Assembly...2234
    TRAVEL MOTOR (S/N 562511001 & ABOVE, 562711001 & ABOVE AND 563011001 & ABOVE)...2244
      Removal And Installation...2244
      Parts Identification...2246
      Disassembly...2247
      Assembly...2261
    TRAVEL MOTOR (S/N 562911001 through 562912751)...2278
      Removal And Installation...2278
      Parts Identification...2280
      Disassembly...2281
      Assembly...2296
    TRAVEL MOTOR (S/N 562912752 & Above)...2312
      Description...2312
      Removal And Installation...2312
      Parts Identification...2313
      Disassembly...2314
      Assembly...2324
    SWIVEL JOINT...2336
      Removal And Installation...2336
      Parts Identification...2338
      Description...2339
      Disassembly...2339
      Assembly...2342
    SWING MOTOR...2346
      Removal And Installation...2346
      Parts Identification...2348
      Disassembly...2349
      Assembly...2354
    SWING MOTOR DRIVE CARRIER...2360
      Removal And Installation...2360
      Parts Identification...2361
      Disassembly...2362
      Assembly...2364
    CONTROL PATTERN SELECTOR VALVE...2366
      Removal And Installation...2366
      Parts Identification...2367
      Disassembly...2368
      Assembly...2370
    RIGHT CONTROL LEVER (JOYSTICK)...2372
      Testing...2372
      Handle Removal And Installation...2373
      Joystick Assembly Removal And Installation...2377
      Parts Identification...2380
      Disassembly...2381
      Assembly...2386
    LEFT CONTROL LEVER (JOYSTICK)...2390
      Testing...2390
      Handle Removal And Installation...2392
      Joystick Assembly Removal And Installation...2395
      Parts Identification...2397
      Disassembly...2398
      Assembly...2403
    TRAVEL CONTROL VALVE (S/N 562511001 & ABOVE, 562711001 & ABOVE AND 563011001 & ABOVE)...2408
      Removal and Installation...2408
      Parts Identification...2409
      Disassembly And Assembly...2410
    TRAVEL CONTROL VALVE (S/N 562911001 & ABOVE)...2416
      Removal and Installation...2416
      Parts Identification...2417
      Disassembly And Assembly...2418
    HOSES...2422
      Hose Guide Location...2422
      Left Control Lever (Joystick) (S/N 562911001 & Above) (Later Models)...2423
      Left Control Lever (Joystick) (S/N 563011001 & Above) (Later Models)...2424
      Right Control Lever (Joystick) (S/N562911001 And Above) (Later Models)...2425
      Right Control Lever (Joystick) (S/N 563011001 & Above) (Later Models)...2426
      Travel Control Valve (S/N 562911001 & Above) (Later Models)...2427
      Travel Control Valve (S/N A563011001 & Above) (Later Models)...2428
      Manifold Assembly / Accumulator (S/N 562911001 & Above) (Later Models)...2429
      Manifold Assembly / Accumulator (S/N 563011001 & Above) (Later Models)...2430
    HYDRAULIC FILTER MOUNT...2432
      Removal And Installation...2432
    HYDRAULIC RESERVOIR...2434
      Removal And Installation...2434
    OIL COOLER...2436
      Removal And Installation...2436
    DIRECT TO TANK VALVE (IF EQUIPPED)...2440
      Removal And Installation...2440
      Parts Identification...2441
      Disassembly And Assembly...2442
    BUILD UP VALVE...2444
    CASE DRAIN FILTER...2446
      Removal And Installation...2446
    COOLING FAN...2448
      Description...2448
      Testing...2448
      Removal And Installation...2449
      Parts Identification...2451
      Disassembly And Assembly...2452
    BOOM SWING LOCK VALVE...2460
      Description...2460
      Removal And Installation...2460
      Parts Identification...2461
      Disassembly...2462
      Assembly...2465
    HYDRAULIC X-CHANGE VALVE...2470
      Removal And Installation...2470
      Parts Identification...2473
      Disassembly...2474
      Assembly...2482
  HYDROSTATIC SYSTEM...2490
    HYDROSTATIC SYSTEM INFORMATION...2492
      Troubleshooting Chart...2492
      Relief/Replenishing Valve Function...2493
      Relief/Replenishing Valve Location...2494
      Relief/Replenishing Valve Removal And Installation...2494
      Charge Pressure Relief Valve Removal And Installation...2495
    TRAVEL PILOT PRESSURE...2496
      Description...2496
      Testing...2496
    HYDROSTATIC PUMP...2498
      Removal And Installation...2498
      Fan/Charge Pump Parts Identification...2501
      Fan/Charge Pump Disassembly And Assembly (S/N 562511001 & Above And 562711001 & Above)...2502
      Parts Identification (Front) (S/N 562511001 & Above, 562711001 & Above And 563111001 & Above)...2507
      Parts Identification (Rear) (S/N 562511001 & Above And 562711001 & Above)...2508
      Parts Identification (Rear) (S/N 563011001 & Above)...2509
      Disassembly...2510
      Inspection...2521
      Assembly...2523
      Hydrostatic Pump Start-Up...2535
    FAN/CHARGE PUMP...2536
      Description (S/N 562511001 & Above And 562711001 & Above)...2536
      Testing...2536
    DRIVE BELT SHIELD...2538
      Removal And Installation...2538
    DRIVE BELT...2540
      Adjustment...2540
      Removal And Installation...2542
  UNDERCARRIAGE...2544
    BLADE...2546
      Removal And Installation...2546
    ANGLE BLADE ASSEMBLY...2548
      Removal And Installation...2548
    ANGLE BLADE...2550
      Removal And Installation...2550
    ANGLE BLADE CUTTING EDGE...2552
      Removal And Installation...2552
    TRACKS...2554
      Track Lug Height...2554
      Rubber Track Clearance...2555
      Steel Track Clearance...2556
      Adjustment...2557
      Rubber Track Removal And Installation...2558
      Steel Track Removal And Installation...2561
    TRACK FRAME...2564
      Disassembly And Assembly...2564
      Recoil Spring Cylinder Disassembly And Assembly (W/O Replaceable Shaft)...2566
      Recoil Spring Cylinder Parts Identification (With Replaceable Shaft)...2568
      Recoil Spring Cylinder Disassembly And Assembly (With Replaceable Shaft)...2569
    TRACK DAMAGE IDENTIFICATION...2572
      Cutting Of Steel Cords...2572
      Abrasion Of Embedded Metals...2573
      Separation Of Embedded Metals...2574
      Separation Of Embedded Metals Due To Corrosion...2575
      Cuts On The Lug Side Rubber...2576
      Cracks On The Lug Side Rubber Due To Fatigue...2577
      Lug Abrasion...2578
      Cracks And Cuts On The Lug Side Rubber...2579
      Abrasion Of The Track Roller Side...2580
      Cuts On The Edges Of Track Roller Side...2581
    TRACK IDLER...2584
      Parts Identification...2584
      Disassembly...2585
      Assembly...2587
    UPPER TRACK ROLLER...2590
      Parts Identification...2590
      Disassembly...2591
      Assembly...2593
    LOWER TRACK ROLLER...2596
      Parts Identification...2596
      Disassembly...2597
      Assembly...2599
    SWING CIRCLE GEAR...2602
      Swing Bearing Removal...2602
      Swing Bearing Installation...2603
  UPPERSTRUCTURE & SWING SECTION...2604
    UPPERSTRUCTURE...2608
      Removal...2608
      Installation...2611
    ROPS CANOPY...2614
      Removal And Installation...2614
    CAB...2618
      Removal And Installation...2618
      Door Removal And Installation...2623
      Front Window Removal And Installation...2624
      Right Side Rear Sliding Window Removal And Installation...2627
      Right Side Front Sliding Window Removal And Installation...2627
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...2628
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...2628
      Glass Removal...2629
      Glass Installation...2630
      Glass Installation (Cont’d)...2631
    SEAT AND SEAT MOUNT...2632
      Removal And Installation...2632
    RIGHT CONSOLE...2634
      Console Cover Removal And Installation...2634
      Console Base Removal And Installation...2635
    LEFT CONSOLE...2638
      Lower Console Cover Removal And Installation...2638
      Upper Console Cover Removal And Installation...2640
      Compression Spring Removal And Installation...2641
      Compression Spring Disassembly And Assembly...2642
      Lock Lever Removal And Installation...2644
      Console Removal And Installation...2645
      Disassembly And Assembly...2649
      Console Switch Removal And Installation...2652
      Console Base Removal And Installation...2653
    ENGINE SPEED CONTROL...2654
      Removal And Installation...2654
      Disassembly And Assembly...2655
      Adjustment (Later Models)...2656
    BLADE CONTROL...2658
      Lever Removal And Installation...2658
      Linkage Removal And Installation...2659
      Linkage Disassembly And Assembly...2660
      Control Cable Removal And Installation...2662
    RIGHT PEDAL AND LINKAGE...2664
      Pedal Removal And Installation...2664
      Pedal Disassembly And Assembly...2665
      Control Cable Removal And Installation...2667
    TRAVEL CONTROLS...2668
      Removal And Installation...2668
      Disassembly And Assembly...2671
      Adjustment...2673
    CONTROL LINKAGE ASSEMBLY...2676
      Removal And Installation...2676
    FLOOR MAT AND FLOOR PLATES...2678
      Removal And Installation...2678
    FUEL TANK...2680
      Removal And Installation...2680
    HORN...2682
      Removal And Installation (Earlier Models)...2682
      Removal And Installation (Later Models)...2682
    SWING FRAME...2684
      Boom Swing Bracket Removal And Installation...2684
      Boom Swing Bracket Hose Installation...2688
      Bushing Removal...2689
      Bushing Installation...2690
    BOOM...2692
      Removal And Installation...2692
    ARM...2694
      Removal And Installation...2694
      Arm To Boom Bushing Removal And Installation...2695
      Arm To Bucket And Bucket Link Bushing Removal And Installation...2696
    BUCKET...2698
      Bucket Teeth Removal And Installation...2698
      Bucket Side Cutting Edge Removal And Installation...2699
    CLAMP...2700
      Removal And Installation...2700
    TAILGATE...2702
      Removal And Installation...2702
    X-CHANGE...2704
      Removal And Installation...2704
      Parts Identification...2706
      Disassembly...2707
      Assembly...2712
      Check Proper Latch Engagement...2718
    X-CHANGE (HYDRAULIC)...2722
      Removal And Installation...2722
      Parts Identification...2725
      Disassembly...2726
      Assembly...2731
    UPPERSTRUCTURE SLEW LOCK...2740
      Removal And Installation...2740
      Disassembly And Assembly...2741
    RIGHT SIDE COVER...2744
      Removal And Installation...2744
    COUNTERWEIGHT...2746
      Removal And Installation...2746
  ELECTRICAL SYSTEM AND ANALYSIS...2748
    ELECTRICAL SCHEMATICS...2750
    ELECTRICAL SYSTEM INFORMATION...2753
      Troubleshooting Chart...2753
      Description...2754
      Fuse And Relay Location...2754
    BATTERY...2755
      Servicing...2755
      Removing And Installing The Battery...2756
      Using A Booster Battery (Jump Starting)...2756
    ALTERNATOR...2759
      Engine Accessory Drive Belt...2759
      Removal And Installation...2760
      Alternator Identification...2761
      Charging System Check...2761
      Alternator Voltage Test...2763
      Low Voltage Test...2763
      High Voltage Test...2764
      Rectifier Continuity (Diode) Test...2764
      Alternator Regulator Test...2765
      Parts Identification...2766
      Disassembly...2766
      Stator Continuity Test...2766
      Stator Ground Test...2767
      Rotor Continuity Test...2767
      Rotor Ground Test...2768
      Assembly...2768
    STARTER...2769
      Removal And Installation...2769
      Parts Identification...2770
      Disassembly...2771
      Inspection And Repair...2776
      Assembly...2779
    LIGHTS...2785
      Removal And Installation...2785
      Boom Light Removal and Installation (Earlier Models)...2786
      Boom Light Removal and Installation (Later Models)...2787
      Boom Light Bulb Replacement (Later Models)...2787
    TWO SPEED SWITCH...2789
      Removal And Installation...2789
    FUEL LEVEL SENDER...2791
      Removal And Installation...2791
      Testing...2791
    DIAGNOSTICS SERVICE CODE...2793
      Number Codes List...2793
    DELUXE INSTRUMENT PANEL SETUP...2795
      Passwords...2795
      Password Entry (For Starting and Operating the Machine)...2795
      Changing The Owner or Operator Password...2795
      Password Lockout Feature...2796
      Job Clock...2796
      RPM...2796
  ENGINE SERVICE...2797
    TROUBLESHOOTING...2799
      Chart...2799
    MUFFLER...2801
      Removal And Installation...2801
    AIR CLEANER...2803
      Removal And Installation...2803
    RADIATOR...2805
      Removal And Installation...2805
    ENGINE COMPONENTS AND TESTING...2811
      Engine Compression Checking...2811
      Glow Plug Removal And Installation...2812
      Checking The Glow Plug...2813
      Fuel Shut-off Solenoid Removal And Installation...2814
      Fuel Injection Pump Check...2816
      Fuel Injection Pump Removal And Installation...2817
      Fuel Injection Pump Timing...2820
      Fuel Injector Nozzles Removal And Installation...2822
      Fuel Injector Nozzle Check...2825
      Valve Clearance Adjustment...2826
    ENGINE...2827
      Removal And Installation...2827
    ENGINE FLYWHEEL (EARLY MODELS)...2835
      Removal And Installation...2835
      Removal And Installation...2836
      Flywheel Ring Gear...2836
    ENGINE FLYWHEEL (LATER MODELS)...2837
      Removal And Installation...2837
      Hydraulic Pump Coupler...2838
      Flywheel Ring Gear...2838
    RECONDITIONING THE ENGINE...2839
      Cylinder Head Removal And Installation...2839
      Cylinder Head Disassembly And Assembly...2842
      Cylinder Head Servicing...2843
      Cylinder Head Top Clearance...2843
      Valve Guide Checking...2844
      Reconditioning The Valve And Valve Seat...2846
      Valve Spring...2847
      Rocker Arm And Shaft Checking...2848
      Timing Gearcase Cover Removal And Installation...2849
      Idler Gear And Camshaft Removal And Installation...2852
      Camshaft Servicing...2853
      Idler Gear And Shaft Servicing...2854
      Timing Gears Checking Backlash...2855
      Fuel Camshaft Removal And Installation...2855
      Fuel Camshaft Governor...2856
      Crankshaft Gear Removal And Installation...2856
      Oil Pump Removal And Installation...2857
      Oil Pump Service...2857
      Checking Engine Oil Pressure...2859
      Valve Tappets...2859
      Piston And Connecting Rod Removal And Installation...2860
      Piston And Connecting Rod Servicing...2862
      Connecting Rod Alignment...2864
      Crankshaft And Bearings Removal And Installation...2865
      Crankshaft And Bearings, Servicing...2867
      Cylinder Bore, Checking...2870
      Water Pump Removal And Installation...2871
      Water Pump Disassembly And Assembly...2871
  HEATING, VENTILATION, AIR CONDITIONING...2873
    HEATER COIL (EARLY MODELS)...2877
      Removal And Installation With A/C...2877
      Removal And Installation Without A/C...2877
    HEATER COIL (LATER MODELS)...2879
      Removal And Installation With A/C...2879
      Removal And Installation Without A/C...2879
    BLOWER FAN (EARLY MODELS)...2881
      Removal And Installation...2881
      Disassembly And Assembly...2882
    BLOWER FAN (LATER MODELS)...2885
      Removal And Installation...2885
      Disassembly And Assembly...2886
      Resistor Removal And Installation...2887
    HEATER VALVE...2889
      Removal And Installation...2889
    AIR CONDITIONING SYSTEM FLOW...2892
      Principals...2892
      Chart...2893
    COMPONENTS...2895
      Identification...2895
    SAFETY...2899
      Safety Equipment...2899
    REGULAR MAINTENANCE...2901
      Heater Air Filter...2901
      Engine Accessory Drive Belt...2901
      Cleaning The Condenser...2901
    BASIC TROUBLESHOOTING (EARLY MODELS)...2903
      Poor A/C Performance...2903
      Cleaning The A/C Evaporator Coil & Heater Coil...2904
      Engine Accessory Drive Belt...2906
      Checking The Electrical System...2907
      Engine Coolant By-Passing The Heater Valve...2917
    BASIC TROUBLESHOOTING (LATER MODELS)...2919
      Poor A/C Performance...2919
      Cleaning The A/C Evaporator Coil & Heater Coil...2920
      Engine Accessory Drive Belt...2921
      Checking The Electrical System...2922
      Engine Coolant By-Passing The Heater Valve...2932
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...2933
      Compressor Oil...2933
      Compressor Oil Check...2933
      Component Replacement And Refrigeration Leaks...2935
    SYSTEM TROUBLESHOOTING CHART...2937
      Blower Motor Does Not Operate...2937
      Gauge Pressure Related Troubleshooting...2938
    TEMPERATURE/PRESSURE...2941
      Chart...2941
    AIR CONDITIONING SERVICE...2943
      Chart...2943
    SYSTEM CHARGING AND RECLAMATION...2945
      Reclamation Procedure...2945
      Charging Procedure With A Manifold Gauge Set...2948
    COMPRESSOR...2951
      Removal And Installation...2951
      Compressor Clutch Disassembly And Assembly...2952
    CONDENSER...2955
      Removal And Installation...2955
    RECEIVER/DRIER...2957
      Removal And Installation...2957
    PRESSURE RELIEF VALVE...2959
      Removal And Installation...2959
    PRESSURE SWITCH...2961
      Removal And Installation...2961
    EVAPORATOR/HEATER UNIT (EARLY MODELS)...2963
      Removal And Installation...2963
      Disassembly And Assembly...2964
    EVAPORATOR/HEATER UNIT (later MODELS)...2965
      Removal And Installation...2965
      Disassembly And Assembly...2966
    THERMOSTAT (EARLY MODELS)...2967
      Removal And Installation...2967
    THERMOSTAT (LATER MODELS)...2969
      Removal And Installation...2969
    EXPANSION VALVE (EARLY MODELS)...2971
      Removal And Installation...2971
    EXPANSION VALVE (LATER MODELS)...2973
      Removal And Installation...2973
    EVAPORATOR (EARLY MODELS)...2975
      Removal And Installation...2975
    EVAPORATOR (LATER MODELS)...2977
      Removal And Installation...2977
  SPECIFICATIONS...2979
    SPECIFICATIONS...2981
      430 W/Extendable Arm Excavator Machine Dimensions...2981
      430 Excavator Machine Dimensions...2982
      430 Excavator W/Long Arm Machine Dimensions...2983
      Excavator Extendable Arm Machine Dimensions...2984
      Performance (S/N 56251101 & Above And 562711001 & Above...2985
      Performance (S/N 562911001 & Above)...2985
      Performance (S/N 563011001 & Above)...2985
      Controls...2985
      Engine...2986
      Hydraulic System...2987
      Hydraulic Cylinders (S/N 562511001 & Above And 562711001 & Above)...2988
      Hydraulic Cylinders (S/N 562911001 & Above And 563011001 & Above)...2988
      Hydraulic Cycle Times...2988
      Drive System (S/N 562511001 & Above And 562711001)...2989
      Drive System (S/N 562911001 & Above)...2989
      Drive System (S/N 563011001 & Above)...2989
      Undercarriage...2989
      Track (S/N 562511001 & Above)...2989
      Track (S/N 562711001 & Above, 562911001 & Above And 563011001 & Above)...2990
      Electrical...2990
    ENGINE SPECIFICATIONS...2991
      Fuel Injection Nozzles...2991
      Fuel Injection Pump (S/N 562511001 & Above)...2991
      Fuel Injection Pump (S/N 562711001 Above, 562911001 & Above And 563011001 & Above)...2991
      Cylinder Head...2991
      Valves...2992
      Valve Springs...2992
      Valve Timing...2992
      Rocker Arms...2992
      Camshaft...2993
      Tappet...2993
      Cylinders...2993
      Piston Rings...2993
      Pistons...2993
      Connecting Rods...2994
      Oil Pump...2994
      Crankshaft...2995
      Timing Gear...2995
      Thermostat...2996
      Engine Bolt Torque...2996
      Crankshaft Re-Grind Data...2997
    TORQUE SPECIFICATIONS...2999
      Torque for General SAE Bolts...2999
      Torque For General Metric Bolts...3000
    HYDRAULIC CONNECTION SPECIFICATIONS...3001
      O-Ring Face Seal Connection...3001
      Straight Thread O-Ring Fitting...3001
      Tubelines And Hoses...3001
      Flare Fitting...3002
      O-Ring Flare Fitting...3003
      Port Seal Fitting...3005
    HYDRAULIC FLUID SPECIFICATIONS...3007
      Specifications...3007
    FUEL, COOLANT AND LUBRICANTS...3009
      Chart...3009
    CONVERSIONS...3011
      Decimal And Millimeter Equivalents...3011
      U.S. To Metric Conversion Chart...3011
  SERVICE MANUAL REVISION...3013
    Revision No: 430 - 1...3013
    Revision No: 430 - 2...3015
    Revision No: 430 - 3...3017
    Revision No: 430 - 4...3019
    Revision No: 430 - 5...3021
    Revision No: 430 - 6...3025
    Revision No: 430 - 7...3027
    Revision No: 430 - 8...3029
    Revision No: 430 - 9...3031
    Revision No: 430 - 10...3033
    Revision No: 430 - 11...3035
    Revision No: 430 - 12...3037
    Revision No: 430 - 13...3039
    Revision No: 430 - 14...3041
    Revision No: 430 - 15...3043
6902330 (8-06) - 435 Compact Excavator Operation & Maintenance Manual...3045
  CONTENTS...3049
  FOREWORD...3051
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...3053
    REGULAR MAINTENANCE ITEMS...3053
    SERIAL NUMBER LOCATIONS...3055
      Excavator Serial Number...3055
      Engine Serial Number...3055
    DELIVERY REPORT...3055
    EXCAVATOR IDENTIFICATION...3056
    FEATURES, ACCESSORIES AND ATTACHMENTS...3057
      Standard Items...3057
      Options and Accessories...3057
      Attachments...3057
      Buckets Available...3057
    FALLING OBJECT GUARDS (FOGS)...3058
      Falling Object Guards (FOGS)...3058
      Special Applications Kit...3058
      Special Applications Kit Inspection And Maintenance...3058
  SAFETY & TRAINING RESOURCES...3059
    SAFETY INSTRUCTIONS...3061
      Before Operation...3061
      Safe Operation Is The Operator’s Responsibility...3062
      Safe Operation Needs A Qualified Operator...3062
      Fire Prevention...3063
    MACHINE SIGNS (DECALS)...3064
    PUBLICATIONS AND TRAINING RESOURCES...3066
  OPERATING INSTRUCTIONS...3067
    INSTRUMENTS AND CONSOLES...3069
      Cab Interior Light (If Equipped)...3069
      Left Console...3069
      Right Console...3070
      Function Icons...3071
      STD/ISO Selector Valve...3072
      Upperstructure Slew Lock...3072
      Raising And Lowering The Console...3072
      Two-Speed Travel...3073
    OPERATOR CANOPY (ROPS / TOPS)...3074
      Description...3074
    OPERATOR CAB (ROPS / TOPS)...3074
      Description...3074
    OPERATOR CAB (ROPS / TOPS)...3075
      Cab Door...3075
      Front Window...3076
      Front Wiper...3077
      Window Washer Reservoir...3077
      Right Side Window (Early Models)...3078
      Right Side Windows (Later Models)...3079
      Heating, Ventilation, and Air Conditioning Duct...3080
    TRAVEL CONTROLS...3081
      Description...3081
      Forward And Reverse...3081
      Turning...3081
    HYDRAULIC CONTROLS...3083
      Description...3083
      Standard Control Pattern...3083
      ISO Control Pattern...3084
      Quick Couplers...3085
      Auxiliary Hydraulics...3086
      Relieving Hydraulic Pressure (Excavator And Attachment)...3086
      Return To Tank Valve (If Equipped)...3086
    BLADE CONTROL LEVER...3087
      Operation...3087
    BOOM SWING PEDAL...3087
      Operation...3087
    DAILY INSPECTION...3088
      Daily Inspection And Maintenance...3089
    PRE-STARTING PROCEDURE...3090
      Operation & Maintenance Manual And Operator’s Handbook Locations...3090
      Entering The Excavator...3090
      Seat Adjustment...3091
      Seat Belt Adjustment...3091
      Control Console...3091
    STARTING THE ENGINE...3092
      Key Switch...3092
      Keyless...3093
      Cold Temperature Starting...3094
      Warming The Hydraulic System...3095
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...3096
      Procedure...3096
      Emergency Exits...3097
    ATTACHMENTS...3098
      Installing And Removing The Attachment (Hydraulic X-Change)...3098
      Installing And Removing The Attachment (Pin-On X- Change)...3103
      Installing And Removing The Attachment (Bolt-On X- Change)...3109
      Installing And Removing The Attachment (Pin-On Attachment)...3115
    OPERATING PROCEDURE...3116
      Inspect The Work Area...3116
      Lowering The Work Equipment (Engine STOPPED)...3116
      Operating On Public Roads...3116
      Horsepower Control System (S/N 562511001 & Above, 562711001 & Above and 563011001 & Above)...3117
      Lifting A Load...3118
      Excavating...3119
      Boom Swing...3121
      Backfilling...3122
      Driving The Excavator...3122
      Operating On Slopes...3123
      Operating In Water...3125
      Avoiding Track Damage...3125
    TOWING THE EXCAVATOR...3125
      Procedure...3125
    LIFTING THE EXCAVATOR...3126
      Procedure...3126
    TRANSPORTING THE EXCAVATOR ON A TRAILER...3127
      Loading And Unloading...3127
      Fastening...3127
  PREVENTIVE MAINTENANCE...3129
    MAINTENANCE SAFETY...3131
    SERVICE SCHEDULE...3133
      Chart...3133
    CONTROL CONSOLE LOCKOUTS...3134
      Inspection And Maintenance...3134
    SEAT BELT...3135
      Inspection And Maintenance...3135
    TAILGATE...3136
      Opening And Closing...3136
      Adjusting The Latch...3136
    RIGHT SIDE COVER...3137
      Opening And Closing...3137
    CAB FILTERS...3138
      Cleaning And Maintenance...3138
    AIR CLEANER SERVICE...3139
      Daily Check...3139
      Replacing Filter Elements...3139
    FUEL SYSTEM...3141
      Fuel Specifications...3141
      Filling The Fuel Tank...3141
      Fuel Filters...3142
      Inline Fuel Filter...3142
      Draining The Fuel Tank...3143
      Removing Air From The Fuel System...3143
    ENGINE LUBRICATION SYSTEM...3144
      Checking And Adding Engine Oil...3144
      Engine Oil Chart...3144
      Removing And Replacing Oil Filter...3145
    ENGINE COOLING SYSTEM...3146
      Cleaning...3146
      Checking Level...3147
      Removing And Replacing Coolant...3148
    ELECTRICAL SYSTEM...3149
      Description...3149
      Fuse And Relay Location/Identification...3149
      Battery Maintenance...3150
      Using A Booster Battery (Jump Starting)...3151
      Removing And Installing Battery...3152
    HYDRAULIC SYSTEM...3153
      Checking And Adding Fluid...3153
      Hydraulic Fluid Chart...3153
      Removing And Replacing The Hydraulic Filter...3154
      Removing And Replacing The Case Drain Filter...3154
      Removing And Replacing The Fan Filter...3155
      Removing And Replacing The Hydraulic Fluid...3156
    SPARK ARRESTOR MUFFLER...3157
      Cleaning Procedure...3157
    TRACK TENSION...3158
      Adjusting...3158
    TRAVEL MOTOR...3160
      Checking And Adding Oil...3160
      Removing And Replacing Oil...3160
    ENGINE ACCESSORY DRIVE BELT...3161
      Belt Adjustment...3161
      Belt Replacement...3161
    DRIVE BELT (FASTTRACK S/N 562611001 & ABOVE AND 562811001 & ABOVE)...3162
      Belt Adjustment...3162
    X-CHANGE...3164
      Inspection And Maintenance...3164
    TRACK ROLLER AND IDLER LUBRICATION...3164
      Procedure...3164
    BUCKET...3165
      Bucket Teeth Removal And Installation...3165
    LUBRICATING THE EXCAVATOR...3166
      Lubrication Locations...3166
    PIVOT PINS...3169
      Inspection And Maintenance...3169
    EXCAVATOR STORAGE AND RETURN TO SERVICE...3170
      Storage...3170
      Return to Service...3170
  SYSTEM SETUP AND ANALYSIS...3171
    DIAGNOSTIC SERVICE CODE...3173
      Service Codes List...3173
    DISPLAY CONTROLLER PANEL SETUP...3174
      Passwords...3174
      Password Entry (For Starting and Operating the Machine)...3174
      Changing The Operator Password...3174
      Password Lockout Feature...3175
      Job Clock...3175
      RPM...3175
      Viewing Service Codes (Key Switch)...3176
      Viewing Service Codes (Keyless)...3176
  MACHINE SIGN TRANSLATIONS...3177
    WARNING (6808185)...3179
    LIFT CHART...3180
      435 STANDARD ARM S/N 562611001 & Above AND 562811001 - 562811302 (7100504)...3180
    LIFT CHART...3183
      435 LONG ARM S/N 562611001 & Above AND 562811001 - 562811302 (7106219)...3183
    LIFT CHART...3186
      435 STANDARD ARM S/N 562811303 & Above, 563111001 & Above and 563211001 & above (7107501)...3186
    LIFT CHART...3189
      435 LONG ARM S/N 562811303 & ABOVE, 563111001 & Above and 563211001 & above (7107502)...3189
    SERVICE SCHEDULE (7125438)...3192
    WARNING (6807776)...3195
    WARNING (6804114, 6817225, 6804233)...3197
    WARNING (6817815)...3198
      WARNING (6808474)...3198
    EMERGENCY EXIT (6815984)...3198
    WARNING (6576048)...3200
    WARNING (6815915)...3201
    WARNING (6817816)...3202
    WARNING (7102651)...3205
    WARNING (6809829)...3208
    JOYSTICK CONTROL PATTERN SELECTOR LEVER (6815957)...3209
  SPECIFICATIONS...3211
    EXCAVATOR SPECIFICATIONS...3213
      435 Dimensions With Standard Arm, Long Arm Option and Extendable Arm Kit...3213
      Excavator Standard Arm Machine Dimensions...3214
      Performance (S/N 562611001 & Above, 562811001 & Above And 563211001 & Above)...3215
      Performance (S/N 563111001 & Above)...3215
      Controls...3215
      Engine...3216
      Hydraulic System...3217
      Hydraulic Cylinders...3217
      Hydraulic Cycle Times...3218
      Electrical...3218
      Drive System...3218
      Slew System...3218
      Undercarriage...3218
      Capacities...3218
      Fuel Tank...3218
      Tracks...3219
      Type...3219
      Ground Pressure...3219
  WARRANTY...3221
  ALPHABETICAL INDEX...3225
6902331 (4-08) - 435 Service Manual...3227
  MAINTENANCE SAFETY...3229
  ALPHABETICAL INDEX...3231
  CONTENTS...3233
    FOREWORD...3235
    SAFETY INSTRUCTIONS...3237
      Fire Prevention...3239
    SERIAL NUMBER LOCATIONS...3241
      Excavator Serial Number...3241
      Engine Serial Number...3241
    DELIVERY REPORT...3242
    BOBCAT EXCAVATOR IDENTIFICATION...3243
  SAFETY AND MAINTENANCE...3245
    LIFTING AND BLOCKING THE EXCAVATOR...3247
      Procedure...3247
    UPPERSTRUCTURE SLEW LOCK...3249
      Operation...3249
    LIFTING THE EXCAVATOR...3251
    OPERATOR CAB (ROPS/TOPS)...3253
      Emergency Exit (Early Models)...3253
      Emergency Exit (Later Models)...3254
      Cab Door...3255
      Front Window...3256
      Right Side Windows (Early Models)...3257
      Right Side Windows (Later Models)...3258
    TRANSPORTING THE EXCAVATOR...3261
      Procedure...3261
    TAILGATE...3263
      Opening And Closing The Tailgate...3263
      Adjusting The Latch...3263
    RIGHT SIDE COVER...3265
      Opening And Closing The Right Side Cover...3265
    SERVICE SCHEDULE...3267
      Chart...3267
    AIR CLEANER...3269
      Daily Check...3269
      Replacing The Filters...3269
    HEATER AIR FILTER (WITH CAB OPTION ONLY)...3271
      Removal And Installation...3271
    COOLING SYSTEM...3273
      Cleaning The Cooling System...3273
      Checking Coolant Level...3273
      Replacing The Coolant...3274
    FUEL SYSTEM...3277
      Fuel Specifications...3277
      Filling The Fuel Tank...3277
      Removing Water From The Fuel Filter...3278
      Draining The Fuel Tank...3278
      Spin On Fuel Filter...3279
      Inline Fuel Filter...3279
    ENGINE LUBRICATION SYSTEM...3281
      Checking Engine Oil...3281
      Replacing Oil And Filter...3281
    HYDRAULIC SYSTEM...3283
      Checking And Adding Hydraulic Oil...3283
      Replacing The Hydraulic Oil...3284
      Replacing The Hydraulic Filter...3285
      Replacing The Case Drain Filter...3285
      Replacing The Fan Filter...3286
      Diagnostic Couplers...3287
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...3289
    TRAVEL MOTOR...3293
      Checking Oil Level...3293
      Draining The Travel Motor...3293
    SPARK ARRESTOR MUFFLER...3295
    ENGINE ACCESSORY DRIVE BELT...3297
      Belt Tension...3297
      Belt Adjustment...3297
  HYDRAULIC SYSTEM...3299
    HYDRAULIC/HYDROSTATIC SCHEMATICS...3307
    HYDRAULIC SYSTEM INFORMATION...3313
      Glossary Of Hydraulic/Hydrostatic Symbols For Excavators...3313
      Troubleshooting The Hydraulic Circuit...3316
      Troubleshooting The Cylinder Circuit...3317
      Troubleshooting The Upperstructure Slew Circuit...3318
    BOOM CYLINDER...3319
      Testing...3319
      Removal And Installation...3321
      Parts Identification...3324
      Disassembly...3325
      Assembly...3328
    ARM CYLINDER...3331
      Testing...3331
      Removal and Installation...3333
      Parts Identification...3335
      Disassembly...3336
      Assembly...3339
    BOOM SWING CYLINDER...3343
      Testing...3343
      Removal And Installation...3345
      Parts Identification...3347
      Disassembly...3348
      Assembly...3351
    BUCKET CYLINDER...3355
      Testing...3355
      Removal And Installation...3357
      Parts Identification...3358
      Disassembly...3359
      Assembly...3361
    BLADE CYLINDER...3365
      Testing...3365
      Removal And Installation...3366
      Parts Identification...3367
      Disassembly...3368
      Assembly...3370
    CLAMP CYLINDER...3373
      Testing...3373
      Removal And Installation...3374
      Parts Identification...3375
      Disassembly...3376
      Assembly...3379
    ANGLE BLADE CYLINDER...3385
      Testing...3385
      Removal And Installation...3386
      Parts Identification...3388
      Disassembly...3389
      Assembly...3391
    MAIN RELIEF VALVES...3395
    PORT RELIEF VALVES...3397
      Port Relief Valve Pressure Setting...3397
      Parts Identification...3397
      Adjustment Procedure...3398
    CROSSPORT RELIEF VALVE...3399
      Testing And Adjusting The Crossport Relief Valve...3399
      Removal And Installation...3401
      Disassembly And Assembly...3402
    PRESSURE REDUCING VALVE...3407
      Description...3407
    ANGLE BLADE VALVE...3409
      Description...3409
      Testing And Adjusting Port Relief Valves...3409
      Testing And Adjusting Sequence Valve...3411
      Removal And Installation...3413
      Parts Identification...3416
      Disassembly...3417
      Assembly...3430
    HYDRAULIC CONTROL VALVE (S/N 562611001 & ABOVE, 562811001 & ABOVE AND 563211001 & ABOVE)...3443
      Removal And Installation...3443
      Parts Identification...3446
      Disassembly...3447
      Slew Valve Section Disassembly And Assembly...3449
      Blade Valve Section Disassembly And Assembly...3455
      Bucket Valve Section Disassembly And Assembly...3467
      Arm Valve Section Disassembly And Assembly...3473
      Boom Valve Section Disassembly And Assembly...3479
      Boom Swing Valve Section Disassembly And Assembly...3485
      Auxiliary Valve Section Disassembly And Assembly...3491
      Inlet Section Disassembly And Assembly...3499
      Assembly...3504
    HYDRAULIC CONTROL VALVE (S/N 563111001 & ABOVE)...3509
      Removal And Installation...3509
      Parts Identification...3512
      Disassembly...3513
      Right Travel Valve Section Disassembly And Assembly...3515
      Left Travel Valve Section Disassembly And Assembly...3518
      Slew Valve Section Disassembly And Assembly...3521
      Blade Valve Section Disassembly And Assembly...3527
      Bucket Valve Section Disassembly And Assembly...3538
      Arm Valve Section Disassembly And Assembly...3544
      Boom Valve Section Disassembly And Assembly...3550
      Boom Swing Valve Section Disassembly And Assembly...3556
      Auxiliary Valve Section Disassembly And Assembly...3562
      Inlet Section Disassembly And Assembly...3570
      Assembly...3575
    HYDRAULIC PUMP (S/N 562611001 & ABOVE AND 562811001 & ABOVE)...3581
      Hydraulic Pump Work Sheet...3581
      Pump Testing...3584
      Test Fitting Installation...3584
      Torque Limiter Adjustment...3593
      Removal And Installation...3597
      Coupler Removal And Installation...3599
      Torque Limiter Valve Parts Identification...3600
      Torque Limiter Valve Removal...3601
      Torque Limiter Valve Disassembly...3601
      Torque Limiter Valve Assembly...3606
      Initial Torque Limiter Valve Setting...3609
      Torque Limiter Valve Installation...3611
      Pump Control Parts Identification...3612
      Pump Control Removal And Installation...3613
      Pump Control Disassembly And Assembly...3613
      Parts Identification...3619
      Disassembly...3620
      Assembly...3629
    HYDRAULIC PUMP (S/N 563111001 & Above AND 563211001 & above)...3639
      Piston Pump Work Sheet...3639
      Piston Pump Testing...3642
      Test Fitting Installation...3642
      Torque Limiter Adjustment...3649
      Description...3652
      Gear Pump Testing...3652
      Removal And Installation...3654
      Coupler Removal And Installation...3656
      Hydraulic Pump Start Up...3657
      Torque Limiter Valve Parts Identification...3658
      Torque Limiter Valve Removal...3659
      Torque Limiter Valve Disassembly...3660
      Torque Limiter Valve Assembly...3664
      Initial Torque Limiter Valve Setting...3667
      Torque Limiter Valve Installation...3669
      Pump Control Parts Identification...3670
      Pump Control Removal And Installation...3671
      Pump Control Disassembly And Assembly...3671
      Parts Identification...3677
      Gear Pump Removal And Installation...3678
      Gear Pump Disassembly And Assembly...3679
      Piston Pump Parts Identification...3684
      Piston Pump Disassembly...3685
      Piston Pump Assembly...3694
    HYDRAULIC PUMP (S/N 563112526 & ABOVE AND 563212618 & ABOVE)...3705
      Hydraulic Pump Work Sheet...3705
      Piston Pump Testing...3708
      Test Fitting Installation...3708
      Back-up Relief Valve Adjustment...3713
      Torque Limiter Adjustment...3717
      Torque Limiter Adjustment...3718
      Description...3720
      Gear Pump Testing...3720
      Removal And Installation...3722
      Coupler Removal And Installation...3724
      Torque Limiter Valve Parts Identification...3725
      Torque Limiter Valve Removal...3726
      Torque Limiter Valve Disassembly...3727
      Torque Limiter Valve Assembly...3731
      Initial Torque Limiter Valve Setting...3734
      Torque Limiter Valve Installation...3736
      Pump Control Parts Identification...3737
      Pump Control Removal And Installation...3738
      Pump Control Disassembly And Assembly...3738
      Parts Identification...3744
      Gear Pump Removal And Installation...3745
      Gear Pump Disassembly And Assembly...3746
    HYDRAULIC PUMP (S/N 563112526 & ABOVE AND 563212618 & ABOVE) (CONT’D)...3751
      Piston Pump Parts Identification...3751
    HYDRAULIC PUMP (S/N 563112526 & ABOVE AND 563212618 & ABOVE) (CONT’D)...3752
      Piston Pump Disassembly...3752
      Piston Pump Assembly...3761
    MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 562611001 & ABOVE, 562811001 & ABOVE, AND 563211001 - 563213999)...3773
      Description...3773
      Testing Pilot Pressure...3774
      Removal And Installation...3775
      Parts Identification...3777
      Disassembly...3778
      Assembly...3791
    MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 563214000 & ABOVE)...3803
      Description...3803
      Testing Pilot Pressure...3804
      Removal And Installation...3805
      Parts Identification...3807
      Disassembly...3808
      Assembly...3821
    MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 563111001 - 563113999)...3833
      Description...3833
      Testing Pilot Pressure...3834
      Removal And Installation...3835
      Parts Identification...3837
      Disassembly...3838
      Assembly...3847
    MANIFOLD ASSEMBLY/ACCUMULATOR (S/N 563114000 & ABOVE)...3857
      Description...3857
      Testing Pilot Pressure...3858
      Removal And Installation...3859
      Parts Identification...3862
      Disassembly...3863
      Assembly...3872
    TRAVEL MOTOR (S/N 562611001 & ABOVE, 562811001 & ABOVE, AND 563211001 & ABOVE)...3881
      Removal And Installation...3881
      Parts Identification...3883
      Disassembly...3884
      Assembly...3898
    TRAVEL MOTOR (S/N 563111001 & ABOVE) (EARLY MODELS)...3915
      Removal And Installation...3915
      Parts Identification...3917
      Disassembly...3918
      Assembly...3933
    TRAVEL MOTOR (S/N 563111001 & ABOVE) (LATER MODELS)...3949
      Removal And Installation...3949
      Parts Identification...3950
      Disassembly...3951
      Assembly...3961
    SWIVEL JOINT...3973
      Removal And Installation...3973
      Parts Identification...3975
      Description...3976
      Disassembly...3976
      Assembly...3979
    SWING MOTOR...3983
      Removal And Installation...3983
      Parts Identification...3987
      Parts Identification (Cont’d)...3988
      Disassembly...3989
      Inspection...3994
      Assembly...3995
    SWING MOTOR DRIVE CARRIER...4001
      Removal And Installation...4001
      Parts Identification...4002
      Checking The Drive Carrier Shaft End Play...4003
      Disassembly...4004
      Inspection...4006
      Assembly...4007
    CONTROL PATTERN SELECTOR VALVE...4011
      Removal And Installation...4011
      Parts Identification...4012
      Disassembly...4013
      Assembly...4015
    RIGHT CONTROL LEVER (JOYSTICK)...4017
      Testing...4017
      Handle Removal And Installation...4018
      Joystick Assembly Removal And Installation...4022
      Parts Identification...4025
      Disassembly...4026
      Assembly...4031
    LEFT CONTROL LEVER (JOYSTICK)...4035
      Testing...4035
      Handle Removal And Installation...4037
      Joystick Assembly Removal And Installation...4040
      Parts Identification...4042
      Disassembly...4043
      Assembly...4048
    TRAVEL CONTROL VALVE (S/N 562611001 & ABOVE, 562811001 & ABOVE AND 563211001 & ABOVE)...4053
      Removal and Installation...4053
      Parts Identification...4054
      Disassembly And Assembly...4055
    TRAVEL CONTROL VALVE (S/N 563111001 & ABOVE)...4061
      Removal and Installation...4061
      Parts Identification...4062
      Disassembly And Assembly...4063
    HOSES...4067
      Hose Guide Location...4067
      Left Control Lever (Joystick) (S/N 563114000-563114006 AND 563115000 & Above)...4068
      Left Control Lever (Joystick) (S/N 563214000 - 563214007 AND 563215000 & Above)...4069
      Right Control Lever (Joystick) (S/N 563114000 - 563114006 AND 563115000 & Above)...4070
      Right Control Lever (Joystick) (S/N 563214000 - 563214007 AND 563215000 & Above)...4071
      Travel Control Valve (S/N 563114000-563114006 AND 563115000 & Above)...4072
      Travel Control Valve (S/N 563214000 - 563214007 AND 563215000 & Above)...4073
      Manifold Assembly / Accumulator (S/N 563114000 - 563114006 AND 563115000 & Above)...4074
      Manifold Assembly / Accumulator (S/N 563214000 - 563214007 AND 563215000 & Above)...4075
    HYDRAULIC FILTER MOUNT...4077
      Removal And Installation...4077
    HYDRAULIC RESERVOIR...4079
      Removal And Installation...4079
    OIL COOLER...4081
      Removal And Installation...4081
    DIRECT TO TANK VALVE (IF EQUIPPED)...4085
      Removal And Installation...4085
      Parts Identification...4086
      Disassembly And Assembly...4087
    DUAL SEQUENCE VALVE (S/N 562611001 & ABOVE, 562811001 & ABOVE, 563111001 - 563113999 563211001 - 563213999)...4089
      Removal And Installation...4089
      Parts Identification...4092
      Disassembly And Assembly...4093
    DUAL SEQUENCE VALVE (S/N 563214000 & Above)...4097
      Removal And Installation...4097
      Parts Identification...4099
      Disassembly And Assembly...4100
    DUAL SEQUENCE VALVE (S/N 563114000 & Above)...4103
      Removal And Installation...4103
      Parts Identification...4105
      Disassembly And Assembly...4106
    BUILD UP VALVE...4109
      Removal And Installation...4109
      Parts Identification...4110
      Disassembly And Assembly...4111
    COOLING FAN...4113
      Description...4113
      Testing...4113
      Removal And Installation...4114
      Parts Identification...4116
      Disassembly And Assembly...4117
    REMOVING AIR FROM HYDRAULIC SYSTEM...4125
      Procedure...4125
    BOOM SWING LOCK VALVE...4129
      Description...4129
      Removal And Installation...4129
      Parts Identification...4131
      Disassembly...4132
      Assembly...4135
    HYDRAULIC X-CHANGE VALVE...4139
      Removal And Installation...4139
      Parts Identification...4142
      Disassembly...4143
      Assembly...4151
  HYDROSTATIC SYSTEM...4159
    HYDROSTATIC SYSTEM INFORMATION...4161
      Troubleshooting Chart...4161
      Relief/Replenishing Valve Function...4162
      Relief/Replenishing Valve Location...4163
      Relief/Replenishing Valve Removal And Installation...4163
      Charge Pressure Relief Valve Removal And Installation...4164
      Charge Pressure Relief Valve Disassembly And Assembly...4164
    TRAVEL PILOT PRESSURE...4165
      Description...4165
      Testing...4165
    HYDROSTATIC PUMP...4167
      Removal And Installation...4167
      Fan/Charge Pump Parts Identification...4170
      Fan/Charge Pump Disassembly And Assembly...4171
      Parts Identification (Front) (S/N 562611001 & Above, 562811001 & Above And 563211001 & Above)...4176
      Parts Identification (Rear) (S/N 562611001 & Above And 562811001 & Above)...4177
      Parts Identification (Rear) (S/N 563211001 & Above)...4178
      Disassembly...4179
      Inspection...4190
      Assembly...4192
      Hydrostatic Pump Start-Up...4204
    FAN/CHARGE PUMP...4205
      Description...4205
      Testing...4205
    DRIVE BELT SHIELD...4207
      Removal And Installation...4207
    DRIVE BELT...4209
      Adjustment...4209
      Removal And Installation...4211
  UNDERCARRIAGE...4213
    BLADE...4215
      Removal And Installation...4215
    ANGLE BLADE ASSEMBLY...4217
      Removal And Installation...4217
    ANGLE BLADE...4219
      Removal And Installation...4219
    ANGLE BLADE CUTTING EDGE...4221
      Removal And Installation...4221
    TRACKS...4223
      Track Lug Height...4223
      Rubber Track Clearance...4224
      Steel Track Clearance...4225
      Adjustment...4225
      Rubber Track Removal And Installation...4226
      Steel Track Removal And Installation...4229
    TRACK FRAME...4235
      Disassembly And Assembly...4235
      Recoil Spring Cylinder Disassembly And Assembly...4238
    TRACK DAMAGE IDENTIFICATION...4239
      Cutting Of Steel Cords...4239
      Abrasion Of Embedded Metals...4240
      Separation Of Embedded Metals...4241
      Separation Of Embedded Metals Due To Corrosion...4242
      Cuts On The Lug Side Rubber...4243
      Cracks On The Lug Side Rubber Due To Fatigue...4244
      Lug Abrasion...4245
      Cracks And Cuts On The Lug Side Rubber...4246
      Abrasion Of The Track Roller Side...4247
      Cuts On The Edges Of Track Roller Side...4248
    TRACK IDLER...4251
      Parts Identification...4251
      Disassembly...4252
      Assembly...4254
    UPPER TRACK ROLLER...4257
      Parts Identification...4257
      Disassembly...4258
      Assembly...4259
    LOWER TRACK ROLLER...4263
      Parts Identification...4263
      Disassembly...4264
      Assembly...4265
    SWING CIRCLE GEAR...4269
      Swing Bearing Removal...4269
      Swing Bearing Installation...4270
  UPPERSTRUCTURE & SWING SECTION...4271
    UPPERSTRUCTURE...4275
      Removal...4275
      Installation...4278
    ROPS CANOPY...4281
      Removal And Installation...4281
    CAB...4285
      Removal And Installation...4285
      Door Removal And Installation...4290
      Front Window Removal And Installation...4291
      Right Side Rear Sliding Window Removal And Installation...4294
      Right Side Front Sliding Window Removal And Installation...4294
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...4295
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...4295
      Glass Removal...4296
      Glass Installation...4297
      Glass Installation (Cont’d)...4298
      Glass Installation (Cont’d)...4299
    SEAT AND SEAT MOUNT...4301
      Removal And Installation...4301
    RIGHT CONSOLE...4303
      Console Cover Removal And Installation...4303
      Console Base Removal And Installation...4304
      Console Base Removal And Installation (Cont’d)...4305
    LEFT CONSOLE...4307
      Lower Console Cover Removal And Installation...4307
      Upper Console Cover Removal And Installation...4309
      Compression Spring Removal And Installation...4310
      Compression Spring Disassembly And Assembly...4311
      Lock Lever Removal And Installation...4313
      Console Removal And Installation...4314
      Disassembly And Assembly...4318
      Console Switch Removal And Installation...4321
      Console Base Removal And Installation...4322
    ENGINE SPEED CONTROL...4323
      Removal And Installation...4323
      Disassembly And Assembly...4324
      Adjustment (Later Models)...4325
    BLADE CONTROL...4327
      Lever Removal And Installation...4327
      Linkage Removal And Installation...4328
      Linkage Disassembly And Assembly...4329
      Control Cable Removal And Installation...4331
    RIGHT PEDAL AND LINKAGE...4333
      Pedal Removal And Installation...4333
      Pedal Disassembly And Assembly...4334
      Control Cable Removal And Installation...4336
    TRAVEL CONTROLS...4337
      Removal And Installation...4337
      Disassembly And Assembly...4340
      Adjustment...4342
    CONTROL LINKAGE ASSEMBLY...4345
      Removal And Installation...4345
    FLOOR MAT AND FLOOR PLATES...4347
      Removal And Installation...4347
    FUEL TANK...4349
      Removal And Installation...4349
    HORN...4351
      Removal And Installation (Earlier Models)...4351
      Removal And Installation (Later Models)...4351
    SWING FRAME...4353
      Boom Swing Bracket Removal And Installation...4353
      Boom Swing Bracket Hose Installation...4357
      Bushing Removal...4358
      Bushing Installation...4359
    BOOM...4361
      Removal And Installation...4361
    ARM...4363
      Removal And Installation...4363
      Arm To Boom Bushing Removal And Installation...4364
      Arm To Bucket And Bucket Link Bushing Removal & Installation...4365
    BUCKET...4367
      Bucket Teeth Removal And Installation...4367
      Bucket Side Cutting Edge Removal And Installation...4368
    TAILGATE...4369
      Removal And Installation...4369
    X-CHANGE...4371
      Removal And Installation...4371
      Parts Identification...4373
      Disassembly...4374
      Assembly...4379
      Check Proper Latch Engagement...4385
    X-CHANGE (PIN ON)...4389
      Removal And Installation...4389
      Parts Identification...4391
      Disassembly And Assembly...4392
    RIGHT SIDE COVER...4393
      Removal And Installation...4393
    X-CHANGE (HYDRAULIC)...4395
      Removal And Installation...4395
      Parts Identification...4398
      Disassembly...4399
      Assembly...4404
    COUNTERWEIGHT...4413
      Removal And Installation...4413
  ELECTRICAL SYSTEM AND ANALYSIS...4415
    ELECTRICAL SCHEMATICS...4417
    ELECTRICAL SYSTEM INFORMATION...4420
      Troubleshooting Chart...4420
      Description...4421
      Fuse And Relay Location...4421
    BATTERY...4422
      Servicing...4422
      Removing And Installing The Battery...4423
      Using A Booster Battery (Jump Starting)...4424
    ALTERNATOR...4426
      Engine Accessory Drive Belt...4426
      Removal And Installation...4426
      Alternator Identification...4427
      Charging System Check...4428
      Alternator Voltage Test...4429
      Low Voltage Test...4429
      High Voltage Test...4430
      Rectifier Continuity (Diode) Test...4430
      Alternator Regulator Test...4431
      Parts Identification...4432
      Disassembly...4432
      Stator Continuity Test...4432
      Stator Ground Test...4433
      Rotor Continuity Test...4433
      Rotor Ground Test...4434
      Assembly...4434
    STARTER...4436
      Removal And Installation...4436
      Parts Identification...4437
      Disassembly...4438
      Inspection And Repair...4443
      Assembly...4446
    LIGHTS...4452
      Removal And Installation...4452
      Boom Light Removal and Installation (Earlier Models)...4453
      Boom Light Removal and Installation (Later Models)...4454
      Boom Light Bulb Replacement (Later Models)...4454
    TWO SPEED SWITCH...4456
      Removal And Installation...4456
    FUEL LEVEL SENDER...4458
      Removal And Installation...4458
      Testing...4459
    DIAGNOSTICS SERVICE CODE...4460
      Number Codes List...4460
    DELUXE INSTRUMENT PANEL SETUP...4462
      Passwords...4462
      Password Entry (For Starting and Operating the Machine)...4462
      Changing The Owner or Operator Password...4462
      Password Lockout Feature...4463
      Job Clock...4463
      RPM...4463
  ENGINE SERVICE...4464
    TROUBLESHOOTING...4468
      Chart...4468
    MUFFLER...4470
      Removal And Installation...4470
    AIR CLEANER...4472
      Removal And Installation...4472
    RADIATOR...4474
      Removal And Installation...4474
    ENGINE COMPONENTS & TESTING (S/N 562611001 & ABOVE)...4480
      Engine Compression Checking...4480
      Glow Plug Removal And Installation...4481
      Checking The Glow Plug...4484
      Fuel Shut-off Solenoid Removal And Installation...4485
      Fuel Injection Pump Check...4487
      Fuel Injection Pump Removal And Installation...4488
      Fuel Injection Pump Timing...4492
      Fuel Injector Nozzles Removal And Installation...4494
      Fuel Injector Nozzle Check...4498
      Valve Clearance Adjustment...4499
    ENGINE COMPONENTS & TESTING (S/N 562811001 & ABOVE, 563111001 & ABOVE AND 563211001 & ABOVE)...4500
      Engine Compression Checking...4500
      Glow Plug Removal And Installation...4501
      Checking The Glow Plug...4504
      Fuel Shut-off Solenoid Removal And Installation...4505
      Fuel Injection Pump Check...4507
      Fuel Injection Pump Removal And Installation...4508
      Fuel Injection Pump Timing...4512
      Fuel Injector Nozzles Removal And Installation...4514
      Fuel Injector Nozzle Check...4518
      Valve Clearance Adjustment...4519
    ENGINE...4520
      Removal And Installation...4520
    ENGINE FLYWHEEL (EARLY MODELS)...4528
      Removal And Installation...4528
      Hydraulic Pump Coupler...4529
      Flywheel Ring Gear...4529
    ENGINE FLYWHEEL (LATER MODELS)...4530
      Removal And Installation...4530
      Hydraulic Pump Coupler...4531
      Flywheel Ring Gear...4531
    RECONDITIONING THE ENGINE (S/N 562611001 AND ABOVE)...4532
      Cylinder Head Removal And Installation...4532
      Cylinder Head Disassembly And Assembly...4534
      Cylinder Head Servicing...4535
      Cylinder Head Top Clearance...4535
      Valve Guide Checking...4536
      Reconditioning The Valve And Valve Seat...4538
      Valve Spring...4539
      Rocker Arm And Shaft Checking...4540
      Timing Gearcase Cover Removal And Installation...4541
      Idler Gear And Camshaft Removal And Installation...4543
      Camshaft Servicing...4544
      Idler Gear And Shaft Servicing...4545
      Timing Gears Checking Backlash...4546
      Fuel Camshaft Removal And Installation...4547
      Fuel Camshaft Governor...4547
      Crankshaft Gear Removal And Installation...4548
      Oil Pump Removal And Installation...4548
      Oil Pump Service...4549
      Checking Engine Oil Pressure...4550
      Relief Valve...4550
      Piston And Connecting Rod Removal And Installation...4551
      Piston And Connecting Rod Servicing...4553
      Connecting Rod Alignment...4555
      Crankshaft And Bearings Removal And Installation...4556
      Crankshaft And Bearings Servicing...4558
      Cylinder Bore Checking...4561
      Water Pump Removal And Installation...4562
      Water Pump Disassembly And Assembly...4562
    RECONDITIONING THE ENGINE (S/N 562811001 & ABOVE, 563111001 & ABOVE AND 563211001 & ABOVE)...4564
      Cylinder Head Removal And Installation...4564
      Cylinder Head Disassembly And Assembly...4567
      Cylinder Head Servicing...4568
      Cylinder Head Top Clearance...4568
      Valve Guide Checking...4569
      Reconditioning The Valve And Valve Seat...4571
      Valve Spring...4572
      Rocker Arm And Shaft Checking...4573
      Timing Gearcase Cover Removal And Installation...4573
      Idler Gear And Camshaft Removal And Installation...4576
      Camshaft Servicing...4577
      Idler Gear And Shaft Servicing...4578
      Timing Gears Checking Backlash...4579
      Fuel Camshaft Removal And Installation...4579
      Fuel Camshaft Governor...4580
      Crankshaft Gear Removal And Installation...4580
      Oil Pump Removal And Installation...4581
      Oil Pump Service...4581
      Checking Engine Oil Pressure...4582
      Valve Tappets...4583
      Piston And Connecting Rod Removal And Installation...4584
      Piston And Connecting Rod Servicing...4586
      Connecting Rod Alignment...4588
      Crankshaft And Bearings Removal And Installation...4589
      Crankshaft And Bearings Servicing...4592
      Cylinder Bore Checking...4596
      Water Pump Removal And Installation...4596
      Water Pump Disassembly And Assembly...4597
  HEATING, VENTILATION, AIR CONDITIONING...4598
    HEATER COIL (EARLY MODELS)...4602
      Removal And Installation...4602
    HEATER COIL (LATER MODELS)...4604
      Removal And Installation With A/C...4604
      Removal And Installation Without A/C...4604
    BLOWER FAN (EARLY MODELS)...4606
      Removal And Installation...4606
      Disassembly And Assembly...4607
    BLOWER FAN (LATER MODELS)...4610
      Removal And Installation...4610
      Disassembly And Assembly...4611
      Resistor Removal And Installation...4612
    HEATER VALVE...4614
      Removal And Installation...4614
    AIR CONDITIONING SYSTEM FLOW...4617
      Principals...4617
      Chart...4618
    COMPONENTS...4620
      Identification...4620
    SAFETY...4624
      Safety Equipment...4624
    REGULAR MAINTENANCE...4626
      Heater Air Filter...4626
      Engine Accessory Drive Belt...4626
      Cleaning The Condenser...4626
    BASIC TROUBLESHOOTING (EARLY MODELS)...4628
      Poor A/C Performance...4628
      Cleaning The A/C Evaporator Coil & Heater Coil...4629
      Engine Accessory Drive Belt...4631
      Checking The Electrical System...4632
      Engine Coolant By-Passing The Heater Valve...4642
    BASIC TROUBLESHOOTING (LATER MODELS)...4644
      Poor A/C Performance...4644
      Cleaning The A/C Evaporator Coil & Heater Coil...4645
      Engine Accessory Drive Belt...4646
      Checking The Electrical System...4647
      Engine Coolant By-Passing The Heater Valve...4657
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...4658
      Compressor Oil...4658
      Compressor Oil Check...4659
      Component Replacement And Refrigeration Leaks...4660
    SYSTEM TROUBLESHOOTING CHART...4662
      Blower Motor Does Not Operate...4662
      Gauge Pressure Related Troubleshooting...4663
    TEMPERATURE/PRESSURE...4666
      Chart...4666
    AIR CONDITIONING SERVICE...4668
      Chart...4668
    SYSTEM CHARGING AND RECLAMATION...4670
      Reclamation Procedure...4670
      Charging Procedure With A Manifold Gauge Set...4673
    COMPRESSOR...4676
      Removal And Installation...4676
      Compressor Clutch Disassembly And Assembly...4677
    CONDENSER...4680
      Removal And Installation...4680
    RECEIVER/DRIER...4682
      Removal And Installation...4682
    PRESSURE RELIEF VALVE...4684
      Removal And Installation...4684
    PRESSURE SWITCH...4686
      Removal And Installation...4686
    EVAPORATOR/HEATER UNIT (EARLY MODELS)...4688
      Removal And Installation...4688
      Disassembly And Assembly...4689
    EVAPORATOR/HEATER UNIT (later MODELS)...4690
      Removal And Installation...4690
      Disassembly And Assembly...4691
    THERMOSTAT (EARLY MODELS)...4692
      Removal And Installation...4692
    THERMOSTAT (LATER MODELS)...4694
      Removal And Installation...4694
    EXPANSION VALVE (EARLY MODELS)...4696
      Removal And Installation...4696
    EXPANSION VALVE (LATER MODELS)...4698
      Removal And Installation...4698
    EVAPORATOR (EARLY MODELS)...4700
      Removal And Installation...4700
    EVAPORATOR (LATER MODELS)...4702
      Removal And Installation...4702
  SPECIFICATIONS...4704
    SPECIFICATIONS...4706
      Excavator Machine Dimensions...4706
      Performance (S/N 562611001 & Above, 562811001 & Above And 563211001 & Above)...4708
      Performance (S/N 563111001 & Above)...4708
      Controls...4708
      Engine...4709
      Hydraulic System...4710
      Hydraulic Cylinders...4711
      Hydraulic Cycle Times...4711
      Drive System (S/N 562611001 & Above, 562811001 & Above And 563211001 & Above)...4711
      Drive System (S/N 563111001 & Above)...4711
      Undercarriage...4712
      Track (S/N 562611001 & Above And 562811001 & Above)...4712
      Track (S/N 563111001 & Above And 563211001 & Above)...4712
      Electrical...4712
    ENGINE SPECIFICATIONS (S/N 562611001 & ABOVE)...4714
      Fuel Injection Nozzles...4714
      Fuel Injection Pump...4714
      Cylinder Head...4714
      Valves...4714
      Valve Springs...4715
      Valve Timing...4715
      Rocker Arms...4715
      Camshaft...4715
      Tappet...4715
      Cylinders...4716
      Piston Rings...4716
      Pistons...4716
      Connecting Rods...4716
      Oil Pump...4716
      Crankshaft...4717
      Timing Gear...4717
      Thermostat...4717
      Engine Bolt Torque...4718
      Crankshaft Re-Grind Data...4719
    ENGINE SPECIFICATIONS (S/N 562811001 & ABOVE, 563111001 & ABOVE AND 563211001 & ABOVE)...4720
      Fuel Injection Nozzles...4720
      Fuel Injection Pump...4720
      Cylinder Head...4720
      Valves...4720
      Valve Springs...4721
      Valve Timing...4721
      Rocker Arms...4721
      Camshaft...4721
      Tappet...4721
      Cylinders...4722
      Piston Rings...4722
      Pistons...4722
      Connecting Rods...4722
      Oil Pump...4722
      Crankshaft...4723
      Timing Gear...4723
      Thermostat...4724
      Engine Bolt Torque...4724
      Crankshaft Re-Grind Data...4725
    TORQUE SPECIFICATIONS...4726
      Torque for General SAE Bolts...4726
      Torque For General Metric Bolts...4727
    HYDRAULIC CONNECTION SPECIFICATIONS...4728
      O-Ring Face Seal Connection...4728
      Straight Thread O-ring Fitting...4728
      Tubelines And Hoses...4728
      Flare Fitting...4729
      O-Ring Flare Fitting...4730
      Port Seal Fitting...4732
    HYDRAULIC FLUID SPECIFICATIONS...4734
      Specifications...4734
    FUEL, COOLANT AND LUBRICANTS...4736
      Chart...4736
    CONVERSIONS...4738
      Decimal And Millimeter Equivalents...4738
      U.S. To Metric Conversion Chart...4738
  SMR...4740
    435-1...4740
    435-2...4742
    435-3...4744
    435-4...4746
    435-5...4748
    435-6...4750
    435-7...4752
    435-8...4754
    435-9...4756
    435-10...4758
    435-11...4760
    435-12...4762
6986748 (10-09) - 435 Compact Excavator Operation & Maintenance Manual...4764
  OPERATOR SAFETY WARNING...4766
  CONTENTS...4768
  FOREWORD...4770
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...4772
    REGULAR MAINTENANCE ITEMS...4772
    SERIAL NUMBER LOCATIONS...4774
      Excavator Serial Number...4774
      Engine Serial Number...4774
    DELIVERY REPORT...4774
    EXCAVATOR IDENTIFICATION...4775
    FEATURES, ACCESSORIES AND ATTACHMENTS...4776
      Standard Items...4776
      Options and Accessories...4776
      Attachments...4776
      Buckets Available...4776
      Falling Object Guards (FOGS)...4777
      Special Applications Kit...4777
      Special Applications Kit Inspection And Maintenance...4777
  SAFETY & TRAINING RESOURCES...4778
    SAFETY INSTRUCTIONS...4780
      Before Operation...4780
      Safe Operation Is The Operator’s Responsibility...4781
      Safe Operation Needs A Qualified Operator...4781
      Avoid Silica Dust...4782
    FIRE PREVENTION...4782
      Maintenance...4782
      Operation...4782
      Electrical...4782
      Hydraulic System...4783
      Fueling...4783
      Starting...4783
      Spark Arrestor Exhaust System...4783
      Welding And Grinding...4783
      Fire Extinguishers...4783
    MACHINE SIGNS (DECALS)...4784
    PUBLICATIONS AND TRAINING RESOURCES...4786
  OPERATING INSTRUCTIONS...4788
    INSTRUMENTS AND CONSOLES...4792
      Cab Interior Light (If Equipped)...4792
      Left Console...4792
      Right Console...4793
      Function Icons...4794
      STD/ISO Selector Valve...4795
      Upperstructure Slew Lock...4795
      Raising And Lowering The Console...4795
      Two-Speed Travel...4796
    OPERATOR CANOPY (ROPS / TOPS)...4797
      Description...4797
    OPERATOR CAB (ROPS / TOPS)...4797
      Description...4797
      Cab Door...4798
      Front Window...4799
      Front Wiper...4800
      Window Washer Reservoir...4800
      Right Side Windows...4801
      Heating, Ventilation, and Air Conditioning Duct...4802
    TRAVEL CONTROLS...4803
      Description...4803
      Forward And Reverse...4803
      Turning...4803
    MOTION ALARM SYSTEM (IF EQUIPPED)...4805
      Operation...4805
    HYDRAULIC CONTROLS...4806
      Description...4806
      Standard Control Pattern...4806
      ISO Control Pattern...4807
      Quick Couplers...4808
      Auxiliary Hydraulics...4809
      Relieving Hydraulic Pressure (Excavator And Attachment)...4809
      Return To Tank Valve (If Equipped)...4809
    BLADE CONTROL LEVER...4810
      Operation...4810
      Angle Blade (If Equipped)...4810
    BOOM SWING PEDAL...4811
      Operation...4811
    DAILY INSPECTION...4812
      Daily Inspection And Maintenance...4813
    PRE-STARTING PROCEDURE...4814
      Operation & Maintenance Manual And Operator’s Handbook Locations...4814
      Entering The Excavator...4814
      Seat Adjustment...4815
      Seat Belt Adjustment...4815
      Control Console...4815
    STARTING THE ENGINE...4816
      Key Switch...4816
      Keyless...4817
      Cold Temperature Starting...4818
      Warming The Hydraulic System...4819
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...4820
      Procedure...4820
      Emergency Exits...4821
    ATTACHMENTS...4822
      Installing And Removing The Attachment (Hydraulic X-Change)...4822
      Installing And Removing The Attachment (Pin-On X- Change)...4827
      Installing And Removing The Attachment (Bolt-On X- Change)...4833
      Installing And Removing The Attachment (Pin-On Attachment)...4839
    OPERATING PROCEDURE...4840
      Inspect The Work Area...4840
      Basic Operating Instructions...4840
      Lowering The Work Equipment (Engine STOPPED)...4840
      Horsepower Control System...4841
      Lifting A Load...4842
      Excavating...4843
      Boom Swing...4845
      Backfilling...4846
      Driving The Excavator...4846
      Operating On Slopes...4847
      Operating In Water...4849
      Avoiding Track Damage...4850
    TOWING THE EXCAVATOR...4851
      Procedure...4851
    LIFTING THE EXCAVATOR...4852
      Procedure...4852
    TRANSPORTING THE EXCAVATOR ON A TRAILER...4853
      Loading And Unloading...4853
      Fastening...4853
  PREVENTIVE MAINTENANCE...4854
    MAINTENANCE SAFETY...4856
    SERVICE SCHEDULE...4858
      Chart...4858
    CONTROL CONSOLE LOCKOUTS...4859
      Inspection And Maintenance...4859
    SEAT BELT...4860
      Inspection And Maintenance...4860
    MOTION ALARM SYSTEM (IF EQUIPPED)...4861
      Description...4861
      Inspecting...4861
      Adjusting Switch Position...4861
    TAILGATE...4862
      Opening And Closing...4862
      Adjusting The Latch...4862
    RIGHT SIDE COVER...4863
      Opening And Closing...4863
    CAB FILTERS...4864
      Cleaning And Maintenance...4864
    AIR CLEANER SERVICE...4865
      Daily Check...4865
      Replacing Filter Elements...4865
    FUEL SYSTEM...4867
      Fuel Specifications...4867
      Biodiesel Blend Fuel...4867
      Filling The Fuel Tank...4868
      Fuel Filters...4868
      Inline Fuel Filter...4869
      Draining The Fuel Tank...4869
      Removing Air From The Fuel System...4869
    ENGINE LUBRICATION SYSTEM...4870
      Checking And Adding Engine Oil...4870
      Engine Oil Chart...4870
      Removing And Replacing Oil Filter...4871
    ENGINE COOLING SYSTEM...4872
      Cleaning...4872
      Checking Level...4873
      Removing And Replacing Coolant...4874
    ELECTRICAL SYSTEM...4875
      Description...4875
      Fuse And Relay Location/Identification...4875
      Battery Maintenance...4876
      Using A Booster Battery (Jump Starting)...4877
      Removing And Installing Battery...4878
    HYDRAULIC SYSTEM...4879
      Checking And Adding Fluid...4879
      Hydraulic / Hydrostatic Fluid Chart...4879
      Removing And Replacing The Hydraulic Filter...4880
      Removing And Replacing The Case Drain Filter...4880
      Removing And Replacing The Fan Filter...4881
      Removing And Replacing The Hydraulic Fluid...4882
    SPARK ARRESTOR MUFFLER...4883
      Cleaning Procedure...4883
    TRACK TENSION...4884
      Adjusting...4884
    TRAVEL MOTOR...4886
      Checking And Adding Oil...4886
      Removing And Replacing Oil...4886
    ENGINE ACCESSORY DRIVE BELT...4887
      Belt Adjustment...4887
      Belt Replacement...4887
    DRIVE BELT (FASTTRACK)...4888
      Belt Adjustment...4888
    X-CHANGE...4890
      Inspection And Maintenance...4890
    TRACK ROLLER AND IDLER LUBRICATION...4890
      Procedure...4890
    BUCKET...4891
      Bucket Teeth Removal And Installation...4891
    CUTTING EDGE (ANGLE BLADE ONLY)...4892
      Removal And Installation...4892
    LUBRICATING THE EXCAVATOR...4893
      Lubrication Locations...4893
    PIVOT PINS...4896
      Inspection And Maintenance...4896
    EXCAVATOR STORAGE AND RETURN TO SERVICE...4897
      Storage...4897
      Return to Service...4897
  SYSTEM SETUP AND ANALYSIS...4898
    DIAGNOSTIC SERVICE CODE...4900
      Service Codes List...4900
    DISPLAY CONTROLLER PANEL SETUP...4901
      Passwords...4901
      Password Entry (For Starting and Operating the Machine)...4901
      Changing The Operator Password...4901
      Password Lockout Feature...4902
      Job Clock...4902
      RPM...4902
      Viewing Service Codes (Key Switch)...4903
      Viewing Service Codes (Keyless)...4903
    MAINTENANCE CLOCK...4904
      Description...4904
      Setup...4904
      Reset...4904
  MACHINE SIGN TRANSLATIONS...4906
    WARNING (6808185)...4908
    LIFT CHART...4909
      435 STANDARD ARM (7107501)...4909
      435 LONG ARM (7107502)...4912
    SERVICE SCHEDULE (7158257)...4915
    WARNING (6807776)...4918
    WARNING (6804114, 6817225, 6804233)...4920
    WARNING (6817815)...4921
    WARNING (6808474)...4921
    WARNING (7142685)...4922
    EMERGENCY EXIT (6815984)...4923
    WARNING (6576048)...4924
    WARNING (6815915)...4925
    WARNING (7102651)...4926
    WARNING (6809829)...4929
    JOYSTICK CONTROL PATTERN SELECTOR LEVER (6815957)...4929
  SPECIFICATIONS...4930
    EXCAVATOR SPECIFICATIONS...4932
      435 Dimensions With Standard Arm and Long Arm Option...4932
    EXCAVATOR SPECIFICATIONS...4933
      435 Dimensions With Optional Angle Blade Dimensions...4934
      Performance (S/N AACD11001 & Above), (AA8A11001 & Above)...4935
      Performance (S/N AACB11001 & Above), (AA8911001 & Above)...4935
      Controls...4935
      Engine...4936
      Hydraulic System...4937
      Hydraulic Cylinders...4937
      Hydraulic Cycle Times...4938
      Electrical...4938
      Drive System...4938
      Slew System...4938
      Undercarriage...4938
      Capacities...4938
      Fuel Tank...4938
      Tracks...4939
      Type...4939
      Ground Pressure...4939
  WARRANTY...4940
    WARRANTY...4942
  ALPHABETICAL INDEX...4944
6986749 (5-10) - 435 Compact Excavator Service Manual...4946
  MAINTENANCE SAFETY...4948
  ALPHABETICAL INDEX...4950
  CONTENTS...4952
    FOREWORD...4954
    SAFETY INSTRUCTIONS...4956
    FIRE PREVENTION...4958
      Maintenance...4958
      Operation...4958
      Electrical...4958
      Hydraulic System...4958
      Fueling...4958
      Starting...4958
      Spark Arrestor Exhaust System...4958
      Welding And Grinding...4959
      Fire Extinguishers...4959
    SERIAL NUMBER LOCATIONS...4960
      Excavator Serial Number...4960
      Engine Serial Number...4960
    DELIVERY REPORT...4961
    BOBCAT EXCAVATOR IDENTIFICATION...4962
  SAFETY AND MAINTENANCE...4964
    LIFTING AND BLOCKING THE EXCAVATOR...4966
      Procedure...4966
    UPPERSTRUCTURE SLEW LOCK...4968
      Operation...4968
    LIFTING THE EXCAVATOR...4970
    OPERATOR CAB (ROPS/TOPS)...4972
      Emergency Exit...4972
      Cab Door...4973
      Front Window...4974
      Right Side Windows...4976
    TRANSPORTING THE EXCAVATOR...4978
      Procedure...4978
    TAILGATE...4980
      Opening And Closing The Tailgate...4980
      Adjusting The Latch...4980
    RIGHT SIDE COVER...4982
      Opening And Closing The Right Side Cover...4982
    SERVICE SCHEDULE...4984
      Chart...4984
    AIR CLEANER...4986
      Daily Check...4986
      Replacing The Filters...4986
    HEATER AIR FILTER (WITH CAB OPTION ONLY)...4988
      Removal And Installation...4988
    COOLING SYSTEM...4990
      Cleaning The Cooling System...4990
      Checking Coolant Level...4990
      Replacing The Coolant...4991
    FUEL SYSTEM...4994
      Fuel Specifications...4994
      Filling The Fuel Tank...4994
      Removing Water From The Fuel Filter...4995
      Draining The Fuel Tank...4995
      Spin On Fuel Filter...4996
      Inline Fuel Filter...4996
    ENGINE LUBRICATION SYSTEM...4998
      Checking Engine Oil...4998
      Replacing Oil And Filter...4998
    HYDRAULIC SYSTEM...5000
      Checking And Adding Hydraulic Oil...5000
      Replacing The Hydraulic Oil...5001
      Replacing The Hydraulic Filter...5002
      Replacing The Case Drain Filter...5002
      Replacing The Fan Filter...5003
      Diagnostic Couplers...5004
    LUBRICATION OF THE HYDRAULIC EXCAVATOR...5006
    TRAVEL MOTOR...5010
      Checking Oil Level...5010
      Draining The Travel Motor...5010
    SPARK ARRESTOR MUFFLER...5012
    ENGINE ACCESSORY DRIVE BELT...5014
      Belt Tension...5014
      Belt Adjustment...5014
  HYDRAULIC SYSTEM...5016
    HYDRAULIC / HYDROSTATIC SCHEMATICS...5024
    HYDRAULIC SYSTEM INFORMATION...5028
      Glossary Of Hydraulic/Hydrostatic Symbols For Excavators...5028
      Troubleshooting The Hydraulic Circuit...5031
      Troubleshooting The Cylinder Circuit...5032
      Troubleshooting The Upperstructure Slew Circuit...5033
    BOOM CYLINDER...5034
      Testing...5034
      Removal And Installation...5036
      Parts Identification...5039
      Disassembly...5040
      Assembly...5043
    ARM CYLINDER...5046
      Testing...5046
      Removal and Installation...5048
      Parts Identification...5050
      Disassembly...5051
      Assembly...5054
    BOOM SWING CYLINDER...5058
      Testing...5058
      Removal And Installation...5060
      Parts Identification...5062
      Disassembly...5063
      Assembly...5066
    BUCKET CYLINDER...5070
      Testing...5070
      Removal And Installation...5072
      Parts Identification...5073
      Disassembly...5074
      Assembly...5076
    BLADE CYLINDER...5080
      Testing...5080
      Removal And Installation...5081
      Parts Identification...5082
      Disassembly...5083
      Assembly...5085
    CLAMP CYLINDER...5088
      Testing...5088
      Removal And Installation...5089
      Parts Identification...5090
      Disassembly...5091
      Assembly...5094
    ANGLE BLADE CYLINDER...5100
      Testing...5100
      Removal And Installation...5102
      Parts Identification...5104
      Disassembly...5105
      Assembly...5107
    MAIN RELIEF VALVES...5110
    PORT RELIEF VALVES...5112
      Port Relief Valve Pressure Setting...5112
      Parts Identification...5112
      Adjustment Procedure...5113
    CROSSPORT RELIEF VALVE...5114
      Testing And Adjusting The Crossport Relief Valve...5114
      Removal And Installation...5116
      Disassembly And Assembly...5117
    PRESSURE REDUCING VALVE...5122
      Description...5122
    ANGLE BLADE VALVE...5124
      Description...5124
      Testing And Adjusting Port Relief Valves...5124
      Testing And Adjusting Sequence Valve...5126
      Removal And Installation...5128
      Parts Identification...5131
      Disassembly...5132
      Assembly...5145
    HYDRAULIC CONTROL VALVE (S/N AA8911001 & ABOVE, AA8A11001 & ABOVE AND AACD11001 & ABOVE)...5158
      Removal And Installation...5158
      Parts Identification...5161
      Disassembly...5162
      Slew Valve Section Disassembly And Assembly...5164
      Blade Valve Section Disassembly And Assembly...5170
      Bucket Valve Section Disassembly And Assembly...5182
      Arm Valve Section Disassembly And Assembly...5188
      Boom Valve Section Disassembly And Assembly...5194
      Boom Swing Valve Section Disassembly And Assembly...5200
      Auxiliary Valve Section Disassembly And Assembly...5206
      Inlet Section Disassembly And Assembly...5214
      Assembly...5219
    HYDRAULIC CONTROL VALVE (S/N AACB11001 & ABOVE AND S/N AA8911001 & ABOVE AND S/N AA8911001 & ABOVE)...5224
      Removal And Installation...5224
      Parts Identification...5227
      Disassembly...5228
      Right Travel Valve Section Disassembly And Assembly...5230
      Left Travel Valve Section Disassembly And Assembly...5233
      Slew Valve Section Disassembly And Assembly...5236
      Blade Valve Section Disassembly And Assembly...5242
      Bucket Valve Section Disassembly And Assembly...5253
      Arm Valve Section Disassembly And Assembly...5259
      Boom Valve Section Disassembly And Assembly...5265
      Boom Swing Valve Section Disassembly And Assembly...5271
      Auxiliary Valve Section Disassembly And Assembly...5277
      Inlet Section Disassembly And Assembly...5285
      Assembly...5290
    HYDRAULIC PUMP...5296
      Piston Pump Work Sheet...5296
      Piston Pump Testing...5299
      Description...5309
      Gear Pump Testing...5309
      Removal And Installation...5311
      Coupler Removal And Installation...5312
      Hydraulic Pump Start Up...5313
      Torque Limiter Valve Parts Identification...5314
      Torque Limiter Valve Removal...5315
      Torque Limiter Valve Disassembly...5316
      Torque Limiter Valve Assembly...5320
      Initial Torque Limiter Valve Setting...5323
      Torque Limiter Valve Installation...5325
      Pump Control Parts Identification...5326
      Pump Control Removal And Installation...5327
      Pump Control Disassembly And Assembly...5327
      Parts Identification...5333
      Gear Pump Removal And Installation...5334
      Gear Pump Disassembly And Assembly...5335
      Piston Pump Parts Identification...5340
      Piston Pump Disassembly...5341
      Piston Pump Assembly...5350
    MANIFOLD ASSEMBLY/ACCUMULATOR (S/N AACD11001 & ABOVE AND S/N AA8A11001 & ABOVE)...5362
      Description...5362
      Testing Pilot Pressure...5363
      Removal And Installation...5364
      Parts Identification...5366
      Disassembly...5367
      Assembly...5380
    MANIFOLD ASSEMBLY/ACCUMULATOR (S/N AACB11001 & ABOVE AND S/N AA8911001 & ABOVE)...5392
      Description...5392
      Testing Pilot Pressure...5393
      Removal And Installation...5394
      Parts Identification...5397
      Disassembly...5398
      Assembly...5407
    TRAVEL MOTOR (S/N AACD11001 & ABOVE, AA8A11001 & ABOVE, AND AA8911001 & ABOVE)...5416
      Removal And Installation...5416
      Parts Identification...5418
      Disassembly...5419
      Assembly...5433
    TRAVEL MOTOR (S/N AACB11001 & ABOVE AND S/N AA8911001 & ABOVE)...5450
      Removal And Installation...5450
      Parts Identification...5451
      Disassembly...5452
      Assembly...5462
    SWIVEL JOINT...5474
      Removal And Installation...5474
      Parts Identification...5476
      Description...5477
      Disassembly...5477
      Assembly...5480
    SWING MOTOR...5484
      Removal And Installation...5484
      Parts Identification...5488
      Disassembly...5490
      Inspection...5495
      Assembly...5496
    SWING MOTOR DRIVE CARRIER...5502
      Removal And Installation...5502
      Parts Identification...5503
      Checking The Drive Carrier Shaft End Play...5504
      Disassembly...5505
      Inspection...5507
      Assembly...5508
    CONTROL PATTERN SELECTOR VALVE...5512
      Removal And Installation...5512
      Parts Identification...5513
      Disassembly...5514
      Assembly...5516
    RIGHT CONTROL LEVER (JOYSTICK)...5518
      Testing...5518
      Handle Removal And Installation...5519
      Joystick Assembly Removal And Installation...5523
      Parts Identification...5526
      Disassembly...5527
      Assembly...5532
    LEFT CONTROL LEVER (JOYSTICK)...5536
      Testing...5536
      Handle Removal And Installation...5538
      Joystick Assembly Removal And Installation...5541
      Parts Identification...5543
      Disassembly...5544
      Assembly...5549
    TRAVEL CONTROL VALVE (S/N AA8A11001 & ABOVE, AA8911001 & ABOVE AND AACD11001 & ABOVE)...5554
      Removal and Installation...5554
      Parts Identification...5555
      Disassembly And Assembly...5556
    TRAVEL CONTROL VALVE (S/N AACB11001 & ABOVE AND S/N AA8911001 & ABOVE)...5562
      Removal and Installation...5562
      Parts Identification...5563
      Disassembly And Assembly...5564
    HOSES...5568
      Hose Guide Location...5568
      Left Control Lever (Joystick) (S/N AACB11001 & Above AND AA8911001 & Above)...5569
      Left Control Lever (Joystick) (S/N AACD11001 & Above AND AA8A11001 & Above)...5570
      Right Control Lever (Joystick) (S/N AACB11001 & Above And AA8911001 & Above)...5571
      Right Control Lever (Joystick) (S/N AACD11001 & Above And AA8A11001 & Above)...5572
      Travel Control Valve (S/N AACB11001 & Above And AA8911001 & Above)...5573
      Travel Control Valve (S/N AACD11001 & Above And AA8A11001 & Above)...5574
      Manifold Assembly / Accumulator (S/N AACB11001 & Above And AA8911001 & Above)...5575
      Manifold Assembly / Accumulator (S/N AACD11001 & Above And AA8A11001 & Above)...5576
    HYDRAULIC FILTER MOUNT...5578
      Removal And Installation...5578
    HYDRAULIC RESERVOIR...5580
      Removal And Installation...5580
    OIL COOLER...5582
      Removal And Installation...5582
    DIRECT TO TANK VALVE (IF EQUIPPED)...5586
      Removal And Installation...5586
      Parts Identification...5587
      Disassembly And Assembly...5588
    DUAL SEQUENCE VALVE (S/N AACD11001 & ABOVE AND S/N AA8A11001 & ABOVE)...5590
      Removal And Installation...5590
      Parts Identification...5592
      Disassembly And Assembly...5593
    DUAL SEQUENCE VALVE (S/N AACB 11001 & Above)...5596
      Removal And Installation...5596
      Parts Identification...5598
      Disassembly And Assembly...5599
    BUILD UP VALVE...5602
      Removal And Installation...5602
      Parts Identification...5603
      Disassembly And Assembly...5604
    COOLING FAN...5606
      Description...5606
      Testing...5606
      Removal And Installation...5607
      Parts Identification...5609
      Disassembly And Assembly...5610
    REMOVING AIR FROM HYDRAULIC SYSTEM...5618
      Procedure...5618
    BOOM SWING LOCK VALVE...5622
      Description...5622
      Removal And Installation...5622
      Parts Identification...5624
      Disassembly...5625
      Assembly...5628
    HYDRAULIC X-CHANGE VALVE...5632
      Removal And Installation...5632
      Parts Identification...5635
      Disassembly...5636
      Assembly...5644
  HYDROSTATIC SYSTEM...5652
    HYDROSTATIC SYSTEM INFORMATION...5654
      Troubleshooting Chart...5654
      Relief/Replenishing Valve Function...5655
      Relief/Replenishing Valve Location...5655
      Relief/Replenishing Valve Removal And Installation...5656
      Charge Pressure Relief Valve Location...5657
      Charge Pressure Relief Valve Removal And Installation...5657
    TRAVEL PILOT PRESSURE...5658
      Description...5658
      Testing...5658
    HYDROSTATIC PUMP...5660
      Removal And Installation...5660
      Parts Identification (Front) (S/N AACG11001 & Above And AA8811001 & Above)...5663
      Disassembly...5664
      Inspection...5679
      Assembly...5683
      Hydrostatic Pump Start-Up...5698
      Mechanical Neutral Adjustment...5698
    FAN/CHARGE PUMP...5702
      Description...5702
      Testing...5702
    DRIVE BELT SHIELD...5704
      Removal And Installation...5704
    DRIVE BELT...5706
      Adjustment...5706
      Removal And Installation...5708
  UNDERCARRIAGE...5710
    BLADE...5712
      Removal And Installation...5712
    ANGLE BLADE ASSEMBLY...5714
      Removal And Installation...5714
    ANGLE BLADE...5716
      Removal And Installation...5716
    ANGLE BLADE CUTTING EDGE...5718
      Removal And Installation...5718
    TRACKS...5720
      Track Lug Height...5720
      Rubber Track Clearance...5721
      Steel Track Clearance...5722
      Adjustment...5722
      Rubber Track Removal And Installation...5723
      Steel Track Removal And Installation...5726
    TRACK FRAME...5732
      Disassembly And Assembly...5732
      Recoil Spring Cylinder Disassembly And Assembly (S/n AACB11378 & Below, AACD11163 & Below, AA8A11150 & Below and AA8911261 & Below Without Replaceable Shaft.)...5735
      Recoil Spring Cylinder Parts Identification (S/N AACB11378 & Below, AACD11163 & Below, AA8A11150 & Below And AA8911261 & Below With Replaceable Shaft)...5736
      Recoil Spring Cylinder Disassembly And Assembly (S/N AACB11378 & Below, AACD11163 & Below, AA8A11150 & Below and AA8911261 & Below With Replaceable Shaft.)...5737
      Recoil Spring Cylinder Parts Identification (S/N AACB11379 & Above, AACD11164 & Above, AA8A11151 & Above And AA8911262 & Above)...5739
      Recoil Spring Cylinder Disassembly And Assembly (S/n AACB11379 & Above, AACD11164 & Above, AA8A11151 & Above and AA8911262 & Above)...5740
    TRACK DAMAGE IDENTIFICATION...5742
      Cutting Of Steel Cords...5742
      Abrasion Of Embedded Metals...5743
      Separation Of Embedded Metals...5744
      Separation Of Embedded Metals Due To Corrosion...5745
      Cuts On The Lug Side Rubber...5746
      Cracks On The Lug Side Rubber Due To Fatigue...5747
      Lug Abrasion...5748
      Cracks And Cuts On The Lug Side Rubber...5749
      Abrasion Of The Track Roller Side...5750
      Cuts On The Edges Of Track Roller Side...5751
    TRACK IDLER...5754
      Parts Identification...5754
      Disassembly...5755
      Assembly...5757
    UPPER TRACK ROLLER...5760
      Parts Identification...5760
      Disassembly...5761
      Assembly...5762
    LOWER TRACK ROLLER...5766
      Parts Identification...5766
      Disassembly...5767
      Assembly...5768
    SWING CIRCLE GEAR...5772
      Swing Bearing Removal...5772
      Swing Bearing Installation...5773
  UPPERSTRUCTURE & SWING SECTION...5774
    UPPERSTRUCTURE...5778
      Removal...5778
      Installation...5781
    ROPS CANOPY...5784
      Removal And Installation...5784
    CAB...5788
      Removal And Installation...5788
      Door Removal And Installation...5793
      Front Window Removal And Installation...5794
      Right Side Rear Sliding Window Removal And Installation...5797
      Right Side Front Sliding Window Removal And Installation...5797
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...5798
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...5798
      Glass Removal...5799
      Glass Installation...5800
    SEAT AND SEAT MOUNT...5804
      Removal And Installation...5804
    RIGHT CONSOLE...5806
      Console Cover Removal And Installation...5806
      Console Base Removal And Installation...5807
    LEFT CONSOLE...5810
      Lower Console Cover Removal And Installation...5810
      Upper Console Cover Removal And Installation...5811
      Compression Spring Removal And Installation...5812
      Compression Spring Disassembly And Assembly...5813
      Lock Lever Removal And Installation...5815
      Console Removal And Installation...5816
      Disassembly And Assembly...5820
      Console Switch Removal And Installation...5823
      Console Base Removal And Installation...5824
    ENGINE SPEED CONTROL...5826
      Removal And Installation...5826
      Disassembly And Assembly...5827
      Adjustment (Later Models)...5828
    BLADE CONTROL...5830
      Lever Removal And Installation...5830
      Linkage Removal And Installation...5831
      Linkage Disassembly And Assembly...5832
      Control Cable Removal And Installation...5833
    RIGHT PEDAL AND LINKAGE...5834
      Pedal Removal And Installation...5834
      Pedal Disassembly And Assembly...5835
      Control Cable Removal And Installation...5837
    TRAVEL CONTROLS...5838
      Removal And Installation...5838
      Disassembly And Assembly...5841
      Adjustment...5843
    CONTROL LINKAGE ASSEMBLY...5846
      Removal And Installation...5846
    FLOOR MAT AND FLOOR PLATES...5848
      Removal And Installation...5848
    FUEL TANK...5850
      Removal And Installation...5850
    HORN...5852
      Removal And Installation...5852
    SWING FRAME...5854
      Boom Swing Bracket Removal And Installation...5854
      Boom Swing Bracket Hose Installation...5858
      Bushing Removal...5859
      Bushing Installation...5860
    BOOM...5862
      Removal And Installation...5862
    ARM...5864
      Removal And Installation...5864
      Arm To Boom Bushing Removal And Installation...5865
      Arm To Bucket And Bucket Link Bushing Removal & Installation...5866
    BUCKET...5868
      Bucket Teeth Removal And Installation...5868
      Bucket Side Cutting Edge Removal And Installation...5869
    CLAMP...5870
      Removal And Installation...5870
    TAILGATE...5872
      Removal And Installation...5872
    X-CHANGE (PIN ON)...5874
      Removal And Installation...5874
      Parts Identification...5876
      Disassembly And Assembly...5877
    RIGHT SIDE COVER...5878
      Removal And Installation...5878
    X-CHANGE (HYDRAULIC)...5880
      Removal And Installation...5880
      Parts Identification...5883
      Disassembly...5884
      Assembly...5889
    COUNTERWEIGHT...5898
      Removal And Installation...5898
    COUNTERWEIGHT...5900
      Removal And Installation...5900
  ELECTRICAL SYSTEM AND ANALYSIS...5902
    ELECTRICAL SCHEMATICS...5904
    ELECTRICAL SYSTEM INFORMATION...5906
      Troubleshooting Chart...5906
      Description...5907
      Fuse And Relay Location...5907
    BATTERY...5908
      Servicing...5908
      Removal And Installation...5909
      Using A Booster Battery (Jump Starting)...5910
    ALTERNATOR...5912
      Engine Accessory Drive Belt...5912
      Removal And Installation...5912
      Alternator Identification...5913
      Charging System Check...5914
      Alternator Voltage Test...5915
      Low Voltage Test...5915
      High Voltage Test...5916
      Rectifier Continuity (Diode) Test...5916
      Alternator Regulator Test...5917
      Parts Identification...5918
      Disassembly...5918
      Stator Continuity Test...5918
      Stator Ground Test...5919
      Rotor Continuity Test...5919
      Rotor Ground Test...5919
      Assembly...5920
    STARTER...5922
      Removal And Installation...5922
      Parts Identification...5923
      Disassembly...5924
      Inspection And Repair...5929
      Assembly...5932
    LIGHTS...5938
      Removal And Installation...5938
      Boom Light Removal and Installation...5939
      Boom Light Bulb Replacement...5939
    TWO SPEED SWITCH...5940
      Removal And Installation...5940
    FUEL LEVEL SENDER...5942
      Removal And Installation...5942
      Testing...5943
    DIAGNOSTICS SERVICE CODE...5944
      Number Codes List...5944
    DELUXE INSTRUMENT PANEL SETUP...5946
      Passwords...5946
      Password Entry (For Starting and Operating the Machine)...5946
      Changing The Owner or Operator Password...5946
      Password Lockout Feature...5947
      Job Clock...5947
      RPM...5947
  ENGINE SERVICE...5948
    TROUBLESHOOTING...5950
      Chart...5950
    MUFFLER...5952
      Removal And Installation...5952
    AIR CLEANER...5954
      Removal And Installation...5954
    RADIATOR...5956
      Removal And Installation...5956
    ENGINE COMPONENTS & TESTING...5962
      Engine Compression Checking...5962
      Glow Plug Removal And Installation...5963
      Checking The Glow Plug...5966
      Fuel Shut-off Solenoid Removal And Installation...5967
      Fuel Injection Pump Check...5969
      Fuel Injection Pump Removal And Installation...5970
      Fuel Injection Pump Timing...5974
      Fuel Injector Nozzles Removal And Installation...5976
      Fuel Injector Nozzle Check...5980
      Valve Clearance Adjustment...5981
    ENGINE...5982
      Removal And Installation...5982
    ENGINE FLYWHEEL...5990
      Removal And Installation...5990
      Hydraulic Pump Coupler...5991
      Flywheel Ring Gear...5991
    ENGINE FLYWHEEL (LATER MODELS)...5992
      Removal And Installation...5992
      Hydraulic Pump Coupler...5993
      Flywheel Ring Gear...5993
    RECONDITIONING THE ENGINE...5994
      Cylinder Head Removal And Installation...5994
      Cylinder Head Disassembly And Assembly...5996
      Cylinder Head Servicing...5997
      Cylinder Head Top Clearance...5997
      Valve Guide Checking...5998
      Reconditioning The Valve And Valve Seat...6000
      Valve Spring...6001
      Rocker Arm And Shaft Checking...6002
      Timing Gearcase Cover Removal And Installation...6003
      Idler Gear And Camshaft Removal And Installation...6005
      Camshaft Servicing...6006
      Idler Gear And Shaft Servicing...6007
      Timing Gears Checking Backlash...6008
      Fuel Camshaft Removal And Installation...6009
      Fuel Camshaft Governor...6009
      Crankshaft Gear Removal And Installation...6010
      Oil Pump Removal And Installation...6010
      Oil Pump Service...6011
      Checking Engine Oil Pressure...6012
      Relief Valve...6012
      Piston And Connecting Rod Removal And Installation...6013
      Piston And Connecting Rod Servicing...6015
      Connecting Rod Alignment...6017
      Crankshaft And Bearings Removal And Installation...6018
      Crankshaft And Bearings Servicing...6020
      Cylinder Bore Checking...6023
      Water Pump Removal And Installation...6024
      Water Pump Disassembly And Assembly...6024
  HEATING, VENTILATION, AIR CONDITIONING...6026
    HEATER COIL...6028
      Removal And Installation With A/C...6028
      Removal And Installation Without A/C...6028
    BLOWER FAN...6030
      Removal And Installation...6030
      Disassembly And Assembly...6031
      Resistor Removal And Installation...6032
    HEATER VALVE...6034
      Removal And Installation...6034
    AIR CONDITIONING SYSTEM FLOW...6036
      Principals...6036
      Chart...6037
    COMPONENTS...6038
      Identification...6038
    SAFETY...6042
      Safety Equipment...6042
    REGULAR MAINTENANCE...6044
      Heater Air Filter...6044
      Engine Accessory Drive Belt...6044
      Cleaning The Condenser...6044
    BASIC TROUBLESHOOTING...6046
      Poor A/C Performance...6046
      Cleaning The A/C Evaporator Coil & Heater Coil...6047
      Engine Accessory Drive Belt...6048
      Checking The Electrical System...6049
      Engine Coolant By-Passing The Heater Valve...6059
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...6060
      Compressor Oil...6060
      Compressor Oil Check...6061
      Component Replacement And Refrigeration Leaks...6062
    SYSTEM TROUBLESHOOTING CHART...6064
      Blower Motor Does Not Operate...6064
      Gauge Pressure Related Troubleshooting...6065
    TEMPERATURE/PRESSURE...6068
      Chart...6068
    AIR CONDITIONING SERVICE...6070
      Chart...6070
    SYSTEM CHARGING AND RECLAMATION...6072
      Reclamation Procedure...6072
      Charging Procedure With A Manifold Gauge Set...6075
    COMPRESSOR...6078
      Removal And Installation...6078
      Compressor Clutch Disassembly And Assembly...6079
    CONDENSER...6082
      Removal And Installation...6082
    RECEIVER/DRIER...6084
      Removal And Installation...6084
    PRESSURE RELIEF VALVE...6086
      Removal And Installation...6086
    PRESSURE SWITCH...6088
      Removal And Installation...6088
    EVAPORATOR/HEATER UNIT...6090
      Removal And Installation...6090
      Disassembly And Assembly...6091
    THERMOSTAT...6092
      Removal And Installation...6092
    EXPANSION VALVE...6094
      Removal And Installation...6094
    EVAPORATOR...6096
      Removal And Installation...6096
  SPECIFICATIONS...6098
    SPECIFICATIONS...6100
      Excavator Machine Dimensions...6100
      Performance (S/N AACD11001 & Above), (AA8A11001 & Above)...6102
      Performance (S/N AACB11001 & Above), (AA8911001 & Above)...6102
      Controls...6102
      Engine...6103
      Hydraulic System...6104
      Hydraulic Cylinders...6105
      Hydraulic Cycle Times...6105
      Drive System...6105
      Slew System...6105
      Undercarriage...6106
      Capacities...6106
      Track...6106
      Electrical...6106
    ENGINE SPECIFICATIONS...6108
      Fuel Injection Nozzles...6108
      Fuel Injection Pump...6108
      Cylinder Head...6108
      Valves...6108
      Valve Springs...6109
      Valve Timing...6109
      Rocker Arms...6109
      Camshaft...6109
      Tappet...6109
      Cylinders...6110
      Piston Rings...6110
      Pistons...6110
      Connecting Rods...6110
      Oil Pump...6110
      Crankshaft...6111
      Timing Gear...6111
      Thermostat...6112
      Engine Bolt Torque...6112
      Crankshaft Re-Grind Data...6113
    TORQUE SPECIFICATIONS...6114
      Torque for General SAE Bolts...6114
      Torque For General Metric Bolts...6115
    HYDRAULIC CONNECTION SPECIFICATIONS...6116
      O-Ring Face Seal Connection...6116
      Straight Thread O-ring Fitting...6116
      Tubelines And Hoses...6116
      Flare Fitting...6117
      O-Ring Flare Fitting...6118
      Port Seal Fitting...6120
    HYDRAULIC FLUID SPECIFICATIONS...6122
      Specifications...6122
    FUEL, COOLANT AND LUBRICANTS...6124
      Chart...6124
    CONVERSIONS...6126
      Decimal And Millimeter Equivalents...6126
      U.S. To Metric Conversion Chart...6126
  SERVICE MANUAL REVISIONS...6128
    SMR-1...6128
    SMR-2...6130
    SMR-3...6132
    SMR-4...6134
    SMR-5...6136
6986749 (7-11) - 435 Compact Excavator Service Manual...6138
  CONTENTS...6142
  FOREWORD...6144
    FOREWORD...6146
    SAFETY INSTRUCTIONS...6148
    FIRE PREVENTION...6150
      Maintenance...6150
      Operation...6150
      Electrical...6150
      Hydraulic System...6150
      Fueling...6150
      Starting...6150
      Spark Arrester Exhaust System...6150
      Welding And Grinding...6151
      Fire Extinguishers...6151
    SERIAL NUMBER LOCATIONS...6152
      Excavator Serial Number...6152
      Engine Serial Number...6152
    DELIVERY REPORT...6153
    BOBCAT EXCAVATOR IDENTIFICATION...6154
  SAFETY & MAINTENANCE...6156
    LIFTING AND BLOCKING THE EXCAVATOR...6158
      Procedure...6158
    UPPERSTRUCTURE SLEW LOCK...6160
      Operation...6160
    LIFTING THE EXCAVATOR...6162
      Procedure...6162
    OPERATOR CAB (ROPS / TOPS)...6164
      Emergency Exit...6164
      Cab Door...6165
      Front Window...6166
      Right Side Windows...6168
    TRANSPORTING THE EXCAVATOR ON A TRAILER...6170
      Loading And Unloading...6170
      Fastening...6170
    TAILGATE...6172
      Opening And Closing The Tailgate...6172
      Adjusting The Latch...6172
    RIGHT SIDE COVER...6174
      Opening And Closing...6174
    SERVICE SCHEDULE...6176
      Chart...6176
    AIR CLEANER SERVICE...6178
      Daily Check...6178
      Replacing The Filters...6178
    CAB FILTERS...6180
      Cleaning And Maintenance...6180
    ENGINE COOLING SYSTEM...6182
      Cleaning...6182
      Checking Level...6182
      Removing And Replacing The Coolant...6183
    FUEL SYSTEM...6186
      Fuel Specifications...6186
      Biodiesel Blend Fuel...6186
      Filling The Fuel Tank...6187
      Fuel Filters...6187
      Inline Fuel Filter...6188
      Draining The Fuel Tank...6188
      Removing Air From The Fuel System...6188
    ENGINE LUBRICATION SYSTEM...6190
      Checking And Adding Engine Oil...6190
      Engine Oil Chart...6190
      Removing And Replacing Oil Filter...6191
    HYDRAULIC SYSTEM...6192
      Checking And Adding Fluid...6192
      Hydraulic / Hydrostatic Fluid Chart...6192
      Removing And Replacing The Hydraulic Filter...6193
      Removing And Replacing The Case Drain Filter...6193
      Removing And Replacing The Fan Filter...6194
      Removing And Replacing The Hydraulic Fluid...6195
      Diagnostic Couplers...6196
    LUBRICATING THE EXCAVATOR...6198
      Lubrication Locations...6198
    TRAVEL MOTOR...6202
      Checking And Adding Oil...6202
      Removing And Replacing Oil...6202
    SPARK ARRESTER MUFFLER...6204
      Cleaning Procedure...6204
    ENGINE ACCESSORY DRIVE BELT...6206
      Belt Adjustment...6206
      Belt Replacement...6206
    SEAT BELT...6208
      Inspection And Maintenance...6208
    REMOTE START TOOL KIT - MEL1563...6210
      Remote Start Tool - MEL1563...6210
      Service Tool Harness Communicator - MEL1566...6212
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...6214
      Description...6214
      Remote Start Tool (Service Tool) - 7003030...6215
      Excavator Service Tool Harness - 6689747...6216
      Computer Service Tool Harness - 6689746...6217
  HYDRAULIC SYSTEM...6218
    HYDRAULIC / HYDROSTATIC SCHEMATICS...6224
    HYDRAULIC SYSTEM INFORMATION...6228
      Glossary Of Hydraulic / Hydrostatic Symbols For Excavators...6228
      Troubleshooting The Hydraulic Circuit...6231
      Troubleshooting The Cylinder Circuit...6232
      Troubleshooting The Upperstructure Slew Circuit...6233
    CYLINDER (BOOM)...6234
      Testing...6234
      Removal And Installation...6236
      Parts Identification...6239
      Disassembly...6240
      Assembly...6243
    CYLINDER (ARM)...6246
      Testing...6246
      Removal And Installation...6248
      Parts Identification...6250
      Disassembly...6251
      Assembly...6254
    CYLINDER (BOOM SWING)...6258
      Testing...6258
      Removal And Installation...6260
      Parts Identification...6262
      Disassembly...6263
      Assembly...6266
    CYLINDER (BUCKET)...6270
      Testing...6270
      Removal And Installation...6272
      Parts Identification...6273
      Disassembly...6274
      Assembly...6276
    CYLINDER (BLADE)...6280
      Testing...6280
      Removal And Installation...6281
      Parts Identification...6282
      Disassembly...6283
      Assembly...6285
    CYLINDER (CLAMP)...6288
      Testing...6288
      Removal And Installation...6289
      Parts Identification...6290
      Disassembly...6291
      Assembly...6294
    CYLINDER (ANGLE BLADE)...6298
      Testing...6298
      Removal And Installation...6300
      Parts Identification...6302
      Disassembly...6303
      Assembly...6305
    VALVE (MAIN RELIEF)...6308
    VALVES (PORT RELIEF)...6310
      Port Relief Valve Pressure Setting...6310
      Parts Identification...6310
      Adjustment Procedure...6311
    VALVES (CROSSPORT RELIEF)...6312
      Testing And Adjusting The Crossport Relief Valve...6312
      Removal And Installation...6314
      Disassembly And Assembly...6315
    VALVE (PRESSURE REDUCING)...6320
      Description...6320
    VALVE (ANGLE BLADE)...6322
      Description...6322
      Testing And Adjusting Port Relief Valves...6322
      Testing And Adjusting Sequence Valve...6324
      Removal And Installation...6326
      Parts Identification...6329
      Disassembly...6330
      Assembly...6343
    HYDRAULIC CONTROL VALVE (S/N AA8A11001 & ABOVE AND AACD11001 & ABOVE)...6356
      Removal And Installation...6356
      Parts Identification...6359
      Disassembly...6360
      Slew Valve Section Disassembly And Assembly...6362
      Blade Valve Section Disassembly And Assembly...6368
      Bucket Valve Section Disassembly And Assembly...6380
      Arm Valve Section Disassembly And Assembly...6386
      Boom Valve Section Disassembly And Assembly...6392
      Boom Swing Valve Section Disassembly And Assembly...6398
      Auxiliary Valve Section Disassembly And Assembly...6404
      Inlet Section Disassembly And Assembly...6412
      Assembly...6417
    HYDRAULIC CONTROL VALVE (S/N AACB11001 & ABOVE AND S/N AA8911001 & ABOVE)...6422
      Removal And Installation...6422
      Parts Identification...6425
      Disassembly...6426
      Right Travel Valve Section Disassembly And Assembly...6428
      Left Travel Valve Section Disassembly And Assembly...6431
      Slew Valve Section Disassembly And Assembly...6434
      Blade Valve Section Disassembly And Assembly...6440
      Bucket Valve Section Disassembly And Assembly...6451
      Arm Valve Section Disassembly And Assembly...6457
      Boom Valve Section Disassembly And Assembly...6463
      Boom Swing Valve Section Disassembly And Assembly...6469
      Auxiliary Valve Section Disassembly And Assembly...6475
      Inlet Section Disassembly And Assembly...6483
      Assembly...6488
    HYDRAULIC PUMP...6494
      Piston Pump Work Sheet...6494
      Piston Pump Testing...6497
      Description...6507
      Gear Pump Testing...6507
      Removal And Installation...6509
      Coupler Removal And Installation...6510
      Hydraulic Pump Start Up...6511
      Torque Limiter Valve Parts Identification...6512
      Torque Limiter Valve Removal...6513
      Torque Limiter Valve Disassembly...6514
      Torque Limiter Valve Assembly...6518
      Initial Torque Limiter Valve Setting...6521
      Torque Limiter Valve Installation...6523
      Pump Control Parts Identification...6524
      Pump Control Removal And Installation...6525
      Pump Control Disassembly And Assembly...6525
      Parts Identification...6531
      Gear Pump Removal And Installation...6532
      Gear Pump Disassembly And Assembly...6533
      Piston Pump Parts Identification...6538
      Piston Pump Disassembly...6539
      Piston Pump Assembly...6548
    MANIFOLD ASSEMBLY / ACCUMULATOR (S/N AACD11001 & ABOVE AND S/N AA8A11001 & ABOVE)...6560
      Description...6560
      Testing Pilot Pressure...6561
      Removal And Installation...6562
      Parts Identification...6564
      Disassembly...6565
      Assembly...6578
    MANIFOLD ASSEMBLY / ACCUMULATOR (S/N AACB11001 & ABOVE AND S/N AA8911001 & ABOVE)...6590
      Description...6590
      Testing Pilot Pressure...6591
      Removal And Installation...6592
      Parts Identification...6595
      Disassembly...6596
      Assembly...6605
    TRAVEL MOTOR (S/N AACD11001 & ABOVE AND AA8A11001 & ABOVE)...6614
      Removal And Installation...6614
      Parts Identification...6616
      Disassembly...6617
      Assembly...6631
    TRAVEL MOTOR (S/N AACB11001 & ABOVE AND S/N AA8911001 & ABOVE)...6648
      Removal And Installation...6648
      Parts Identification...6649
      Disassembly...6650
      Assembly...6660
    SWIVEL JOINT...6672
      Removal And Installation...6672
      Parts Identification...6674
      Description...6675
      Disassembly...6675
      Assembly...6678
    SWING MOTOR...6682
      Removal And Installation...6682
      Parts Identification...6686
      Disassembly...6688
      Inspection...6693
      Assembly...6694
    SWING MOTOR DRIVE CARRIER...6700
      Removal And Installation...6700
      Parts Identification...6701
      Checking The Drive Carrier Shaft End Play...6702
      Disassembly...6703
      Inspection...6705
      Assembly...6706
    CONTROL PATTERN SELECTOR VALVE...6710
      Removal And Installation...6710
      Parts Identification...6711
      Disassembly...6712
      Assembly...6714
    RIGHT CONTROL LEVER (JOYSTICK)...6716
      Testing...6716
      Handle Removal And Installation...6717
      Joystick Assembly Removal And Installation...6721
      Parts Identification...6724
      Disassembly...6725
      Assembly...6730
    LEFT CONTROL LEVER (JOYSTICK)...6734
      Testing...6734
      Handle Removal And Installation...6736
      Joystick Assembly Removal And Installation...6739
      Parts Identification...6741
      Disassembly...6742
      Assembly...6747
    TRAVEL CONTROL VALVE (S/N AA8A11001 & ABOVE AND AACD11001 & ABOVE)...6752
      Removal And Installation...6752
      Parts Identification...6753
      Disassembly And Assembly...6754
    TRAVEL CONTROL VALVE (S/N AACB11001 & ABOVE AND S/N AA8911001 & ABOVE)...6760
      Removal And Installation...6760
      Parts Identification...6761
      Disassembly And Assembly...6762
    HOSES...6766
      Hose Guide Location...6766
      Left Control Lever (Joystick) (S/N AACB11001 & Above And AA8911001 & Above)...6767
      Left Control Lever (Joystick) (S/N AACD11001 & Above And AA8A11001 & Above)...6768
      Right Control Lever (Joystick) (S/N AACB11001 & Above And AA8911001 & Above)...6769
      Right Control Lever (Joystick) (S/N AACD11001 & Above And AA8A11001 & Above)...6770
      Travel Control Valve (S/N AACB11001 & Above And AA8911001 & Above)...6771
      Travel Control Valve (S/N AACD11001 & Above And AA8A11001 & Above)...6772
      Manifold Assembly / Accumulator (S/N AACB11001 & Above And AA8911001 & Above)...6773
      Manifold Assembly / Accumulator (S/N AACD11001 & Above And AA8A11001 & Above)...6774
    HYDRAULIC FILTER MOUNT...6776
      Removal And Installation...6776
    HYDRAULIC RESERVOIR...6778
      Removal And Installation...6778
    OIL COOLER...6780
      Removal And Installation...6780
    DIRECT TO TANK VALVE (IF EQUIPPED)...6784
      Removal And Installation...6784
      Parts Identification...6785
      Disassembly And Assembly...6786
    DUAL SEQUENCE VALVE (S/N AACD11001 & ABOVE AND S/N AA8A11001 & ABOVE)...6788
      Removal And Installation...6788
      Parts Identification...6790
      Disassembly And Assembly...6791
    DUAL SEQUENCE VALVE (S/N AACB11001 & ABOVE AND AA8911001 & ABOVE)...6794
      Removal And Installation...6794
      Parts Identification...6796
      Disassembly And Assembly...6797
    BUILD UP VALVE...6800
      Removal And Installation...6800
      Parts Identification...6801
      Disassembly And Assembly...6802
    COOLING FAN...6804
      Description...6804
      Testing...6804
      Removal And Installation...6805
      Parts Identification...6807
      Disassembly And Assembly...6808
    REMOVING AIR FROM HYDRAULIC SYSTEM...6816
      Procedure...6816
    BOOM SWING LOCK VALVE...6820
      Description...6820
      Removal And Installation...6820
      Parts Identification...6822
      Disassembly...6823
      Assembly...6826
    HYDRAULIC X-CHANGE VALVE...6830
      Removal And Installation...6830
      Parts Identification...6833
      Disassembly...6834
      Assembly...6842
  HYDROSTATIC SYSTEM...6850
    HYDROSTATIC SYSTEM INFORMATION...6852
      Troubleshooting Chart...6852
      Relief / Replenishing Valve Function...6853
      Relief / Replenishing Valve Location...6853
      Relief / Replenishing Valve Removal And Installation...6854
      Charge Pressure Relief Valve Location...6855
      Charge Pressure Relief Valve Removal And Installation...6855
    TRAVEL PILOT PRESSURE...6856
      Description...6856
      Testing...6856
    HYDROSTATIC PUMP...6860
      Removal And Installation...6860
      Parts Identification (Front) (S/N AACD11001 & Above And AA8A11001 & Above)...6863
      Disassembly...6864
      Inspection...6879
      Assembly...6883
      Hydrostatic Pump Start-Up...6898
      Mechanical Neutral Adjustment...6898
    FAN / CHARGE PUMP...6902
      Description...6902
      Testing...6902
    DRIVE BELT SHIELD...6904
      Removal And Installation...6904
    DRIVE BELT...6906
      Adjustment...6906
      Removal And Installation...6908
  UNDERCARRIAGE...6910
    BLADE...6912
      Removal And Installation...6912
    ANGLE BLADE ASSEMBLY...6914
      Removal And Installation...6914
    ANGLE BLADE...6916
      Removal And Installation...6916
    ANGLE BLADE CUTTING EDGE...6918
      Removal And Installation...6918
    TRACKS...6920
      Track Lug Height...6920
      Rubber Track Clearance...6921
      Steel Track Clearance...6922
      Adjustment...6922
      Rubber Track Removal And Installation...6923
      Steel Track Removal And Installation...6926
    TRACK FRAME...6932
      Disassembly And Assembly...6932
      Recoil Spring Cylinder Disassembly And Assembly (S/N AACB11378 & Below, AACD11163 & Below, AA8A11150 & Below and AA8911261 & Below Without Replaceable Shaft.)...6935
      Recoil Spring Cylinder Parts Identification (S/N AACB11378 & Below, AACD11163 & Below, AA8A11150 & Below And AA8911261 & Below With Replaceable Shaft)...6936
      Recoil Spring Cylinder Disassembly And Assembly (S/N AACB11378 & Below, AACD11163 & Below, AA8A11150 & Below and AA8911261 & Below With Replaceable Shaft.)...6937
      Recoil Spring Cylinder Parts Identification (S/N AACB11379 & Above, AACD11164 & Above, AA8A11151 & Above And AA8911262 & Above)...6939
      Recoil Spring Cylinder Disassembly And Assembly (S/N AACB11379 & Above, AACD11164 & Above, AA8A11151 & Above and AA8911262 & Above)...6940
    TRACK DAMAGE IDENTIFICATION...6942
      Cutting Of Steel Cords...6942
      Abrasion Of Embedded Metals...6943
      Separation Of Embedded Metals...6944
      Separation Of Embedded Metals Due To Corrosion...6945
      Cuts On The Lug Side Rubber...6946
      Cracks On The Lug Side Rubber Due To Fatigue...6947
      Lug Abrasion...6948
      Cracks And Cuts On The Lug Side Rubber...6949
      Abrasion Of The Track Roller Side...6950
      Cuts On The Edges Of Track Roller Side...6951
    TRACK IDLER...6954
      Parts Identification...6954
      Disassembly...6955
      Assembly...6957
    UPPER TRACK ROLLER...6960
      Parts Identification...6960
      Disassembly...6961
      Assembly...6962
    LOWER TRACK ROLLER...6966
      Parts Identification...6966
      Disassembly...6967
      Assembly...6968
    SWING CIRCLE GEAR...6972
      Swing Bearing Removal...6972
      Swing Bearing Installation...6973
  UPPERSTRUCTURE AND SWING SECTION...6974
    UPPERSTRUCTURE...6978
      Removal...6978
      Installation...6981
    ROPS CANOPY...6984
      Removal And Installation...6984
    CAB...6988
      Removal And Installation...6988
      Door Removal And Installation...6993
      Front Window Removal And Installation...6994
      Right Side Rear Sliding Window Removal And Installation...6997
      Right Side Front Sliding Window Removal And Installation...6997
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...6998
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...6998
      Glass Removal...6999
      Glass Installation...7000
    SEAT AND SEAT MOUNT...7004
      Removal And Installation...7004
    RIGHT CONSOLE...7006
      Console Cover Removal And Installation...7006
      Console Base Removal And Installation...7007
    LEFT CONSOLE...7010
      Lower Console Cover Removal And Installation...7010
      Upper Console Cover Removal And Installation...7011
      Compression Spring Removal And Installation...7012
      Compression Spring Disassembly And Assembly...7013
      Lock Lever Removal And Installation...7015
      Console Removal And Installation...7016
      Disassembly And Assembly...7020
      Console Switch Removal And Installation...7023
      Console Base Removal And Installation...7024
    ENGINE SPEED CONTROL...7026
      Removal And Installation...7026
      Disassembly And Assembly...7027
      Adjustment (Later Models)...7028
    BLADE CONTROL...7030
      Lever Removal And Installation...7030
      Linkage Removal And Installation...7031
      Linkage Disassembly And Assembly...7032
      Control Cable Removal And Installation...7033
    RIGHT PEDAL AND LINKAGE...7034
      Pedal Removal And Installation...7034
      Pedal Disassembly And Assembly...7035
      Control Cable Removal And Installation...7037
    TRAVEL CONTROLS...7038
      Removal And Installation...7038
      Disassembly And Assembly...7041
      Adjustment...7043
    CONTROL LINKAGE ASSEMBLY...7046
      Removal And Installation...7046
    FLOOR MAT AND FLOOR PLATES...7048
      Removal And Installation...7048
    FUEL TANK...7050
      Removal And Installation...7050
    HORN...7052
      Removal And Installation...7052
    SWING FRAME...7054
      Boom Swing Bracket Removal And Installation...7054
      Boom Swing Bracket Hose Installation...7058
      Bushing Removal...7059
      Bushing Installation...7060
    BOOM...7062
      Removal And Installation...7062
    ARM...7064
      Removal And Installation...7064
      Arm To Boom Bushing Removal And Installation...7065
      Arm To Bucket And Bucket Link Bushing Removal And Installation...7066
    BUCKET...7068
      Bucket Teeth Removal And Installation...7068
      Bucket Side Cutting Edge Removal And Installation...7069
    CLAMP...7070
      Removal And Installation...7070
    TAILGATE...7072
      Removal And Installation...7072
    X-CHANGE (PIN ON)...7074
      Removal And Installation...7074
      Parts Identification...7076
      Disassembly And Assembly...7077
    RIGHT SIDE COVER...7078
      Removal And Installation...7078
    X-CHANGE (HYDRAULIC)...7080
      Removal And Installation...7080
      Parts Identification...7083
      Disassembly...7084
      Assembly...7089
    COUNTERWEIGHT...7098
      Removal And Installation...7098
    QUICK COUPLER (KLAC™ SYSTEM)...7100
      Troubleshooting...7100
      Daily Inspection...7100
      Removal And Installation...7101
      Parts Identification...7103
      Disassembly...7104
      Assembly...7105
    QUICK COUPLER (LEHNHOFF® SYSTEM)...7108
      Troubleshooting...7108
      Daily Inspection...7108
      Removal (MS03 And MS08)...7109
      Installation (MS03 And MS08)...7110
      Parts Identification (MS03)...7111
      Disassembly And Assembly (MS03)...7112
      Parts Identification (MS08)...7113
      Disassembly (MS08)...7114
      Assembly (MS08)...7117
  ELECTRICAL SYSTEM & ANALYSIS...7122
    ELECTRICAL SCHEMATICS...7124
    ELECTRICAL SYSTEM INFORMATION...7126
      Troubleshooting Chart...7126
      Description...7127
      Fuse And Relay Location...7127
    BATTERY...7128
      Servicing...7128
      Removal And Installation...7129
      Using A Booster Battery (Jump Starting)...7130
    ALTERNATOR...7132
      Engine Accessory Drive Belt...7132
      Removal And Installation...7132
      Alternator Identification...7133
      Charging System Check...7134
      Alternator Voltage Test...7135
      Low Voltage Test...7135
      High Voltage Test...7136
      Rectifier Continuity (Diode) Test...7137
      Alternator Regulator Test...7138
      Parts Identification...7138
      Disassembly...7138
      Stator Continuity Test...7139
      Stator Ground Test...7139
      Rotor Continuity Test...7140
      Rotor Ground Test...7140
      Assembly...7140
    STARTER...7142
      Removal And Installation...7142
      Parts Identification...7143
      Disassembly...7144
      Inspection And Repair...7149
      Assembly...7152
    LIGHTS...7158
      Removal And Installation...7158
      Boom Light Removal and Installation...7159
      Boom Light Bulb Replacement...7159
    TWO-SPEED SWITCH...7160
      Removal And Installation...7160
    FUEL LEVEL SENDER...7162
      Removal And Installation...7162
      Testing...7163
    DIAGNOSTICS SERVICE CODE...7164
      Number Codes List...7164
    DELUXE INSTRUMENT PANEL SETUP...7166
      Passwords...7166
      Password Entry (For Starting and Operating the Machine)...7166
      Changing The Owner or Operator Password...7166
      Password Lockout Feature...7167
      Job Clock...7167
      RPM...7167
  ENGINE SYSTEM...7168
    TROUBLESHOOTING...7170
      Chart...7170
    MUFFLER...7172
      Removal And Installation...7172
    AIR CLEANER...7174
      Removal And Installation...7174
    RADIATOR...7176
      Removal And Installation...7176
    ENGINE COMPONENTS AND TESTING...7182
      Engine Compression Checking...7182
      Glow Plug Removal And Installation...7183
      Checking The Glow Plug...7186
      Fuel Shut-off Solenoid Removal And Installation...7187
      Fuel Injection Pump Check...7189
      Fuel Injection Pump Removal And Installation...7190
      Fuel Injection Pump Timing...7194
      Fuel Injector Nozzles Removal And Installation...7196
      Fuel Injector Nozzle Check...7200
      Valve Clearance Adjustment...7201
    ENGINE...7202
      Removal And Installation...7202
    ENGINE FLYWHEEL...7210
      Removal And Installation...7210
      Hydraulic Pump Coupler...7211
      Flywheel Ring Gear...7211
    ENGINE FLYWHEEL (LATER MODELS)...7212
      Removal And Installation...7212
      Hydraulic Pump Coupler...7213
      Flywheel Ring Gear...7213
    RECONDITIONING THE ENGINE...7214
      Cylinder Head Removal And Installation...7214
      Cylinder Head Disassembly And Assembly...7216
      Cylinder Head Servicing...7217
      Cylinder Head Top Clearance...7217
      Valve Guide Checking...7218
      Reconditioning The Valve And Valve Seat...7220
      Valve Spring...7221
      Rocker Arm And Shaft Checking...7222
      Timing Gearcase Cover Removal And Installation...7223
      Idler Gear And Camshaft Removal And Installation...7225
      Camshaft Servicing...7226
      Idler Gear And Shaft Servicing...7227
      Timing Gears Checking Backlash...7228
      Fuel Camshaft Removal And Installation...7229
      Fuel Camshaft Governor...7229
      Crankshaft Gear Removal And Installation...7230
      Oil Pump Removal And Installation...7230
      Oil Pump Service...7231
      Checking Engine Oil Pressure...7232
      Relief Valve...7232
      Piston And Connecting Rod Removal And Installation...7233
      Piston And Connecting Rod Servicing...7235
      Connecting Rod Alignment...7237
      Crankshaft And Bearings Removal And Installation...7238
      Crankshaft And Bearings Servicing...7240
      Cylinder Bore Checking...7243
      Water Pump Removal And Installation...7244
      Water Pump Disassembly And Assembly...7244
  HEATING, VENTILATION, AIR CONDITIONING...7246
    HEATER COIL...7248
      Removal And Installation With A/C...7248
      Removal And Installation Without A/C...7248
    BLOWER FAN...7250
      Removal And Installation...7250
      Disassembly And Assembly...7251
      Resistor Removal And Installation...7252
    HEATER VALVE...7254
      Removal And Installation...7254
    AIR CONDITIONING SYSTEM FLOW...7256
      Principals...7256
      Chart...7257
    COMPONENTS...7258
      Identification...7258
    SAFETY...7262
      Safety Equipment...7262
    REGULAR MAINTENANCE...7264
      Heater Air Filter...7264
      Engine Accessory Drive Belt...7264
      Cleaning The Condenser...7264
    BASIC TROUBLESHOOTING...7266
      Poor A/C Performance...7266
      Cleaning The A/C Evaporator Coil And Heater Coil...7267
      Engine Accessory Drive Belt...7268
      Checking The Electrical System...7269
      Engine Coolant Bypassing The Heater Valve...7279
    GENERAL AIR CONDITIONING SERVICE GUIDELINES...7280
      Compressor Oil...7280
      Compressor Oil Check...7281
      Component Replacement And Refrigeration Leaks...7282
    SYSTEM TROUBLESHOOTING CHART...7284
      Blower Motor Does Not Operate...7284
      Gauge Pressure Related Troubleshooting...7285
    TEMPERATURE / PRESSURE...7288
      Chart...7288
    AIR CONDITIONING SERVICE...7290
      Chart...7290
    SYSTEM CHARGING AND RECLAMATION...7292
      Reclamation Procedure...7292
      Charging Procedure With A Manifold Gauge Set...7295
    COMPRESSOR...7298
      Removal And Installation...7298
      Compressor Clutch Disassembly And Assembly...7299
    CONDENSER...7302
      Removal And Installation...7302
    RECEIVER / DRIER...7304
      Removal And Installation...7304
    PRESSURE RELIEF VALVE...7306
      Removal And Installation...7306
    PRESSURE SWITCH...7308
      Removal And Installation...7308
    EVAPORATOR / HEATER UNIT...7310
      Removal And Installation...7310
      Disassembly And Assembly...7311
    THERMOSTAT...7312
      Removal And Installation...7312
    EXPANSION VALVE...7314
      Removal And Installation...7314
    EVAPORATOR...7316
      Removal And Installation...7316
  SPECIFICATIONS...7318
    SPECIFICATIONS...7320
      Excavator Machine Dimensions...7320
      Performance (S/N AACD11001 & Above), (AA8A11001 & Above)...7322
      Performance (S/N AACB11001 & Above), (AA8911001 & Above)...7322
      Controls...7322
      Engine...7323
      Hydraulic System...7324
      Hydraulic Cylinders...7325
      Hydraulic Cycle Times...7325
      Drive System...7325
      Slew System...7325
      Undercarriage...7326
      Capacities...7326
      Track...7326
      Electrical...7326
    ENGINE SPECIFICATIONS...7328
      Fuel Injection Nozzles...7328
      Fuel Injection Pump...7328
      Cylinder Head...7328
      Valves...7328
      Valve Springs...7329
      Valve Timing...7329
      Rocker Arms...7329
      Camshaft...7329
      Tappet...7329
      Cylinders...7330
      Piston Rings...7330
      Pistons...7330
      Connecting Rods...7330
      Oil Pump...7330
      Crankshaft...7331
      Timing Gear...7331
      Thermostat...7332
      Engine Bolt Torque...7332
      Crankshaft Re-Grind Data...7333
    TORQUE SPECIFICATIONS...7334
      Torque for General SAE Bolts...7334
      Torque For General Metric Bolts...7335
    HYDRAULIC CONNECTION SPECIFICATIONS...7336
      O-ring Face Seal Connection...7336
      Straight Thread O-ring Fitting...7336
      Tubelines And Hoses...7336
      Flare Fitting...7337
      O-ring Flare Fitting...7338
      Port Seal Fitting...7340
    HYDRAULIC FLUID SPECIFICATIONS...7342
      Specifications...7342
    FUEL, COOLANT AND LUBRICANTS...7344
      Chart...7344
    CONVERSIONS...7346
      Decimal And Millimeter Equivalents...7346
      U.S. To Metric Conversion Chart...7346
  ALPHABETICAL INDEX...7348
  SERVICE MANUAL REVISIONS...7352
    Revision No: 435-1...7352
    Revision No: 435-2...7354
    Revision No: 435-3...7356
    Revision No: 435-4...7358
    Revision No: 435-5...7360
    Revision No: 435 - 6...7362
6986954 (2-08) - 430 Compact Excavator Operation & Maintenance Manual...7364
  OPERATOR SAFETY WARNING...7366
  CONTENTS...7368
  FOREWORD...7370
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED...7372
    REGULAR MAINTENANCE ITEMS...7372
    SERIAL NUMBER LOCATIONS...7374
      Excavator Serial Number...7374
      Engine Serial Number...7374
    DELIVERY REPORT...7374
    EXCAVATOR IDENTIFICATION...7375
    FEATURES, ACCESSORIES AND ATTACHMENTS...7376
      Standard Items...7376
      Options and Accessories...7376
      Attachments...7376
      Buckets Available...7376
    FALLING OBJECT GUARDS (FOGS)...7377
      Falling Object Guards (FOGS)...7377
      Special Applications Kit...7377
      Special Applications Kit Inspection And Maintenance...7377
  SAFETY & TRAINING RESOURCES...7378
    SAFETY INSTRUCTIONS...7380
      Before Operation...7380
      Safe Operation Is The Operator’s Responsibility...7381
      Safe Operation Needs A Qualified Operator...7381
      Avoid Silica Dust...7382
    FIRE PREVENTION...7382
      Maintenance...7382
      Operation...7382
      Electrical...7382
      Hydraulic System...7383
      Fueling...7383
      Starting...7383
      Spark Arrestor Exhaust System...7383
      Welding And Grinding...7383
      Fire Extinguishers...7383
    MACHINE SIGNS (DECALS)...7384
    PUBLICATIONS AND TRAINING RESOURCES...7386
  OPERATING INSTRUCTIONS...7388
    INSTRUMENTS AND CONSOLES...7392
      Cab Interior Light (If Equipped)...7392
      Left Console...7392
      Right Console...7393
      Function Icons...7394
      STD/ISO Selector Valve...7395
      Upperstructure Slew Lock...7395
      Raising And Lowering The Console...7395
      Two-Speed Travel...7396
    OPERATOR CANOPY (ROPS / TOPS)...7397
      Description...7397
    OPERATOR CAB (ROPS / TOPS)...7397
      Description...7397
      Cab Door...7398
      Front Window...7399
      Front Wiper...7400
      Window Washer Reservoir...7400
      Right Side Window...7401
      Heating, Ventilation, and Air Conditioning Duct...7402
    TRAVEL CONTROLS...7403
      Description...7403
      Forward And Reverse...7403
      Turning...7403
    HYDRAULIC CONTROLS...7405
      Description...7405
      Standard Control Pattern...7405
      ISO Control Pattern...7406
      Quick Couplers...7407
      Auxiliary Hydraulics...7408
      Relieving Hydraulic Pressure (Excavator And Attachment)...7408
      Return To Tank Valve (If Equipped)...7408
    BLADE CONTROL LEVER...7409
      Raising And Lowering The Blade...7409
      Angling Blade...7409
    BOOM SWING PEDAL...7410
      Operation...7410
    DAILY INSPECTION...7411
      Daily Inspection And Maintenance...7412
    PRE-STARTING PROCEDURE...7413
      Operation & Maintenance Manual And Operator’s Handbook Locations...7413
      Entering The Excavator...7413
      Seat Adjustment...7414
      Seat Belt Adjustment...7414
      Control Console...7414
    STARTING THE ENGINE...7415
      Key Switch...7415
      Keyless...7416
      Cold Temperature Starting...7417
      Warming The Hydraulic System...7418
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...7419
      Procedure...7419
      Emergency Exits...7420
    ATTACHMENTS...7421
      Installing And Removing The Attachment (Hydraulic X-Change)...7421
      Installing And Removing The Attachment (Pin-On X- Change)...7425
      Installing And Removing The Attachment (Bolt-On X- Change)...7431
      Installing And Removing The Attachment (Pin-On Attachment)...7437
    OPERATING PROCEDURE...7438
      Inspect The Work Area...7438
      Lowering The Work Equipment (Engine STOPPED)...7438
      Operating On Public Roads...7438
      Horsepower Control System (S/N AACG11001 & Above and AA8811001 & Above)...7439
      Lifting A Load...7440
      Excavating...7441
      Boom Swing...7443
      Backfilling...7444
      Driving The Excavator...7444
      Operating On Slopes...7445
      Operating In Water...7447
      Avoiding Track Damage...7447
      Extending The Arm (Extendable Arm Option Only)...7447
    TOWING THE EXCAVATOR...7448
      Procedure...7448
    LIFTING THE EXCAVATOR...7449
      Procedure...7449
    TRANSPORTING THE EXCAVATOR ON A TRAILER...7450
      Loading And Unloading...7450
      Fastening...7450
  PREVENTIVE MAINTENANCE...7452
    MAINTENANCE SAFETY...7454
    SERVICE SCHEDULE...7456
      Chart...7456
    CONTROL CONSOLE LOCKOUTS...7457
      Inspection And Maintenance...7457
    SEAT BELT...7458
      Inspection And Maintenance...7458
    MOTION ALARM SYSTEM (IF EQUIPPED)...7459
      Description...7459
      Inspecting...7459
      Adjusting Switch Position...7459
    TAILGATE...7460
      Opening And Closing...7460
      Adjusting The Latch...7460
    RIGHT SIDE COVER...7461
      Opening And Closing...7461
    CAB FILTERS...7462
      Cleaning And Maintenance...7462
    AIR CLEANER SERVICE...7463
      Daily Check...7463
      Replacing Filter Elements...7463
    FUEL SYSTEM...7465
      Fuel Specifications...7465
      Biodiesel Blend Fuel...7465
      Filling The Fuel Tank...7466
      Fuel Filters...7467
      Draining The Fuel Tank...7467
      Removing Air From The Fuel System...7467
    ENGINE LUBRICATION SYSTEM...7468
      Checking And Adding Engine Oil...7468
      Engine Oil Chart...7468
      Removing And Replacing Oil Filter...7469
    ENGINE COOLING SYSTEM...7470
      Cleaning...7470
      Checking Level...7471
      Removing And Replacing Coolant...7472
    ELECTRICAL SYSTEM...7473
      Description...7473
      Fuse And Relay Location/Identification...7473
      Battery Maintenance...7474
      Using A Booster Battery (Jump Starting)...7475
      Removing And Installing Battery...7476
    HYDRAULIC SYSTEM...7477
      Checking And Adding Fluid...7477
      Hydraulic Fluid Chart...7477
      Removing And Replacing The Hydraulic Filter...7478
      Removing And Replacing The Case Drain Filter...7478
      Removing And Replacing The Fan Filter...7479
      Removing And Replacing The Hydraulic Fluid...7480
    SPARK ARRESTOR MUFFLER...7481
      Cleaning Procedure...7481
    TRACK TENSION...7482
      Adjusting...7482
    TRAVEL MOTOR...7484
      Checking And Adding Oil...7484
      Removing And Replacing Oil...7484
    ENGINE ACCESSORY DRIVE BELT...7485
      Belt Adjustment...7485
      Belt Replacement...7485
    DRIVE BELT...7486
      Belt Adjustment...7486
    X-CHANGE...7488
      Inspection And Maintenance...7488
    TRACK ROLLER AND IDLER LUBRICATION...7488
      Procedure...7488
    BUCKET...7489
      Bucket Teeth Removal And Installation...7489
    CUTTING EDGE (ANGLE BLADE ONLY)...7490
      Removal And Installation...7490
    LUBRICATING THE EXCAVATOR...7491
      Lubrication Locations...7491
    PIVOT PINS...7494
      Inspection And Maintenance...7494
    EXCAVATOR STORAGE AND RETURN TO SERVICE...7495
      Storage...7495
      Return to Service...7495
  SYSTEM SETUP AND ANALYSIS...7496
    DIAGNOSTIC SERVICE CODES...7498
      Service Codes List...7498
    DISPLAY CONTROLLER PANEL SETUP...7499
      Passwords...7499
      Password Entry (For Starting and Operating the Machine)...7499
      Changing The Operator Password...7499
      Password Lockout Feature...7500
      Job Clock...7500
      RPM...7500
      Viewing Service Codes (Key Switch)...7501
      Viewing Service Codes (Keyless)...7501
  MACHINE SIGN TRANSLATIONS...7502
    WARNING (6808185)...7504
    LIFT CHART...7505
      430 STANDARD ARM (7107910)...7505
      430 LONG ARM (7107911)...7508
      430 Extendable ARM (7107912)...7511
    SERVICE SCHEDULE (7158257)...7514
    WARNING (6807776)...7517
    WARNING (6804114, 6817225, 6804233)...7520
    WARNING (6817815)...7521
      WARNING (6808474)...7521
    WARNING (6576048)...7522
    WARNING (6815915)...7523
    USING THE X-CHANGE SYSTEM (7102651)...7524
    USING THE X-CHANGE SYSTEM (7134587)...7527
    WARNING (6809829)...7530
    JOYSTICK CONTROL PATTERN SELECTOR LEVER (6815957)...7531
  SPECIFICATIONS...7532
    EXCAVATOR SPECIFICATIONS...7534
      Excavator Dimensions With Standard Arm, Long Arm Option and Extendable Arm Kit...7534
      Excavator Standard Arm Machine Dimensions...7535
      Excavator Long Arm Machine Dimensions...7536
      Excavator Extendable Arm Machine Dimensions...7537
      Excavator With Optional Angle Blade Dimensions...7538
      Performance - Conventional (S/N AACF11001 & Above And AA8711001 & Above)...7539
      Performance - FastTrack (S/N AACG11001 & Above And AA8811001 & Above)...7539
      Controls...7539
      Engine...7540
      Hydraulic System...7541
      Hydraulic Cylinders...7542
      Hydraulic Cycle Times...7542
      Electrical...7542
      Undercarriage...7543
      Capacities...7543
      Fuel Tank...7543
      Tracks...7543
      Type...7543
      Drive System- Conventional (S/N AACF11001 & Above, AA8711001 & Above)...7544
      Drive System - FastTrack (S/N AACG11001 & Above, AA8811001 & Above)...7544
      Slew System...7544
      Ground Pressure - Conventional...7544
      Ground Pressure - FastTrack...7544
  WARRANTY...7546
  ALPHABETICAL INDEX...7550
6986955 (07-12) - 430 Compact Excavator Service Manual...7552
  MAINTENANCE SAFETY...7554
  CONTENTS...7556
  FOREWORD...7558
    FOREWORD...7560
    SAFETY INSTRUCTIONS...7562
    FIRE PREVENTION...7564
      Maintenance...7564
      Operation...7564
      Electrical...7564
      Hydraulic System...7564
      Fueling...7564
      Starting...7564
      Spark Arrester Exhaust System...7564
      Welding And Grinding...7565
      Fire Extinguishers...7565
    SERIAL NUMBER LOCATIONS...7566
      Excavator Serial Number...7566
      Engine Serial Number...7566
    DELIVERY REPORT...7567
    BOBCAT EXCAVATOR IDENTIFICATION...7568
  SAFETY AND MAINTENANCE...7570
    LIFTING AND BLOCKING THE EXCAVATOR...7574
      Procedure...7574
    UPPERSTRUCTURE SLEW LOCK...7576
      Operation...7576
    LIFTING THE EXCAVATOR...7578
      Procedure...7578
    OPERATOR CAB (ROPS / TOPS)...7580
      Description...7580
      Cab Door...7580
      Front Window...7581
      Front Wiper...7583
      Window Washer Reservoir...7583
      Right Side Window...7584
      Heating, Ventilation, And Air Conditioning Duct...7585
    TRANSPORTING THE EXCAVATOR ON A TRAILER...7586
      Loading And Unloading...7586
      Fastening...7586
    TAILGATE...7588
      Opening And Closing The Tailgate...7588
      Adjusting The Latch...7588
    RIGHT SIDE COVER...7590
      Opening And Closing The Right Side Cover...7590
    SERVICE SCHEDULE...7592
      Chart...7592
    AIR CLEANER...7594
      Daily Check...7594
      Replacing The Elements...7594
    HEATER AIR FILTER (WITH CAB OPTION ONLY)...7596
      Removal And Installation...7596
    ENGINE COOLING SYSTEM...7598
      Cleaning The Cooling System...7598
      Checking Coolant Level...7598
      Removing And Replacing Coolant...7599
    FUEL SYSTEM...7602
      Fuel Specifications...7602
      Biodiesel Blend Fuel...7602
      Filling The Fuel Tank...7603
      Removing Water...7604
      Replacing Element...7604
      Draining The Fuel Tank...7605
      Inline Fuel Filter...7605
      Removing Air From The Fuel System...7605
    ENGINE LUBRICATION SYSTEM...7606
      Checking And Adding Engine Oil...7606
      Engine Oil Chart...7606
      Removing And Replacing Oil And Filter...7606
    HYDRAULIC SYSTEM...7608
      Checking And Adding Fluid...7608
      Hydraulic Fluid Chart...7609
      Removing And Replacing The Hydraulic Fluid...7610
      Removing And Replacing The Hydraulic Filter...7611
      Removing And Replacing The Case Drain Filter...7611
      Removing And Replacing The Fan Filter...7612
      Diagnostic Couplers...7612
    LUBRICATNG THE EXCAVATOR...7614
      Lubrication Locations...7614
    TRAVEL MOTOR...7618
      Checking And Adding Oil...7618
      Removing And Replacing Oil...7618
    SPARK ARRESTER MUFFLER...7620
      Cleaning Procedure...7620
    ALTERNATOR BELT...7622
      Belt Tension...7622
      Belt Adjustment...7622
    SEAT BELT...7624
      Inspection And Maintenance...7624
    PIVOT PINS...7626
      Inspection And Maintenance...7626
    EXCAVATOR STORAGE AND RETURN TO SERVICE...7628
      Storage...7628
      Return To Service...7628
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...7630
      Procedure...7630
      Emergency Exits...7631
    MOTION ALARM SYSTEM...7632
      Description...7632
      Inspecting...7632
      Adjusting Switch Position...7632
  HYDRAULIC SYSTEM...7634
    HYDRAULIC / HYDROSTATIC SCHEMATICS...7642
    HYDRAULIC SYSTEM INFORMATION...7646
      Glossary Of Hydraulic / Hydrostatic Symbols...7646
      Troubleshooting The Hydraulic Circuit...7650
      Troubleshooting The Cylinder Circuit...7650
      Troubleshooting The Swing (Upperstructure Slew) Circuit...7651
      Troubleshooting The Travel Circuit...7652
    CYLINDER (BOOM)...7654
      Testing...7654
      Removal And Installation...7657
      Parts Identification...7660
      Disassembly...7661
      Assembly...7663
    CYLINDER (ARM)...7666
      Testing...7666
      Removal And Installation...7668
      Parts Identification...7670
      Disassembly...7671
      Assembly...7673
    CYLINDER (BOOM SWING)...7676
      Testing...7676
      Removal And Installation...7677
      Parts Identification...7679
      Disassembly...7680
      Assembly...7682
    CYLINDER (BUCKET)...7686
      Testing...7686
      Removal And Installation...7688
      Parts Identification...7690
      Disassembly...7691
      Assembly...7693
    CYLINDER (BLADE)...7698
      Testing...7698
      Removal And Installation...7699
      Parts Identification...7700
      Disassembly...7701
      Assembly...7703
    CYLINDER (CLAMP)...7706
      Testing...7706
      Removal And Installation...7707
      Parts Identification...7708
      Disassembly...7709
      Assembly...7712
    CYLINDER (ANGLE BLADE)...7718
      Testing...7718
      Removal And Installation...7719
      Parts Identification...7721
      Disassembly...7722
      Assembly...7724
    CYLINDER (EXTENDIBLE ARM)...7728
      Removal And Installation...7728
      Parts Identification...7730
      Disassembly...7731
      Assembly...7733
    VALVES (MAIN RELIEF)...7738
      Testing And Adjusting The Main Relief Valves (S/N AACF11001 & Above And AA8711001 & Above)...7738
      System Pressures At Gauge Port Specifications...7738
      Testing And Adjusting The Main Relief Valves (S/N AACG11001 & Above And AA8811001 & Above)...7741
      System Pressures At Gauge Port Specifications...7741
    VALVES (PORT RELIEF)...7744
      Testing And Adjusting Port Relief Valve Pressure...7744
    VALVES (CROSSPORT RELIEF)...7748
      Testing And Adjusting The Crossport Relief Valves (S/N AACF11001 & Above And AA8711001 & Above)...7748
      Testing And Adjusting The Crossport Relief Valves (S/N AACG11001 & Above And AA8811001 & Above)...7750
    VALVE (PRESSURE REDUCING)...7752
      Description...7752
    VALVE (ANGLE BLADE)...7754
      Description...7754
      Testing And Adjusting Port Relief Valves...7754
      Testing And Adjusting Sequence Valve...7756
      Removal And Installation...7758
      Parts Identification...7761
      Disassembly...7762
      Assembly...7775
    HYDRAULIC CONTROL VALVE (S/N AACF11001 & ABOVE AND AA8711001 & ABOVE)...7788
      Description...7788
      Removal And Installation...7788
      Parts Identification...7794
      Disassembly...7795
      Right Travel Valve Section Disassembly And Assembly...7797
      Left Travel Valve Section Disassembly And Assembly...7801
      Blade Valve Section Disassembly And Assembly...7805
      Slew Valve Section Disassembly And Assembly...7814
      Auxiliary Valve Section Disassembly And Assembly...7819
      Bucket Valve Section Disassembly And Assembly...7824
      Arm Valve Section Disassembly And Assembly...7829
      Boom Valve Section Disassembly And Assembly...7834
      Boom Swing Valve Section Disassembly And Assembly...7839
      Inlet Section Disassembly And Assembly...7844
      Assembly...7849
    HYDRAULIC CONTROL VALVE (S/N AACG11001 & ABOVE AND AA8811001 & ABOVE)...7856
      Description...7856
      Removal And Installation...7856
      Parts Identification...7859
      Disassembly...7860
      Blade Valve Section Disassembly And Assembly...7861
      Slew Valve Section Disassembly And Assembly...7870
      Auxiliary Valve Section Disassembly And Assembly...7875
      Bucket Valve Section Disassembly And Assembly...7880
      Arm Valve Section Disassembly And Assembly...7885
      Boom Valve Section Disassembly And Assembly...7890
      Boom Swing Valve Section Disassembly And Assembly...7895
      Inlet Section Disassembly And Assembly...7900
      Assembly...7905
    HYDRAULIC PUMP...7910
      Description...7910
      Torque Adjustment...7911
      Testing The Piston Pump...7912
      Testing The Gear Pump...7914
      Testing Auxiliary Flow...7916
      Removal And Installation...7917
      Coupler Removal And Installation...7918
      Hydraulic Pump Start Up...7919
      Gear Pump Parts Identification...7920
      Piston Pump Parts Identification...7921
      Disassembly...7922
      Gear Pump Disassembly...7924
      Gear Pump Assembly...7927
      Piston Pump Disassembly...7930
      Piston Pump Assembly...7937
      Assembly...7944
    MANIFOLD ASSEMBLY / ACCUMULATOR (S/N AACG11001 & ABOVE AND AA8811001 & ABOVE)...7946
      Description...7946
      Testing Pilot Pressure...7947
      Removal And Installation...7948
      Parts Identification...7950
      Disassembly...7951
      Assembly...7963
    MANIFOLD ASSEMBLY / ACCUMULATOR (S/N AACF11001 & ABOVE AND AA8711001 & ABOVE)...7976
      Description...7976
      Testing Pilot Pressure...7977
      Removal And Installation...7978
      Parts Identification...7980
      Disassembly...7981
      Assembly...7990
    TRAVEL MOTOR (S/N AACG11001 & ABOVE AND AA8811001)...8000
      Description...8000
      Removal And Installation...8000
      Parts Identification...8002
      Disassembly...8003
      Assembly...8017
    TRAVEL MOTOR (S/N AACF11001 & ABOVE AND AA8711001 & ABOVE)...8034
      Description...8034
      Removal And Installation...8034
      Parts Identification...8035
      Disassembly...8036
      Assembly...8046
    SWIVEL JOINT...8058
      Removal And Installation...8058
      Parts Identification...8060
      Description...8061
      Disassembly...8061
      Assembly...8064
    SWING MOTOR...8068
      Description...8068
      Removal And Installation...8068
      Parts Identification...8070
      Disassembly...8071
      Assembly...8076
    SWING MOTOR (DRIVE CARRIER)...8082
      Description...8082
      Removal And Installation...8082
      Parts Identification...8083
      Disassembly...8084
      Assembly...8086
    CONTROL PATTERN SELECTOR VALVE...8090
      Description...8090
      Removal And Installation...8090
      Parts Identification...8091
      Disassembly...8092
      Assembly...8094
    RIGHT CONTROL LEVER (JOYSTICK)...8096
      Description...8096
      Testing...8096
      Handle Removal And Installation...8097
      Joystick Assembly Removal And Installation...8101
      Parts Identification...8104
      Disassembly...8105
      Assembly...8110
    LEFT CONTROL LEVER (JOYSTICK)...8114
      Description...8114
      Testing...8114
      Handle Removal And Installation...8116
      Joystick Assembly Removal And Installation...8119
      Parts Identification...8121
      Disassembly...8122
      Assembly...8127
    TRAVEL CONTROL VALVE (S/N AACG11001 & ABOVE AND AA8811001 & ABOVE)...8132
      Removal and Installation...8132
      Parts Identification...8133
      Disassembly And Assembly...8134
    TRAVEL CONTROL VALVE (S/N AACF11001 & ABOVE AND AA8711001 & ABOVE)...8140
      Removal and Installation...8140
      Parts Identification...8141
      Disassembly And Assembly...8142
    HOSES...8146
      Hose Guide Location...8146
      Left Control Lever (Joystick) (S/N AACF11001 & Above AND AA8711001 & Above)...8147
      Left Control Lever (Joystick) (S/N AACG11001 AND AA8811001 & Above)...8148
      Right Control Lever (Joystick) (S/N AACF11001 And Above AA8711001 & Above)...8149
      Right Control Lever (Joystick) (S/N AACG11001 & Above And AA8811001 & Above)...8150
      Travel Control Valve (S/N AACF11001 & Above And AA8711001 & Above)...8151
      Travel Control Valve (S/N AACG11001 & Above And AA8811001 & Above)...8152
      Manifold Assembly / Accumulator (S/N AACF11001 & Above And AA8711001 & Above)...8153
      Manifold Assembly / Accumulator (S/N AACG11001 & Above And AA8811001 & Above)...8154
    HYDRAULIC FILTER...8156
      Description...8156
      Housing Removal And Installation...8156
    CASE DRAIN FILTER...8158
      Removal And Installation...8158
    HYDRAULIC RESERVOIR...8160
      Description...8160
      Removal And Installation...8160
    OIL COOLER...8162
      Description...8162
      Removal And Installation...8162
    DIRECT TO TANK VALVE...8166
      Description...8166
      Removal And Installation...8166
      Parts Identification...8167
      Disassembly And Assembly...8168
    BUILD UP VALVE...8170
    COOLING FAN...8172
      Description...8172
      Testing...8172
      Removal And Installation...8173
      Parts Identification...8175
      Disassembly And Assembly...8176
    BOOM SWING LOCK VALVE...8184
      Description...8184
      Removal And Installation...8184
      Parts Identification...8185
      Disassembly...8186
      Assembly...8189
    HYDRAULIC X-CHANGE™ VALVE...8194
      Removal And Installation...8194
      Parts Identification...8197
      Disassembly...8198
      Assembly...8206
    SLEW LOCK VALVE...8214
      Description...8214
      Removal And Installation...8214
      Parts Identification...8215
      Disassembly And Assembly...8216
  HYDROSTATIC SYSTEM...8220
    HYDROSTATIC SYSTEM INFORMATION...8222
      Troubleshooting Chart...8222
      Relief / Replenishing Valve Function...8223
      Relief / Replenishing Valve Location...8223
      Relief / Replenishing Valve Removal And Installation...8224
      Charge Pressure Relief Valve Location...8225
      Charge Pressure Relief Valve Removal And Installation...8225
    TRAVEL PILOT PRESSURE...8226
      Description...8226
      Testing...8226
    HYDROSTATIC PUMP...8228
      Removal And Installation...8228
      Parts Identification (Front) (S/N AACG11001 & Above And AA8811001 & Above)...8231
      Disassembly...8232
      Inspection...8247
      Assembly...8251
      Hydrostatic Pump Start-Up...8266
      Mechanical Neutral Adjustment...8266
    DRIVE BELT SHIELD...8270
      Removal And Installation...8270
    DRIVE BELT...8272
      Adjustment...8272
      Removal And Installation...8274
  UNDERCARRIAGE...8276
    BLADE...8278
      Removal And Installation...8278
    ANGLE BLADE ASSEMBLY...8280
      Removal And Installation...8280
    ANGLE BLADE...8282
      Removal And Installation...8282
    ANGLE BLADE CUTTING EDGE...8284
      Removal And Installation...8284
    TRACK FRAME COMPONENTS...8286
      Description...8286
      Track Lug Height...8286
      Checking Tension...8287
      Adjusting Tension...8289
      Rubber Track Removal And Installation...8290
      Steel Track Removal And Installation...8293
      Idler (Front) Removal And Installation...8296
      Idler (Front) Parts Identification...8298
      Idler (Front) Disassembly...8299
      Idler (Front) Assembly...8301
      Coil Spring Assembly And Cylinder (S/N AACF11246 & Below, AACG11102 & Below, AA8711102 & Below And AA8811101 & Below)...8304
      Coil Spring Cylinder Parts Identification (S/N AACF11247 & Above, AACG11103 & Above, AA8711103 & Above And AA8811102 & Above)...8305
      Coil Spring Cylinder Disassembly And Assembly (S/ N AACF11247 & Above, AACG11103 & Above, AA8711103 & Above And AA8811102 & Above)...8306
      Roller Removal And Installation...8308
      Roller Parts Identification...8309
      Roller Disassembly...8310
      Roller Assembly...8312
      Track Damage Identification...8314
      Abrasion Of Embedded Metals...8315
    SWING CIRCLE GEAR...8326
      Swing Bearing Removal...8326
      Swing Bearing Installation...8327
  UPPERSTRUCTURE AND SWING SECTION...8328
    UPPERSTRUCTURE...8332
      Description...8332
      Removal...8332
      Installation...8335
    CANOPY...8338
      Removal And Installation...8338
    CAB...8342
      Removal And Installation...8342
      Door Removal And Installation...8346
      Front Window Removal And Installation...8347
      Right Side Rear Sliding Window Removal And Installation...8350
      Right Side Front Sliding Window Removal And Installation...8350
      Glass Removal...8351
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...8351
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...8351
      Glass Installation...8352
    SEAT AND SEAT MOUNT...8354
      Seat Mount Removal And Installation...8354
      Seat Removal And Installation...8354
    RIGHT CONSOLE...8356
      Description...8356
      Console Cover Removal And Installation...8356
      Console Frame Removal And Installation...8357
    LEFT CONSOLE...8360
      Description...8360
      Joystick Console Cover (Bottom) Removal And Installation...8360
      Joystick Console Cover (Top) Removal And Installation...8360
      Compression Spring Removal And Installation...8362
      Compression Spring Disassembly And Assembly...8363
      Lever Removal And Installation...8365
      Joystick Console Frame Removal And Installation...8366
      Joystick Console Frame Disassembly And Assembly...8370
      Left Rear Console Cover Removal And Installation...8372
      Left Rear Console Frame Removal And Installation...8373
    BLADE CONTROL...8374
      Removal And Installation...8374
      Linkage Removal And Installation...8375
      Linkage Disassembly And Assembly...8375
      Control Cable Removal And Installation...8377
    UPPERSTRUCTURE SLEW LOCK...8378
      Removal And Installation...8378
      Disassembly And Assembly...8379
    FLOOR MAT AND FLOOR PLATES...8382
      Description...8382
      Removal And Installation...8382
    BOOM SWING PEDAL...8384
      Description...8384
      Pedal Removal And Installation...8384
      Pedal Disassembly And Assembly...8385
      Control Cable Removal And Installation...8387
    TRAVEL LEVERS / PEDALS...8388
      Description...8388
      Adjustment...8388
      Removal And Installation...8391
      Disassembly And Assembly...8394
      Control Linkage Assembly Removal And Installation...8396
    FUEL TANK...8398
      Removal And Installation...8398
    HORN...8400
      Removal And Installation...8400
    SWING FRAME...8402
      Description...8402
      Removal And Installation...8402
      Hose Routing...8406
      Bushing Removal...8407
      Bushing Installation...8408
    BOOM...8410
      Description...8410
      Removal And Installation...8410
    ARM...8412
      Description...8412
      Removal And Installation...8412
      Arm To Boom Bushing Removal And Installation...8413
      Arm To Bucket And Bucket Link Bushing Removal And Installation...8414
    BUCKET...8416
      Removal And Installation (Pin-On X-Change™)...8416
      Removal And Installation (Bolt-On X-Change™)...8422
      Removal And Installation (Pin-On Attachment)...8428
      Removal And Installation (Hydraulic X-Change™)...8429
      Bucket Teeth Removal And Installation...8434
      Bucket Side Cutting Edge Removal And Installation...8435
    CLAMP...8436
      Removal And Installation...8436
    TAILGATE...8438
      Removal And Installation...8438
    X-CHANGE™...8440
      Removal And Installation...8440
      Parts Identification...8442
      Disassembly...8443
      Assembly...8448
      Check Proper Latch Engagement...8454
    X-CHANGE™ (HYDRAULIC)...8458
      Removal And Installation...8458
      Parts Identification...8461
      Disassembly...8462
      Assembly...8467
    RIGHT SIDE COVER...8476
      Removal And Installation...8476
    COUNTERWEIGHT...8478
      Removal And Installation...8478
    QUICK COUPLER (KLAC™ SYSTEM)...8480
      Troubleshooting...8480
      Daily Inspection...8480
      Removal And Installation...8481
      Parts Identification...8483
      Disassembly...8484
      Assembly...8485
    QUICK COUPLER (LEHNHOFF® SYSTEM)...8488
      Troubleshooting...8488
      Daily Inspection...8488
      Removal (MS03 And MS08)...8489
      Installation (MS03 And MS08)...8490
      Parts Identification (MS03)...8491
      Disassembly And Assembly (MS03)...8492
      Parts Identification (MS08)...8493
      Disassembly (MS08)...8494
      Assembly (MS08)...8497
  ELECTRICAL SYSTEM AND ANALYSIS...8502
    ELECTRICAL SCHEMATICS...8504
    ELECTRICAL SYSTEM INFORMATION...8506
      Troubleshooting Chart...8506
      Description...8507
      Fuse And Relay Location...8507
    BATTERY...8508
      Removing And Installing The Battery...8508
      Servicing...8509
      Using A Booster Battery (Jump Starting)...8510
    ALTERNATOR...8512
      Belt Adjustment...8512
      Belt Replacement...8512
      Charging System Inspection...8513
      Alternator Description...8514
      High Voltage Test...8515
      Rectifier Continuity (Diode) Test...8515
      Alternator Voltage Test...8516
      Low Voltage Test...8516
      Alternator Regulator Test...8517
      Parts Identification...8518
      Disassembly...8518
      Stator Continuity Test...8518
      Stator Ground Test...8519
      Rotor Continuity Test...8519
      Rotor Ground Test...8520
      Assembly...8520
      Removal And Installation...8521
    STARTER...8522
      Testing...8522
      Removal And Installation...8522
      Parts Identification...8523
      Disassembly...8524
      Inspection And Repair...8529
      Assembly...8532
    LIGHTS...8538
      Upperstructure Light Removal And Installation...8538
      Upperstructure Light Disassembly And Assembly...8538
      Boom Light Removal And Installation...8539
      Boom Light Bulb Replacement...8539
    MAGNETIC LOCKOUT SENSOR...8540
      Testing Left Console Magnetic Lockout Sensor...8540
      Console Switch Removal And Installation...8541
    FUEL LEVEL SENDER...8542
      Removal And Installation...8542
      Testing...8542
    DIAGNOSTICS SERVICE CODES...8544
      Description...8544
    DELUXE INSTRUMENT PANEL SETUP...8546
      Passwords...8546
      Password Entry (For Starting And Operating The Machine)...8546
      Changing The Owner or Operator Password...8546
      Password Lockout Feature...8547
      Job Clock...8547
      RPM...8547
    TWO-SPEED SWITCH...8548
      Removal And Installation...8548
  ENGINE SERVICE...8550
    ENGINE INFORMATION...8552
      Description...8552
      Specifications...8553
      Torque Values...8559
      Troubleshooting Chart...8560
      Removal And Installation...8561
      Compression Checking...8569
    ENGINE SPEED CONTROL...8570
      Removal And Installation...8570
      Disassembly And Assembly...8571
      Adjustment (S/N AA8711001 & Above And AA8811001 & Above)...8572
    SPARK ARRESTER MUFFLER...8574
      Removal And Installation...8574
    AIR CLEANER...8576
      Removal And Installation...8576
    ENGINE COOLING SYSTEM...8578
      Radiator Removal And Installation...8578
      Testing The Thermostat...8583
      Thermostat Housing Removal And Installation...8584
      Water Pump Removal And Installation...8585
      Water Pump Disassembly And Assembly...8585
    LUBRICATION SYSTEM...8586
      Oil Pan Removal And Installation...8586
      Oil Pump Removal And Installation...8586
      Oil Pump Inspection...8587
      Engine Oil Pressure - Testing...8588
    FUEL SYSTEM...8590
      Fuel Camshaft Removal And Installation...8590
      Fuel Camshaft Governor Disassembly And Assembly...8590
      Fuel ShutOff Solenoid - Checking...8591
      Fuel Shut-off Solenoid Removal And Installation...8592
      Fuel Injection Pump Removal And Installation...8594
      Injection Pump Timing...8597
      Fuel Injector Removal And Installation...8599
      Fuel Injector Nozzle Pressure - Checking...8602
      Nozzle Spray Condition...8602
      Valve Seat Tightness...8603
    ENGINE FLYWHEEL (LATER MODELS)...8604
      Removal And Installation...8604
      Hydraulic Pump Coupler...8605
      Flywheel Ring Gear...8605
    CYLINDER HEAD...8606
      Glow Plug Testing...8606
      Glow Plug Removal And Installation...8607
      Valve Clearance Adjustment...8608
      Valve Timing - Checking...8608
      Cylinder Head Removal And Installation...8609
      Cylinder Head Disassembly And Assembly...8612
      Cylinder Head Servicing...8613
      Cylinder Head Top Clearance...8613
      Valve Guide Checking...8614
      Reconditioning The Valve And Valve Seat...8616
      Valve Spring...8617
      Valve Tappets...8618
      Rocker Arm And Shaft - Checking...8618
    CRANKSHAFT AND PISTONS...8620
      Piston And Connecting Rod Removal And Installation...8620
      Piston And Connecting Rod Servicing...8622
      Connecting Rod Alignment...8624
      Crankshaft And Bearings Removal And Installation...8625
      Crankshaft And Bearings Servicing...8627
      Cylinder Bore, Checking...8630
    CRANKSHAFT AND TIMING GEARS...8632
      Timing Gearcase Cover Removal And Installation...8632
      Timing Gears Backlash - Checking...8634
      Idler Gear And Shaft Removal And Installation...8635
      Camshaft Servicing...8636
      Idler Gear And Shaft Servicing...8637
    ENGINE FLYWHEEL...8638
      Hydraulic Pump Coupler Removal And Installation...8638
      Flywheel Removal And Installation...8638
      Flywheel Ring Gear...8638
  HEATING, VENTILATION, AIR CONDITIONING...8640
    HEATER SYSTEM...8642
      Description...8642
      Components...8642
    REGULAR MAINTENANCE...8646
      Filter Element Removal And Installation...8646
      Engine Accessory Drive Belt...8646
      Cleaning The Condenser...8647
      Cleaning The A/C Evaporator Coil And Heater Coil...8648
    TROUBLESHOOTING...8650
      Blower Motor Does Not Operate...8650
      Blower Motor Operators Normally, But Air Flow Is Insufficient...8650
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...8650
      The Compressor Does Not Operate At All, Or Operates Improperly...8650
      Gauge Pressure Related Troubleshooting...8651
      Electrical System...8653
      Engine Coolant Bypassing The Heater Valve...8663
      Poor A/C Performance...8664
    EVAPORATOR / HEATER UNIT...8666
      Removal And Installation...8666
      Disassembly And Assembly...8667
    HEATER COIL...8668
      Removal And Installation With A/C...8668
      Removal And Installation Without A/C...8668
    BLOWER FAN...8670
      Removal And Installation...8670
      Disassembly And Assembly...8671
      Resistor Removal And Installation...8672
    HEATER VALVE...8674
      Removal And Installation...8674
    AIR CONDITIONING SERVICE...8676
      Safety Equipment...8676
      Chart...8677
      Reclamation Procedure...8678
      Compressor Oil...8681
      Compressor Oil Check...8682
      Component Replacement And Refrigeration Leaks...8684
      Temperature / Pressure Chart...8685
      Charging Procedure With A Manifold Gauge Set...8686
    COMPRESSOR...8690
      Removal And Installation...8690
      Compressor Clutch Disassembly And Assembly...8691
    CONDENSER...8694
      Removal And Installation...8694
    RECEIVER / DRIER...8696
      Removal And Installation...8696
    PRESSURE RELIEF VALVE...8698
      Removal And Installation...8698
    PRESSURE SWITCH...8700
      Removal And Installation...8700
    THERMOSTAT...8702
      Removal And Installation...8702
    EXPANSION VALVE...8704
      Removal And Installation...8704
    EVAPORATOR...8706
      Removal And Installation...8706
  SPECIFICATIONS...8708
    EXCAVATOR SPECIFICATIONS...8710
      Excavator Dimensions With Standard Arm, Long Arm Option And Extendable Arm Kit...8710
      Excavator Standard Arm Machine Dimensions...8711
      Excavator Long Arm Machine Dimensions...8712
      Excavator Extendable Arm Machine Dimensions...8713
      Excavator With Optional Angle Blade Dimensions...8714
      Performance - Conventional (S/N AACF11001 & Above And AA8711001 & Above)...8715
      Performance - FastTrack (S/N AACG11001 & Above And AA8811001 & Above)...8715
      Controls...8715
      Engine...8716
      Hydraulic System...8717
      Hydraulic Cylinders...8718
      Hydraulic Cycle Times...8718
      Electrical...8718
      Undercarriage...8719
      Capacities...8719
      Tracks...8719
      Drive System- Conventional (S/N AACF11001 & Above, AA8711001 & Above)...8720
      Drive System - FastTrack (S/N AACG11001 & Above, AA8811001 & Above)...8720
      Slew System...8720
      Ground Pressure - Conventional...8720
      Ground Pressure - FastTrack...8720
    TORQUE SPECIFICATIONS FOR BOLTS...8722
      Torque For General SAE Bolts...8722
      Torque For General Metric Bolts...8723
    HYDRAULIC CONNECTION SPECIFICATIONS...8724
      O-ring Face Seal Connection...8724
      Straight Thread O-ring Fitting...8724
      Tubelines And Hoses...8724
      Flare Fitting...8725
      O-ring Flare Fitting...8726
      Port Seal Fitting...8728
    HYDRAULIC FLUID SPECIFICATIONS...8730
      Specifications...8730
    FUEL, COOLANT AND LUBRICANTS...8732
      Chart...8732
    CONVERSIONS...8734
      Decimal And Millimeter Equivalents Chart...8734
      U.S. To Metric Conversion Chart...8734
  ALPHABETICAL INDEX...8736
  SERVICE MANUAL REVISION...8740
    Revision No: 430 - 1...8740
    Revision No: 430 - 2...8742
    Revision No: 430 - 3...8744
    Revision No: 430 - 4...8746
6986955 (9-09) - 430 Compact Excavator Service Manual...8748
  MAINTENANCE SAFETY...8750
  ALPHABETICAL INDEX...8752
  CONTENTS...8754
    FOREWORD...8755
    SAFETY INSTRUCTIONS...8757
    FIRE PREVENTION...8759
      Maintenance...8759
      Operation...8759
      Electrical...8759
      Hydraulic System...8759
      Fueling...8759
      Starting...8759
      Spark Arrestor Exhaust System...8759
      Welding And Grinding...8760
      Fire Extinguishers...8760
    SERIAL NUMBER LOCATIONS...8761
      Excavator Serial Number...8761
      Engine Serial Number...8761
    DELIVERY REPORT...8762
    BOBCAT EXCAVATOR IDENTIFICATION...8763
  SAFETY & MAINTENANCE...8764
    LIFTING AND BLOCKING THE EXCAVATOR...8768
      Procedure...8768
    UPPERSTRUCTURE SLEW LOCK...8770
      Operation...8770
    LIFTING THE EXCAVATOR...8772
      Procedure...8772
    OPERATOR CAB (ROPS/TOPS)...8774
      Description...8774
      Cab Door...8774
      Front Window...8775
      Front Wiper...8777
      Window Washer Reservoir...8777
      Right Side Window...8778
      Heating, Ventilation, and Air Conditioning Duct...8779
    TRANSPORTING THE EXCAVATOR ON A TRAILER...8780
      Loading And Unloading...8780
      Fastening...8780
    TAILGATE...8784
      Opening And Closing The Tailgate...8784
      Adjusting The Latch...8784
    RIGHT SIDE COVER...8786
      Opening And Closing The Right Side Cover...8786
    SERVICE SCHEDULE...8788
      Chart...8788
    AIR CLEANER...8790
      Daily Check...8790
      Replacing The Elements...8790
    HEATER AIR FILTER (WITH CAB OPTION ONLY)...8792
      Removal And Installation...8792
    ENGINE COOLING SYSTEM...8794
      Cleaning The Cooling System...8794
      Checking Coolant Level...8794
      Removing And Replacing Coolant...8795
    FUEL SYSTEM...8798
      Fuel Specifications...8798
      Biodiesel Blend Fuel...8798
      Filling The Fuel Tank...8799
      Removing Water...8800
      Replacing Element...8800
      Draining The Fuel Tank...8801
      Inline Fuel Filter...8801
      Removing Air From The Fuel System...8801
    ENGINE LUBRICATION SYSTEM...8802
      Checking And Adding Engine Oil...8802
      Engine Oil Chart...8802
      Removing And Replacing Oil And Filter...8802
    HYDRAULIC SYSTEM...8804
      Checking And Adding Fluid...8804
      Hydraulic Fluid Chart...8805
      Removing And Replacing The Hydraulic Fluid...8806
      Removing And Replacing The Hydraulic Filter...8807
      Removing And Replacing The Case Drain Filter...8807
      Removing And Replacing The Fan Filter...8808
      Diagnostic Couplers...8808
    LUBRICATNG THE EXCAVATOR...8810
      Lubrication Locations...8810
    TRAVEL MOTOR...8814
      Checking And Adding Oil...8814
      Removing And Replacing Oil...8814
    SPARK ARRESTOR MUFFLER...8816
      Cleaning Procedure...8816
    ALTERNATOR BELT...8818
      Belt Tension...8818
      Belt Adjustment...8818
    SEAT BELT...8820
      Inspection And Maintenance...8820
    PIVOT PINS...8822
      Inspection And Maintenance...8822
    EXCAVATOR STORAGE AND RETURN TO SERVICE...8824
      Storage...8824
      Return to Service...8824
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR...8826
      Procedure...8826
      Emergency Exits...8827
    MOTION ALARM SYSTEM (IF EQUIPPED)...8828
      Description...8828
      Inspecting...8828
      Adjusting Switch Position...8828
  HYDRAULIC SYSTEM...8830
    HYDRAULIC / HYDROSTATIC SCHEMATICS...8838
    HYDRAULIC SYSTEM INFORMATION...8842
      Glossary Of Hydraulic / Hydrostatic Symbols...8842
      Troubleshooting The Hydraulic Circuit...8846
      Troubleshooting The Cylinder Circuit...8846
      Troubleshooting The Swing (Upperstructure Slew) Circuit...8847
      Troubleshooting The Travel Circuit...8848
    BOOM CYLINDER...8850
      Testing...8850
      Removal And Installation...8853
      Parts Identification...8856
      Disassembly...8857
      Assembly...8859
    ARM CYLINDER...8862
      Testing...8862
      Removal And Installation...8864
      Parts Identification...8866
      Disassembly...8867
      Assembly...8869
    BOOM SWING CYLINDER...8872
      Testing...8872
      Removal And Installation...8873
      Parts Identification...8875
      Disassembly...8876
      Assembly...8878
    BUCKET CYLINDER...8882
      Testing...8882
      Removal And Installation...8884
      Parts Identification...8886
      Disassembly...8887
      Assembly...8889
    BLADE CYLINDER...8894
      Testing...8894
      Removal And Installation...8895
      Parts Identification...8896
      Disassembly...8897
      Assembly...8899
    CLAMP CYLINDER...8902
      Testing...8902
      Removal And Installation...8903
      Parts Identification...8904
      Disassembly...8905
      Assembly...8908
    ANGLE BLADE CYLINDER...8914
      Testing...8914
      Removal And Installation...8915
      Parts Identification...8917
      Disassembly...8918
      Assembly...8920
    EXTENDIBLE ARM CYLINDER...8924
      Removal And Installation...8924
      Parts Identification...8926
      Disassembly...8927
      Assembly...8929
    MAIN RELIEF VALVES...8934
      Testing And Adjusting The Main Relief Valves (S/N AACF11001 & Above And AA8711001 & Above)...8934
      System Pressures At Gauge Port Specifications...8934
      Testing And Adjusting The Main Relief Valves (S/N AACG11001 & Above And AA8811001 & Above)...8937
      System Pressures At Gauge Port Specifications...8937
    PORT RELIEF VALVES...8940
      Testing And Adjusting Port Relief Valve Pressure...8940
    CROSSPORT RELIEF VALVES...8944
      Testing And Adjusting The Crossport Relief Valves (S/N AACF11001 & Above And AA8711001 & Above)...8944
      Testing And Adjusting The Crossport Relief Valves (S/N AACG11001 & Above And AA8811001 & Above)...8946
    PRESSURE REDUCING VALVE...8948
      Description...8948
    ANGLE BLADE VALVE...8950
      Description...8950
      Testing And Adjusting Port Relief Valves...8950
      Testing And Adjusting Sequence Valve...8952
      Removal And Installation...8954
      Parts Identification...8957
      Disassembly...8958
      Assembly...8971
    HYDRAULIC CONTROL VALVE (S/N AACF11001 & Above And AA8711001 & Above)...8984
      Description...8984
      Removal And Installation...8984
      Parts Identification...8990
      Disassembly...8991
      Right Travel Valve Section Disassembly And Assembly...8993
      Left Travel Valve Section Disassembly And Assembly...8997
      Blade Valve Section Disassembly And Assembly...9001
      Slew Valve Section Disassembly And Assembly...9010
      Auxiliary Valve Section Disassembly And Assembly...9015
      Bucket Valve Section Disassembly And Assembly...9020
      Arm Valve Section Disassembly And Assembly...9025
      Boom Valve Section Disassembly And Assembly...9030
      Boom Swing Valve Section Disassembly And Assembly...9035
      Inlet Section Disassembly And Assembly...9040
      Assembly...9045
    HYDRAULIC CONTROL VALVE (S/N AACG11001 & Above And AA8811001 & Above)...9052
      Description...9052
      Removal And Installation...9052
      Parts Identification...9055
      Disassembly...9056
      Blade Valve Section Disassembly And Assembly...9057
      Slew Valve Section Disassembly And Assembly...9066
      Auxiliary Valve Section Disassembly And Assembly...9071
      Bucket Valve Section Disassembly And Assembly...9076
      Arm Valve Section Disassembly And Assembly...9081
      Boom Valve Section Disassembly And Assembly...9086
      Boom Swing Valve Section Disassembly And Assembly...9091
      Inlet Section Disassembly And Assembly...9096
      Assembly...9101
    HYDRAULIC PUMP...9106
      Description...9106
      Torque Adjustment...9107
      Testing The Piston Pump...9108
      Testing The Gear Pump...9110
      Testing Auxiliary Flow...9112
      Removal And Installation...9113
      Coupler Removal And Installation...9114
      Hydraulic Pump Start Up...9115
      Gear Pump Parts Identification...9116
      Piston Pump Parts Identification...9117
      Disassembly...9118
      Gear Pump Disassembly...9120
      Gear Pump Assembly...9123
      Piston Pump Disassembly...9126
      Piston Pump Assembly...9133
      Assembly...9140
    MANIFOLD ASSEMBLY/ACCUMULATOR (S/N AACG11001 & Above And AA8811001 & Above)...9142
      Description...9142
      Testing Pilot Pressure...9143
      Removal And Installation...9144
      Parts Identification...9146
      Disassembly...9147
      Assembly...9159
    MANIFOLD ASSEMBLY/ACCUMULATOR (S/N AACF11001 & Above And AA8711001 & Above)...9172
      Description...9172
      Testing Pilot Pressure...9173
      Removal And Installation...9174
      Parts Identification...9176
      Disassembly...9177
      Assembly...9186
    TRAVEL MOTOR (S/N AACG11001 & Above And AA8811001)...9196
      Description...9196
      Removal And Installation...9196
      Parts Identification...9198
      Disassembly...9199
      Assembly...9213
    TRAVEL MOTOR (S/N AACF11001 & Above And AA8711001 & Above)...9230
      Description...9230
      Removal And Installation...9230
      Parts Identification...9231
      Disassembly...9232
      Assembly...9242
    SWIVEL JOINT...9254
      Removal And Installation...9254
      Parts Identification...9256
      Description...9257
      Disassembly...9257
      Assembly...9260
    SWING MOTOR...9264
      Description...9264
      Removal And Installation...9264
      Parts Identification...9266
      Disassembly...9267
      Assembly...9272
    SWING MOTOR DRIVE CARRIER...9278
      Description...9278
      Removal And Installation...9278
      Parts Identification...9279
      Disassembly...9280
      Assembly...9282
    CONTROL PATTERN SELECTOR VALVE...9284
      Description...9284
      Removal And Installation...9284
      Parts Identification...9285
      Disassembly...9286
      Assembly...9288
    RIGHT CONTROL LEVER (JOYSTICK)...9290
      Description...9290
      Testing...9290
      Handle Removal And Installation...9291
      Joystick Assembly Removal And Installation...9295
      Parts Identification...9298
      Disassembly...9299
      Assembly...9304
    LEFT CONTROL LEVER (JOYSTICK)...9308
      Description...9308
      Testing...9308
      Handle Removal And Installation...9310
      Joystick Assembly Removal And Installation...9313
      Parts Identification...9315
      Disassembly...9316
      Assembly...9321
    TRAVEL CONTROL VALVE (S/N AACG11001 & ABOVE AND AA8811001 & ABOVE)...9326
      Removal and Installation...9326
      Parts Identification...9327
      Disassembly And Assembly...9328
    TRAVEL CONTROL VALVE (S/N AACF11001 & ABOVE AND AA8711001 & Above)...9334
      Removal and Installation...9334
      Parts Identification...9335
      Disassembly And Assembly...9336
    HOSES...9340
      Hose Guide Location...9340
      Left Control Lever (Joystick) (S/N AACF11001 & Above AND AA8711001 & Above)...9341
      Left Control Lever (Joystick) (S/N AACG11001 AND AA8811001 & Above)...9342
      Right Control Lever (Joystick) (S/N AACF11001 And Above AA8711001 & Above)...9343
      Right Control Lever (Joystick) (S/N AACG11001 & Above And AA8811001 & Above)...9344
      Travel Control Valve (S/N AACF11001 & Above And AA8711001 & Above)...9345
      Travel Control Valve (S/N AACG11001 & Above And AA8811001 & Above)...9346
      Manifold Assembly / Accumulator (S/N AACF11001 & Above And AA8711001 & Above)...9347
      Manifold Assembly / Accumulator (S/N AACG11001 & Above And AA8811001 & Above)...9348
    HYDRAULIC FILTER...9350
      Description...9350
      Housing Removal And Installation...9350
    CASE DRAIN FILTER...9352
      Removal And Installation...9352
    HYDRAULIC RESERVOIR...9354
      Description...9354
      Removal And Installation...9354
    OIL COOLER...9356
      Description...9356
      Removal And Installation...9356
    DIRECT TO TANK VALVE (IF EQUIPPED)...9360
      Description...9360
      Removal And Installation...9360
      Parts Identification...9361
      Disassembly And Assembly...9362
    BUILD UP VALVE...9364
    COOLING FAN...9366
      Description...9366
      Testing...9366
      Removal And Installation...9367
      Parts Identification...9369
      Disassembly And Assembly...9370
    BOOM SWING LOCK VALVE...9378
      Description...9378
      Removal And Installation...9378
      Parts Identification...9379
      Disassembly...9380
      Assembly...9383
    HYDRAULIC X-CHANGE VALVE...9388
      Removal And Installation...9388
      Parts Identification...9391
      Disassembly...9392
      Assembly...9400
    SLEW LOCK VALVE...9408
      Description...9408
      Removal And Installation...9408
      Parts Identification...9409
      Disassembly And Assembly...9410
  HYDROSTATIC SYSTEM...9414
    HYDROSTATIC SYSTEM INFORMATION...9416
      Troubleshooting Chart...9416
      Relief/Replenishing Valve Function...9417
      Relief/Replenishing Valve Location...9417
      Relief/Replenishing Valve Removal And Installation...9418
      Charge Pressure Relief Valve Location...9419
      Charge Pressure Relief Valve Removal And Installation...9419
    TRAVEL PILOT PRESSURE...9420
      Description...9420
      Testing...9420
    HYDROSTATIC PUMP...9422
      Removal And Installation...9422
      Parts Identification (Front) (S/N AACG11001 & Above And AA8811001 & Above)...9425
      Disassembly...9426
      Inspection...9441
      Assembly...9445
      Hydrostatic Pump Start-Up...9460
      Mechanical Neutral Adjustment...9460
    DRIVE BELT SHIELD...9464
      Removal And Installation...9464
    DRIVE BELT...9466
      Adjustment...9466
      Removal And Installation...9468
  UNDERCARRIAGE...9470
    BLADE...9472
      Removal And Installation...9472
    ANGLE BLADE ASSEMBLY...9474
      Removal And Installation...9474
    ANGLE BLADE...9476
      Removal And Installation...9476
    ANGLE BLADE CUTTING EDGE...9478
      Removal And Installation...9478
    TRACK FRAME COMPONENTS...9480
      Description...9480
      Track Lug Height...9480
      Checking Tension...9481
      Adjusting Tension...9483
      Rubber Track Removal And Installation...9484
      Steel Track Removal And Installation...9487
      Idler (Front) Removal And Installation...9490
      Idler (Front) Parts Identification...9492
      Idler (Front) Disassembly...9493
      Idler (Front) Assembly...9495
      Coil Spring Assembly And Cylinder (S/N AACF11246 & Below, AACG11102 & Below, AA8711102 & Below And AA8811101 & Below)...9498
      Coil Spring Cylinder Parts Identification (S/N AACF11247 & Above, AACG11103 & Above, AA8711103 & Above And AA8811102 & Above)...9499
      Coil Spring Cylinder Disassembly And Assembly (S/ N AACF11247 & Above, AACG11103 & Above, AA8711103 & Above And AA8811102 & Above)...9500
      Roller Removal And Installation...9502
      Roller Parts Identification...9503
      Roller Disassembly...9504
      Roller Assembly...9506
      Track Damage Identification...9508
      Abrasion Of Embedded Metals...9509
    SWING CIRCLE GEAR...9520
      Swing Bearing Removal...9520
      Swing Bearing Installation...9521
  UPPERSTRUCTURE & SWING SECTION...9522
    UPPERSTRUCTURE...9526
      Description...9526
      Removal...9526
      Installation...9529
    CANOPY...9532
      Removal And Installation...9532
    CAB...9536
      Removal And Installation...9536
      Door Removal And Installation...9540
      Front Window Removal And Installation...9541
      Right Side Rear Sliding Window Removal And Installation...9544
      Right Side Front Sliding Window Removal And Installation...9544
      Glass Removal...9545
      Right Side Front And Rear Sliding Window Weather Strip Removal And Installation...9545
      Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation...9545
      Glass Installation...9546
      Glass Installation (Cont’d)...9547
    SEAT AND SEAT MOUNT...9548
      Seat Mount Removal And Installation...9548
      Seat Removal And Installation...9548
    RIGHT CONSOLE...9550
      Description...9550
      Console Cover Removal And Installation...9550
      Console Frame Removal And Installation...9551
    LEFT CONSOLE...9554
      Description...9554
      Joystick Console Cover (Bottom) Removal And Installation...9554
      Joystick Console Cover (Top) Removal And Installation...9554
      Compression Spring Removal And Installation...9556
      Compression Spring Disassembly And Assembly...9557
      Lever Removal And Installation...9559
      Joystick Console Frame Removal And Installation...9560
      Joystick Console Frame Disassembly And Assembly...9564
      Left Rear Console Cover Removal And Installation...9566
      Left Rear Console Frame Removal And Installation...9567
    BLADE CONTROL...9568
      Removal And Installation...9568
      Linkage Removal And Installation...9569
      Linkage Disassembly And Assembly...9569
      Control Cable Removal And Installation...9571
    UPPERSTRUCTURE SLEW LOCK...9572
      Removal And Installation...9572
      Disassembly And Assembly...9573
    FLOOR MAT AND FLOOR PLATES...9576
      Description...9576
      Removal And Installation...9576
    BOOM SWING PEDAL...9578
      Description...9578
      Pedal Removal And Installation...9578
      Pedal Disassembly And Assembly...9579
      Control Cable Removal And Installation...9581
    TRAVEL LEVERS/PEDALS...9582
      Description...9582
      Adjustment...9582
      Removal And Installation...9585
      Disassembly And Assembly...9588
      Control Linkage Assembly Removal And Installation...9590
    FUEL TANK...9592
      Removal And Installation...9592
    HORN...9594
      Removal And Installation...9594
    SWING FRAME...9596
      Description...9596
      Removal And Installation...9596
      Hose Routing...9600
      Bushing Removal...9601
      Bushing Installation...9602
    BOOM...9604
      Description...9604
      Removal And Installation...9604
    ARM...9606
      Description...9606
      Removal And Installation...9606
      Arm To Boom Bushing Removal And Installation...9607
      Arm To Bucket And Bucket Link Bushing Removal And Installation...9608
    BUCKET...9610
      Removal And Installation (Pin-On X-Change)...9610
      Removal And Installation (Bolt-On X-Change)...9616
      Removal And Installation (Pin-On Attachment)...9622
      Removal And Installation (Hydraulic X-Change)...9623
      Bucket Teeth Removal And Installation...9628
      Bucket Side Cutting Edge Removal And Installation...9629
    CLAMP...9630
      Removal And Installation...9630
    TAILGATE...9632
      Removal And Installation...9632
    X-CHANGE™...9634
      Removal And Installation...9634
      Parts Identification...9636
      Disassembly...9637
      Assembly...9642
      Check Proper Latch Engagement...9648
    X-CHANGE (HYDRAULIC)...9652
      Removal And Installation...9652
      Parts Identification...9655
      Disassembly...9656
      Assembly...9661
    RIGHT SIDE COVER...9670
      Removal And Installation...9670
    COUNTERWEIGHT...9672
      Removal And Installation...9672
  ELECTRICAL SYSTEM & ANALYSIS...9674
    ELECTRICAL SCHEMATICS...9676
    ELECTRICAL SYSTEM INFORMATION...9678
      Troubleshooting Chart...9678
      Description...9679
      Fuse And Relay Location...9679
    BATTERY...9680
      Removing And Installing The Battery...9680
      Servicing...9681
      Using A Booster Battery (Jump Starting)...9682
    ALTERNATOR...9684
      Belt Adjustment...9684
      Belt Replacement...9684
      Charging System Inspection...9685
      Alternator Description...9686
      High Voltage Test...9687
      Rectifier Continuity (Diode) Test...9687
      Alternator Voltage Test...9688
      Low Voltage Test...9688
      Alternator Regulator Test...9689
      Parts Identification...9690
      Disassembly...9690
      Stator Continuity Test...9690
      Stator Ground Test...9691
      Rotor Continuity Test...9691
      Rotor Ground Test...9692
      Assembly...9692
      Removal And Installation...9693
    STARTER...9694
      Testing...9694
      Removal And Installation...9694
      Parts Identification...9695
      Disassembly...9696
      Inspection And Repair...9701
      Assembly...9704
    LIGHTS...9710
      Upperstructure Light Removal And Installation...9710
      Upperstructure Light Disassembly And Assembly...9710
      Boom Light Removal and Installation...9711
      Boom Light Bulb Replacement...9711
    MAGNETIC LOCKOUT SENSOR...9712
      Testing Left Console Magnetic Lockout Sensor...9712
      Console Switch Removal And Installation...9713
    FUEL LEVEL SENDER...9714
      Removal And Installation...9714
      Testing...9714
    DIAGNOSTICS SERVICE CODES...9716
      Description...9716
      Number Codes List...9717
    DELUXE INSTRUMENT PANEL SETUP...9718
      Passwords...9718
      Password Entry (For Starting and Operating the Machine)...9718
      Changing The Owner or Operator Password...9718
      Password Lockout Feature...9719
      Job Clock...9719
      RPM...9719
    TWO SPEED SWITCH...9720
      Removal And Installation...9720
  ENGINE SERVICE...9722
    ENGINE INFORMATION...9726
      Description...9726
      Specifications...9727
      Fuel Injection Nozzles...9727
      Fuel Injection Pump...9727
      Cylinder Head...9727
      Valves...9728
      Valve Springs...9728
      Valve Timing...9728
      Rocker Arms...9728
      Camshaft...9729
      Tappet...9729
      Cylinders...9729
      Piston Rings...9730
      Pistons...9730
      Connecting Rods...9730
      Oil Pump...9730
      Crankshaft...9731
      Timing Gear...9731
      Thermostat...9732
      Engine Bolt Torque...9732
      Torque Values...9733
      Troubleshooting Chart...9734
      Removal And Installation...9735
      Compression Checking...9743
    ENGINE SPEED CONTROL...9744
      Removal And Installation...9744
      Disassembly And Assembly...9745
      Adjustment (S/N AA8711001 & Above And AA8811001 & Above)...9746
    SPARK ARRESTOR MUFFLER...9748
      Removal And Installation...9748
    AIR CLEANER...9750
      Removal And Installation...9750
    ENGINE COOLING SYSTEM...9752
      Radiator Removal And Installation...9752
      Testing The Thermostat...9757
      Thermostat Housing Removal And Installation...9758
      Water Pump Removal And Installation...9759
      Water Pump Disassembly And Assembly...9759
    LUBRICATION SYSTEM...9760
      Oil Pan Removal And Installation...9760
      Oil Pump Removal And Installation...9760
      Oil Pump Inspection...9761
      Engine Oil Pressure - Testing...9762
    FUEL SYSTEM...9764
      Fuel Camshaft Removal And Installation...9764
      Fuel Camshaft Governor Disassembly And Assembly...9764
      Fuel ShutOff Solenoid - Checking...9765
      Fuel Shut-off Solenoid Removal And Installation...9766
      Fuel Injection Pump Removal And Installation...9768
      Injection Pump Timing...9771
      Fuel Injector Removal And Installation...9773
      Fuel Injector Nozzle Pressure - Checking...9776
      Nozzle Spray Condition...9776
      Valve Seat Tightness...9777
    ENGINE FLYWHEEL (LATER MODELS)...9778
      Removal And Installation...9778
      Hydraulic Pump Coupler...9779
      Flywheel Ring Gear...9779
    CYLINDER HEAD...9780
      Glow Plug Testing...9780
      Glow Plug Removal And Installation...9781
      Valve Clearance Adjustment...9782
      Valve Timing - Checking...9782
      Cylinder Head Removal And Installation...9783
      Cylinder Head Disassembly And Assembly...9786
      Cylinder Head Servicing...9787
      Cylinder Head Top Clearance...9787
      Valve Guide Checking...9788
      Reconditioning The Valve And Valve Seat...9790
      Valve Spring...9791
      Valve Tappets...9792
      Rocker Arm And Shaft - Checking...9792
    CRANKSHAFT AND PISTONS...9794
      Piston And Connecting Rod Removal And Installation...9794
      Piston And Connecting Rod Servicing...9796
      Connecting Rod Alignment...9798
      Crankshaft And Bearings Removal And Installation...9799
      Crankshaft And Bearings Servicing...9801
      Cylinder Bore, Checking...9804
    CRANKSHAFT AND TIMING GEARS...9806
      Timing Gearcase Cover Removal And Installation...9806
      Timing Gears Backlash - Checking...9808
      Idler Gear And Shaft Removal And Installation...9809
      Camshaft Servicing...9810
      Idler Gear And Shaft Servicing...9811
    ENGINE FLYWHEEL...9812
      Hydraulic Pump Coupler Removal And Installation...9812
      Flywheel Removal And Installation...9812
      Flywheel Ring Gear...9812
  HEATING, VENTILATION, AIR CONDITIONING...9814
    HEATER SYSTEM...9816
      Description...9816
      Components...9816
    REGULAR MAINTENANCE...9820
      Filter Element Removal And Installation...9820
      Engine Accessory Drive Belt...9820
      Cleaning The Condenser...9821
      Cleaning The A/C Evaporator Coil & Heater Coil...9822
    TROUBLESHOOTING...9824
      Blower Motor Does Not Operate...9824
      Blower Motor Operators Normally, But Air Flow Is Insufficient...9824
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...9824
      The Compressor Does Not Operate At All, Or Operates Improperly...9824
      Gauge Pressure Related Troubleshooting...9825
      Electrical System...9827
      Engine Coolant By-Passing The Heater Valve...9837
      Poor A/C Performance...9838
    EVAPORATOR/HEATER UNIT...9840
      Removal And Installation...9840
      Disassembly And Assembly...9841
    HEATER COIL...9842
      Removal And Installation With A/C...9842
      Removal And Installation Without A/C...9842
    BLOWER FAN...9844
      Removal And Installation...9844
      Disassembly And Assembly...9845
      Resistor Removal And Installation...9846
    HEATER VALVE...9848
      Removal And Installation...9848
    AIR CONDITIONING SERVICE...9850
      Safety Equipment...9850
      Chart...9851
      Reclamation Procedure...9852
      Compressor Oil...9855
      Compressor Oil Check...9856
      Component Replacement And Refrigeration Leaks...9858
      Temperature/Pressure Chart...9859
      Charging Procedure With A Manifold Gauge Set...9860
    COMPRESSOR...9864
      Removal And Installation...9864
      Compressor Clutch Disassembly And Assembly...9865
    CONDENSER...9868
      Removal And Installation...9868
    RECEIVER/DRIER...9870
      Removal And Installation...9870
    PRESSURE RELIEF VALVE...9872
      Removal And Installation...9872
    PRESSURE SWITCH...9874
      Removal And Installation...9874
    THERMOSTAT...9876
      Removal And Installation...9876
    EXPANSION VALVE...9878
      Removal And Installation...9878
    EVAPORATOR...9880
      Removal And Installation...9880
  SPECIFICATIONS...9882
    EXCAVATOR SPECIFICATIONS...9884
      Excavator Dimensions With Standard Arm, Long Arm Option and Extendable Arm Kit...9884
      Excavator Standard Arm Machine Dimensions...9885
      Excavator Long Arm Machine Dimensions...9886
      Excavator Extendable Arm Machine Dimensions...9887
      Excavator With Optional Angle Blade Dimensions...9888
      Performance - Conventional (S/N AACF11001 & Above And AA8711001 & Above)...9889
      Performance - FastTrack (S/N AACG11001 & Above And AA8811001 & Above)...9889
      Controls...9889
      Engine...9890
      Hydraulic System...9891
      Hydraulic Cylinders...9892
      Hydraulic Cycle Times...9892
      Electrical...9892
      Undercarriage...9893
      Capacities...9893
      Fuel Tank...9893
      Tracks...9893
      Type...9893
      Drive System- Conventional (S/N AACF11001 & Above, AA8711001 & Above)...9894
      Drive System - FastTrack (S/N AACG11001 & Above, AA8811001 & Above)...9894
      Slew System...9894
      Ground Pressure - Conventional...9894
      Ground Pressure - FastTrack...9894
    TORQUE SPECIFICATIONS FOR BOLTS...9896
      Torque For General SAE Bolts...9896
      Torque For General Metric Bolts...9897
    HYDRAULIC CONNECTION SPECIFICATIONS...9898
      O-Ring Face Seal Connection...9898
      Straight Thread O-Ring Fitting...9898
      Tubelines And Hoses...9898
      Flare Fitting...9899
      O-Ring Flare Fitting...9900
      Port Seal Fitting...9902
    HYDRAULIC FLUID SPECIFICATIONS...9904
      Specifications...9904
    FUEL, COOLANT AND LUBRICANTS...9906
      Chart...9906
    CONVERSIONS...9908
      Decimal And Millimeter Equivalents...9908
      U.S. To Metric Conversion Chart...9908
  SERVICE MANUAL REVISION...9910
    Revision No: 430 - 1...9910
    Revision No: 430 - 2...9912
    Revision No: 430 - 3...9914
    
Bobcat Excavators 430, 435 Repair Service Manuals