Bobcat 435 Compact Excavator Service Manual – 6986749

Download Ebook


(S/N: AACB11001 & Above – S/N: AACD11001 & Above – S/N: AA8911001 & Above – S/N: AA8A11001 & Above)

This service manual PDF download for the Bobcat 435 Mini Hydraulic Excavator has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Excavator 435
S/N: AACB11001 & Above
S/N: AACD11001 & Above
S/N: AA8911001 & Above
S/N: AA8A11001 & Above

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6986749 (5-10)
Total Pages : 1192

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Excavator Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT EXCAVATOR IDENTIFICATION
SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE EXCAVATOR
Procedure
UPPERSTRUCTURE SLEW LOCK
Operation
LIFTING THE EXCAVATOR
OPERATOR CAB (ROPS/TOPS)
Emergency Exit
Cab Door
Front Window
Right Side Windows
TRANSPORTING THE EXCAVATOR
Procedure
TAILGATE
Opening And Closing The Tailgate
Adjusting The Latch
RIGHT SIDE COVER
Opening And Closing The Right Side Cover
SERVICE SCHEDULE
Chart
AIR CLEANER
Daily Check
Replacing The Filters
HEATER AIR FILTER (WITH CAB OPTION ONLY)
Removal And Installation
COOLING SYSTEM
Cleaning The Cooling System
Checking Coolant Level
Replacing The Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Removing Water From The Fuel Filter
Draining The Fuel Tank
Spin On Fuel Filter
Inline Fuel Filter
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Replacing Oil And Filter
HYDRAULIC SYSTEM
Checking And Adding Hydraulic Oil
Replacing The Hydraulic Oil
Replacing The Hydraulic Filter
Replacing The Case Drain Filter
Replacing The Fan Filter
Diagnostic Couplers
LUBRICATION OF THE HYDRAULIC EXCAVATOR
TRAVEL MOTOR
Checking Oil Level
Draining The Travel Motor
SPARK ARRESTOR MUFFLER
ENGINE ACCESSORY DRIVE BELT
Belt Tension
Belt Adjustment
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators
Troubleshooting The Hydraulic Circuit
Troubleshooting The Cylinder Circuit
Troubleshooting The Upperstructure Slew Circuit
BOOM CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
ARM CYLINDER
Testing
Removal and Installation
Parts Identification
Disassembly
Assembly
BOOM SWING CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
BUCKET CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
BLADE CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CLAMP CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
ANGLE BLADE CYLINDER
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVES
PORT RELIEF VALVES
Port Relief Valve Pressure Setting
Parts Identification
Adjustment Procedure
CROSSPORT RELIEF VALVE
Testing And Adjusting The Crossport Relief Valve
Removal And Installation
Disassembly And Assembly
PRESSURE REDUCING VALVE
Description
ANGLE BLADE VALVE
Description
Testing And Adjusting Port Relief Valves
Testing And Adjusting Sequence Valve
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC CONTROL VALVE (S/N AA8911001 & ABOVE, AA8A11001 & ABOVE AND AACD11001 & ABOVE)
Removal And Installation
Parts Identification
Disassembly
Slew Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Arm Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Boom Swing Valve Section Disassembly And Assembly
Auxiliary Valve Section Disassembly And Assembly
Inlet Section Disassembly And Assembly
Assembly
HYDRAULIC CONTROL VALVE (S/N AACB11001 & ABOVE AND S/N AA8911001 & ABOVE AND S/N AA8911001 & ABOVE)
Removal And Installation
Parts Identification
Disassembly
Right Travel Valve Section Disassembly And Assembly
Left Travel Valve Section Disassembly And Assembly
Slew Valve Section Disassembly And Assembly
Blade Valve Section Disassembly And Assembly
Bucket Valve Section Disassembly And Assembly
Arm Valve Section Disassembly And Assembly
Boom Valve Section Disassembly And Assembly
Boom Swing Valve Section Disassembly And Assembly
Auxiliary Valve Section Disassembly And Assembly
Inlet Section Disassembly And Assembly
Assembly
HYDRAULIC PUMP
Piston Pump Work Sheet
Piston Pump Testing
Description
Gear Pump Testing
Removal And Installation
Coupler Removal And Installation
Hydraulic Pump Start Up
Torque Limiter Valve Parts Identification
Torque Limiter Valve Removal
Torque Limiter Valve Disassembly
Torque Limiter Valve Assembly
Initial Torque Limiter Valve Setting
Torque Limiter Valve Installation
Pump Control Parts Identification
Pump Control Removal And Installation
Pump Control Disassembly And Assembly
Parts Identification
Gear Pump Removal And Installation
Gear Pump Disassembly And Assembly
Piston Pump Parts Identification
Piston Pump Disassembly
Piston Pump Assembly
MANIFOLD ASSEMBLY/ACCUMULATOR (S/N AACD11001 & ABOVE AND S/N AA8A11001 & ABOVE)
Description
Testing Pilot Pressure
Removal And Installation
Parts Identification
Disassembly
Assembly
MANIFOLD ASSEMBLY/ACCUMULATOR (S/N AACB11001 & ABOVE AND S/N AA8911001 & ABOVE)
Description
Testing Pilot Pressure
Removal And Installation
Parts Identification
Disassembly
Assembly
TRAVEL MOTOR (S/N AACD11001 & ABOVE, AA8A11001 & ABOVE, AND AA8911001 & ABOVE)
Removal And Installation
Parts Identification
Disassembly
Assembly
TRAVEL MOTOR (S/N AACB11001 & ABOVE AND S/N AA8911001 & ABOVE)
Removal And Installation
Parts Identification
Disassembly
Assembly
SWIVEL JOINT
Removal And Installation
Parts Identification
Description
Disassembly
Assembly
SWING MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
SWING MOTOR DRIVE CARRIER
Removal And Installation
Parts Identification
Checking The Drive Carrier Shaft End Play
Disassembly
Inspection
Assembly
CONTROL PATTERN SELECTOR VALVE
Removal And Installation
Parts Identification
Disassembly
Assembly
RIGHT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly
Assembly
LEFT CONTROL LEVER (JOYSTICK)
Testing
Handle Removal And Installation
Joystick Assembly Removal And Installation
Parts Identification
Disassembly
Assembly
TRAVEL CONTROL VALVE (S/N AA8A11001 & ABOVE, AA8911001 & ABOVE AND AACD11001 & ABOVE)
Removal and Installation
Parts Identification
Disassembly And Assembly
TRAVEL CONTROL VALVE (S/N AACB11001 & ABOVE AND S/N AA8911001 & ABOVE)
Removal and Installation
Parts Identification
Disassembly And Assembly
HOSES
Hose Guide Location
Left Control Lever (Joystick) (S/N AACB11001 & Above AND AA8911001 & Above)
Left Control Lever (Joystick) (S/N AACD11001 & Above AND AA8A11001 & Above)
Right Control Lever (Joystick) (S/N AACB11001 & Above And AA8911001 & Above)
Right Control Lever (Joystick) (S/N AACD11001 & Above And AA8A11001 & Above)
Travel Control Valve (S/N AACB11001 & Above And AA8911001 & Above)
Travel Control Valve (S/N AACD11001 & Above And AA8A11001 & Above)
Manifold Assembly / Accumulator (S/N AACB11001 & Above And AA8911001 & Above)
Manifold Assembly / Accumulator (S/N AACD11001 & Above And AA8A11001 & Above)
HYDRAULIC FILTER MOUNT
Removal And Installation
HYDRAULIC RESERVOIR
Removal And Installation
OIL COOLER
Removal And Installation
DIRECT TO TANK VALVE (IF EQUIPPED)
Removal And Installation
Parts Identification
Disassembly And Assembly
DUAL SEQUENCE VALVE (S/N AACD11001 & ABOVE AND S/N AA8A11001 & ABOVE)
Removal And Installation
Parts Identification
Disassembly And Assembly
DUAL SEQUENCE VALVE (S/N AACB 11001 & Above)
Removal And Installation
Parts Identification
Disassembly And Assembly
BUILD UP VALVE
Removal And Installation
Parts Identification
Disassembly And Assembly
COOLING FAN
Description
Testing
Removal And Installation
Parts Identification
Disassembly And Assembly
REMOVING AIR FROM HYDRAULIC SYSTEM
Procedure
BOOM SWING LOCK VALVE
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC X-CHANGE VALVE
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Relief/Replenishing Valve Function
Relief/Replenishing Valve Location
Relief/Replenishing Valve Removal And Installation
Charge Pressure Relief Valve Location
Charge Pressure Relief Valve Removal And Installation
TRAVEL PILOT PRESSURE
Description
Testing
HYDROSTATIC PUMP
Removal And Installation
Parts Identification (Front) (S/N AACG11001 & Above And AA8811001 & Above)
Disassembly
Inspection
Assembly
Hydrostatic Pump Start-Up
Mechanical Neutral Adjustment
FAN/CHARGE PUMP
Description
Testing
DRIVE BELT SHIELD
Removal And Installation
DRIVE BELT
Adjustment
Removal And Installation
UNDERCARRIAGE
BLADE
Removal And Installation
ANGLE BLADE ASSEMBLY
Removal And Installation
ANGLE BLADE
Removal And Installation
ANGLE BLADE CUTTING EDGE
Removal And Installation
TRACKS
Track Lug Height
Rubber Track Clearance
Steel Track Clearance
Adjustment
Rubber Track Removal And Installation
Steel Track Removal And Installation
TRACK FRAME
Disassembly And Assembly
Recoil Spring Cylinder Disassembly And Assembly (S/n AACB11378 & Below, AACD11163 & Below, AA8A11150 & Below and AA8911261 & Below Without Replaceable Shaft.)
Recoil Spring Cylinder Parts Identification (S/N AACB11378 & Below, AACD11163 & Below, AA8A11150 & Below And AA8911261 & Below With Replaceable Shaft)
Recoil Spring Cylinder Disassembly And Assembly (S/N AACB11378 & Below, AACD11163 & Below, AA8A11150 & Below and AA8911261 & Below With Replaceable Shaft.)
Recoil Spring Cylinder Parts Identification (S/N AACB11379 & Above, AACD11164 & Above, AA8A11151 & Above And AA8911262 & Above)
Recoil Spring Cylinder Disassembly And Assembly (S/n AACB11379 & Above, AACD11164 & Above, AA8A11151 & Above and AA8911262 & Above)
TRACK DAMAGE IDENTIFICATION
Cutting Of Steel Cords
Abrasion Of Embedded Metals
Separation Of Embedded Metals
Separation Of Embedded Metals Due To Corrosion
Cuts On The Lug Side Rubber
Cracks On The Lug Side Rubber Due To Fatigue
Lug Abrasion
Cracks And Cuts On The Lug Side Rubber
Abrasion Of The Track Roller Side
Cuts On The Edges Of Track Roller Side
TRACK IDLER
Parts Identification
Disassembly
Assembly
UPPER TRACK ROLLER
Parts Identification
Disassembly
Assembly
LOWER TRACK ROLLER
Parts Identification
Disassembly
Assembly
SWING CIRCLE GEAR
Swing Bearing Removal
Swing Bearing Installation
UPPERSTRUCTURE & SWING SECTION
UPPERSTRUCTURE
Removal
Installation
ROPS CANOPY
Removal And Installation
CAB
Removal And Installation
Door Removal And Installation
Front Window Removal And Installation
Right Side Rear Sliding Window Removal And Installation
Right Side Front Sliding Window Removal And Installation
Right Side Front And Rear Sliding Window Weather Strip Removal And Installation
Right Side Front And Rear Sliding Window Wiper Strip Removal And Installation
Glass Removal
Glass Installation
SEAT AND SEAT MOUNT
Removal And Installation
RIGHT CONSOLE
Console Cover Removal And Installation
Console Base Removal And Installation
LEFT CONSOLE
Lower Console Cover Removal And Installation
Upper Console Cover Removal And Installation
Compression Spring Removal And Installation
Compression Spring Disassembly And Assembly
Lock Lever Removal And Installation
Console Removal And Installation
Disassembly And Assembly
Console Switch Removal And Installation
Console Base Removal And Installation
ENGINE SPEED CONTROL
Removal And Installation
Disassembly And Assembly
Adjustment (Later Models)
BLADE CONTROL
Lever Removal And Installation
Linkage Removal And Installation
Linkage Disassembly And Assembly
Control Cable Removal And Installation
RIGHT PEDAL AND LINKAGE
Pedal Removal And Installation
Pedal Disassembly And Assembly
Control Cable Removal And Installation
TRAVEL CONTROLS
Removal And Installation
Disassembly And Assembly
Adjustment
CONTROL LINKAGE ASSEMBLY
Removal And Installation
FLOOR MAT AND FLOOR PLATES
Removal And Installation
FUEL TANK
Removal And Installation
HORN
Removal And Installation
SWING FRAME
Boom Swing Bracket Removal And Installation
Boom Swing Bracket Hose Installation
Bushing Removal
Bushing Installation
BOOM
Removal And Installation
ARM
Removal And Installation
Arm To Boom Bushing Removal And Installation
Arm To Bucket And Bucket Link Bushing Removal & Installation
BUCKET
Bucket Teeth Removal And Installation
Bucket Side Cutting Edge Removal And Installation
CLAMP
Removal And Installation
TAILGATE
Removal And Installation
X-CHANGE (PIN ON)
Removal And Installation
Parts Identification
Disassembly And Assembly
RIGHT SIDE COVER
Removal And Installation
X-CHANGE (HYDRAULIC)
Removal And Installation
Parts Identification
Disassembly
Assembly
COUNTERWEIGHT
Removal And Installation
COUNTERWEIGHT
Removal And Installation
ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuse And Relay Location
BATTERY
Servicing
Removal And Installation
Using A Booster Battery (Jump Starting)
ALTERNATOR
Engine Accessory Drive Belt
Removal And Installation
Alternator Identification
Charging System Check
Alternator Voltage Test
Low Voltage Test
High Voltage Test
Rectifier Continuity (Diode) Test
Alternator Regulator Test
Parts Identification
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Assembly
STARTER
Removal And Installation
Parts Identification
Disassembly
Inspection And Repair
Assembly
LIGHTS
Removal And Installation
Boom Light Removal and Installation
Boom Light Bulb Replacement
TWO SPEED SWITCH
Removal And Installation
FUEL LEVEL SENDER
Removal And Installation
Testing
DIAGNOSTICS SERVICE CODE
Number Codes List
DELUXE INSTRUMENT PANEL SETUP
Passwords
Password Entry (For Starting and Operating the Machine)
Changing The Owner or Operator Password
Password Lockout Feature
Job Clock
RPM
ENGINE SERVICE
TROUBLESHOOTING
Chart
MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
RADIATOR
Removal And Installation
ENGINE COMPONENTS & TESTING
Engine Compression Checking
Glow Plug Removal And Installation
Checking The Glow Plug
Fuel Shut-off Solenoid Removal And Installation
Fuel Injection Pump Check
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Timing
Fuel Injector Nozzles Removal And Installation
Fuel Injector Nozzle Check
Valve Clearance Adjustment
ENGINE
Removal And Installation
ENGINE FLYWHEEL
Removal And Installation
Hydraulic Pump Coupler
Flywheel Ring Gear
ENGINE FLYWHEEL (LATER MODELS)
Removal And Installation
Hydraulic Pump Coupler
Flywheel Ring Gear
RECONDITIONING THE ENGINE
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head Servicing
Cylinder Head Top Clearance
Valve Guide Checking
Reconditioning The Valve And Valve Seat
Valve Spring
Rocker Arm And Shaft Checking
Timing Gearcase Cover Removal And Installation
Idler Gear And Camshaft Removal And Installation
Camshaft Servicing
Idler Gear And Shaft Servicing
Timing Gears Checking Backlash
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor
Crankshaft Gear Removal And Installation
Oil Pump Removal And Installation
Oil Pump Service
Checking Engine Oil Pressure
Relief Valve
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Servicing
Connecting Rod Alignment
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings Servicing
Cylinder Bore Checking
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
HEATING, VENTILATION, AIR CONDITIONING
HEATER COIL
Removal And Installation With A/C
Removal And Installation Without A/C
BLOWER FAN
Removal And Installation
Disassembly And Assembly
Resistor Removal And Installation
HEATER VALVE
Removal And Installation
AIR CONDITIONING SYSTEM FLOW
Principals
Chart
COMPONENTS
Identification
SAFETY
Safety Equipment
REGULAR MAINTENANCE
Heater Air Filter
Engine Accessory Drive Belt
Cleaning The Condenser
BASIC TROUBLESHOOTING
Poor A/C Performance
Cleaning The A/C Evaporator Coil & Heater Coil
Engine Accessory Drive Belt
Checking The Electrical System
Engine Coolant By-Passing The Heater Valve
GENERAL AIR CONDITIONING SERVICE GUIDELINES
Compressor Oil
Compressor Oil Check
Component Replacement And Refrigeration Leaks
SYSTEM TROUBLESHOOTING CHART
Blower Motor Does Not Operate
Gauge Pressure Related Troubleshooting
TEMPERATURE/PRESSURE
Chart
AIR CONDITIONING SERVICE
Chart
SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
Charging Procedure With A Manifold Gauge Set
COMPRESSOR
Removal And Installation
Compressor Clutch Disassembly And Assembly
CONDENSER
Removal And Installation
RECEIVER/DRIER
Removal And Installation
PRESSURE RELIEF VALVE
Removal And Installation
PRESSURE SWITCH
Removal And Installation
EVAPORATOR/HEATER UNIT
Removal And Installation
Disassembly And Assembly
THERMOSTAT
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR
Removal And Installation
SPECIFICATIONS
SPECIFICATIONS
Excavator Machine Dimensions
Performance (S/N AACD11001 & Above), (AA8A11001 & Above)
Performance (S/N AACB11001 & Above), (AA8911001 & Above)
Controls
Engine
Hydraulic System
Hydraulic Cylinders
Hydraulic Cycle Times
Drive System
Slew System
Undercarriage
Capacities
Track
Electrical
ENGINE SPECIFICATIONS
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
Cylinders
Piston Rings
Pistons
Connecting Rods
Oil Pump
Crankshaft
Timing Gear
Thermostat
Engine Bolt Torque
Crankshaft Re-Grind Data
TORQUE SPECIFICATIONS
Torque for General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O-Ring Face Seal Connection
Straight Thread O-ring Fitting
Tubelines And Hoses
Flare Fitting
O-Ring Flare Fitting
Port Seal Fitting
HYDRAULIC FLUID SPECIFICATIONS
Specifications
FUEL, COOLANT AND LUBRICANTS
Chart
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion Chart
SERVICE MANUAL REVISIONS
SMR-1
SMR-2
SMR-3
SMR-4
SMR-5

 

Download Ebook

Bobcat 435 Compact Excavator Service Manual – 6986749.pdf

Leave a Reply

Your email address will not be published. Required fields are marked *