Manual Formacion 430

SERVICE TRAINING
Foreword
430 EXCAVATOR SERVICE TRAINING
Table of Contents
1. HYDRAULICS LOAD SENSING...........................................................................1-1

2. HYDRAULICS HYDROSTATIC ............................................................................2-1
3. ELECTRICS.............................................................................................................3-1
4. MAINTENANCE.......................................................................................................4-1
5. SAFETY...................................................................................................................5-1
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SERVICE TRAINING
Foreword
FOREWORD
This manual is primarily intended for the training of mechanics with some knowledge of hydraulic
components, not total beginners.
Its principal objective is to give the reader the knowledge required for a better understanding of the
equipment and for effective maintenance and repair of the different hydraulic components.
We would like to draw your attention to the fact that this manual is not intended to replace training given in
college; it is a supplement to it.
The goal is to give the basic explanation of the Bobcat Excavator without theory, with the maximum of detail
given to the components.
The hydraulic drawings in this manual are made up in several stages for a better understanding of the
complete system.
The original Bobcat 430 Service Manual remains the principal tool to use in case of repair.
JCL Dubelloy
01-2005
ii
SERVICE TRAINING
Hydraulics Load Sensing
HYDRAULICS
LOAD SENSING
430 S/N 562911001 & above
430 S/N 563011001 & above
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SERVICE TRAINING
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SERVICE TRAINING
Table of Contents
1. Specifications ..........................................................................................................1-5
2. Hydraulic symbols....................................................................................................1-6
3. Hydraulic schematic...............................................................................................1-13
4. Components layout ................................................................................................1-15
5. External gear pump, fixed displacement ................................................................1-16
6. Variable displacement piston pump .......................................................................1-17
7. Spool valve layout..................................................................................................1-18
8. Load sensing spool valve function .........................................................................1-19
9. Load sensing relief valve .......................................................................................1-22
10. Spool valve section ................................................................................................1-23
11. Port relief valve ......................................................................................................1-25
12. Swing motor...........................................................................................................1-26
13. Drive motor ............................................................................................................1-28
14. Center post ............................................................................................................1-31
15. Hydraulic cooling motor .........................................................................................1-32
16. Pilot oil feeding block .............................................................................................1-34
17. Solenoid valve .......................................................................................................1-35
18. Pressure reducing valve ........................................................................................1-36
19. Joystick..................................................................................................................1-37
20. Direct to tank valve ................................................................................................1-38
21. Cylinder .................................................................................................................1-38
22. Pressure and flow test ...........................................................................................1-39
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SERVICE TRAINING
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SERVICE TRAINING
1. SPECIFICATIONS
Hydraulics
Hydraulic pump
Circuit pressure
Boom port relief valve
Dipper port relief valve
Bucket port relief valve
Auxiliary port relief valve
Blade port relief valve
Hydraulic reservoir
Breather cap
Fan motor relief valve
Auxiliary flow
Swing motor pressure
Pilot pressure
2 x 38 L/min
1 x 29 L/min
240 bar
270 bar
270 bar
270 bar
180 bar
270 bar
37 L
0,34 bar
69 bar
62 L/min
141 bar
30 bar
Cycle times
Bucket curl
Bucket dump
Dipper retract
Dipper extend
Boom raise
Boom lower
Offset left
Offset right
Blade raise
Blade lower
Swing
Travel high speed
Travel low speed
Engine speed
Date
Apr 04
Dec 04
Feb 05
01-2005
Model
430 G
430 AG
430 HAG
2,6 s.
1,8 s.
3,3 s.
2,7 s.
4,6 s.
5,4 s.
6,9 s.
5,7 s.
2,4 s.
3,1 s.
8,8 RPM
4,7 Km
2,4 Km
2600 RPM
Prefix/SN
562711001
562911001
563011001
Fast Track
Yes
No
Yes
1-5
Load Sensing
No
Yes
Yes
SERVICE TRAINING
2. HYDRAULIC SYMBOLS
Fixed displacement pump

used to operate all hydraulic functions
Variable displacement pump

used to operate all hydraulic functions
Variable displacement pump

operates the travel system
One way motor

used to cool the hydraulic oil
Fixed displacement motor

operates the swing motor
Two speed drive motor

operates the travel system
Double variable piston pump

operates the hydraulic system
Center post
allows the upper frame to turn 360 degrees
without damaging the hoses
Diesel engine
Direct operating relief valve

Protects the hydraulic circuit from peak pressures
Piloted/adjustable relief valve

to adjust the circuit pressure at a certain value
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SERVICE TRAINING
Relief valve with anti-cavitation valve

to protect the hydraulic circuit from over pressure and
to avoid cavitation
Pressure reducing valve

it uses flow from the hydraulic circuit and
reduces the pressure to feed the joysticks
One way restrictor

to limit the flow in one direction
but not in the opposite direction
Bouble piloted check valve

to keep the offset cylinder in the chosen position
Quick coupler
Pressurized filler cap

to maintain a low pressure inside the reservoir
to avoid cavitation in the hydraulic circuit
Hydraulic reservoir
Hydraulic filter with by-pass

to filter the hydraulic oil
Hydraulic cooler
to cool the hydraulic oil
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SERVICE TRAINING
Drain line filter

to catch solid particles of different components
Piloted operated spool

this spool is controlled by a joystick
Electric operated spool

this spool is controlled by the control panel
Electro/hydraulic operated spool

this spool is controlled by the control panel
Spool operated by solid linkages

operated by foot or hand
Centering spring
to keep the spool in the center position
Detent mechanism
to block the spool in a given position
Progressive spool
used in the load sensing circuit
Double acting cylinder
Double acting cylinder with cushions
Holding valve
used on lifting devices, it controls the lowering speed and
is a safety in case of a hose burst
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SERVICE TRAINING
Mechanically applied brake

used on the drive system
6/3 spool parallel design

used for hydraulic function
6/3 spool series design

used for hydraulic function
Load sensing spool and compensator
Hydrostatic pump, servos operated
3/2 solenoid
used to operate the front auxiliaries
3/2 solenoid
used to operate the pilot oil
3/2 spool
operates different hydraulic components
3/2 spool
routes the return flow from the auxiliaries to the spool valve
or directly to the tank
Selector valve
used to select a signal and send it to a hydraulic component
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SERVICE TRAINING
Back pressure valve
Accumulator
Double stage relief valve

electrically operated
Replenishing/relief valve
used in close loop transmission
Double stage relief valve

hydraulically operated
Flushing and back pressure valve

used in close loop transmission
Feeding lines
Drain lines
Pilot lines
Components assembly
Connected lines
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SERVICE TRAINING
Non connected lines
Circuit pressure (red)
Main return lines (blue)
Charge pressure or pilot oil (yellow)
Drain and pump inlet (green)
Static oil (brown)
Bleed valve
to cancel the LS signal in the neutral position
Joystick
to operate all the hydraulic functions
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SERVICE TRAINING
Variable piston pump

with power spool, flow spool and torque limiter

with the torque limiter
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SERVICE TRAINING
3. HYDRAULIC SCHEMATIC
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SERVICE TRAINING
Legend
1
2
3
4
5
6
7
8
9
10
11
12
Secondary auxiliary (optional)

Offset cylinder
Boom cylinder
Dipper cylinder
Bucket cylinder
Front auxiliary
Swing motor
Double piloted check valve
Spool valve
ISO/STD converter
Right joystick
Left joystick
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14
15
16
17
18
19
20
21
22
23
24
Drive joystick
Hydraulic cooler
Main hydraulic filter
Hydraulic reservoir
Pilot Block
Hydraulic pump
Cooling motor
Drain filters
Right drive motor
Left drive motor
Centre post
Dozer blade cylinders
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SERVICE TRAINING
4. COMPONENTS LAYOUT
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SERVICE TRAINING
5. EXTERNAL GEAR PUMP, FIXED DISPLACEMENT

External gear pumps have two gears in mesh, closely fitted inside a housing.
The drive shaft drives one gear. Shaft bushing and machined surfaces or wear plates are used to seal the
working gears.
Operation is quite simple:
As the gears rotate and come out of mesh, they trap inlet oil
between the gear teeth and the housing.
The trapped oil is carried around to the outlet chamber.
As the gears mesh again they form a seal which prevents oil from
going back to the inlet.
The oil is forced out at the outlet port and sent through the system.
This oil is pushed out by a continuous flow of trapped oil coming
into the outlet chamber with each rotation of the gears.
At the inlet side, gravity feeds in more oil from the reservoir to
replace that drawn out by the running gears.
Gear pumps have two pressurized plates (see figure A and B)

working against the gears to increase pump efficiency.
A small amount of pressure oil is fed under the backing plates
pressing them against the gears and forming a tighter seal against
leakage.
View of seals around compensation plates.

The oil sent out the outlet of the pump is also routed through an
internal channel to pressurize three quarters of the total surface of
the compensation plate, the inlet side is not pressurized because it
is at the atmospheric pressure.
The gear pump used in the excavator operates the cooling system.
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SERVICE TRAINING
6. VARIABLE DISPLACEMENT PISTON PUMP
Legend
1
2
3
4
Pump shaft
Swash plate
Barrel unit
Destroke pistons (x3)
5 Gear pump
6 Torque adjusting screw
7 Set of springs
8 Wear plate
When the drive shaft (1) of the piston pump is rotated by the engine, the piston block (3) which is splined to
the drive shaft also turns.
The piston block contains 10 piston assemblies which have a free swiveling shoe swaged on the ball end of
the piston assembly. Five pistons deliver flow to P1 and the other five to P2, note the position of the grooves.
The shoe end of the piston rides against a smooth surface of the swash plate (2). The piston shoe folows the
inclined surface of the swash plate (2) and begins moving in the piston block (3) bores. Half of the piston
assemblies are being pulled out of the piston block (3) while the remaining half of the pistons are being
pushed back into the piston block. This action causes the piston pump to pump oil.
The pistons being pulled out from the piston block (3) suck oil
into the piston block bores through the suction port and inlet
slot.
As the pistons cross top dead centre, the pistons push the oil
out of the piston block bores and into the pressure slot (P1 and
P2) and out the pressure port.
Each piston assembly completes this cycle, each revolution of
the pump shaft causes a continuous even flow of oil from the
pump.
The maximum swash angle of this pump is around 18.
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INLET
SERVICE TRAINING
7. SPOOL VALVE LAYOUT
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SERVICE TRAINING
8. LOAD SENSING SPOOL VALVE FUNCTION

Spool valve in neutral
When the engine is running, the hydraulic pump delivers flow to the spool valve and the flow is blocked
there. At that time the flushing valve (3) opens to route its flow back to the tank.
(This is called an open centre load sensing cicuit)
The cylinder is kept in a chosen position due to the close port of the spool valve.
The stand-by pressure is adjusted with the spring force located behind the flushing valve (3).
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SERVICE TRAINING
Spool shifted
The spool (1) is shifted to the left, the flow from the pump is routed through the spool and pushes the
compensator (2) to the left, that flow is divided in two directions.
The first direction becomes the load sensing signal and is routed to the bleed valve (4), to the one way orifice
(5) and the LS signal which closes the flushing valve (3) by means of the jumper hose (7).
The flow from the second direction from the compensator is routed back to the spool (1) then opens the load
check valve and finally to the base end of the cylinder. The rod end routes its flow back to the spool section
and to the main return line.
The flushing valve (3) is adjusting the needed flow to each cylinder (s) or motor (s) depending the position of
the spool (1).
When the maximum working pressure is reached, the LSRV (6) opens to release the LS signal then the
flushing valve opens to route the flow back to the tank.
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SERVICE TRAINING
The spool valve inlet section has different in and outlet, a tank port (T), a feeding port (P), a load sensing
port (LS) and a jumper port (J).
The pump flow is routed to the inlet (P) and the flushing valve (3) which is in the close or working position.
The main return (T) is routed to the cooler and filter and finally to the reservoir. The load sensing channel is
connected to all compensators and is routed back to the flushing valve (3).
The load sensing relief valve (LSRV) (2) opens when the maximum working pressure is reached.
The flushing valve (3) is metering the flow to the outlet depending the position of the joystick(s).
The bleed valve (2) releases some flow back to the main return, it is an fixed orifice. It will dump the load
sensing signal back to the reservoir when no functions are operated.
A diagnostic coupler is located onto the inlet section to check the working pressure and the stand-by
pressure.
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SERVICE TRAINING
9. LOAD SENSING RELIEF VALVE

The main relief valve located in the inlet section of the spool valve
is a direct operating relief valve.
It is assisted by its opening due to the special washer (2).

The pressure setting is adjusted by the screw (4) and the
mechanical force of the spring (3) will keep the valve (1) closed
until the maximum pressure setting is reached.
2
1
The maximum circuit pressure is reached, the valve (1) opens due
to the hydraulic oil force with the assistance of the concave
washer.
This valve is called LSRV (Load Sensing Relief Valve)
Look at the action of the oil against the concave washer when the
valve opens.
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SERVICE TRAINING
10. SPOOL VALVE SECTION

Neutral position
This type of spool valve is a new concept, it is mounted by means of tie bolts (three) and with ten sections to
operate all the functions. This is a compact load sensing spool valve and is operated with a compensator (1)
in each sections, the spool which has the load chek valve (2) located inside the spool (5). The outlet port can
have different valve such as a port relief valve (4), a plug (3) or an anti-cavitation valve.
In the neutral position, the ports (A and B) are closed, the (P) chanel is kept under the stand-by pressure
adjusted by the spring of the flushing valve located inside the inlet section.
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SERVICE TRAINING
Spool shifted
The spool is shifted to the left, the stand-by pressure (P) routes its oil to the compensator (1) which opens,
the flow enters inside the spool (5) opens the load check valve and then routes its flow to the outlet port (B).
The flow from the outlet (B) is routed to one of the equipment and back to the spool section and finally to the
tank chanel (T).
The load sensing signal (LS) is routed to the flushing valve which is metering the flow between the feeding
chanel and the outlet depending the demand of flow of the digging equipment.
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SERVICE TRAINING
11. PORT RELIEF VALVE

The port relief valve is in the close position, the outlet
port (red) is connected to one of the digging
equippment.
The internal channel (blue) is routed to the main
return.
As soon as a peak pressure appears, the internal

needle moves to the right and opens to release some
flow to the main return line.
In case of cavitation, the relief valve will move to the

left and opens. The tank channel feeds the needed
flow to the corresponding cylinder.
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SERVICE TRAINING
12. SWING MOTOR

The swing motor is a geroller type and is assembled by
four bolts onto the motor carrier (see below).
The relief valves (1) are part of the motor cover, the relief
valves have a lower setting than the circuit pressure. (168
bar).
Futher rmore in the head, we find two check valves (4) to
prevent cavitation, the feeding port (3) is connected to the
main return and feeds the anti-cavitation valves.
The ports (2 and 5) are used to rotate the swing motor.
The hydraulic circuit main return is also connected to the

ports (6 and 8), this is also a feeding for the anti-cavitation
valves and the dog bone area (9).
The back pressure of the circuit is high enough to lubricate
the splines (9) and the motor shaft (10).
The port (7) is a free drain line to tank.
Swing motor carrier
The carrier consits of a housing with two tapered bearings
(which are maintained preloaded) and the shaft (see
below).
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SERVICE TRAINING
Geroller motor, cutaway
The geroller swing motor is a fixed, positive displacement motor that provides the output necessary to swing
the upper frame of Bocat mini excavator.
The main elements of the geroller swing motors are are the outer ring, rotor star (3) and a disk valve (2).
The disk valve (2) and the back of the rotor star (3) function together to direct the incoming high pressure to
the proper oil chambers and direct the return oil back to the end cap (1).
The high pressure (red) oil flows in sequence from the disk valve (2) to the rotor star back to the disk valve
(3) and finally to one of the oil chambers. In actual operation four of the oil chambers are filled with high
pressure oil (red) at one time. A similar situation also occures in the return oil path. The disk valve (2) and
rotor star (3) direct the path of the four oil chambers with low pressure oil to the end cap (1).
Notice that one oil chamber is always in transition from low pressure to high pressure oil. Each time the rotor
star turns, it redirects high pressure oil to the chamber in transition and redirects oil to the remaining oil
chamber so there are always four oil chambres filled with high pressure oil and four filled with low pressure
oil.
When a chamber is filled with high pressure, the rotor star (3) is forced towards the middle of the outer ring
and split by the rotors. The rotor star (3) rotates clock wise until it is in the new position.
Also notice that the rotor (3) does not turn on its axis. Rather it walks eccentrically around the outside ring.
Becouse of this, the circumference of the rotor appears to rotate in the opposit direction to the rotor. Dont be
confused, the rotor actually is turning clock wise.
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SERVICE TRAINING
13. DRIVE MOTOR
Legend
1
2
3
4
5
6
7
8
Rear cover
Rotating group
Motor housing
Face seals
Motor bearings
Adjusting nut
Reduction gear box
Front cover
9
10
11
12
13
14
15
16
Filler plug
Reduction box housing
Lip seal
Second speed piston
Swash plate
Motor piston
Drive shaft
Second speed piston
This drive motor is an axial piston swash plate type. The front part consists of a planetary gear box (7) which
is lubricated with 90 W gear oil, two ball bearings (5) held by a counter nut and two face seals (4). The mid
section has a rotating group (2), a wear plate and the swash plate (13). The swash plate (13) can take two
possible positions, maximum swash angle for low speed and minimum swash angle for high speed.
The rear cover has several components such as a brake spool, a two speed spool (16) and its two speed
piston (12). The A and B ports are used to drive forward and reverse.
The second speed is controlled by a solenoid located in the pilot control block.
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SERVICE TRAINING
Drive motor not activated
When the drive motor is not used, the double check valve is closed. The second speed spool is in the neutral
position, the two cylinders (12) route their oil free into the drain lines.
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SERVICE TRAINING
Driving in the first peed
The spool in the main spool valve is shifted, the oil is routed to the double check valves which opens, this
flow (red) is then routed to the motor it self. The drive motor start to run, this is the low speed mode or
maximum capacity and high torque. The signal to the two speed spool is blocked off. The return of the drive
motor (blue) is routed back to the main spool valve.
Driving in the second speed
The solenoid located in the pilot feeding block sends pilot oil to the Pp port which then moves the second
spool to the right. The high pressure will destroke the swash plate with one of the two cylinders. We are then
in the high speed or low displacement and low torque mode.
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SERVICE TRAINING
14. CENTER POST
Legend
1
2
3
4
Drive motors drain return port

Dozer blade port
Drive motor port
Drive motor port
5 Second speed connection port

6 Centre post housing
7 Centre post piston
8 Combined seals
The purpose of the centre post is to feed hydraulic oil from the upper part of the excavator to the hydraulic
components located in the lower frame and to give the possibility to rotate the upper frame for 360 degrees.
The centre post is made of two main parts:
A central piston (7) which has internal passages drilled and seals and an external housing which has in and
outlet ports. The upper part of the centre post is mounted on the upper frame by a pin (X) and rotates with it
during operation. The housing (6) is bolted onto the lower frame and does not move during operation.
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SERVICE TRAINING
15. HYDRAULIC COOLING MOTOR

The hydraulic motor is fed by a separate pump located
on the hydraulic pump driven by the engine, the flow
enters in the inlet port of the gear motor, the flow forces
the pinions to turn, the top pinion rotates clock wise and
the lower pinion rotates counter clock wise.
The outlet flow is routed back to the return filter and to
the main return.
Cooling motor
A solenoid (2) is mounted onto the fan motor and is
acting like a thermostat, it increases or decreases the
RPM of the motor depending on the hydraulic oil
temperature of the circuit.
The over flow is routed back to the tank via the port (1).
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SERVICE TRAINING
Cooling solenoid
When the engine is running, the controller energizes the
solenoid (1) and keeps the valve (5) open to release
some flow to the tank line via the port T.
The other part of the flow is routed to the cooling motor
via the port P.
The solenoid (1) energized lifts the piston (2) as well as
the needle valve (3), the chambre (4) is no longer under
pressure.
The piston (5) is lifted up without resistance and routes
some flow from the P chanel to the T chanel.
The fan motor runs at a lower speed. In fact the solenoid
valve (1) works like an electric relief valve.
When the oil reaches 70C, the temperature sender is

sending the information to the controller and it will cut the
power off the solenoid (1).
The piston (2) closes the needle valve (3) on its seat, the
chamber (4) is kept under pressure and closes the piston
(5).
At this time, the total amound of oil is used to run the
hydraulic motor and increases the cooling capacity.
The pressure setting is 70 bar, adjusting the top screw
may cause a lack of cooling!
The adjustment of this kind of valve is factory set.
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SERVICE TRAINING
16. PILOT OIL FEEDING BLOCK
Legend
1
2
3
Accumulator
Pilot supply solenoid (green)
Two speed solenoid (yellow)
4 Front aux solenoid (red)

5 Front aux solenoid (blue)
6 Pressure reducing valve
This control block activates or deactivates the oil pressure from

different functions as above mentioned.
The wires on the solenoids have a coloured strap which corresponds to
the colour straps on colour to the machine wiring.
Accumulator
Used in the pilot pressure circuit. The accumulator gives the operator
the possibility to put the digging equippment on the ground in case of
an engine shutdown.
The accumulator consists of a nitrogen chambre on top (yellow), a
diaphragm in synthetic material and a pressure chambre on the bottom
(red).
When the inlet is fed with oil, the nitrogen chambre is compressed to
have a reserve of energy. The accumulator also kills the hydraulic
pump pulses for a good controllability of the joysticks.
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SERVICE TRAINING
17. SOLENOID VALVE

Four solenoids are used to operate the auxiliaries, the second
speed and the pilot cut off.
The auxiliary solenoid is operated with a progressive system called
PWM. (pulse width modulation).
When the coil is not energized, the internal spool closes the pilot
oil (yellow) passage.
The internal pilot oil is released to the drain channel (green) and
free to tank.
As soon as the solenoid is energized, the internal spool moves

down to close the drain chanel (green) and opens the pilot oil
supply (yellow) that oil is sent to the main spool valve to operate
the corresponding spool.
The pilot cancellation solenoid has a variable pilot pressure
depending the engine RPM, this to prevent stalling the engine.
When taking the pilot pressure, always disconnect the engine RPM
sender to make the test.
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SERVICE TRAINING
18. PRESSURE REDUCING VALVE

With the engine stopped, the spring force will keep the internal
spool open until the engine is running, the pump flow will feed the
internal channel (red) with oil.
When the pilot pressure (30 bar) is reached, the hydraulic force will
lift the internal spool to close the passage.
Red:
circuit pressure
Yellow: pilot pressure
Green: drain oil
If for any reasons there is a peak pressure in the pilot block, the
internal spool lifts a little more to eliminate the over pressure to the
drain line.
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SERVICE TRAINING
19. JOYSTICK
A joystick is a hydraulic remote control which operate as a
pressure reducing valve.
When not actuated the control lever is held in its neutral
position by the four return spring (3). The control ports are
connected to the tank port (T-green) via the drilled holes (5).
When the lever (1) is moved out of neutral, the plunger (2)
pushes against the return spring (3) and the control spring (4).
The control spring (4) first moves the control spool (6)
downwards and closes the connection between the
appropriate port and the tank port (T-green).
At the same time the appropriate port is connected to the inlet
port (P-yellow) via the drilled chanel (5).
The control phase begins as soon as the control spool (6) has
found its balance between the force of the control spring (4)
and the force which results from the hydraulic pressure in the
appropriate port.
Through the interaction of the control spool (6) and the control
spring (4) the pressure in the appropriate ports in proportional
with the stroke of the plunger (2) and thus the position of the
control lever (1).
A similar joystick is used to operate the travel, but the control
lever is replaced by a longer lever and solid linkages.
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SERVICE TRAINING
20. DIRECT TO TANK VALVE

Using a hydraulic breaker
The port A, which is the return from the auxiliaries is routed
to the port B and from there directly to the main return line.
Using an auger (reversible attachment)

The spool is shifted to the left and the flow from the port A is
now returned to the main spool valve.
This position allows to use an auger in both directions, left or
right rotation.
21. CYLINDER
Legend
1
2
3
4
5
6
7
Bushings
Inlet fitting (base end)
Piston nut
Cylinder housing
Square seal
O-ring
Piston
8
9
10
11
12
13
Cylinder rod
Inlet fitting (rod end)
O-ring and back-up seal
Cylinder head
Seal V-type
Scraper seal
All cylinders on the excavator are the same design, just the length and diametres are different.
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SERVICE TRAINING
22. PRESSURE AND FLOW TEST

Pilot pressure test
Connect a pressure gauge (50 bar) onto the
diagnostic coupler located on the port block.
Start the engine and warm up the hydraulic oil until it
reaches 50 to 60C and make some mouvements to
fill the accumulator.
The pressure on the gauge should be 30 bar.
If the pressure is not correct, adjust the pressure
reducing valve located on the same port block.
Circuit pressure check

diagnostic coupler located on the right end side of
the spool valve and below the inlet section.
Start the engine and warm up the oil until it reaches
50 to 60C.
Use one of the digging equippment (boom for
example), dead end the lift cylinder.
The reading on the gauge should be 240 bar.
If the reading is not correct, adjust this valve (see

arrow).
01-2005
1-39
SERVICE TRAINING
Port relief valves

The most port relief valves are set at 270 bar and
can be checked with an hand pump, but can not be
adjusted.
See the mini excavator specifications for more
details.
Flow test
Disconnect the hose on the P1 port and plug off the
hose.
Use the hydraulic tester 6558197.
Connect the inlet hose from the flow tester to the P1
port.
The other end of the hose to the flow tester, the

return hose of the flow tester directly in to the tank
(below the oil level) this to avoid cavitation.
01-2005
1-40
SERVICE TRAINING
Restrictor
Flow tester
Pressure gauge
With the restrictor fully open, start the engine at its maximum RPM (2600). The free flow should be 38 L/min,
then screw in the restrictor until the pressure reaches 200 bar. The reading should be at least 80% of the
flow.
Note: Do not increase the pressure over 240 bar, there is no relief in the circuit during the test!
Do the same test for P2 and P3.
P1 and P2
P3
01-2005
38 L/min
29 L/min
1-41
SERVICE TRAINING
01-2005
1-42
SERVICE TRAINING
Hydraulics Hydrostatic
HYDRAULICS
WITH HYDROSTATIC TRANSMISSION
430 S/N 562711001 & above
01-2005
2-1
SERVICE TRAINING
01-2005
2-2
SERVICE TRAINING
Table of Contents
1. Hydraulic/hydrostatic schematic ..............................................................................2-5

2. Component layout....................................................................................................2-7
3. Basic close loop circuit ............................................................................................2-8
4. Hydrostatic pump .....................................................................................................2-9
5. Replenishing/relief valve ........................................................................................2-11
6. Basic drive motor circuit.........................................................................................2-12
7. Drive motor cutaway ..............................................................................................2-15
8. Spool valve layout..................................................................................................2-16
9. Basic spool valve circuit.........................................................................................2-17
10. Inlet section-view ...................................................................................................2-20
11. Digging section-view ..............................................................................................2-21
12. Port/anti-cavitation valve........................................................................................2-22
13. Main relief valve.....................................................................................................2-23
14. Pilot control block ..................................................................................................2-24
15. Check flow and pressure .......................................................................................2-25
01-2005
2-3
SERVICE TRAINING
01-2005
2-4
SERVICE TRAINING
1. HYDRAULIC/HYDROSTATIC SCHEMATIC
01-2005
2-5
SERVICE TRAINING
Legend
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Hydrostatic pumps
Cooling pump
Hydraulic pump
Drive joystick
Cooling motor
Charge oil filter
Right drive motor
Left drive motor
Blade cylinders
Centre post
Hydraulic reservoir
Drain filter
Pilot oil drain filter
Hydraulic oil cooler
Right joystick
Left joystick
Converter valve ISO/STD
Pressure reducing valve
Work group lockout solenoid
Travel pilot solenoid
01-2005
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
2-6
Two speed solenoid

Front auxiliary, male coupler
Front auxiliary, female coupler
Swing spool section
Blade spool section
Boost spool section
Auxiliary spool section
Bucket spool section
Dipper spool section
Boom spool section
Offset spool section
Second auxiliary block (optional)
Second auxiliary lines (optional)
Offset cylinder
Boom cylinder
Dipper cylinder
Bucket cylinder
Front auxiliary lines
Direct to tank valve
Swing motor
SERVICE TRAINING
2. COMPONENT LAYOUT
Legend
1
2
3
4
5
6
7
Hydraulic reservoir
Spool valve
Water reservoir
Hydraulic filter
Hydraulic cooler
Water radiator
Drain filter
01-2005
8
9
10
11
12
13
14
2-7
Cooling and pilot oil pump

Hydrostatic pump
Pilot control block
Hydraulic pump, gear type
Direct to tank valve
Drain filter
SERVICE TRAINING
3. BASIC CLOSE LOOP CIRCUIT

Neutral position, engine running
In the neutral position, the hydrostatic pump (1) does not deliver flow to the drive motor (5). The charge
pump (2) keeps the close loop circuit under charge pressure due to the charge relief valve (4). The
replenishing valves (3) are kept open.
Driving forward
The travel lever is shifted in forward motion, the hydrostatic pump (1) supplies oil to the drive motor (5).The
replenishing valve (3), pressure side is closed. The flushing valve (6) is shifted to remove some flow out of
the return loop to be cooled.
The charge pump (2) supplies oil to the low pressure side, the replenishing valve (3) at low pressure side is
kept open.
01-2005
2-8
SERVICE TRAINING
Driving backwards
The travel lever is shifted in rear motion, the hydrostatic pump (1) supplies oil to the drive motor in the
opposite way (5).The replenishing valve (3) at the pressure side is closed. The flushing valve (6) is shifted to
remove some flow out of the return loop to be cooled.
The charge pump (2) supplies oil to the low pressure side, the replenishing valve (3) at the low pressure side
is kept open.
4. HYDROSTATIC PUMP
The hydrostatic pump is an axial piston type that is operated with a swash plate by a servo piston.
1. The pump is in the neutral position, the barrel rotates but does not supply oil, the outlets are kept under
charge pressure (yellow).
2. The swash plate is shifted in the forward motion, the pistons supplies oil (red) to the drive motor.
The return oil from the motor is send back to the hydrostatic pump (yellow) and is kept under charge
pressure.
3. Same as above but in reverse mode.
The swash plate can take an angle of 18 degrees in forward and reverse.
01-2005
2-9
SERVICE TRAINING
Hydrostatic pump cutaway
The hydrostatic pump unit consists of two hydrostatic pumps, mounted in tandem. They are indefinitely
variable and reversible by servos. Inside the two pumps are located four replenishing/relief valves and two
charge relief valve. The internal channel replenishes the two pumps, the outlet ports (5 and 6) are routed to
the drive motors.
Functions
The pump shaft (7) rotates in one direction and requires a change of internal ports (5 and 6) to change to the
opposite rotation of the drive motor. The motor shaft rotates in two directions. With a hydrostatic
transmission, machine control can be achieved by a joystick, which provides smooth, step less speed and
direction changes. Placing the joystick in neutral (O swash plate angle n 2) stops the transmission and
motor output which usually eliminates the need for a clutching system.
Charge system
A fixed displacement gear pump is integrated into the variable displacement pump.(not shown) The charge
pump supplies oil to the system, keeping the system charged. Charge pressure is limited by a relief valve in
the pump.
The combination replenishing/relief valve is mounted for overload protection and is located in the main pump
housing. These replenishing/relief valves are set at the factory.
01-2005
2-10
SERVICE TRAINING
5. REPLENISHING/RELIEF VALVE
In the neutral position of the travel lever, the
replenishing/relief valve is kept open due to the charge
pressure.
High pressure channel
It replenishes the hydrostatic transmission and keeps it

at low pressure.
Charge pressure
When one of the travel levers is shifted in forward

motion, the replenishing/relief valve closes due to the
high pressure in the close loop system (red).
As soon as the maximum pressure is reached, the

replenishing valve stays closed, the internal spool
moves to the right to send the flow back to the charge
chanel (yellow).
01-2005
2-11
SERVICE TRAINING
6. BASIC DRIVE MOTOR CIRCUIT

Drive system in the neutral position
Legend
1
2
3
4
5
6
7
8
Second speed solenoid

Drive solenoid
Brake solenoid
Drive joystick
Brake spool
Selector valve
Hydrostatic pump
Flushing valve
9
10
11
12
13
14
15
Drive motor
Second speed spool
Swash plate piston
Brake system
Reduction gear box
Charge/pilot oil
Pump servos piston
The solenoids 1, 2 and 3 are closed, the pilot oil is blocked. The joystick is also in the neutral, if one of the
travel levers is moved there will be no pilot oil to feed the servo piston. The charge pressure will keep the
close loop under low pressure (30 bar) fed by a separate pump (not shown). The brake (12) in the drive
motor remains closed due to the spring action and the drive motor swash plate is kept at the maximum angle
or displacement.
01-2005
2-12
SERVICE TRAINING
Drive motor in low speed mode
Legend
1
2
3
4
5
6
7
8

Drive solenoid
Brake solenoid
Drive joystick
Brake spool
Selector valve
Hydrostatic pump
Flushing valve
9
10
11
12
13
14
15
Drive motor
Second speed spool
Swash plate piston
Brake system
Reduction gear box
Charge/pilot oil
Pump servos piston
The engine is running, the solenoids 2 and 3 are energized this to feed the control lever (joystick 4). When
one of the control levers is shifted, the pilot pressure is routed to the pump swash plate piston (15), the pump
(7) start to deliver flow. At the same time, the spool (5) located in the joystick is shifted with the selector valve
(6), the pilot oil (14) is then routed to release the brake system (12) and the motor (9) start to turn. The
flushing valve (8) is also operational at that time.
01-2005
2-13
SERVICE TRAINING
Drive motor in the high speed mode
Legend
1
2
3
4
5
6
7
8

Drive solenoid
Brake solenoid
Drive joystick
Brake spool
Selector valve
Hydrostatic pump
Flushing valve
9
10
11
12
13
14
15
Drive motor
Second speed spool
Swash plate piston
Brake system
Reduction gear box
Charge/pilot oil
Pump servos piston
The drive motor (9) is still running (see previous page).

The second speed solenoid (1) is energized, the oil is then routed to the second speed spool (10) located in
the travel motor (9). The pump flow (7) is routed to the drive motor (9) but also to the selector valve (6) and
then through the spool (10) and finally to the cylinder (11). This will destroke the swash plate to its minimum
displacement thus the motor is in high speed mode.
01-2005
2-14
SERVICE TRAINING
7. DRIVE MOTOR CUTAWAY
This motor is an axial piston swash plate type. The front part consist of a planetary gear box which is
lubricated with 90W gear oil, two tapered bearings preloaded with a large nut and two face seals. The mid
section has brake discs mechanically applied by means of springs, a barrel unit with its wear plate and
swash plate. The swash plate can take two possible positions, maximum swash angle for a low speed and
minimum swash angle for high speed.
The rear cover has several components such as a brake spool, a brake selector valve, an over center valve
with check valves and a second speed spool and piston. The connecting ports (A & B) are used to drive
forward and reverse. XB is used to destroke the brake discs. XA is where we select high or low speed and T
a drain port.
The brake and the second speed are controlled by two solenoids located in the pilot control block.
01-2005
2-15
SERVICE TRAINING
8. SPOOL VALVE LAYOUT
Hydraulic pump
01-2005
P1 29 L/min
P2 29 L/min
P3 33 L/min
2-16
SERVICE TRAINING
9. BASIC SPOOL VALVE CIRCUIT

All spools in the neutral position
Swing
Blade
Boost
Lift
All spools are in the neutral position; the flow from P3 feeds the inlet at the swing spool section, through the
open center until it reaches the blade and the boost spool. P3 is then routed to the join the flow from P2. The
combination of the two pumps will feed other functions such as the auxiliaries, the bucket and dipper (not
shown).
Swing spool shifted
The swing spool is shifted, the flow from P3 is routed through the load check valve, the spool and then to the
swing motor. The return of the swing motor is then routed to the swing spool section and routed to the next
spool to operate the blade cylinders.
01-2005
2-17
SERVICE TRAINING
Swing and blade spool shifted
The swing and the blade spools are shifted; the flow from P3 is routed to the inlet of the swing spool, through
the load check valve and to the swing motor. The return oil is send back to the swing spool and feeds the
blade cylinders; the return of it is then routed to the main return (T).
Blade spool shifted in floatation position
The blade spool section has a detent mechanism to block the spool in the flotation position. At this time no
flow is used, the base and the rod ends are connected with the main return (T).The dozer blade can move
freely up and down.
01-2005
2-18
SERVICE TRAINING
Lift and boost spool shifted
When the lift cylinder is used to lift the boom arm, two spools are used at the same time, the boom spool
section and the boost spool section.
A combination of two pumps P1 and P3 is used until a pressure of 160 bar. Then the port relief on the boost
spool section opens to cancel the pump P3. The check valve closes so that the maximum pressure can be
used to lift the boom arm with 195 bar from pump P1.
01-2005
2-19
SERVICE TRAINING
10. INLET SECTION-VIEW
The swing section is a series design and serves as an inlet section this due to the special fitting (1). The
spool is in the neutral position; the pump flow enters in the fitting (1) and then routes the flow through the
open center. The flow is then routed through different spool sections until it reaches the outlet port.
The ports A and B are closed; the spool (3) is kept in the center due to the springs (4).
The inlet fitting (1) and the plug (5) have seals (6) to seal the high pressure channel from the low pressure
channel. If one of those seals (6) is damaged, the excavator will have a lack of power.
The spool (3) is shifted to the left, the open center closes. The pump flow is routed to the load check valve,
the load check valve opens and the flow is then routed to the port A. It feeds the swing motor; the return flow
is then routed back to the port B of the spool section. The return oil from that section is available for the next
functions.
Note: The swing section is the only one in series, the others are parallel design.
01-2005
2-20
SERVICE TRAINING
11. DIGGING SECTION-VIEW
The spool is in the neutral position. The pump flow is routed through the open center until it reaches the
outlet port. The ports A and B can be open or closed, used by a motor or a cylinder. Some sections have a
relief valve (2) or a plug.
The spool (1) can be shifted with pilot oil by means off a joystick or manually with a cable.
The spool (1) is shifted to the left, the open center closes. The pump flow is routed to the load check valve,
opens the load check valve and feeds the port B which is connected to one of the cylinders. The return of it
is routed to the spool valve in port A and then to the tank line.
The port relief (2) takes the peak pressures out of the circuit to prevent hoses bursting or cylinder getting
damaged.
01-2005
2-21
SERVICE TRAINING
12. PORT/ANTI-CAVITATION VALVE

The port relief valve is in the closed position; the outlet
port (red) is connected to one of the digging equipment.
The internal channel (blue) is routed to the main return.
As soon as a peak pressure appears the internal needle

moves to the right and opens to release the some flow to
the main return line.
In case of cavitations, the relief valve will move to the left

and opens and the return flow feeds the needed flow to
the corresponding digging cylinder.
01-2005
2-22
SERVICE TRAINING
13. MAIN RELIEF VALVE
Legend
1
2
3
Adjusting screw
Spring cup
Spring
4 Special washer
5 Valve seat
6 Needle valve
Direct operated relief valve

Three relief valves are used in the spool valve and used as main relief valves. The needle valve (6) has a
larger surface on the bottom so that the needle valve lifts up when the maximum pressure is reached. The
free play on the bottom allows oil to enter in the lower chamber and guide the valve when opening.
A special washer (4) is installed to assist the valve when opening, the washer is hollow on one side, so do
not mount the washer in the wrong way. Then it could increase the speed of the flow and also the oil
temperature.
01-2005
2-23
SERVICE TRAINING
14. PILOT CONTROL BLOCK
Legend
P Pilot pressure entry
T Oil back to the tank
B Pilot oil cut off
C Drive levers cut off
D Two speed cut off
E To auxiliary male coupler
F To auxiliary female coupler
G1 Diagnostic coupler
A Accumulator
R Pressure reducing valve
1
2
3
4
5
Solenoid (green)
Solenoid (orange)
Solenoid (yellow)
Solenoid (blue)
Solenoid (red)
This control block activates or activates the pilot pressure from different functions as above mentioned.
The wires on the solenoids have a colored strap which corresponds to the color straps on color to the
machine wiring.
01-2005
2-24
SERVICE TRAINING
15. CHECK FLOW AND PRESSURE

Pilot pressure test
Connect a pressure gauge onto the diagnostic
coupler on the port block.
Run the engine and warm up the hydraulic oil until it
reaches 50 to 60C and make some movements to
fill the accumulator.
The pressure reading must be 30 bar.
Pump pressure test
P1
All pressure testing shall be done with an oil

temperature between 50 and 60C.
Gear pump:
diagnostic coupler (P3)
Lift the blade until the end of stroke, the reading on
the gauge should be 265 bar.
Piston pump:
diagnostic coupler (P1).
Dead end the offset cylinder, the reading on the
gauge should be 195 bar.
diagnostic coupler (P2).
Dead end the bucket cylinder, the reading should be
175 bar.
01-2005
2-25
P2
P3
SERVICE TRAINING
Flow test
Run the engine and warm up the hydraulic oil until it
reaches 50 to 60 C.
Stop the engine and remove the hydraulic filler cap,
this to remove the hydraulic tank pressure.
Each outlet (P1, P2 and P3) must be tested
separately.
Take off the hose on P1 port and plug it off.
Connect the inlet hose from the flow meter to the P1

port. (Outlet from the pump.)
Put the return hose from the flow meter into the tank,
below the oil level to avoid cavitations during the
test.
01-2005
2-26
SERVICE TRAINING
Restrictor
Hydraulic tester
Pressure gauge
The hydraulic tester 6598439 is difficult to use because of the low volume of oil coming out the hydraulic
pumps, use a lower scale tester to have a better reading.
With the restrictor fully open, start the engine at its maximum RPM. The free flow should be 28,8 L/min, then
screw in the restrictor until the pressure reaches 200 bar. The reading should be at least 80 % of the flow.
Note: Do not increase the pressure over 200 bar, there is no relief valve in the circuit during the
test!
After testing the three outlet ports (P1, P2 and P3) we should have:
P1 and P2:
P3:
01-2005
28,8 L/min
33,3 L/min
2-27
SERVICE TRAINING
01-2005
2-28
SERVICE TRAINING
Electrics
ELECTRICS
430 S/N 562711001 & above
430 S/N 562911001 & above
430 S/N 563011001 & above
01-2005
3-1
SERVICE TRAINING
01-2005
Electrics
3-2
SERVICE TRAINING
Electrics
Table of Contents
1. Electric symbols.......................................................................................................3-5
2. Fuse and relay box ..................................................................................................3-8
3. Bobcat display and controller .................................................................................3-9
4. Electric block diagram............................................................................................3-10
5. Bobcat excavator controller..................................................................................3-11
6. Diagnostic service code .........................................................................................3-13
7. Keyless controller ..................................................................................................3-14
8. Solenoid valve .......................................................................................................3-15
9. Engine speed sensor .............................................................................................3-15
10. Engine and hydraulic temperature sender .............................................................3-16
11. Engine oil pressure sender ....................................................................................3-16
12. Fuel stop solenoid..................................................................................................3-16
13. Fuel level sensor....................................................................................................3-17
14. Cooling motor ........................................................................................................3-17
01-2005
3-3
SERVICE TRAINING
01-2005
Electrics
3-4
SERVICE TRAINING
Electrics
1. ELECTRIC SYMBOLS
Alternator
Starter
Cooling fan
Fuse
4
2 1
Timer
Sender
(normally closed)
Sender
(normally open)
Temperature sender
Battery
Solenoid
Lock solenoid
01-2005
3-5
SERVICE TRAINING
Electrics
Light
Relay
Diode
Ignition switch
Hourmeter
Light switch
Engine solenoid
Seat sensor
01-2005
3-6
SERVICE TRAINING
Electrics
Horn/back up alarm
Two speed switch
Wire number
1000-1999
2000-2999
3000-3999
4000-4999
5000-5999
6000-6999
7000-7999
8000-8999
9000-9999
01-2005
Wire color
red, red / white, orange
black
light blue
light green
yellow
pink
white
tan
purple
3-7
Wire function
power wires
ground
monitoring
hydraulic
attachment control
lights
accessories
engine
communication
SERVICE TRAINING
Electrics
2. FUSE AND RELAY BOX
18
19
10
11
12
13
14
15
16
Legend
1
2
3
4
5
6
7
8
9
10
11
Not used
Heater 25A
Ignition 5A
Fuel solenoid 25A
Wiper 5A
Switch power 20A
Alternator/heater 25A
ACD 25A
Switch power relay
Fuel solenoid relay
Not used
01-2005
12
13
14
15
16
17
18
19
20
21
3-8
Light relay
Not used
Glow plug relay
Switch not used
Starter relay
Controller 25A
ACD 25A
Lights 20A
Acc plug 15A
Engine harness
17
20
21
SERVICE TRAINING
Electrics
3. BOBCAT DISPLAY AND CONTROLLER
Sensors
Fuel level
Speed
Engine oil pressure
Engine coolant temperature
Hydraulic temperature
Hydraulic filter condition
Console position Hall effect
Hydraulic charge pressure
Load moment (optional)
01-2005
3-9
SERVICE TRAINING
Electrics
4. ELECTRIC BLOCK DIAGRAM
01-2005
3-10
SERVICE TRAINING
Electrics
5. BOBCAT EXCAVATOR CONTROLLER

325, 328, 331, 334, 337 & 341 (D & G Series)
Connector J1
A starter relay
B fuel hold
C light relay
D open
E unswitched battery in
F open
G open
H glow plug relay
J fuel pull relay
K sw batt acc relay
Connector J2
A front rod
B front base
C spare solenoid
D spare relay
E 2 speed out
F spare keyless out
G diverter
H workgroup lockout
J piezo buzzer
K load moment
Connector J3
A fuel sensor
B engine coolant temperature
C hydraulic temperature
D console sensor
E spare analog
F LH pot
G +8V sensor pwr
H GND
Connector J4
A hall engine speed
B glow plug status
C fuel pull status
D starter status
E ignition key
F hydraulic filter
G engine oil pressure
H travel pedal
J crank
K VR engine speed
Connector J5
A can LO
B can HI
C RH ski up
D RH ski down
E two speed
F RH pot
G detent
H LH ski down
J LH ski up
K can shield
Connector J6
A spare analog 2
B spare digital 1
C spare digital 2
D open
E open
F open
01-2005
3-11
SERVICE TRAINING
Electrics
430 & 435 (G Series)
Connector J1
A starter relay
B fuel hold
C light relay
D ground
E battery
F battery
G ground
H glow plug relay
J fuel pull relay
K switched power relay
Connector J2
A auxiliary male coupler
B auxiliary female coupler
C PMW work group
D unused
E 2 speed PMW
F unused
G unused
H unused
J piezo out
K load moment
Connector J3
A fuel sensor
B engine coolant temperature
C hydraulic temperature
D console sensor
E hydraulic charge signal
F LH pot signal
G +8V sensor power
H sensor ground
Connector J4
A hall engine speed
B glow plug status
C fuel pull status
D starter status
E ignition key
F hydraulic filter
G engine oil pressure
H unused
J crank
K VR engine speed
Connector J5
A can LO
B can HI
C RH ski up
D RH ski down
E two speed
F RH pot signal
G detent
H LH ski down
J LH ski up
K can shield
Connector J6
A unused
B AC on input
C spare digital 1
D travel pilot
E spare digital 2
F unused
G unused
H spare analog 2
J cooling fan
K unused
01-2005
3-12
SERVICE TRAINING
Electrics
6. DIAGNOSTIC SERVICE CODE

02-16 Hydraulic charge filter not connected
14-02 Fuel shut-off hold solenoid short to battery
02-17 Hydraulic charge filter plugged
14-03 Fuel shut-off hold solenoid short to ground
03-09 Battery voltage low
20-02 Two speed output error ON
03-10 Battery voltage high
20-03 Two speed output error OFF
03-11 Battery voltage extremely high
21-02 Glow plug output error ON
03-14 Battery voltage extremely low
21-03 Glow plug output error OFF
03-22 Battery voltage out of range low
22-02 Starter relay output error ON
04-14 Oil pressure extremely low
22-03 Starter relay output error OFF
04-15 Oil pressure shutdown level
26-02 Front base output error ON
05-09 Hydraulic charge pressure low
26-03 Front base output error OFF
05-14 Hydraulic charge pressure extremely low
27-02 Front rod output error ON
05-15 Hydraulic charge pressure shutdown level
27-03 Front rod output error OFF
05-21 Hydraulic charge pressure out of range high
28-02 Diverter output error ON
05-22 Hydraulic charge pressure out of range low
28-03 Diverter output error OFF
06-10 Engine speed high
30-28 Watch dog failure
06-11 Engine speed extremely high
31-28 Recovery mode failure
06-15 Engine speed shutdown level
35-05 Hydraulic fan solenoid short to battery
06-18 Engine speed out of range high
35-06 Hydraulic fan solenoid short to ground
07-10 Hydraulic oil temperature high
60-21 Sec. aux. thumbswitch out of range high
07-11 Hydraulic oil temperature extremely high
60-22 Sec. aux. thumbswitch out of range low
07-15 Hydraulic oil temperature shutdown level
60-23 Sec. aux. thumbswitch not calibrated
07-21 Hydraulic oil temperature out of range high
62-24 Load moment monitoring in error
07-22 Hydraulic oil temperature out of range low
63-05 Work group/travel console sensor
08-10 Engine coolant temperature high
63-06 Work group/travel console sensor
08-11 Engine coolant temperature extremely high
64-05 Switched power/acc. relay short to battery
08-15 Engine coolant temperature shutdown level
64-06 Switched power/acc. relay short to ground
08-21 Engine coolant temperature out of range high 64-07 Switched power/acc. relay open circuit
08-22 Engine coolant temperature out of range low
65-02 Work group/travel lockout solenoid error ON
09-09 Fuel level low
65-03 Work group/travel lockout solenoid error OFF
09-21 Fuel level out of range high
65-04 Work group/travel lock. sol. short to battery
09-22 Fuel level out of range low
65-05 Work group/travel lock. sol. sort to ground
12-21 Primary aux. PWM switch out of range high
65-07 Work group/travel lock. sol. open circuit
12-22 Primary aux. PWM switch out of range low
66-05 Travel solenoid short to battery
12-23 Primary aux. PWM switch not calibrated
66-06 Travel solenoid short to ground
13-05 Fuel shut-off hold solenoid short to battery

13-06 Fuel shut-off hold solenoid short to ground
01-2005
3-13
SERVICE TRAINING
Electrics
7. KEYLESS CONTROLLER
Turning Machine On
Locked
Press Enter code
Displays display code
Enter code
Displays hours and icons light up momentarily
(Note: if you enter an incorrect code error is displayed)
Repeat procedure
Unlocked
Press Enter Code
Displays hours immediately and icons lights up momentarily
Turning Machine Off
Locked
Press Stop Button
Display counts down then powers off
During countdown you can press stop again to immediately power off
Unlocked
Press Stop Button
Displays unlocked for 10 seconds then powers off
This reminds operator that the machine is not locked
Locking machine
With panel on, press the lock unlock button
Displays unlock code
Enter code
Unlock icon lights up on panel
Setting passwords
Panel must be in locked condition
Press and hold the Enter Code button for 3 seconds
Displays code 0
Press Enter Code to change from code 0 through code 3
Passwords codes
Code 0 Owner
Code 1 User
Code 2 User
Code 3 User
Starts engine and can change passwords

Starts engine only
Starts engine only
Starts engine only
Points to remember when using service PC

Always, always, always leave the remote start tool key ON.
Remote start key does not operate machine.
When installing new controller, password will be set by PC.
When installing controller from another machine, password will not be set manually set password using
keypad.
01-2005
3-14
SERVICE TRAINING
Electrics
8. SOLENOID VALVE
These solenoids operates the console lockout, the two speed, the auxiliary and the pilot pressure
cancellation. Some coils are working with the PWM system to have a progressive function. Use a multi meter
to test the coils between the wires:
Two speed solenoid: 8 Ohms
Lockout solenoid: 8 Ohms
Auxiliary male solenoid: 7,2 Ohms
Auxiliary female solenoid: 7,2 Ohms
Pilot pressure cancellation: 7,2 Ohms
If a hydraulic motor is used for cooling, the solenoid located on the motor must have 9 Ohms.
9. ENGINE SPEED SENSOR
Located on the flywheel side, it reads the flywheel starting teeth and sends the RPM information to the
Bobcat controller. The sender has a plastic spacer in front of it for assembly, when the engine runs it will
chop off the plastic spacer but the sender can be reused, the gap between the sender and the flywheel is 1,2
mm.
01-2005
3-15
SERVICE TRAINING
Electrics
10. ENGINE AND HYDRAULIC TEMPERATURE SENDER

These two senders are similar to each other but the
values are different.
Use a multi meter and take the values between the
internal pins, the reading should be:
Engine coolant sender: 500 to 3000 Ohms.
Hydraulic coolant sender: 538 to 1824 Ohms.
11. ENGINE OIL PRESSURE SENDER

The sender has a voltage range between 0,5 to 7,5V
and depending of the engine RPM.
12. FUEL STOP SOLENOID

Hold coil,
red
Pull coil,
white
Ground,
black
The fuel stop solenoid is mounted onto the engine by means of a linkage or direct onto the engine casting
with the Tier 2 engines. Two coils are mounted inside the solenoid and are controlled by the Bobcat
controller.
To test the coils, use a multi meter and note the values in Ohms.
Between the white and black wire we should have 0,26 Ohms.
Between the red and black wire we should have 10,9 Ohms.
01-2005
3-16
SERVICE TRAINING
Electrics
13. FUEL LEVEL SENSOR
The fuel sensor is a variable resistance operated with a magnetic bushing (X). The magnetic bushing moves
up and down along the central tube sensing the fuel level.
Check the resistance between the two terminals of the sensor, we should have 33 to 270 Ohms.
14. COOLING MOTOR
The cooling gear motor is fed by a separate hydraulic pump in the circuit, the full amount of flow is not used
with a cold machine. The solenoid valve is kept more or less open this to divide the flow between the tank
line and the motor. When the hydraulic oil is at temperature the solenoid valve closes to force more oil into
the cooling motor and to increase the speed of it.
The solenoid is controlled by the Bobcat controller and the temperature sender.
Check the resistance between the two pins on the solenoid, we should have 9 Ohms with an engine stopped
and at 20C.
01-2005
3-17
SERVICE TRAINING
01-2005
Electrics
3-18
SERVICE TRAINING
Maintenance
MAINTENANCE
430 S/N 562711001 & above
430 S/N 562911001 & above
430 S/N 563011001 & above
01-2005
4-1
SERVICE TRAINING
01-2005
Maintenance
4-2
SERVICE TRAINING
Maintenance
Table of Contents
1. Component location .................................................................................................4-5

2. Service schedule .....................................................................................................4-6
3. Maintenance ............................................................................................................4-7
01-2005
4-3
SERVICE TRAINING
01-2005
Maintenance
4-4
SERVICE TRAINING
Maintenance
1. COMPONENT LOCATION
01-2005
4-5
SERVICE TRAINING
Maintenance
2. SERVICE SCHEDULE
Check every x hours
8-10
Check the engine oil level
Check the coolant level
Check the hydraulic oil level
Check the air filter (if needed)
Check the track tension
Grease all pivot points
Check the cab heater filter
Lubricate X-change
Grease the swing circle and pinion
Drain water from the fuel filter
Check the battery cables and electrolyte level
Check the main drive belt
Clean the spark arrestor chamber
Replace the fuel filter
Replace the inline fuel filter
Clean the radiator fins
Replace the engine oil and filter
Replace the main hydraulic filter
Replace the case drain filters (2)
Replace the engine coolant system
Replace the hydraulic oil and filter
Replace the travel motor oil (90 W)
01-2005
4-6
50
100
250
500
1000
SERVICE TRAINING
Maintenance
3. MAINTENANCE
Every 8-10 hours, check the coolant level in the
recovery tank and add if needed.
Use propylene glycol coolant (purple color) or
Bobcat coolant.
Every 8-10 hours, check the coolant level in the

radiator and add if needed.
Use propylene glycol coolant (purple color) or
Bobcat coolant.
Every 8-10 hours, check the engine oil level and add
if needed.
01-2005
4-7
SERVICE TRAINING
Maintenance
Engine oil filler cap.

Use 10W 30 or 15W 40 engine oil.
Every 8-10 hours, check the hydraulic oil level and

add if needed.
Hydraulic oil filler cap.

Use 10W 30 or 15W 40 engine oil.
01-2005
4-8
SERVICE TRAINING
Maintenance
Every 8-10 hours, check the air filter condition.

Clean or replace only when required.
Every 8-10 hours, remove the trapped water

(depending the weather condition) at the fuel filter.
Every 8-10 hours, inspect the rubber tracks for wear

or damages and the correct tension.
01-2005
4-9
SERVICE TRAINING
Maintenance
Every 8-10 hours, check the coolant radiator for dirt

depending on the working condition.
Take off the two nuts to separate the radiators.
Use pressurized air or water to clean the radiators,
this to prevent overheating, loss of performance or
engine damage.
Every 8-10 hours, lubricate with multi-purpose lithium

based grease all pivot points such as dozer blade
cylinders, boom, dipper and bucket.
Every 50 hours, lubricate with multi-purpose lithium

based grease the swing circle and pinion.
01-2005
4-10
SERVICE TRAINING
Maintenance
Every 50 hours, drain water and sediment from the

fuel tank (depending the weather condition).
A plug is located under the reservoir.
Every 50 hours, check

connections and electrolyte.
the
battery
cables,
Add distilled water if needed.
Every 100 hours, check the accessory V-belt, adjust

or replace as needed.
01-2005
4-11
SERVICE TRAINING
Maintenance
Every 100 hours, clean the spark chamber.
Every 250 hours, replace the fuel filter.

Use a genuine Bobcat filter; lubricate the filter seal
before installing.
Replace inline fuel filter located just behind the fuel
filter.
Every 500 hours, flush the engine oil.
01-2005
4-12
SERVICE TRAINING
Maintenance
Use 10W 30 or 15W 40 oil to fill the engine.
Every 500 hours, replace the engine oil filter.

Use a genuine Bobcat filter; lubricate the filter seal
before installing.
Every 500 hours, replace the hydraulic filter.

Use a genuine Bobcat oil filter and lubricate the
filter seal before installing.
01-2005
4-13
SERVICE TRAINING
Maintenance
Every 500 hours, replace the fan hydraulic filter.

Use a genuine Bobcat oil filter.
Every 500 hours, replace the case drain filter.

The filter is the same as on the picture above.
Use a genuine Bobcat oil filter.
The filter is located behind the fuel filter.
Every 250 hours, check the tension of the multi Vbelt.

The idler has a tension indicator, if the multi V-belt is
worn out, it must be replaced by a new one.
01-2005
4-14
SERVICE TRAINING
Maintenance
Every 1000 hours, drain and flush the cooling

system.
Use propylene glycol coolant (purple color) to fill the
radiator.
Use the same coolant for the recovery bottle.
Do not mix propylene glycol with ethylene glycol.
Every 1000 hours, replace the oil in the reduction

gear box.
Drive the excavator until one of the plug is at the
bottom to flush the oil.
The second plug must be horizontal to fill the
reduction gear box.
Use 90 W gear oil to fill the reduction gear box.
Every 1000 hours, flush the hydraulic oil with the

flushing hose.
01-2005
4-15
SERVICE TRAINING
Maintenance
Use 10W 30 or 15W40 to fill the hydraulic reservoir.

Replace the breather cap at the same time.
Fill the hydraulic oil until the correct level is reached.
01-2005
4-16
SERVICE TRAINING
Safety
SAFETY
430 S/N 562711001 & above
430 S/N 562911001 & above
430 S/N 563011001 & above
01-2005
5-1
SERVICE TRAINING
01-2005
Safety
5-2
SERVICE TRAINING
Safety
1
7
8
6
5
2
READ THE OPERATOR MANUAL BEFORE USING THE EXCAVATOR!
LIFT THE ARM REST BEFORE LEAVING THE EXCAVATOR!
LOWER THE DOZER BLADE BEFORE LEAVING THE EXCAVATOR!
PUT THE DIGGING EQUIPMENT ONTO THE GROUND WHEN YOU FINISH A JOB!
DO NOT WALK UNDER THE BOOM ARM!
DO NOT GRAB THE JOYSTICK TO ENTER THE CAB!
DO NEVER CUT OR MODIFY THE CAB STRUCTURE (ROPS AND FOPS CAB)!
USE THE GRAB HANDLE TO ENTER THE CAB!
KEEP ALL COVERS CLOSED WHEN OPERATING THE EXCAVATOR!
01-2005
5-3
SERVICE TRAINING
Safety
Never service the Bobcat

excavator without instruction.
Use the correct procedure to lift

and support the excavator.
Cleaning and maintenance are

required daily.
Have good ventilation when

welding or grinding painted
parts.
Wear dust mask when grinding
painted parts.
Toxic dust and gas can be
produced.
Vent exhaust to outside when

engine must be run for service.
Exhaust system must be tightly
sealed.
Exhaust fumes can kill without
warning.
Always lower the bucket and

blade to the ground before
doing any maintenance.
Never modify equipment or add
attachments not approved by
Bobcat Company.
Stop, cool and clean engine of

flammable materials before
checking fluids.
Never service or adjust machine
with the engine running unless
instructed to do so in the
manual.
Keep body, jewelry and clothing

away from moving parts.
Wear eye protection to guard
from battery acid.
Lead-acid batteries produce

flammable and explosive gases.
Batteries contains acid which
burns eyes or skin on contact.
Wear protective clothing.
01-2005
5-4
SERVICE TRAINING
01-2005
Safety
Check that the ROPS/FOPS is in

good condition and is not modified.
Safety treads must be in good

condition.
Check that ROPS/TOPS mounting

hardware is tightened and is Bobcat
approved.
Check for correct function of

indicator lamps (optional on some
models).
The seat belt must be correctly

installed, functional and in good
condition.
Check hydraulic fluid level, engine oil

level and fuel supply.
Inspect for loose or broken parts or

connections.
Inspect for fuel, oil or hydraulic fluid

leaks.
Machine signs must be legible and in

the correct location.
Lubricate the excavator.
Steering levers, control levers and

foot pedals must return to neutral.
Check that foot pedals lock and
control lever locks are in working
order.
Check the condition of the battery

and cables.
Inspect the air cleaner for damage or

leaks. Check the condition of the
filters.
Recommend to the owner that all

necessary corrections be made
before the excavator is returned to
service.
5-5
SERVICE TRAINING
01-2005
Safety
5-6

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SERVICE TRAINING

430 EXCAVATOR SERVICE TRAINING

1. HYDRAULICS LOAD SENSING...........................................................................1-1

Hydraulics Load Sensing

Hydraulics Load Sensing

Hydraulics Load Sensing

Hydraulics Load Sensing

Hydraulics Load Sensing

Hydraulics Load Sensing

Fixed displacement pump

Variable displacement pump

Variable displacement pump

One way motor

Fixed displacement motor

Two speed drive motor

Double variable piston pump

Direct operating relief valve

Piloted/adjustable relief valve

Hydraulics Load Sensing

Relief valve with anti-cavitation valve

Pressure reducing valve

One way restrictor

Bouble piloted check valve

Pressurized filler cap

Hydraulic filter with by-pass

Hydraulics Load Sensing

Drain line filter

Piloted operated spool

Electric operated spool

Electro/hydraulic operated spool

Spool operated by solid linkages

Double acting cylinder

Double acting cylinder with cushions

Hydraulics Load Sensing

Mechanically applied brake

6/3 spool parallel design

6/3 spool series design

Load sensing spool and compensator

Hydrostatic pump, servos operated

Hydraulics Load Sensing

Back pressure valve

Double stage relief valve

Double stage relief valve

Flushing and back pressure valve

Hydraulics Load Sensing

Non connected lines

Circuit pressure (red)

Main return lines (blue)

Charge pressure or pilot oil (yellow)

Drain and pump inlet (green)

Static oil (brown)

Hydraulics Load Sensing

Variable piston pump

Variable piston pump

Hydraulics Load Sensing

Hydraulics Load Sensing

Secondary auxiliary (optional)

Hydraulics Load Sensing

Hydraulics Load Sensing

5. EXTERNAL GEAR PUMP, FIXED DISPLACEMENT

Gear pumps have two pressurized plates (see figure A and B)

View of seals around compensation plates.

Hydraulics Load Sensing

6. VARIABLE DISPLACEMENT PISTON PUMP