440 & 443 Skid Steer

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1 Bobcat 440 & 443 Skid Steer THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF BOBCAT OR IT S SUCCESSORS. BOBCAT AND IT S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. BC-S-440,443

2 .r bobcat CUARK Melroe Division

3 FOREWORD This gives the instructions for correct servicing, adjustment and overhauling of the Bobcat loader Hydraulic/Hydrostatic System, Drive System, Main Frame, Electrical System and Engine Service. Make reference to the Operator's Manual for operating instructions (Starting, Daily Checks, Loader Operation, etc.). ~ PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM A general inspection of the following items must be made when the Bobcat loader has had service or repair. HYDROSTATIC - SYSTEM 1. Check hydraulic/hydrostatic fluid level, engine oil level and fuel supply. 2. Inspect for any sign of fuel, oil or hydraulic fluid leaks. 3. Lubricate the loader. 4. Check the condition of the battery(ies) and the cables. 5. Inspect the air cleaner system for damage or leaks. DRIVE SYSTEM MAIN FRAME 6. Check the warning lights to see if they light. 7. Check the tires for wear and pressure. 8. Check the Bob-Tach for wear and see if the wedges are damaged. 9. Check the safety items for condition (Operator Cab, Seat Belt, Seat Bar, Safety Signs (Decals), Safety Treads, etc.). 10. Make an inspection for loose or broken parts or connections. 11. Operate the loader, checking all functions. Check the above items. If any are in need of repair or adjustment, contact the owner. ELECTRICAL SYSTEM ENGINE SERVICE TECHNICAL DATA ALPHABETICAL INDEX CONTENTS ALPHABETICAL INDEX DRIVE SYSTEM... 4 ELECTRICAL SYSTEM... 6 ENGINE SERVICE HYDRAULIC SYSTEM... 2 HYDROSTATIC SYSTEM... 3 MAIN FRAME... 5 PREVENTIVE MAINTENANCE TECHNICAL OAT A ,443 Loader

4 Remove the shrouding on the engine (Fig. 1-23) to clean the cooling fins. Make sure you wear safety goggles when using air pressure or water spray for cleaning. Use a brush and a scraper tool to remove the hard deposits on the cooling fins (Fig. 1-24). Make sure to replace all the covers and shrouding after cleaning the engine. - IMPORTANT Fig Cleaning Cooling Fins N ever run the engine with any of the covers or ducts removed. Overheating will result and cause damage to the engine or hydraulic/hydrostatic system Fig Removing Engine Shrouding Use air pressure or water spray to clean the hydraulic/hydrostatic oil cooler (Fig. 1-25). Fig Cleaning Oil Cooler Engine Cooling System (443) The cooling system has a coolant recovery tank. The location of the tank is on the right up-right on the engine compartment (Fig. 1-26). Check the coolant level, when the engine is cool. The recovery tank must be 1/3 full. Add coolant to the recovery tank (Fig. 1-26) when the coolant level is low. NOTE: Protect the cooling system from freezing temperature by adding SO/50 (PRE-MIXED) mixture of ethylene glycol and water to the cooling system. To remove the coolant from the system, use the following procedure: Fig Coolant Recovery Tank AWARNING Do not remove radiator cap when engine is hot. W-1030 ( 1 ) Raise the operator cab (See Paragraph 5-1.1, Page 5-1 for the correct procedure). (2) Open the coolant valve (Fig. 1-27) on the front side of the engine block. Connect a hose to the valve to keep the coolant from getting into the engine compartment Fig Engine Coolant Valve 440,443 loader

5 ( 1 0) Install the drive shaft and install the snap ring (Fig ). ( 11) Install the rotating group in the housing (Fig ). (12) Install the center section on the pump housing (Fig ). Fig Installing Snap Ring Fig Installing Rotating Group B-6064 (13) Install the bolts and tighten to ft.-ibs. (23-27 Nm) torque (Fig ). (14) Install the coupler into the center section (Fig ). Fig Installing Pump Center Section I~( \ (15) Install the other pump housing assembly on the center section. (1 6) Install the centering bracket and bolts in the center section (Fig ). Fig Center Section Bolts Fig Center Section Coupler (17) Tighten the bolts to ft.-ibs. (37-42 Nm) torque. (18) Install the replenishing valves (4) (Fig ) and tighten the plugs. Fig Installing Centering Bracket Fig. 3 - /. II 1- ~~ B Installing Replenishing Valves ,443 Loader

6 7A-S RECONDITIONING THE ENGINE 7 A - S. 1 Disassembling the Engine The tools listed will be needed to do the following procedure: MEL MEL Strap Wrench Barrel Wrench (1) Remove the engine from the loader (See Paragraph 7 A - 2. i ). Remove the governor arm clamp, spring and linkage. (2) Disconnect fuel line from carburetor. Fig. 7 A - 41 Loosen Flywheel Bolts Fig. 7 A - 42 Remov;ng :ne Flywheel (3) Disconnect the wires to the coil and the spark plugs. (4) Remove the intake manifold. (5) Remove all the air shrouding from the engine. (6) Remove the exhaust manifolds. Use procedure in manual for removing flywheel to avoid cracked flywheel or broken crankshaft. Do not use flywheel puller which holds the outside only of the flywheel. Damaged parts can fail explosively during use and cause injury or death. W-1041 Fig. 7 A - 43 Removing the Stator (n Use a strap wrench to hold the flywheel and loosen the flywheel bolt (Fig. 7A-41). (8) Remove the flywheel with a puller (Fig. 7A-42). (9) Remove the stator (Fig. 7A-43). (10) Mark the crankcase halves (Fig. 7A-44). Side one is the closest to the flywheel. It contains the governor, oil pump gear and dipstick tube. (11) Remove the point cover and the breaker points. Remove the fuel pump. (12) Remove the starter. Fig. 7A-44 Marking Crankcase Halves (13) Remove the cylinder heads. Remove the cylinder barrels and gaskets. NOTE: The pistons can stay in the cylinders if so desired. (14) Make sure the cylinder barrels are stamped #1 and #2 (Fig. 7A-4S). NOTE: Make sure to mark all the parts (tappets, valve springs, retainers, pistons. rods) for the #1 or #2 side. Fig. 7A-45 Cylinder Barrel Identification -7A-15- A loader

7 All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. BA-2 ENGINE SPECIFICATIONS LOADER (KOHLER) BA-2.1 Engine (General) Ignition Point Gap (0,432-0,580) Spark Plug Gap (0,635) Compression at Cranking Speed PSI ( kpa) High Idle No Load RPM Low Idle No Load... " 1200 RPM Oil Pressure (Idle RPM) PSI ( kpa) BA-2.2 Cylinder Bore New Diameter... " 3.125(79,38) Wear Diameter (Maximum) S (79,45) Taper (Maximum) (0,03S) Out-of-Round (Maximum)... _ (0,05) SA-2.3 Crankshaft End Play (0,051-0,580) Crankpin - New Diameter (34,S9-34,90) Crankpin - Out-of-Round (Maximum) (0,013) Crankpin - Taper (Maximum) (0,025) Sleeve Bearing - Running Clearance (0,034-0,083) Bearing Diameter (Minimum) (44,22) SA-2.4 Camshaft End Play (0,077-0,330) Shaft to Bearing Clearance (0,025-0,063) BA-2.5 Connec.ting Rod Big End - New Diameter (34,925-34,937) Big End - Wear Diameter (Maximum) (34,950) Small End - New Diameter (15,891) Rod to Piston Pin - Clearance (0,016-0,027) Side Play on Crankpin (0,13-0,41) Crankpin Running Clearance (0,030-0,056) SA-2.6 Piston, Pin & Rings * Thrust Face - Wear Diameter (Maximum) (79,159) * Thrust Face to Bore Running (@Gauge Dia.) (0,15-0,20) Ring-Side Clearance - Top (0,51-0,10) Second... _ (0,025-0,077) Oil (0,025-0,077) Ring-End Gap (0,254-0,508) Wrist Pin to Boss (Maximum)... " (O.OOS) Wrist Pinto Rod (0,016-0,027) BA-2.7 Valves. Guides & Tappets I Intake Valve to Tappet Clearance (Cold) (O,076-0,150) Exhaust Valve to Tappet Clearance (Cold) (0, ) Valve Lift - Zero Clearance S0 (7,11 ) Intake Valve Stem to Guide (Maximum) (0,114) Exhaust Valve Stem to Guide (Maximum) (0,165) Tappet Clearance in Guide (Maximum) (0,013-0,060) Valve Guide Interference Fit ( ,051) Valve Guide Ream Diameter ( ) * Measured just below oil ring at right angles to the pin. -8A-3-440, 443 Loader

8 9 ALPHABETICAL INDEX Subject Page Subject Page Air Cleaner Service (440) Air Cleaner Service (443) Alternator, belt adjustment for the (443) Alternator Circuit, checking the (440) Alternator, checking the (443) Alternator, installing the (443) Alternator, precautions for the Alternator, removing the (443) Alternator, repairing the (443) Alternator System (440) Alternator System (443) Axle, assembly ofthe Axle and Bearings Axle(s) and Bearings, installating the Axle(s) and Bearings, removing the Battery Battery, checking the Battery, installing new Battery, installing the Battery, removing the Battery, safety procedures for the Belt, fan blower and water pump (443)... 7B-1 5 Blower Fan and Shrouding, Engine (443)... 7B-1 5 Bob-Tach Bob-Tach, assembly of the Bob-Tach, disassembly of the Bob-Tach, installing the Bob-Tach, removing the Breaker Points (440) A - 8 Camshaft and Timing Gears, installing the (443)... 7B-30 Carburetor, adjustment to the (440)... 7 A-11 Carburetor and Governor (440)... 7 A-11 Carburetor, reconditioning the (440)... 7 A-13 Chaincase Fluid Chaincase Fluid, checking/adding Chaincase Fluid, replacing Charge Pressure, checking Compression Test (440) A-11 Compression Test, Engine (443)... 7B-8 Condenser (440)... 7 A-9 Connecting Rods and Pistons, servicing the (443) Control Pedal, installing the Control Pedal, linkage and locks Control Pedal, removing the Control Valve, assembly ofthe Control Valve, disassembly of the Control Valve, hydraulic Control Valve, inspection of the Control Valve, installation of the Control Valve, removal of the hydraulic Conversion, U.S. to Metric... 8C-14 Crankshaft and Connecting Rods (440)... 7 A-18 Crankshaft, installing the (443)... 7B- 29 Crankshaft, servicing the (443)... 7B-26 Cylinder Barrels and Valves (440)... 7 A-17 Cylinder Head (440)... 7 A-1 6 Cylinder Head (443)... 7B-16 Cylinder Head, assembly of the (443)... 7B- 20 Cylinder Head, disassembly of the (443)... 7B-18 Cylinder Head, installing the (443)... 7B-20 Cylinder Head, removing the (443)... 7B-1 6 Cylinder Head, servicing the (443)... 7B-18 Cylinder Liners, servicing the (443) Cylinder Repair, hydraulic Decimal and Millimeter Equivalents... 8C-14 Delivery Report Drive Belt Removal- in the loader Drive Belt and Tension Pulley Drive Chains Drive Chain(s), installing the Drive Chain(s), removing the Drive System Electrical System , 6-1 Electrical System Service Engine, assembling the (440)... 7 A-19 Engine, assembly of the (443) Engine and Attaching Parts (440)... 7 A-3 Engine and Attaching Parts (443)... 7 B-9 Engine Cooling System (440) Engine Cooling System (443) Engine, disassembly of the (440)... 7B-1 5 Engine, installing the (440)... 7A-6 Engine, installing the (443) Engine Lubrication System Engine Oil and Filter, replacement of the Engine, reconditioning the (440)... 7 A -15 Engine, removing the (440)... 7A-3 Engine, removing the (443) Engine, repairing the (443) Engine Service (General) Engine Service (440)... 7 A - 1 Fastening the Loader to Transport Vehicle. : Final Drive Transmission (Chaincase) Fitting, straight thread o-ring Flare Connections, Flywheel, engine (443) Fuel Filter Fuel Filter, replacing the (443)... 7B- 3 Fuel Injection Pump... 7B-4 Fuel Injection Pump, timing the (443) Fuel Injector Nozzles (443)... 7B-6 Fuel Injector Nozzles, checking (443)... 7B- 7 Fuel System Fuel System (443)... 7B-3 Fuel System, removing air from the... 7B-3 FuelTank Fuel Tank, installing the Fuel Tank, removing the Gear Case Cover, installing the (443)... 7B- 31 Gear Case, remove the (443)... 7B- 22 Glow Plugs (443)... 7B-8 Governor and Adjustment (440)... 7 A-14 Governor and Oil Pump (440)... 7 A-19 Hydraulic Cylinder, assembly of the Hydraulic Cylinder, disassembly of the Hydraulic Filter, replacing the Hydraulic Fluid, check and adding , 443 Loader

9 9 ALPHABETICAL INDEX (Cont'd) Subject Page SUbject Page Hydraulic/Hydrostatic Fluid, removing the Hydraulic/Hydrostatic Reservoir Hydraulic/Hydrostatic Reservoir, installation of the Hydraulic/Hydrostatic Reservoir, removing the Hydraulic/Hydrostatic System Hydraulic Pump Hydraulic Pump, assembly of the Hydraulic Pump, checking output of the Hydraulic Pump, disassembly of the Hydraulic Pump, inspection of the Hydraulic Pump, installation of the Hydraulic Pump, removal of the Hydraulic Pump, start up procedure for the Hydraulic System Hydrostatic Motor Hydrostatic Motor, assembly of the Hydrostatic Motor, disassembly of the Hydrostatic Motor, inspection Hydrostatic Motor, installing the Hydrostatic Motor, removing the Hydrostatic Motor, start-up procedure Hydrostatic Pump Hydrostatic Pumps, assembling the Hydrostatic Pumps, disassembly of the Hydrostatic Pumps, inspection of the Hydrostatic Pumps, installing the Hydrostatic Pumps, removing the Hydrostatic Pump Start-Up Procedure Ignition Coil (440)... 7 A-9 Ignition System (440)... 7 A- 8 Ignition Timing (440)... 7 A- 9 Information, electrical system I nformation, hydraulic system Information, hydrostatic system Introduction Jumper Start Switch Lift Arms Lift Arms, installing the Lift Arms, removing Lift Arm Stop Lift Arm Stop, installing the Lift Cylinders Lift Cylinders, checking the Lift Cylinder, installation of the Lift Cylinder, removal ofthe Loading the Bobcat Loader Lubrication ofthe Loader Main Frame Muffler, engine (440)... '.'... 7 A - 7 Muffler, spark arrestor Oil Cooler (440)... 7 A- 7 Oil Cooler and Shrouding (443)... 7B-13 Oil Pump, servicing the (443)... 7B- 28 Operator Cab Operator Cab, installing the Operator Cab, lowering the Operator Cab, raising the Operator Cab, removing Parking Brake Parking Brake Adjustment Parking Brake, inspection of the Parking Brake, installing the Parking Brake, removing Pedal Lock Linkage Pintle Arms, installing the Pintle Arms, removing the Pistons and Crankshaft, removing (443)... 7B- 23 Pistons, installing the (443)... 7B- 29 Pistons and Piston Rings (440)... 7 A Port Block Preventive Maintenance Radiator, engine (443)... 7B-13 Rear Door Rear Door, installing the Rear Door, removing the Relief Valve Rollover Protection Structure (ROPS and FOPS) Serial Number, engine Serial Number Identification Serial Number, loader Service Schedule Shutdown Control Solenoid (440)... 7 A-12 Spark Plugs (440)... 7 A- 8 Specifications, 440 loader.,..,,,,,.. 8A-1 Specifications, 443 loader..,,,,,,.,,,.,..,,8b-1 Specifications, engine (440),,..,.,,...,,,. 8A- 3 Specifications, engine (443),.,,... 8B- 3 Specifications, hydraulic/hydrostatic fluid... 8C Starter (440),...,.,...,...,.,.., 6-11 Starter (443)...,.. ".,...," Starter, checking the (440). '...,...,,.,6-11 Starter, checking the (443)..,...,.. '.. ', Starter, installing the (440)...,.,6-1 3 Starter, installing the (443).,..., Starter, removing the (440)..., Starter, removing the (443)...,... ' Starter, repairing the (440)...,.,, Starter, repairing the (443)...,.6-14 Stator, replacement of the, Steering Levers Steering Levers, installing the Steering Levers, removing the..., Steering Levers, repairing the... " Steering Linkage...,3-4 Steering Linkage, adjustment of the Stopping the Bobcat Loader..., Tension Pulley, installing the Tension Pulley, removing the Tilt Cylinder Tilt Cylinder, checking the Tift Cylinder, installation ofthe Tilt Cylinder, removing the Timing Gear, camshaft and oil pump removing the (443)... 7B-22 Timing Gear and Camshaft, servicing the (443)... 7B- 25 Tire Maintenance Tire Rotation , 443 Loader

10 9 ALPHABETICAL INDEX (Cont'd) Subject Page Torque, bob-tach and lift arm group... 8C-6 Torque, brake, chaincase and axle group... 8C- 8 Torque, engine group (440)... 8C-1 Torque, engine group (443)... 8C-2, 8C-3 Torque, fuel system group... 8C-4 Torque, hydraulic group C - 9 Torque, hydrostatic group (440)... 8C-11 Torque, operator cab, mainframe and rear door group... 8C-1 0 Torque, seat bar and pedal group... 8C-7 Torque, standard bolts... 8C-15 Torque, steering controls and panel group... 8C- 5 Transporting the Bobcat Loader Troubleshooting, electrical system Troubleshooting, engine service (440)... 7 A-1 Troubleshooting, engine service (443)... 7B-1 Troubleshooting, hydraulic system Troubleshooting, hydrostatic system Tubelines & Hoses Using an Extra Battery (Jump Starting) Valve, charge pressure relief Valve, cold weather by-pass Valve, removing the charge pressure relief Water Pump, servicing the (443)... 7B-29 Wheel Nuts Wire Harness for the Operator Cab Wire Harness for the Engine Wire Harness for the Operator Cab, installing the Wire Harness for the Operator Cab, removing the , 443 Loader

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