Bobcat 440 443 443B Loader Service Manual 6566694 (6-12) – PDF DOWNLOAD

Description

Bobcat 440 443 443B Loader Service Manual 6566694 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 440 443 443B Loader Service Manual 6566694 (6-12) – PDF DOWNLOAD

Language : English
Pages : 348
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat 440 443 443B Loader Service Manual 6566694 (6-12) – PDF DOWNLOAD

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS:

The following publications provide information on the safe use and maintenance of the loader and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine maintenance
and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The handbook is available from your dealer in an English edition or one of the following languages: French,
German, Italian, Dutch & Spanish edition.
• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.
• The Skid–Steer Loader Operator Training Course is available through your local Bobcat dealer. This course is intended
to provide rules and practices for correct operation of the Bobcat loader. This course is available in English and Spanish
versions.
• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

TABLE OF CONTENTS:

Bobcat 440 443 443B Loader Service Manual 6566694 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
SAFETY INSTRUCTIONS 9
PREVENTIVE MAINTENANCE 11
SERVICE SCHEDULE 13
PREVENTIVE MAINTENANCE 14
Serial Number Identification 14
Loader Serial Number 14
Engine Serial Number 14
Delivery Report 14
ENGINE SERVICE (General) 15
Air Cleaner Service – 440 15
Air Cleaner Service – 443 16
Fuel System 17
Fuel Filter – 440 17
Fuel Filter – 443, 443B 18
Engine Lubrication System 18
Engine Cooling System (440) 21
Engine Cooling System (443 & 443B) 22
Replacement Of The Engine Oil And Filter 18
ELECTRICAL SYSTEM 23
Electrical System Service 23
Using An Extra Battery (Jump Starting) 23
Installing A New Battery 25
SPARK ARRESTOR MUFFLER 26
HYDRAULIC/HYDROSTATIC SYSTEM 27
Replacing The Hydraulic Filter Element 27
Checking & Adding Hydraulic Fluid 28
Removing The Hydraulic/Hydrostatic Fluid 29
FINAL DRIVE TRANSMISSION (CHAINCASE) 29
Checking/Adding Chaincase Fluid 29
TIRE MAINTENANCE 30
Tire Rotation 30
Wheel Nuts 30
LUBRICATION OF THE LOADER 31
ROLL OVER PROTECTIVE STRUCTURE (ROPS &FOPS) 32
Operator Cab 32
TRANSPORTING THE BOBCAT LOADER 33
Loading The Bobcat Loader 33
Fastening The Loader To The Transport Vehicle 33
LIFT ARM SUPPORT DEVICE 34
Installing The Lift Arm Support Device 34
STOPPING THE BOBCAT LOADER 34
HYDRAULIC SYSTEM 35
HYDRAULIC / HYDROSTATIC SCHEMATICS 37
TROUBLESHOOTING 49
HYDROSTATIC SYSTEM INFORMATION 50
37° Flare Connections 50
Straight Thread O–Ring Fitting 50
Tubelines And Hoses 50
HYDRAULIC CONTROL VALVE 51
Relief Valve 51
Removal Of The Hydraulic Control Valve 54
Disassembly Of The Control Valve 56
Inspection Of The Control Valve 60
Assembly Of The Control Valve 60
Installing The Control Valve 63
HYDRAULIC PUMP 65
Checking Output Of The Hydraulic Pump 65
Removal Of The Hydraulic Pump 66
Disassembly Of The Hydraulic Pump 68
Inspection Of The Hydraulic Pump 70
Assembly Of The Hydraulic Pump 70
Installation Of The Hydraulic Pump 71
Start Up Procedure For The Hydraulic Pump 72
LIFT CYLINDER 73
Checking The Lift Cylinders 73
Removing The Lift Cylinder 73
Installation Of The Lift Cylinder 74
TILT CYLINDER 75
Checking The Tilt Cylinder 75
Removing The Tilt Cylinder 75
Installing The Tilt Cylinder 76
HYDRAULIC CYLINDER REPAIR 77
Disassembly Of The Hydraulic Cylinder 77
Assembly Of The Hydraulic Cylinder 79
HYDRAULIC/HYDROSTATIC RESERVOIR 84
Removing The Hydraulic/Hydrostatic Reservoir 84
CONTROL PEDAL, LINKAGE & LOCKS 86
Removing The Control Pedal 86
Installing The Control Pedal 87
Pedal Lock Linkage 88
Removal 88
Installation 89
SEAT BAR SYSTEM 90
Seat Bar Installation 90
Seat Bar Maintenance 90
HYDROSTATIC SYSTEM 91
TROUBLESHOOTING 93
HYDROSTATIC SYSTEM INFORMATION 94
Replenishing Valves Function 94
STEERING LEVERS 94
Removing The Steering Levers 94
Repairing The Steering Levers 96
Installing The Steering Levers 97
STEERING LINKAGE 98
Adjusting The Steering Linkage 98
Removing The Pintle Arms 99
Installing The Pintle Arms 100
PORT BLOCK 101
Checking Charge Pressure 101
Charge Pressure Relief Valve 102
Cold Weather By–Pass Valve 103
Removing The Port Block 103
Installing The Port Block 104
HYDROSTATIC MOTOR 105
Removing The Hydrostatic Motor 105
Disassembly Of The Hydrostatic Motor 107
Hydrostatic Motor Inspection 111
Assembly Of The Hydrostatic Motor 112
Start Up Procedure For The Hydrostatic Motor 117
HYDROSTATIC PUMP 118
Removing The Hydrostatic Pumps 118
Disassembly Of The Hydrostatic Pump 124
Inspection Of The Hydrostatic Pumps 127
Assembly Of The Hydrostatic Pumps 129
Installing The Hydrostatic Pumps 134
Hydrostatic Pump Start Up Procedure 136
DRIVE BELT AND TENSION PULLEY 137
Removing Tension Pulley 137
Installing Tension Pulley 137
Drive Belt Removal–In The Loader 138
TOWING THE BOBCAT LOADER 139
DRIVE SYSTEM 141
PARKING BRAKE 143
Parking Brake Adjustment 143
Removing Parking Brake 144
Inspecting The Parking Brake 145
Installing The Parking Brake 145
DRIVE CHAINS 147
Removing The Drive Chain(s) 147
Installing The Drive Chain(s) 148
AXLES AND BEARINGS 150
Removing The Axle(s) And Bearings 150
Assembly Of The Axle 152
Installing The Axle(s) And Bearings 152
CHAINCASE FLUID 155
Replacing Chaincase Fluid 155
MAIN FRAME 157
OPERATOR CAB 159
Raising The Operator Cab 159
Lowering The Operator Cab 160
Jumper Start Switch 160
Removing The Operator Cab 161
Installing The Operator Cab 161
LIFT ARMS 162
Removing The Lift Arms 162
Installing The Lift Arms 163
BOB–TACH 164
Removing The Bob–Tach 164
Disassembly Of The Bob–Tach 165
Assembly Of The Bob–Tach 167
Installing The Bob–Tach 168
REAR DOOR 169
Removing The Rear Door 169
FUEL TANK 170
Removing The Fuel Tank 170
Installing The Fuel Tank 170
REAR WINDOW 171
Installing Rear Window 171
ELECTRICAL SYSTEM 173
ELECTRICAL SCHEMATICS 176
TROUBLESHOOTING 189
ELECTRICAL SYSTEM 190
Electrical Circuitry 190
Safety Procedures For The Batteries 190
Precautions For The Alternator 191
BATTERY 192
Removing The Battery 192
Checking The Battery 193
Installing The Battery 193
OPERATOR CAB WIRE HARNESS 194
Removing The Wire Harness 194
Installing The Wire Harness 195
ENGINE WIRE HARNESS 195
ALTERNATOR SYSTEM (440) 196
Replacing The Stator 197
ALTERNATOR SYSTEM (443) 198
Adjusting The Alternator 198
Checking The Alternator (443) (Early Models) 198
Removing The Alternator 199
Repairing The Alternator (Early Models) 200
Install The Alternator 202
ALTERNATOR (Melroe) 203
Alternator Output Test (New Style) 203
Rectifier (Diode) Test (New Style) 203
Alternator Regulator Test (New Style) 204
Disassembly And Inspection (New Style) 205
Stator Continuity Test (New Style) 205
Stator Ground Test (New Style) 205
Rotor Continuity Test (New Style) 206
Rotor Ground Test (New Style) 206
Rectifier Continuity (Diode) Test (New Style) 206
Assembly (New Style) 207
STARTER (440) 208
Checking The Starter (440) 208
Removing The Starter 209
Repairing The Starter 210
Installing The Starter 211
STARTER (443) 212
Checking The Starter (443) 212
Removing The Starter 212
Repairing The Starter 213
Installing The Starter 215
ALTERNATOR (Motorola) 216
Belt Tension 216
Troubleshooting The Alternator 216
Checking The Alternator Output 217
Removal And Installation 218
Disassembly And Assembly 218
ENGINE SERVICE 225
ENGINE SERVICE – KOHLER (440) 227
TROUBLESHOOTING 229
ENGINE & ATTACHING PARTS 231
Removing The Engine (Early Model) 231
Installing The Engine 235
Removing The Engine (Later Model) 235
Oil Cooler Removal 239
Engine Muffler Removal 239
Engine Muffler Installation 240
IGNITION SYSTEM 241
Spark Plugs 241
Breaker Points 241
Condenser 242
Ignition Coil 242
Static Ignition Timing 242
Timing Light 243
Valve & Tappet Clearance 244
Compression Test 244
CARBURETOR AND GOVERNOR 245
Carburetor Adjustment On The Engine 245
Main Fuel Adjustment 245
Idle Fuel Adjustment 245
Idle Speed Setting 246
Shutdown Control Solenoid 246
Reconditioning the Carburetor 247
Disassembly 247
Assembly 247
Governor and Adjustment 248
Adjustments 248
Carburetor 249
Adjusting the Carburetor 249
Throttle Shaft 251
Choke Shaft 251
Float Level 252
RECONDITIONING THE ENGINE 253
Engine Disassembly 253
Cylinder Head 255
Cylinder Barrels 256
Cylinder Bore 256
Valves 256
Valve Guide 256
Valve Seat Inserts 256
Valve Springs 256
Piston And Piston Rings 257
Crankshaft And Connecting Rods 257
Connecting Rods 257
Governor Inspection 258
Oil Pump Inspection 258
Assembling The Engine 258
ENGINE SERVICE – KOHLER (443) 267
TROUBLESHOOTING 269
FUEL SYSTEM 271
Replacing The Fuel Filter 271
Removing The Air From The Fuel System 271
Fuel Injection Pump 272
Checking The Injection Pump 272
Removing Injection Pump 273
Installation 274
Timing The Fuel Injection Pump 274
Fuel Injector Nozzles 275
Nozzle Removal 275
Checking Fuel Injector Nozzles 276
Nozzle Installation 276
Checking Glow Plugs 277
Engine Compression Test 277
ENGINE & ATTACHING PARTS 278
Removing The Engine 278
Installing The Engine 283
Oil Cooler & Shrouding 284
Removal 284
Installation 284
Engine Radiator Removal 285
Engine Radiator Installation 286
Engine Blower Fan & Shrouding 287
Installation 287
Fan Blower & Water Pump Belt 288
Adjustment 288
Engine Flywheel Removal 288
Engine Flywheel Installation 288
CYLINDER HEAD 289
Removing The Cylinder Head 289
Disassembly Of The Cylinder Head 291
Servicing The Cylinder Head 292
Assembly Of The Cylinder Head 294
Installing The Cylinder Head 294
REPAIRING THE ENGINE 296
Removing The Gear Case 296
Removing The Timing Gear, Camshaft & Oil Pump 298
Removing Pistons & Crankshaft 300
Servicing The Timing Gear And Camshaft 302
Servicing The Connecting Rods And Pistons 304
Servicing The Crankshaft 305
Servicing The Cylinder Liners 307
Servicing The Oil Pump 308
Servicing The Water Pump 308
ASSEMBLY OF THE ENGINE 309
Installing The Crankshaft 309
Installing The Pistons 309
Installing The Camshaft And Timing Gears 310
Installing The Gearcase Cover 312
TECHNICAL DATA 313
440 LOADER SPECIFICATIONS 315
LOADER DIMENSIONS 315
OPERATIONS & PERFORMANCE 315
ENGINE 315
HYDRAULIC SYSTEM 316
ELECTRICAL 316
DRIVE SYSTEM 316
CAPACITIES 316
TIRES 316
ENGINE SPECIFICATIONS – 440 (KOHLER) 317
Engine (General) 317
Cylinder Bore 317
Crankshaft 317
Camshaft 317
Connecting Rod 317
Piston, Pin & Rings 317
Valves, Guides & Tappet 317
Oil Pump 318
Engine Torque 318
443 LOADER SPECIFICATIONS 319
LOADER DIMENSIONS 319
OPERATIONS & PERFORMANCE 319
ENGINE 319
HYDRAULIC SYSTEM 320
ELECTRICAL 320
DRIVE SYSTEM 320
CAPACITIES 320
TIRES 320
ENGINE SPECIFICATIONS – 443 (KUBOTA) 321
Fuel Injector Nozzles 321
Fuel Injection Pump 321
Cylinder Head 321
Valves 321
Valve Springs 321
Rocker Arms 321
Camshaft 321
Cylinders 322
Piston Rings 322
Pistons 322
Crankshaft 322
Oil Pump 322
Thermostat 322
Engine Torque 323
Crankshaft Re–Grind Data 324
SPECIFICATIONS 325
TORQUE SPECIFICATIONS 327
Engine Group – 440 Loader 327
Engine Group – 443 Loader 328
Fuel System Group 330
Steering Controls & Panel Group 331
Bob–Tach & Lift Arm Group 332
Seat Bar & Pedal Group 333
Brake, Chaincase & Axle Group 334
Hydraulic Group (Auxiliary Hydraulic–Optional) 335
Operator Cab, Main Frame & Rear Door Group 336
Hydrostatic Group – 440 Loader 337
Hydrostatic Group – 443 Loader 338
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 339
DECIMAL AND MILLIMETER EQUIVALENTS 340
U S TO METRIC CONVERSION 340
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 341
SERVICE MANUAL REVISIONS 343
440-1 343
440-2 345
440-3 347

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• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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