Bobcat 440B Loader Service Manual 6570160 (6-12) – PDF DOWNLOAD

Description

Bobcat 440B Loader Service Manual 6570160 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 440B Loader Service Manual 6570160 (6-12) – PDF DOWNLOAD

Language : English
Pages : 180
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat 440B Loader Service Manual 6570160 (6-12) – PDF DOWNLOAD

FOREWORD:

This manual gives the owner/operator necessary operating, servicing and adjustment of the
Bobcat loader and overhaul instructions of the drive system, loader hydraulic/hydrostatic
system and general main frame parts.
Refer to the Operator’s Manual for operating instructions (Starting Procedure, Daily Checks,
Bucket Operation, etc.)
A general inspection of the following items must be made whenever the loader has had service
or repair:
1. Check hydraulic 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 and cables.
5. Inspect air cleaner for damage or leaks. Check element and replace as needed.
6. Check electrical charging system.
7. Check tires for wear and pressure.
8. Inspect Operator Cab, Seat Belt, Seat Bar, Safety Treads, Lights, Horn, Safety Signs
(Decals), Brake etc.
9. Inspect for loose or broken parts or connections.
10. Operate the loader and check all functions.
11. Inform the Owner/Operator of any items that need service.

TABLE OF CONTENTS:

Bobcat 440B Loader Service Manual 6570160 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 5
SAFETY INSTRUCTIONS 7
SAFETY IS YOUR RESPONSIBILITY 7
BEFORE YOU OPERATE THE BOBCAT LOADER 7
SAFE OPERATION NEEDS A QUALIFIED OPERATOR 8
FIRE PREVENTION 8
SERIAL NUMBER LOCATIONS 9
LOADER SERIAL NUMBER 9
ENGINE SERIAL NUMBER LOCATION 9
DELIVERY REPORT 9
BOBCAT LOADER IDENTIFICATION 10
PREVENTIVE MAINTENANCE 11
SERVICE SCHEDULE 13
PREVENTIVE MAINTENANCE 14
LIFTING AND BLOCKING THE FELLER BUNCHER 14
Procedure 14
TRANSPORTING THE LOADER 15
Procedure 15
LIFT ARM STOP 16
Procedure 16
OPERATOR CAB 17
Seat Bar System 17
Seat Bar Inspection 17
Seat Bar Maintenance 18
Raising the Operator Cab 19
Lowering the Operator Cab 19
USING AND EXTRA BATTERY (JUMP START) 20
Procedure 20
HYDRAULIC SYSTEM 21
HYDRAULIC / HYDROSTATIC FLOW CHART 23
HYDRAULIC SYSTEM 29
TROUBLESHOOTING 29
HYDRAULIC SYSTEM INFORMATION 30
Flare Connections 30
Straight Thread O–ring Fitting 30
Tubelines and Hoses 30
LIFT CYLINDER 31
Checking the Lift Cylinder(s) 31
Removal and Installation 32
TILT CYLINDER 33
Checking the Tilt Cylinder 33
Removal and Installation 33
HYDRAULIC CYLINDER REPAIR 34
Disassembly 34
Assembly 36
HYDRAULIC CONTROL VALVE 39
Checking the Main Relief Valve 39
Removal and Installation 40
Disassembly and Assembly 42
Inspection 43
HYDRAULIC PUMP 44
Checking Output of Hydraulic Pump 44
Removal and Installation 46
Disassembly and Assembly 47
Inspection 49
HYDRAULIC/HYDROSTATIC FLUID RESERVOIR 50
Removing Fluid from Reservoir 50
Removal and Installation 50
CONTROL PEDALS 51
Removal and Installation 51
PEDAL LOCK LINKAGE 52
Removal and Installation 52
HYDROSTATIC SYSTEM 53
TROUBLESHOOTING 55
HYDROSTATIC SYSTEM INFORMATION 56
High Pressure Relief Replenishing Valves Function 56
FRONT PANEL 57
Removal and Installation 57
STEERING LEVERS 58
Removal and Installation 58
Disassembly and Assembly 59
Neutral Adjustment 59
PINTLE ARMS 61
Removal and Installation 61
Disassembly and Assembly 62
HYDROSTATIC MOTOR 63
Removal and Installation 63
Disassembly and Assembly 65
Inspection 70
Start Up Procedure 70
Timing the Hydrostatic Motor 71
HYDROSTATIC PUMP 72
Checking Charge Pressure 72
Removal and Installation 73
Disassembly and Assembly 75
Inspection 79
Start Up Procedure 80
DRIVE BELT & TENSION PULLEY 81
Tension Pulley Removal and Installation 81
Drive Belt Replacement In Loader Removal and Installation 82
PORT BLOCK 83
Charge Pressure Relief Valve Removal and Installation 83
Cold Weather By–Pass Valve Removal and Installation 83
TOWING THE BOBCAT LOADER 84
Procedure 84
DRIVE SYSTEM 85
PARKING BRAKE 87
Adjustment 87
Removal and Installation 87
Calipers and Bushings 88
AXLE, AXLE SEAL AND BEARINGS 90
Removal 90
Installation 92
DRIVE CHAINS 95
Removal 95
Installation 95
Removal and Installation 97
MAIN FRAME 99
OPERATOR CAB 101
Removal and Installation 101
SEAT BAR 102
Removal and Installation 102
REAR DOOR 103
Removal and Installation 103
LIFT ARMS 104
Removal and Installation 104
BUCKETS AND ATTACHMENTS 105
Removal 105
Installation 105
FUEL TANK 106
Removal and Installation 106
ELECTRICAL SYSTEM 107
ELECTRICAL SCHEMATICS 110
ELECTRICAL SYSTEM INFORMATION 113
Description 113
TROUBLESHOOTING 113
BATTERY 114
Checking the Battery 114
Removal and Installation 114
ALTERNATOR 115
Description 115
Checking Alternator Circuit 116
Replacement of the Stator 116
STARTER 117
Checking the Starter 117
Removal and Installation 117
Disassembly and Assembly 118
ENGINE SERVICE 121
TROUBLESHOOTING 123
ENGINE COMPRESSION 124
Checking 124
CARBURETOR AND GOVERNOR 125
Carburetor Adjustment 125
Carburetor Removal and Installation 126
Carburetor Disassembly and Assembly 126
Governor Adjustment 127
CARBURETOR (Fixed Main Jet) 128
Description 128
Adjusting the Carburetor 128
Disassembly and Assembly 129
Throttle Shaft 130
Choke Shaft 130
Float Level 131
FUEL PUMP 131
Removal & Installation 131
IGNITION SYSTEM 132
Igintion System Information 132
Troubleshooting 132
Ignition System Tester 133
Spark Plugs 133
Ignition Module 133
CRANKCASE VACUUM 134
Manometer Tube 134
Vacuum Test 134
ENGINE 135
Removal and Installation 135
ENGINE MUFFLER 139
Removal and Installation 139
RECONDITIONING THE ENGINE 140
Disassembly 140
Assembly 142
CYLINDER HEAD 150
Checking 150
CYLINDER BARRELS 150
Checking 150
VALVES (Engine S/N 1917809295 & Below) 151
VALVE GUIDES 151
Removal and Installation 151
Checking 151
VALVE SEAT INSERTS (Engine S/N 1917809295 & Below) 151
Removal and Installation 151
VALVE SPRINGS 151
Checking 151
VALVES (Engine S/N 1917809296 & Above) 153
Checking 153
VALVE SEAT INSERTS (Engine S/N 1917809296 & Above) 153
Removal and Installation 153
PISTON AND PISTON RINGS 154
Checking 154
CRANKSHAFT AND CONNECTING RODS 155
Checking 155
GOVERNOR AND OIL PUMP 155
Governor Inspection 155
Oil Pump Inspection 155
TECHNICAL DATA 157
LOADER SPECIFICATIONS 159
OPERATIONS & PERFORMANCE 159
ENGINE 159
LOADER HYDRAULICS 160
ELECTRICAL 160
DRIVE SYSTEM 160
CAPACITIES 160
TIRES 160
ENGINE SPECIFICATIONS 161
Engine (General) 161
Cylinder Bore 161
Crankshaft 161
Camshaft 161
Connecting Rod 161
Piston, Pin & Rings 161
Valves, Guides & Tappets 161
Oil Pump 162
Engine Torque 162
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 163
Hydraulic/Hydrostatic Fluid 163
DECIMAL AND MILLIMETER EQUIVALENTS 164
U S TO METRIC CONVERSION 164
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 165
SERVICE MANUAL REVISIONS 167
FB-1 167
FB-2 169
440B/FB-3 171
440B/FB-4 173
440B/FB-5 175
440B/FB-6 177
440B/FB-7 179

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