4 4 0
4 4 3 Service Manual
4 4 3 B
6566694 (11–95)
Printed in U.S.A.
© Melroe Company 1995
MAINTENANCE SAFETY WARNING
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.
CORRECT
CORRECT
CORRECT
B-10731a
B-12365
B-7469
Never service the Bobcat SkidSteer Loader without instructions.
Use the correct procedure to lift or lower operator cab.
Cleaning and maintenance are required daily.
WRONG
WRONG
WRONG
B-11799
B-15231
B-15280
Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.
Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged.
Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company.
WRONG
WRONG
WRONG
B-6590
B-6580 B-16102
B-6589 B-16102
Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame.
Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the loader.
Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. MSW01-0805
CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.
REFERENCE INFORMATION
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
Write the correct information for Your Bobcat loader in the spaces below. Always use these numbers when referring to your Bobcat loader.
ELECTRICAL SYSTEM
Loader Serial Number . . . . . . . . . . Engine Serial Number . . . . . . . . . .
ENGINE SERVICE NOTES:
TECHNICAL DATA
SPECIFICATIONS
YOUR LOADER DEALER: ADDRESS: PHONE:
i
440, 443 & 443B Loader Service Manual
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. A general inspection of the following items must be made after the loader has had service or repair: 1. Check that the ROPS/FOPS (Including sidescreens) is in good condition and is not modified.
9. Enclosure door latches must open and close freely.
2. Check that ROPS mounting hardware is tightened and is Melroe approved.
10. Bob–Tach wedges and linkages must function correctly and be in good condition.
3. The seat belt must be correctly installed, functional and in good condition.
11. Safety treads must in good condition.
4. The seat bar and pedal interlocks must be correctly adjusted, clean and lubricated.
12. Check for correct function of indicator lamps (Optional on some models).
5. Machine signs must be legible and in the correct location.
13. Check hydraulic fluid level, engine oil level and fuel supply.
6. Steering levers and foot pedals must return to neutral.
14. Inspect for fuel, oil or hydraulic fluid leaks.
7. Check for correct funtion of the work lights.
15. Lubricate the loader.
8. The parking brake function correctly.
16. Check the condition of the battery and cables.
must
iii
440, 443 & 443B Loader Service Manual
17. Inspect the air cleaner for damage or leaks. Check the condition of the element.
18. Check the electrical charging system.
19. Check tires for wear and pressure.
20. Inspect for loose or broken parts or connections.
21. Operate the loader and check all functions.
22. Check for any field modification not completed.
Recommend to the owner that all necessary corrections be made before the machine is returned to service.
iv
440, 443 & 443B Loader Service Manual
SAFETY INSTRUCTIONS
Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.
W–2003–1289
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 mainte-
nance 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.
Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.
This notice identifies procedures which must be followed to avoid damage to the machine. I–2019–0284
W–2044–1285
Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this symbol follow the safety message to avoid personal injury or death.
v
440, 443 & 443B Loader Service Manual
SAFETY INSTRUCTIONS (Cont’d) 440,443,443B ServiceManual#6566694–ContentsSection
• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing protection or loader special applications kit are required for some work. See your dealer for Melroe Safety equipment.
• Know where fire extinguishers and first aid kits are located and how to use them. • Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.
• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating.
• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.
• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti–freeze. • Do not use ether or starting fluids on engines which have glow plugs. These starting aids can cause explosion and injure you or bystanders.
• Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.
• Stop the engine and let it cool before adding fuel. No smoking! • Use the procedure in the Operation & Maintenance or Service Manuals for connecting the battery. • Use the procedure in the Operation & Maintenance or Service Manuals for cleaning the spark arrestor muffler. A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].
A
P–3705
vi
440, 443 & 443B Loader Service Manual
PREVENTIVE MAINTENANCE Page Number
PREVENTIVE MAINTENANCE
ENGINE SERVICE Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 Engine Cooling System (440) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 Engine Cooling System (443 & 443B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Replacement of The Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 FINAL DRIVE TRANSMISSION (CHAINCASE) Checking & Adding Chaincase Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19 ELECTRICAL SYSTEM Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 Install a New Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15 Using an Extra Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 HYDRAULIC/HYDROSTATIC SYSTEM Checking & Adding Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 Removing the Hydraulic/Hydrostatic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 1–19 Replacing the Hydraulic Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 LIFT ARM SUPPORT DEVICE Installing the Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24 LUBRICATION OF THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 PREVENTIVE MAINTENANCE Delivery Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Serial Number Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 ROLL OVER PROTECTIVE STRUCTURE Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24 TIRE MAINTENANCE Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20 TRANSPORTING THE BOBCAT LOADER Loading the Bobcat Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23 Fastening the Loader to the Transport Vehicle . . . . . . . . . . . . . . . . . . . . 1–23
–1–1–
440, 443 & 443B Loader Service Manual
SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader. Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manual when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death. W–2003–1289
443 440 443B
SERVICE REQUIRED
ITEM Engine Air Cleaner
Empty the dust cup.
Engine Oil
Check level & add oil as needed.
Engine Cooling System
Check & clean as needed (Including oil cooler).
Engine Cooling System
Check coolant level in recovery tank.
Tires
Check air pressure & check for damage.
Indicators & Gauges
Check for correct operation of all indicators, switches and lights.
Seat Belt & Seat Bar
Check the condition of seat belt. Check the seat bar, when raised it must lock both pedals.
Safety Signs (Decals)
Check for damaged signs (decals). Replace any signs (decals) that are not in correct location.
All Loader Pivot Pins
Add grease to the fittings until extra grease shows.
Hydraulic/Hydrostatic Fluid
Check fluid level in the reservoir & add fluid as needed.
Engine Oil
Replace the engine oil.
Engine Air Cleaner
Replace the filter element.
Engine Air Shrouding
Remove & clean shrouding & cooling fins.
Engine Oil & Filter
Replace engine oil & filter.
Battery
Check cables & water level.
Control Pedals & Steering Linkage
Check operation. Make repairs & adjustments as needed.
Bob–Tach
Check locking lever & wedges for condition & operation.
Wheel Nuts
Check for loose wheel nuts (See Page 1–17).
Parking Brake
Check operation. Make adjustment as needed.
Alternator Belt
Check tension, make adjustment as needed.
Engine Fuel Filter
Remove water from the filter.
Engine Ignition System
Check & clean spark plugs.
Hydraulic/Hydrostatic Filter Element
Replace the filter element.
Spark Arrestor Muffler
Clean the spark chamber.
Steering Levers
Lubricate the grease fittings.
Engine Fuel Filter
Remove & replace the filter element.
Engine Ignition System
Check points & timing. Replace spark plugs.
Engine Compression
Check the compression.
Engine Valves
Check & set clearance at valves.
Cylinder Head
Service
Starter Drive
Service
Chaincase
Replace the fluid.
Hydraulic/Hydrostatic Reservoir
Replace the fluid & filter element.
8–10
25
50
100
250 500 1000
More often in dusty conditions. 250 hours when leaded gasoline is used. –1–3–
440, 443 & 443B Loader Service Manual
PREVENTIVE MAINTENANCE
A
The Preventive Maintenance Section of this Service Manual gives general maintenance procedures. The other sections of the Service Manual will give the detailed description needed for disassembly and assembly and when replacement parts are needed. Serial Number Identification It is important to make correct reference to the Serial Number of the Bobcat loader and/or engine when making repairs or ordering parts. It is possible that the present loaders do not use all the same parts as the earlier loaders. It is possible that different procedures are used for service repair.
B–6085
Loader Serial Number
B
The Bobcat loader serial number plate location is in the operator cab area on the right fender and in front of the seat [A].
440
Explanation of the Serial Number
XXXX
M
XXXX Production Sequence (Series) B–6213
Factory Use Only Model, Engine Version
C
Engine Serial Number
443
The engine serial number for the 440 Bobcat loader is located on the blower housing at the front side of the engine [B]. The engine serial number for the 443 Bobcat loader is located at the front of the engine on the fuel injection pump housing [C].
B–6183
Delivery Report
D
The Delivery Report [D] is to be filled out by the dealer and signed by the power/operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely.
–1–4–
440, 443 & 443B Loader Service Manual
ENGINE SERVICE (General)
A
AVOID INJURY OR DEATH Stop, cool and clean engine of flammable material. Never service or adjust loader with engine running unless instructed to do so in manual.
W–2061–0887 B–9035
Open the rear door to service the engine. Pull the latch pin (rotate clockwise) on the left side of the rear door [A].
B
Open the rear door to the right.
440
Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander. W–2020–1285
Air Cleaner Service
B–6131
440 – Bobcat Loader
C
It is important to service the air cleaner cup at regular intervals for good engine performance and long service life. Remove the dust cup [B] every day and clean it.
440
Replace the air filter element every 50 hours of loader operation or more if the loader is operated in dusty conditions. To replace the air cleaner element, use the following procedure: NOTE: Contamination can enter the system whenever the element is removed. DO NOT use air pressure to clean the air filter housing or the filter element.
B–6132
Loosen the clamp and remove the dust cup [B]. Remove the wing nut and remove the filter element from the air cleaner [C]. Clean the inside of the air cleaner housing so that the filter element has a smooth surface to contact at the seal. Check the filter housing for holes from corrosion, especially if the Bobcat loader is used in fertilizer application. Install a new filter element [C] and tighten the wing nut. Install the dust cup [B] and tighten the clamp. Check to make sure that all the hoses and clamps are tight. –1–5–
440, 443 & 443B Loader Service Manual
ENGINE SERVICE (Cont’d)
A
Air Cleaner Service (Cont’d)
443
443 Bobcat Loader It is important to service the air cleaner cup at regular intervals for good engine performance and long service life. Remove the dust cup [A] every day and clean it. Replace the air filter element every 50 hours of loader operation or more often if the loader is operated in dusty conditions. To replace the air cleaner element, use the following procedure:
B–6141
NOTE: Contamination can enter the system whenever the element is removed. DO NOT use pressure to clean the air filter housing or the filter element.
B 443B 1
Loosen the clamp and remove the dust cup [A]. Remove the rubber cup (Item 1) [B] and remove the dirt from the dust cup.
P–0772
Remove the wing nut and remove the filter element from the air cleaner housing [C].
C
Clean the inside of the air cleaner housing so that the filter element has a smooth surface to contact at the seal. Check the filter housing for holes from corrosion, especially if the bobcat loader is used in fertilizer application.
443
Install a new filter element [C] and tighten the wing nut. Install the dust cup [A] and tighten the clamp. Check to make sure that all the hoses and clamps are tight. B–6109
–1–6–
440, 443 & 443B Loader Service Manual
ENGINE SERVICE (Cont’d)
A
Fuel System
ON
OFF
Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire. W–2063–0887 B–6099
Use 85 octane unleaded or regular gasoline in the engine of the 440 Bobcat loader.
B
Use only clean, high quality fuel. Use number 2 diesel fuel above 40°F (4°C) in the engine of the 443 & 443B Bobcat loaders. During temperatures below 40°F, number 1 fuel is recommended.
440 3
2
1
NOTE: The fuel gauge and fuel shut–off valve are located on the right side of the loader [A]. the fuel filler cap (Item 1 [440] [B]) or (Item 1 [443] [C]) are located on the left side of the bobcat loader. Remove the filler cap (Item 1 [B], [440] or, Item 1 [C] [443]) to service the fuel tank as follows:
B–6100
C
Use clean, approved safety containers to add the fuel.
443 The engine must be STOPPED and cool.
1
Add fuel only in an area that has a free movement of air and NO open flames or sparks. NO SMOKING [D]. Use only clean fuel of the correct specifications. Tighten the cap on the fuel tank.
B–6142
Fuel Filter 440 Bobcat Loader
D
There is a fuel filter (Item 2) [B] in the fuel line by the fuel tank. The fuel filter must be replaced every 250 hours of loader operation.
WRONG
Remove the fuel filter, replace with a new filter, make sure all the connections are tight. NOTE: The electrical fuel solenoid (Item 3) [B] is located by the fuel filter.
B–6108
–1–7–
440, 443 & 443B Loader Service Manual
ENGINE SERVICE (Cont’d)
A
Fuel Filter (Cont’d)
440
443, 443B Bobcat Loader There is a fuel filter located on the right hand side of the engine compartment. Replace the fuel filter every 250 hours of loader operation. See Section 7B for the correct replacement procedure. Engine Lubrication System Check the oil level each day.
B–6128
To check the oil level, stop the engine. Open the rear door and remove the dipstick [A] or [B].
B
NOTE: 443, 443B ONLY – The dipstick may indicate an incorrect level of oil when first removed because of pressure in the crankcase. Always (1) Remove the dipstick, (2) wipe the dipstick, (3) insert dipstick again and (4) recheck the oil level.
443
Keep the oil level between the marks on the dipstick [C]. DO NOT fill above the top mark. Use a good quality motor oil that meets API Standard Classification. (See the Chart Below.) Replacement of the Engine Oil and Filter B–6147
440 – Replace engine oil every 25 hours of loader operation. (S/N 25000 & Above) replace engine oil every 50 hours of operation.
C
NOTE: Use only straight SAE 30 above 32°F/ (0°C.) in 440 engine.
Keep Oil Level Between These Marks
443 – Replace the engine oil and filter every 100 hours of loader operation. RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE)
A–1528
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (GASOLINE: USE API CLARIFICATION SE or SF) (DIESEL: USE API CLASSIFICATION CC or CD)
–1–8–
440, 443 & 443B Loader Service Manual
ENGINE SERVICE (Cont’d)
A
Replacement of the Engine Oil Filter (Cont’d) 440 Bobcat Loader NOTE: Do Not use multi–viscosity oils in gasoline engine except when ambient temperature is below 32°F. (0°C.). Run the engine until it is at operating temperature. Stop the engine and open the rear door. Remove the drain plug [A].
B–6127
After all the oil is removed from the engine, install the oil plug and tighten.
B Remove the oil fill cap [B].
B–6129
Add the correct amount of oil to the engine [C]. (See Oil Chart for the correct oil.)
C
Install the oil fill cap and tighten. Start the engine and let it run for several minutes. Stop the engine. Check the oil level. Add oil if the level is not at the top mark on the dipstick.
B–6130
–1–9–
440, 443 & 443B Loader Service Manual
ENGINE SERVICE (Cont’d)
A
443, 443B Bobcat Loader Operate the engine for about 15 minutes. Stop the engine and open the rear door. Remove the oil drain plug (Item 1) [A] from the end of the hose. Remove all the oil from the engine. Remove the oil filter (Item 2) [A] with an oil filter wrench.
2
Clean the filter housing surface. Put clean oil on the gasket of the new filter. Install the filter and tighten the filter by hand only.
1 B–6144
Install the plug in the hose and tighten. Remove the oil fill cap.
B
Add the correct amount of oil to the engine [B]. (See the Oil Chart for the correct oil.)
443 & 443B
Install the oil fill cap and tighten. Start the engine and let it run for several minutes. Stop the engine. Check for leaks at the filter. Check the oil level. Add oil if the level is not at the top mark on the dipstick.
B–6148
–1–10–
440, 443 & 443B Loader Service Manual
ENGINE SERVICE (Cont’d)
A
Engine Cooling System (440) The loader uprights and the engine cooling fins must be kept clean and free of debris or over–heating will result.
Wear safety glasses to prevent eye injury when any of the following conditions exist:
• • • •
B–6212
When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used.
B
W–2019–1285
Use air pressure or water spray to clean the loader uprights [A]. Remove the shrouding on the engine to clean the cooling fins [B]. Make sure you wear safety goggles when using air pressure or water spray for cleaning.
B–6210
C
Use a brush and a scraper tool to remove the hard deposits on the cooling fins [C].
Never run the engine with any of the covers or air ducts removed. Overheating can damage the engine and hydraulic/hydrostatic system. I–2020–1285
B–6211
D
Use air pressure or water spray to clean the hydraulic/hydrostatic oil cooler [D].
B–6215
–1–11–
440, 443 & 443B Loader Service Manual
ENGINE SERVICE (Cont’d)
A
Engine Cooling System (443 & 443B) The cooling system has a coolant recovery tank. The location of the tank is on the right upright in the engine compartment [A]. The coolant recovery tank must be 1/3 full. PROPYLENE GLYCOL Add premixed coolant, 47% water and 53% propylene glycol to the recovery tank if the coolant level is low. One gallon and one pint of propylene glycol mixed with one gallon of water is the correct mixture of coolant to provide a –34°F (–37°C) freeze protection.
B–6150
B
ETHYLENE GLYCOL Add premixed coolant, 50% water and 50% ethylene glycol to the recovery tank if the coolant level is low. To remove the coolant from the system, use the following procedure:
B–6393
Do not remove radiator cap when the engine is hot. You can be seriously burned. W–2070–1285
C
Raise the operator cab. (See Page 5–1 for the correct procedure.) Open the coolant valve on the front side of the engine block [B]. Connect a hose to the valve to keep the coolant from getting into the engine compartment. Remove the radiator cap [C]. Turn the valve to the off position after all the coolant is removed from the system. B–6185
Fill the radiator and install the radiator cap [C]. Fill the coolant recovery tank 1/3 full [A].
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440, 443 & 443B Loader Service Manual
ELECTRICAL SYSTEM
A
Electrical System Service
Water and Baking Soda Solution
Check the battery cables and make sure they are clean and tight. Check the water level of the battery. Remove any acid or corrosion from the battery and cables with a sodium bicarbonate and water solution [A]. Cover the battery terminals and cables with grease. Check the tension of the alternator belt. (See Section 6 for the correct procedure.) Check all wires for being broken or open wires.
A–2741
NOTE: The warning lights (on the dash panel) will come ON (transmission light only on 440) when the key switch is turned ON. When the engine is started, the warning lights must go OFF. If they do not, stop the engine and find the problem.
Using an Extra Battery (Jump Starting)
Keep arcs, sparks, flames and lighted tobacco away from batteries. When ‘‘jumping’’ from booster battery make final connection (negative) at engine frame. Do not jump start or charge a frozen battery. Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Battery gas can explode and cause serious injury.
W–2066–0490
If it is necessary to use an extra battery to start the engine, BE CAREFUL! This is a two–person operation. There must be one person in the operator’s seat and one person to connect and disconnect the battery cables.
Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body. In case of acid contact, wash immediately with water for several minutes and get medical attention in case of eye contact. W–2065–1286
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440, 443 & 443B Loader Service Manual
ELECTRICAL SYSTEM (Cont’d)
A
Using An Extra Battery (Jump Starting) (Cont’d)
440
The ignition must be in the OFF position. The battery must be 12 volt. Connect the end of the first cable to the positive terminal (+) of the booster battery. Connect the other end of the same cable to the loader battery positive (+) terminal [A] & [B]. Connect the end of the second cable to the negative terminal (–) of the booster battery. Connect the other end of second cable to the engine [A] & [B].
B–9083
Keep the cables away from moving parts.
B
Start the engine. After the engine has started, remove the ground cable connected to the engine first.
443 & 443B
Remove the cable connected to the loader battery.
Keep arcs, sparks, flames and lighted tobacco away from batteries. When ‘‘jumping’’ from booster battery make final connection (negative) at engine frame.
P–0766
Do not jump start or charge a frozen battery. Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Battery gas can explode and cause serious injury.
W–2066–0490
Damage to the alternator can occur if:
• Engine is operated with battery cables disconnected.
• Battery cables are connected when using a •
fast charger or when welding on the loader (Remove both cables from the battery). Extra battery cables (booster cables) are connected wrong. I–2023–1285
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440, 443 & 443B Loader Service Manual
ELECTRICAL SYSTEM (Cont’d)
A
Installing a New Battery NOTE: See Page 6–6 for more information on removing and replacing batteries.
Remove the negative battery cable from the battery first, using a cable puller [A]. Remember the position of the battery cables so you can connect the cables correctly when installing the battery. B–3709
Remove the battery hold–down clamps [B] or [C]. Remove the battery from the compartment.
B 440
B–6096
C 443
B–6110
Clean the terminal posts and the ends of the battery cables [D].
D
Install the new battery in the battery compartment. Install the holddown clamps. Install the positive battery cable first and tighten. Connect the negative cable last to prevent sparks.
P–0746
–1–15–
P–0744
440, 443 & 443B Loader Service Manual
SPARK ARRESTOR MUFFLER
A
The spark arrestor muffler must be cleaned every 100 hours of loader operation.
440
Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles. Failure to obey can cause serious injury.
W–2011–1285 B–6101
Open the rear door.
B
Remove the plug at the bottom of the muffler [A] or [B].
443
Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death. W–2068–1285 B–6146
Hold a block of wood over the outlet of the muffler. Start the engine and run at high idle for 10 seconds. Stop the engine and install the plug. Close the rear door.
This loader is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation. If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC. Make reference to local laws and regulations for spark arrestor requirements. I–2022–1285
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440, 443 & 443B Loader Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM
A
The hydraulic system must be approached with great care. Hydraulic pressure can drive hydraulic fluid through the skin. Never check for leaks in a hydraulic system with your bare hands. Use a piece of wood or piece of cardboard [A]. If the skin is penetrated by a fluid under pressure, consult a qualified medical service.
B–6596
Wear safety glasses to prevent eye injury when any of the following conditions exist:
• • • •
B
When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used. W–2019–1285
NOTE: For more information on the Hydraulic System, see Section 2 and for more information on the Hydrostatic System, see Section 3 of this Service Manual. Replacing the Hydraulic Filter Element
B–6102
The tool listed will be needed to do the following procedure:
C
MEL1183 Filter Wrench Replace the hydraulic filter element every 100 hours of loader operation or as needed. To replace the filter element, use the following procedure: Stop the engine. Raise the operator cable. (See Page 5–1 for the correct procedure.) Clean the area around the filter housing [B]. The plug is located on the outside of the loader on the right side. Remove the plug from the filter housing [C]. This plug is removed so the fluid will drain from the filter element.
B–6104
Remove the filter element with a filter wrench. Clean the surface of the filter housing head where the filter element seal contacts the filter housing. Install the plug [C]. Install the filter element and hand tighten only. Check the fluid reservoir and add fluid as needed.
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440, 443 & 443B Loader Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)
A
Checking & Adding Hydraulic Fluid
440
Use only recommended fluid in the hydraulic/hydrostatic system. (See Specifications Page 8–25 for the correct fluid.) Put the loader on a level surface. Lower the lift arms and tilt the Bob–Tach fully backward. Stop the engine. Open the rear door. Remove the dipstick at the reservoir full tube [A] or [B].
B–6125
NOTE: Always (1) remove the dipstick, (2) wipe the dipstick, (3) insert the dipstick again and (4) then recheck the fluid level.
B 443
B–6145
C
If the fluid level is not at the top mark, add the correct fluid [C] or [D] to the reservoir until the fluid is at the top mark on the dipstick. Install the dipstick.
440
B–6126
D 443
B–6149
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440, 443 & 443B Loader Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)
A
Removing the Hydraulic/Hydrostatic Fluid The hydraulic/hydrostatic fluid must be replaced every 1000 hours of loader operation. Replace the hydraulic/hydrostatic fluid more often if it becomes dirty or after any major repairs. Open the rear door. Remove the fill cap/dipstick from the reservoir fill tube [A]. Remove the nut which fastens the reservoir fill tube to the loader frame.
B–6125
Loosen the hose clamp and turn the fill tube down to drain the fluid from the reservoir [B].
B–6145
B
After the fluid is removed put the fill tube in the correct position, tighten the hose clamp and hold down nut. Raise the operator cab. (See Page 5–1 for the correct procedure.)
P–0785
C
Remove the hydraulic filter element and install a new filter element [C]. Add hydraulic/hydrostatic fluid to the reservoir. (See Page 1–18.) DO NOT fill above the top mark on the dipstick. Lower the operator cab. (See Page 5–1 for the correct procedure.) Operate the loader through all the functions and then check the fluid level again.
FINAL DRIVE TRANSMISSION (CHAINCASE) B–6102
The chaincase is filled with the same type of fluid as the hydraulic/hydrostatic system for the chain lubrication. (See Page 8–1 for the correct fluid.)
D
Checking/Adding Chaincase Fluid
440
443
Put the Bobcat loader on a level surface. Stop the engine and lower the lift arms. Remove the plug at the front of the chaincase housing [D]. Add fluid through the check plug hole until the fluid flows from the check plug hole. Install the plug and tighten. B–6105
–1–19–
B–6187
440, 443 & 443B Loader Service Manual
TIRE MAINTENANCE
A
Check the tires regularly for wear, damage and correct tire pressure. (See Page 8–4 for the correct tire pressure.) Tire Rotation When two tires become worn more than the other two tires, put the two worn tires on the same side of the loader. To keep tire wear even, rotate the front tires to the rear and the rear tires to the front [A]. Tires must be the same size and pressure for the best handling of the loader. If the tires are worn different amounts the loader durability is improved by matching pairs of tires on each side of the loader.
C–1965R
Recommended tire pressure must be maintained to avoid loss of stability and handling capability. Tire pressure must be checked regularly. The operating pressure is listed under the loader specifications for the recommended tire size. Tires are sometimes inflated above or below operating pressure for shipping, check for the correct pressure before operating the loader. If the tires are changed on the rims, it is important during mounting to avoid excess pressure which can cause rupture of the tire and serious personal injury. During inflation of the tire, check the tire pressure frequently with a pressure gauge to avoid over inflation.
Do not inflate tires above specified pressure. Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death. W–2078–1285 Before tire is mounted, the rim must be clean and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire on the rim to avoid damage to the tire and rim. Wheel Nuts Check the wheel nuts for correct tightness every 8 hours curing the first 20 hours of loader operation and every 50 hours after that. The correct torque is 40–45 ft.–lbs. (54–61 Nm) torque.
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440, 443 & 443B Loader Service Manual
LUBRICATION OF THE LOADER
A
Lubricate the Bobcat loader as specified in the Service Schedule on Page 1–4 for the best performance of the loader. See Figure [A] for the location of the grease fittings. Always use a good quality lithium based multi–purpose grease when you lubricate the Bobcat loader. Apply lubrication until extra grease shows. Lubricate the seat rails for easy movement when adjusting the seat.
NOTE: Raise the operator cab to lubricate some of the grease fittings. (See Page 5–1 for the correct procedure.)
6561387
Lubricate the pivot bearings every 500 hours of loader operation [B]. Add oil as needed to the steering control shaft [C].
B
B–6204
B–6203
C
B–6205
–1–21–
440, 443 & 443B Loader Service Manual
ROLL OVER PROTECTIVE STRUCTURE (ROPS & FOPS)
A
EARLY MODELS
Operator Cab The Bobcat loader has an operator cab as standard equipment. The operator cab protects the operator from roll over and falling objects.
Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Melroe Company. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.
6565933
B
CURRENT MODELS
W–2069–1285
Stop the loader on a level surface. Lower the lift arms fully. Stop the engine and engage the brake. Put jackstands under the rear of the loader. Remove the two fasteners at the front corners of the operator cab [A] or [B].
MC–1973
NOTE: See Raising the Operator Cab Page 5–1.
–1–22–
440, 443 & 443B Loader Service Manual
TRANSPORTING THE BOBCAT LOADER
A
Loading the Bobcat Loader Metal ramps are available to be used to load the Bobcat loader onto a transport vehicle.
Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.
B–6198
B
W–2058–0494
440 A loader with empty bucket or no attachment must be loaded backward onto the transport vehicle [A]. Fastening the Loader to the Transport Vehicle Lower the bucket or attachment to the floor and stop the engine. Engage the parking brake. B–6200
Install the chains to hold the Bobcat loader in position to prevent it from moving during sudden stops or when going up or down slopes.
C
Put a chain through the front axle gusset and fasten the Bobcat loader to the transport vehicle [B] & [C].
443
B–6184
Fasten the chains on the rear axle gussets on the loader and to the transport vehicle [D].
D
B–13842
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440, 443 & 443B Loader Service Manual
LIFT ARM SUPPORT DEVICE
A
440,443,443B ServiceManual#6566694–PreventiveMaintenanceSection
Never work on a machine with the lift arms up unless the lift arms are secured by a lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0991 B–6202
Installing the Lift Arm Support Device Two persons are needed to install or remove the lift arm support device. One person must be in the operator seat, with the seat belt fastened and the seat bar lowered until the lift arm is installed. Start the engine and raise the lift arms all the way up. Have the second person install the lift arm support device over the rod of one of the lift cylinders [A]. Make sure the lift arm support device is tight against the cylinder rod. Lower the lift arms until the support device is held between the lift arms and the cylinder. Stop the engine. STOPPING THE BOBCAT LOADER When you are stopping and leaving the Bobcat loader, use the following procedure: Stop the Bobcat loader on level ground. Lower the lift arms all the way down and put the edge of the bucket on the ground. Pull the engine speed control all the way backward to decrease the engine RPM. Turn the key switch to the OFF position. NOTE: On the 443 pull the stop control fully out to stop the engine. Engage the parking brake. Lift the seat bar. Move the pedals up and down until locked. Disconnect the seat belt. Make sure the hydraulic controls are in the locked position when the seat bar is raised. Remove the key from the switch to prevent operation of the Bobcat loader by unauthorized personnel.
–1–24–
440, 443 & 443B Loader Service Manual
HYDRAULIC SYSTEM Page Number CONTROL PEDAL, LINKAGE & LOCKS Installing the Control Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedal Lock Linkage (Removal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedal Lock Linkage (Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Control Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–41 2–42 2–43 2–40
LIFT CYLINDER Checking the Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27 Installation of the Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–28 Removing the Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27 HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly of the Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly of the Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection of the Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of the Hydraulic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . .
2–5 2–14 2–10 2–14 2–17 2–5 2–8
HYDRAULIC CYLINDER REPAIR Assembly of the Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–33 Disassembly of the Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31 HYDRAULIC/HYDROSTATIC RESERVOIR Installing the Hydraulic/Hydrostatic Reservoir . . . . . . . . . . . . . . . . . . . . . 2–39 Removing the Hydraulic/Hydrostatic Reservoir . . . . . . . . . . . . . . . . . . . . 2–38 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 of the Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . .
2–24 2–19 2–22 2–24 2–25 2–20 2–26
HYDROSTATIC SYSTEM INFORMATION 37° Flare Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 Straight Thread O–Ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 Tubelines and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 SEAT BAR SYSTEM Seat Bar Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–44 Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–44 TILT CYLINDER Checking the Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29 Installing the Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30 Removing the Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
–2–1–
440, 443 & 443B Loader Service Manual
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