Complete workshop repair & service manual with electrical wiring diagrams for Bobcat 440, 440B, 443, 443B Loader. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Bobcat 440, 440B, 443, 443B Loader service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

6566475 (9-96) - 440 Operation & Maintenance Manual.pdf
6566477 (11-98) - 443 Operation & Maintenance Manual.pdf
6566694 (11–95) - 440, 443, 443B Loader Service Manual.pdf
6570155 (4-97) - 440B Operation & Maintenance Manual.pdf
6570160 (1–87) - 440B Service Manual.pdf
6722481 (3-99) - 443B Operation & Maintenance Manual.pdf

EXCERPT:
PARKING BRAKE
Parking Brake Adjustment
To adjust the parking brake use the following procedure:
Raise the operator cab. (See Page 5–1 for the correct procedure.)
Remove the front panel from the steering levers [A].
Remove the brake cover [B].
Remove the nut from the end of the brake linkage [C].
Remove the brake cover from the linkage rod.
Install the brake linkage rod and nut.
Remove or add shims (Item 1) [D] between the brake calipers so there is 1/2’’ (12,7 mm) of movement at the brake lever (Item 2) [D].
Loosen the locknut at the pedal linkage and adjust so there is 1/4’’ (6,35 mm) (Item 3) [D] at the nut and pivot mounting of the pedal. Tighten the locknut.
Remove the nut from the brake linkage. Install the brake cover. Connect the brake linkage and install the nut [C].
Install the brake cover and bolts [B].
Install the front panel [A].
Lower the operator cab. (See Page 5–1 for the correct procedure.)
…

6556520 (06-12) - 444, 500 & Early 600 Service Manual Supplement....1
  MAINTENANCE SAFETY....3
  CONTENTS....5
    FOREWORD....5
  HYDRAULIC SYSTEM....7
    HYDRAULIC SYSTEM....9
    CHANGING AND ADDING HYDRAULIC OIL....9
    DRAINING CONDENSATION....9
    DESCRIPTION OF HYDRAULIC CIRCUIT....9
    OIL FILTRATION....9
    TUBLINES, HOSES, FITTING....10
      37° Flare Connection....10
      Straight Thread O-Ring Fitting (Elbow, Adapter, Etc.)....10
      Pipe Thread Fittings....10
      Tubelines and Hoses....10
    HYDRAULIC SYSTEM (444 & 500)....11
    CHANGING HYDRAULIC OIL FILTER ELEMENT....11
    CHECKING THE OVERALL CONDITION OF HYDRAULIC SYSTEM....14
    CHANGING MASTER RELIEF SETTING....16
    CARTRIDGE RELIEF PRESSURE SETTING....16
    VARIABLE SPEED VALVE....16
    VARIABLE SPEED CHECK (LOCK) VALVE....17
    CLUTCH PRESSURE RELIEF VALVE....18
    CONTROL VALVE SEAL REPLACEMENT....18
    HYDRAULIC PUMP REPAIR (Webster Pump)....21
    HYDRAULIC CYLINDER REPAIR....23
    HYDRAULIC PUMP ALIGNMENT (M–500 and M–444 Gasoline or LP Gas)....24
  ELECTRICAL SYSTEM....25
    ALTERNATOR CHARGE SYSTEM (500, 600)....27
      Installation of Equipment Solenoids....29
      Rectifier–Regulator Mounting....29
      Flywheel Alternator System....29
      Servicing the Alternator System....30
    CHECKING THE RECTIFIER AND REGULATOR....33
    STATOR CHECKS....34
  ENGINE SERVICE....39
    WISCONSIN ENGINE SERVICE (M–600)....41
      RESTORING COMPRESSION....41
      GOVERNOR ADJUSTMENT....41
      STORAGE OF ENGINES....41
      RETURNING STORED ENGINE TO SERVICE....42
      CARBURETOR ADJUSTMENT....42
      CARBURETOR RECONDITIONING....42
      LPG CARBURETOR SERVICE....46
      VAPORIZER – PRIMARY REGULATOR SERVICE....47
      SECONDARY REGULATOR SERVICE....49
      LP FUEL FILTER LOCK....51
      IGNITION TIMING....51
      DISTRIBUTOR MAINTENANCE....52
      SPARK PLUG....52
      HIGH TEMPERATURE SAFETY SWITCH....52
      ENGINE RECONDITIONING....53
      ACCESSORIES....53
      FLYWHEEL....53
      AIR SHROUDING....53
      CARBURETOR & MANIFOLDS....53
      CYLINDER HEAD....53
      GEAR COVER....54
      CAMSHAFT GEAR....54
      IDLER GEAR AND SHAFT....54
      OIL PAN....54
      OIL PUMP....54
      PISTONS AND CONNECTING RODS....54
      PISTON RINGS....55
      CYLINDER BLOCKS....55
      VALVES & SEAT INSERTS....56
      CRANKSHAFT....57
      CAMSHAFT....57
      VALVE TAPPETS....57
      TECHNICAL DATA (Wisconsin)....58
        FITS & CLEARANCES....58
        TORQUE VALUES....58
      Untitled....59
    ONAN ENGINE SERVICE (444)....63
      ENGINE OIL....63
      CRANKCASE BREATHER....63
      GOVERNOR & SPEED CONTROL....63
      CARBURETOR ADJUSTMENT....63
      CARBURETOR RECONDITIONING (Gasoline)....63
      FUEL PUMP....64
      CARBURETOR RECONDITIONING (LP Gas)....64
      VAPORIZER – PRIMARY REGULATOR SERVICE....65
      VALVE SYSTEM....66
      TAPPET ADJUSTMENT....66
      IGNITION TIMING....67
      SPARK PLUGS....67
      ENGINE RECONDITIONING....69
      TECHNICAL DATA (Onan)....74
        FITS & CLEARANCES....74
        TORQUE VALUES....74
    KOHLER ENGINE SERVICE (500)....77
      ENGINE OIL....77
      COMPRESSION CHECK....77
      CRANKCASE BREATHER....77
      GOVERNOR & SPEED CONTROL....77
      CARBURETOR ADJUSTMENT....78
      CARBURETOR RECONDITIONING....78
      ELECTRIC FUEL PUMP SERVICE....81
      CARBURETOR ADJUSTMENTS (LPG)....81
      CARBURETOR RECONDITIONING (LP Gas)....82
      VAPORIZER–PRIMARY REGULATOR SERVICE....84
      IGNITION TIMING....85
      USING TIMING LIGHT....85
      MAGNETO SERVICE....85
      ELECTRICAL SYSTEM....86
      ENGINE RECONDITIONING....89
      TECHNICAL DATA (Kohler)....97
        RUNNING CLEARANCES....97
        OIL PUMP....97
        MAGNETO IGNITION....97
        TORQUE VALUES....98
  SERVICE MANUAL REVISIONS....99
    600-01....99
    600-02....101
6566475 (9-96) - 440 Operation & Maintenance Manual....103
  OPERATOR SAFETY WARNINGS....105
  FOREWORD....107
    CONTENTS....107
    SAFETY INSTRUCTIONS....109
      Safety Is Your Responsibility....109
      Before You Operate The Bobcat Loader....109
      Safe Operation Needs A Qualified Operator....110
    FIRE PREVENTION....110
    SERIAL NUMBER LOCATION....111
      Loader Serial Number....111
      Engine Serial Number Location....111
    DELIVERY REPORT....111
    440 BOBCAT SKIDSTEER LOADER IDENTIFICATION....112
    REFERENCE INFORMATION....107
  OPERATING INSTRUCTIONS....113
    SEAT BAR SYSTEM....114
      Inspection Of The Seat Bar System....114
      Service The Seat Bar System....114
    OPERATING INSTRUCTIONS....115
    CONTROLS....116
    DASH PANEL....119
    THROTTLE CONTROL....119
    CHOKE CONTROL....119
    PARKING BRAKE....119
    STOPPING THE ENGINE....120
    STEERING LEVERS....120
    HYDRAULIC CONTROLS....121
      Foot Pedals (Hydraulic)....121
      Lift Arm Operation....121
      Float Position....121
      Tilt (Bucket) Operation....121
      Auxiliary Lever Operation....122
    BEFORE YOU START THE ENGINE....123
    STARTING THE ENGINE....124
      Normal Starting Condition....125
      Cold Temperature Starting Condition....125
    ATTACHMENTS AND BUCKETS FOR THE BOBCAT LOADER....126
      Installation Of Attachments....127
      Removal Of Attachments....127
    OPERATING PROCEDURES....128
      Filling The Bucket....129
      To Empty The Bucket....129
      Digging Into The Ground....130
      Making The Ground Level....130
      Filling A Hole....130
    PARKING THE BOBCAT LOADER....131
    TRANSPORTING THE BOBCAT LOADER....131
    LIFT ARM SUPPORT DEVICE....132
    LIFTING THE OPERATOR CAB....132
    LOWERING THE OPERATOR CAB....133
    LIFTING THE BOBCAT LOADER....134
  PREVENTIVE MAINTENANCE....135
    MAINTENANCE SAFETY....136
    SERVICE SCHEDULE....137
    ENGINE SERVICE....138
    AIR CLEANER SERVICE....138
    FUEL SYSTEM....139
    FUEL SYSTEM SERVICE....139
    FUEL FILTER....139
    ENGINE LUBRICATION SYSTEM....140
    REPLACEMENT OF ENGINE OIL....140
    ENGINE COOLING SYSTEM....141
    ELECTRICAL SYSTEM....141
      Electrical System Service....144
    USING AN EXTRA BATTERY....144
    INSTALLING A NEW BATTERY....145
    SPARK ARRESTOR MUFFLER....145
    HYDRAULIC/HYDROSTAIC SYSTEM....146
    REPLACEMENT OF THE HYDRAULIC FILTER ELEMENT....148
    HYDRAULIC/HYDROSTATIC FLUID RESERVOIR....148
      Checking And Adding Fluid....148
      Removing The Hydraulic/Hydrostatic Fluid....149
    FINAL DRIVE TRANSMISSION (CHAINCASE)....149
    TIRE MAINTENANCE....149
      Tire Rotation....149
      Wheel Nuts....150
    LUBRICATION OF THE BOBCAT LOADER....150
    OPERATOR CAB (ROPS & FOPS)....151
    BOB-TACH....151
    PIVOT PINS....151
    BRAKE PEDAL ADJUSTMENT....152
  TROUBLESHOOTING....153
    TROUBLESHOOTING....155
    Troubleshooting The Engine....155
    Troubleshooting The Hydraulic System....156
    Troubleshooting The Drive System....157
  MAJOR PARTS....159
    MAIN FRAME....161
    PANEL, SEAT, SEAT BAR & FUEL SYSTEM....162
    BRAKES, CHAINCASE & AXLE....163
    HYDRAULIC SYSTEM....164
    HYDROSTATIC CIRCUITRY....165
    STEERING CONTROLS....166
    ROPS ELECTRICAL SYSTEM....167
    ENGINE ELECTRICAL SYSTEM....168
    ENGINE & ATTACHING PARTS....169
  WARNING SIGNS....171
    WARNING DECAL - 6565980....173
    SERVICE SCHEDULE - 6567875....174
    WARNING DECAL - 6563380....176
    WARNING DECAL - 6561380....177
    INPORTANT - 6560573....178
    WARNING DECAL - 6568646....179
  GENERAL INFORMATION....181
    440 LOADER SPECIFICATIONS....183
      Operation & Performance....183
      Engine....183
      Loader Hydraulics....184
      Electrical....184
      Drive System....184
      Capacities....184
      Tires....184
    ADDITIONAL PUBLICATIONS....185
  WARRANTY....187
6566477 (11-98) - 443 Operation & Maintenance Manual....189
  OPERATOR SAFETY WARNINGS....191
  CONTENTS....193
    REFERENCE INFORMATION....193
  FOREWORD....195
    SERIAL NUMBER LOCATIONS....197
    LOADER SERIAL NUMBER....197
    ENGINE SERIAL NUMBER....197
    DELIVERY REPORT....197
    BOBCAT LOADER IDENTIFICATION....198
  SAFETY....199
    SAFETY INSTRUCTIONS....201
      Safety Is The Operator's Responsibility....201
      Before Operating The Bobcat Loader....202
      Safe Operation Needs A Qualified Operator....202
    FIRE PREVENTION....203
    MACHINE SIGNS (DECALS)....204
  OPERATING INSTRUCTIONS....207
    INSTRUMENT PANEL....209
    ENGINE SPEED CONTROL....209
    ENGINE STOP CONTROL....209
    PARKING BRAKE....210
    STEERING LEVERS....211
    HYDRAULIC CONTROLS....212
      Foot Pedals (Hydraulics)....212
      Lift Arm Operation....212
      Tilt (Bucket) Operation....212
      Auxiliary Hydraulics Operation (Optional)....213
    DAILY INSPECTION....214
    SEAT BAR RESTRAINT SYSTEM....215
    GETTING READY FOR OPERATION....216
    STARTING THE ENGINE....217
      Normal Starting Condition....218
      Cold Temperature Starting Condition....219
      Warming The Hydraulic / Hydrostatic System....219
    ATTACHMENTS AND BUCKETS....220
      Installation And Removal....221
    OPERATING PROCEDURES....222
      Filling The Bucket....223
      Emptying The Bucket....223
      Digging Into The Ground....224
      Leveling The Ground (Using Lift Arms In Float Position)....225
      Backfilling....225
    PARKING THE BOBCAT LOADER....226
    TRANSPORTING THE BOBCAT LOADER....226
    LIFTING THE BOBCAT LOADER....227
    TOWING THE LOADER....227
  PREVENTIVE MAINTENANCE....229
    MAINTENANCE SAFETY....230
    SERVICE SCHEDULE....231
    LIFT ARM SUPPORT DEVICE....232
    OPERATOR CAB....232
      Raising The Operator Cab....232
      Lowering The Operator Cab....233
      Emergency Exit....234
    SEAT BAR SYSTEM....235
      Seat Bar Inspection....235
      Seat Bar Maintenance....235
    REAR DOOR....236
    AIR CLEANER SERVICE....236
    FUEL SYSTEM....237
      Specification....237
      Filling The Fuel System....237
      Fuel Filter....237
      Removing Air From The Fuel System....238
    ENGINE LUBRICATION SYSTEM....239
      Replacing Oil And Filter....239
    COOLANT SYSTEM....240
      Checking The Coolant Level....240
      Removing The Coolant....240
    ALTERNATOR DRIVE BELT....241
      Adjustment....241
    ELECTRICAL SYSTEM....242
      Description....242
      Electrical System Service....242
      Using A Booster Battery (Jump Starting)....242
      Battery Removal And Installation....243
    HYDRAULIC / HYDROSTATIC SYSTEM....244
      Hydraulic Filter Element Replacement....245
      Removing The Hydraulic / Hydrostatic Fluid....245
    SPARK ARRESTOR MUFFLER....246
    TIRE MAINTENANCE....247
      Wheel Nuts....247
      Tire Rotation....247
      Tire Inflation....247
    FINAL DRIVE TRANSMISSION (CHAINCASE)....248
    LUBRICATION OF THE BOBCAT LOADER....249
    BOB-TACH....250
    PIVOT PINS....251
    PARKING BRAKE ADJUSTMENT....251
  TROUBLESHOOTING....253
    TROUBLESHOOTING....255
      Troubleshooting The Engine....255
      Troubleshooting The Hydraulic System....256
      Troubleshooting The Drive System....257
  MACHINE SIGN TRANSLATIONS....259
    WARNING - 6579511....261
    SERVICE SCHEDULE - 6567875....262
    WARNING - 6579510....264
    IMPORTANT - 6560573....265
    WARNING - 6579628....266
    DANGER - 6579639....266
    WARNING - 6577754....266
    DANGER - 6579509....266
  SPECIFICATIONS....267
    LOADER SPECIFICATIONS....269
      Loader Dimensions....269
      Operation & Performance....269
      Engine....269
      Hydraulic System....270
      Electrical....270
      Drive System....270
      Capacities....270
      Tires....270
    MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES....271
    ADDITIONAL PUBLICATIONS....272
  WARRANTY....273
6566694 (06–12) - 440, 443, 443B Loader Service Manual....275
  MAINTENANCE SAFETY....277
  CONTENTS....279
    FOREWORD....281
    SAFETY INSTRUCTIONS....283
  PREVENTIVE MAINTENANCE....285
    SERVICE SCHEDULE....287
    PREVENTIVE MAINTENANCE....288
      Serial Number Identification....288
      Loader Serial Number....288
      Engine Serial Number....288
      Delivery Report....288
    ENGINE SERVICE (General)....289
      Air Cleaner Service - 440....289
      Air Cleaner Service - 443....290
      Fuel System....291
      Fuel Filter - 440....291
      Fuel Filter - 443, 443B....292
      Engine Lubrication System....292
      Engine Cooling System (440)....295
      Engine Cooling System (443 & 443B)....296
      Replacement Of The Engine Oil And Filter....292
    ELECTRICAL SYSTEM....297
      Electrical System Service....297
      Using An Extra Battery (Jump Starting)....297
      Installing A New Battery....299
    SPARK ARRESTOR MUFFLER....300
    HYDRAULIC/HYDROSTATIC SYSTEM....301
      Replacing The Hydraulic Filter Element....301
      Checking & Adding Hydraulic Fluid....302
      Removing The Hydraulic/Hydrostatic Fluid....303
    FINAL DRIVE TRANSMISSION (CHAINCASE)....303
      Checking/Adding Chaincase Fluid....303
    TIRE MAINTENANCE....304
      Tire Rotation....304
      Wheel Nuts....304
    LUBRICATION OF THE LOADER....305
    ROLL OVER PROTECTIVE STRUCTURE (ROPS &FOPS)....306
      Operator Cab....306
    TRANSPORTING THE BOBCAT LOADER....307
      Loading The Bobcat Loader....307
      Fastening The Loader To The Transport Vehicle....307
    LIFT ARM SUPPORT DEVICE....308
      Installing The Lift Arm Support Device....308
    STOPPING THE BOBCAT LOADER....308
  HYDRAULIC SYSTEM....309
    HYDRAULIC / HYDROSTATIC SCHEMATICS....311
    TROUBLESHOOTING....323
    HYDROSTATIC SYSTEM INFORMATION....324
      37° Flare Connections....324
      Straight Thread O–Ring Fitting....324
      Tubelines And Hoses....324
    HYDRAULIC CONTROL VALVE....325
      Relief Valve....325
      Removal Of The Hydraulic Control Valve....328
      Disassembly Of The Control Valve....330
      Inspection Of The Control Valve....334
      Assembly Of The Control Valve....334
      Installing The Control Valve....337
    HYDRAULIC PUMP....339
      Checking Output Of The Hydraulic Pump....339
      Removal Of The Hydraulic Pump....340
      Disassembly Of The Hydraulic Pump....342
      Inspection Of The Hydraulic Pump....344
      Assembly Of The Hydraulic Pump....344
      Installation Of The Hydraulic Pump....345
      Start Up Procedure For The Hydraulic Pump....346
    LIFT CYLINDER....347
      Checking The Lift Cylinders....347
      Removing The Lift Cylinder....347
      Installation Of The Lift Cylinder....348
    TILT CYLINDER....349
      Checking The Tilt Cylinder....349
      Removing The Tilt Cylinder....349
      Installing The Tilt Cylinder....350
    HYDRAULIC CYLINDER REPAIR....351
      Disassembly Of The Hydraulic Cylinder....351
      Assembly Of The Hydraulic Cylinder....353
    HYDRAULIC/HYDROSTATIC RESERVOIR....358
      Removing The Hydraulic/Hydrostatic Reservoir....358
    CONTROL PEDAL, LINKAGE & LOCKS....360
      Removing The Control Pedal....360
      Installing The Control Pedal....361
      Pedal Lock Linkage....362
        Removal....362
        Installation....363
    SEAT BAR SYSTEM....364
      Seat Bar Installation....364
      Seat Bar Maintenance....364
  HYDROSTATIC SYSTEM....365
    TROUBLESHOOTING....367
    HYDROSTATIC SYSTEM INFORMATION....368
      Replenishing Valves Function....368
    STEERING LEVERS....368
      Removing The Steering Levers....368
      Repairing The Steering Levers....370
      Installing The Steering Levers....371
    STEERING LINKAGE....372
      Adjusting The Steering Linkage....372
      Removing The Pintle Arms....373
      Installing The Pintle Arms....374
    PORT BLOCK....375
      Checking Charge Pressure....375
      Charge Pressure Relief Valve....376
      Cold Weather By–Pass Valve....377
      Removing The Port Block....377
      Installing The Port Block....378
    HYDROSTATIC MOTOR....379
      Removing The Hydrostatic Motor....379
      Disassembly Of The Hydrostatic Motor....381
      Hydrostatic Motor Inspection....385
      Assembly Of The Hydrostatic Motor....386
      Start Up Procedure For The Hydrostatic Motor....391
    HYDROSTATIC PUMP....392
      Removing The Hydrostatic Pumps....392
      Disassembly Of The Hydrostatic Pump....398
      Inspection Of The Hydrostatic Pumps....401
      Assembly Of The Hydrostatic Pumps....403
      Installing The Hydrostatic Pumps....408
      Hydrostatic Pump Start Up Procedure....410
    DRIVE BELT AND TENSION PULLEY....411
      Removing Tension Pulley....411
      Installing Tension Pulley....411
      Drive Belt Removal–In The Loader....412
    TOWING THE BOBCAT LOADER....413
  DRIVE SYSTEM....415
    PARKING BRAKE....417
      Parking Brake Adjustment....417
      Removing Parking Brake....418
      Inspecting The Parking Brake....419
      Installing The Parking Brake....419
    DRIVE CHAINS....421
      Removing The Drive Chain(s)....421
      Installing The Drive Chain(s)....422
    AXLES AND BEARINGS....424
      Removing The Axle(s) And Bearings....424
      Assembly Of The Axle....426
      Installing The Axle(s) And Bearings....426
    CHAINCASE FLUID....429
      Replacing Chaincase Fluid....429
  MAIN FRAME....431
    OPERATOR CAB....433
      Raising The Operator Cab....433
      Lowering The Operator Cab....434
      Jumper Start Switch....434
      Removing The Operator Cab....435
      Installing The Operator Cab....435
    LIFT ARMS....436
      Removing The Lift Arms....436
      Installing The Lift Arms....437
    BOB–TACH....438
      Removing The Bob–Tach....438
      Disassembly Of The Bob–Tach....439
      Assembly Of The Bob–Tach....441
      Installing The Bob–Tach....442
    REAR DOOR....443
      Removing The Rear Door....443
    FUEL TANK....444
      Removing The Fuel Tank....444
      Installing The Fuel Tank....444
    REAR WINDOW....445
      Installing Rear Window....445
  ELECTRICAL SYSTEM....447
    ELECTRICAL SCHEMATICS....450
    TROUBLESHOOTING....463
    ELECTRICAL SYSTEM....464
      Electrical Circuitry....464
      Safety Procedures For The Batteries....464
      Precautions For The Alternator....465
    BATTERY....466
      Removing The Battery....466
      Checking The Battery....467
      Installing The Battery....467
    OPERATOR CAB WIRE HARNESS....468
      Removing The Wire Harness....468
      Installing The Wire Harness....469
    ENGINE WIRE HARNESS....469
    ALTERNATOR SYSTEM (440)....470
      Replacing The Stator....471
    ALTERNATOR SYSTEM (443)....472
      Adjusting The Alternator....472
      Checking The Alternator (443) (Early Models)....472
      Removing The Alternator....473
      Repairing The Alternator (Early Models)....474
      Install The Alternator....476
    ALTERNATOR (Melroe)....477
      Alternator Output Test (New Style)....477
      Rectifier (Diode) Test (New Style)....477
      Alternator Regulator Test (New Style)....478
      Disassembly And Inspection (New Style)....479
      Stator Continuity Test (New Style)....479
      Stator Ground Test (New Style)....479
      Rotor Continuity Test (New Style)....480
      Rotor Ground Test (New Style)....480
      Rectifier Continuity (Diode) Test (New Style)....480
      Assembly (New Style)....481
    STARTER (440)....482
      Checking The Starter (440)....482
      Removing The Starter....483
      Repairing The Starter....484
      Installing The Starter....485
    STARTER (443)....486
      Checking The Starter (443)....486
      Removing The Starter....486
      Repairing The Starter ....487
      Installing The Starter....489
    ALTERNATOR (Motorola)....490
      Belt Tension....490
      Troubleshooting The Alternator....490
      Checking The Alternator Output....491
      Removal And Installation....492
      Disassembly And Assembly....492
  ENGINE SERVICE....499
    ENGINE SERVICE - KOHLER (440)....501
      TROUBLESHOOTING....503
      ENGINE & ATTACHING PARTS....505
        Removing The Engine (Early Model)....505
        Installing The Engine....509
        Removing The Engine (Later Model)....509
        Oil Cooler Removal....513
        Engine Muffler Removal....513
        Engine Muffler Installation....514
      IGNITION SYSTEM....515
        Spark Plugs....515
        Breaker Points....515
        Condenser....516
        Ignition Coil....516
        Static Ignition Timing....516
        Timing Light....517
        Valve & Tappet Clearance....518
        Compression Test....518
      CARBURETOR AND GOVERNOR....519
        Carburetor Adjustment On The Engine....519
          Main Fuel Adjustment....519
          Idle Fuel Adjustment....519
          Idle Speed Setting....520
          Shutdown Control Solenoid....520
        Reconditioning the Carburetor....521
          Disassembly....521
          Assembly....521
        Governor and Adjustment....522
          Adjustments....522
        Carburetor....523
        Adjusting the Carburetor....523
        Throttle Shaft....525
        Choke Shaft....525
        Float Level....526
      RECONDITIONING THE ENGINE....527
        Engine Disassembly....527
        Cylinder Head....529
        Cylinder Barrels....530
        Cylinder Bore....530
        Valves....530
        Valve Guide....530
        Valve Seat Inserts....530
        Valve Springs....530
        Piston And Piston Rings....531
        Crankshaft And Connecting Rods....531
        Connecting Rods....531
        Governor Inspection....532
        Oil Pump Inspection....532
        Assembling The Engine....532
    ENGINE SERVICE - KOHLER (443)....541
      TROUBLESHOOTING....543
      FUEL SYSTEM....545
        Replacing The Fuel Filter....545
        Removing The Air From The Fuel System....545
        Fuel Injection Pump....546
        Checking The Injection Pump....546
        Removing Injection Pump....547
          Installation....548
        Timing The Fuel Injection Pump....548
        Fuel Injector Nozzles....549
        Nozzle Removal....549
        Checking Fuel Injector Nozzles....550
        Nozzle Installation....550
        Checking Glow Plugs....551
        Engine Compression Test....551
      ENGINE & ATTACHING PARTS....552
        Removing The Engine....552
        Installing The Engine....557
        Oil Cooler & Shrouding....558
          Removal....558
          Installation....558
        Engine Radiator Removal....559
        Engine Radiator Installation....560
        Engine Blower Fan & Shrouding....561
          Installation....561
        Fan Blower & Water Pump Belt....562
          Adjustment....562
        Engine Flywheel Removal....562
        Engine Flywheel Installation....562
      CYLINDER HEAD....563
        Removing The Cylinder Head....563
        Disassembly Of The Cylinder Head....565
        Servicing The Cylinder Head....566
        Assembly Of The Cylinder Head....568
        Installing The Cylinder Head....568
      REPAIRING THE ENGINE....570
        Removing The Gear Case....570
        Removing The Timing Gear, Camshaft & Oil Pump....572
        Removing Pistons & Crankshaft....574
        Servicing The Timing Gear And Camshaft....576
        Servicing The Connecting Rods And Pistons....578
        Servicing The Crankshaft....579
        Servicing The Cylinder Liners....581
        Servicing The Oil Pump....582
        Servicing The Water Pump....582
      ASSEMBLY OF THE ENGINE....583
        Installing The Crankshaft....583
        Installing The Pistons....583
        Installing The Camshaft And Timing Gears....584
        Installing The Gearcase Cover....586
  TECHNICAL DATA....587
    440 LOADER SPECIFICATIONS....589
      LOADER DIMENSIONS....589
      OPERATIONS & PERFORMANCE....589
      ENGINE....589
      HYDRAULIC SYSTEM....590
      ELECTRICAL....590
      DRIVE SYSTEM....590
      CAPACITIES....590
      TIRES....590
    ENGINE SPECIFICATIONS – 440 (KOHLER)....591
      Engine (General)....591
      Cylinder Bore....591
      Crankshaft....591
      Camshaft....591
      Connecting Rod....591
      Piston, Pin & Rings....591
      Valves, Guides & Tappet....591
      Oil Pump....592
      Engine Torque....592
    443 LOADER SPECIFICATIONS....593
      LOADER DIMENSIONS....593
      OPERATIONS & PERFORMANCE....593
      ENGINE....593
      HYDRAULIC SYSTEM....594
      ELECTRICAL....594
      DRIVE SYSTEM....594
      CAPACITIES....594
      TIRES....594
    ENGINE SPECIFICATIONS – 443 (KUBOTA)....595
      Fuel Injector Nozzles....595
      Fuel Injection Pump....595
      Cylinder Head....595
      Valves....595
      Valve Springs....595
      Rocker Arms....595
      Camshaft....595
      Cylinders....596
      Piston Rings....596
      Pistons....596
      Crankshaft....596
      Oil Pump....596
      Thermostat....596
      Engine Torque....597
      Crankshaft Re–Grind Data....598
  SPECIFICATIONS....599
    TORQUE SPECIFICATIONS....601
      Engine Group – 440 Loader....601
      Engine Group – 443 Loader....602
      Fuel System Group....604
      Steering Controls & Panel Group....605
      Bob–Tach & Lift Arm Group....606
      Seat Bar & Pedal Group....607
      Brake, Chaincase & Axle Group....608
      Hydraulic Group (Auxiliary Hydraulic–Optional)....609
      Operator Cab, Main Frame & Rear Door Group....610
      Hydrostatic Group – 440 Loader....611
      Hydrostatic Group – 443 Loader....612
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....613
    DECIMAL AND MILLIMETER EQUIVALENTS....614
    U.S. TO METRIC CONVERSION....614
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS....615
  SERVICE MANUAL REVISIONS....617
    440-1....617
    440-2....619
    440-3....621
6566694 (11–95) - 440, 443, 443B Loader Service Manual....623
  MAINTENANCE SAFETY....625
  CONTENTS....627
    FOREWORD....629
    SAFETY INSTRUCTIONS....631
  PREVENTIVE MAINTENANCE....633
    SERVICE SCHEDULE....635
    PREVENTIVE MAINTENANCE....636
      Serial Number Identification....636
      Loader Serial Number....636
      Engine Serial Number....636
      Delivery Report....636
    ENGINE SERVICE (General)....637
      Air Cleaner Service - 440....637
      Air Cleaner Service - 443....638
      Fuel System....639
      Fuel Filter - 440....639
      Fuel Filter - 443, 443B....640
      Engine Lubrication System....640
      Engine Cooling System (440)....643
      Engine Cooling System (443 & 443B)....644
      Replacement Of The Engine Oil And Filter....640
    ELECTRICAL SYSTEM....645
      Electrical System Service....645
      Using An Extra Battery (Jump Starting)....645
      Installing A New Battery....647
    SPARK ARRESTOR MUFFLER....648
    HYDRAULIC/HYDROSTATIC SYSTEM....649
      Replacing The Hydraulic Filter Element....649
      Checking & Adding Hydraulic Fluid....650
      Removing The Hydraulic/Hydrostatic Fluid....651
    FINAL DRIVE TRANSMISSION (CHAINCASE)....651
      Checking/Adding Chaincase Fluid....651
    TIRE MAINTENANCE....652
      Tire Rotation....652
      Wheel Nuts....652
    LUBRICATION OF THE LOADER....653
    ROLL OVER PROTECTIVE STRUCTURE (ROPS &FOPS)....654
      Operator Cab....654
    TRANSPORTING THE BOBCAT LOADER....655
      Loading The Bobcat Loader....655
      Fastening The Loader To The Transport Vehicle....655
    LIFT ARM SUPPORT DEVICE....656
      Installing The Lift Arm Support Device....656
    STOPPING THE BOBCAT LOADER....656
  HYDRAULIC SYSTEM....657
    HYDRAULIC / HYDROSTATIC SCHEMATICS....659
    TROUBLESHOOTING....671
    HYDROSTATIC SYSTEM INFORMATION....672
      37° Flare Connections....672
      Straight Thread O–Ring Fitting....672
      Tubelines And Hoses....672
    HYDRAULIC CONTROL VALVE....673
      Relief Valve....673
      Removal Of The Hydraulic Control Valve....676
      Disassembly Of The Control Valve....678
      Inspection Of The Control Valve....682
      Assembly Of The Control Valve....682
      Installing The Control Valve....685
    HYDRAULIC PUMP....687
      Checking Output Of The Hydraulic Pump....687
      Removal Of The Hydraulic Pump....688
      Disassembly Of The Hydraulic Pump....690
      Inspection Of The Hydraulic Pump....692
      Assembly Of The Hydraulic Pump....692
      Installation Of The Hydraulic Pump....693
      Start Up Procedure For The Hydraulic Pump....694
    LIFT CYLINDER....695
      Checking The Lift Cylinders....695
      Removing The Lift Cylinder....695
      Installation Of The Lift Cylinder....696
    TILT CYLINDER....697
      Checking The Tilt Cylinder....697
      Removing The Tilt Cylinder....697
      Installing The Tilt Cylinder....698
    HYDRAULIC CYLINDER REPAIR....699
      Disassembly Of The Hydraulic Cylinder....699
      Assembly Of The Hydraulic Cylinder....701
    HYDRAULIC/HYDROSTATIC RESERVOIR....706
      Removing The Hydraulic/Hydrostatic Reservoir....706
    CONTROL PEDAL, LINKAGE & LOCKS....708
      Removing The Control Pedal....708
      Installing The Control Pedal....709
      Pedal Lock Linkage....710
        Removal....710
        Installation....711
    SEAT BAR SYSTEM....712
      Seat Bar Installation....712
      Seat Bar Maintenance....712
  HYDROSTATIC SYSTEM....713
    TROUBLESHOOTING....715
    HYDROSTATIC SYSTEM INFORMATION....716
      Replenishing Valves Function....716
    STEERING LEVERS....716
      Removing The Steering Levers....716
      Repairing The Steering Levers....718
      Installing The Steering Levers....719
    STEERING LINKAGE....720
      Adjusting The Steering Linkage....720
      Removing The Pintle Arms....721
      Installing The Pintle Arms....722
    PORT BLOCK....723
      Checking Charge Pressure....723
      Charge Pressure Relief Valve....724
      Cold Weather By–Pass Valve....725
      Removing The Port Block....725
      Installing The Port Block....726
    HYDROSTATIC MOTOR....727
      Removing The Hydrostatic Motor....727
      Disassembly Of The Hydrostatic Motor....729
      Hydrostatic Motor Inspection....733
      Assembly Of The Hydrostatic Motor....734
      Start Up Procedure For The Hydrostatic Motor....739
    HYDROSTATIC PUMP....740
      Removing The Hydrostatic Pumps....740
      Disassembly Of The Hydrostatic Pump....746
      Inspection Of The Hydrostatic Pumps....749
      Assembly Of The Hydrostatic Pumps....751
      Installing The Hydrostatic Pumps....756
      Hydrostatic Pump Start Up Procedure....758
    DRIVE BELT AND TENSION PULLEY....759
      Removing Tension Pulley....759
      Installing Tension Pulley....759
      Drive Belt Removal–In The Loader....760
    TOWING THE BOBCAT LOADER....761
  DRIVE SYSTEM....763
    PARKING BRAKE....765
      Parking Brake Adjustment....765
      Removing Parking Brake....766
      Inspecting The Parking Brake....767
      Installing The Parking Brake....767
    DRIVE CHAINS....769
      Removing The Drive Chain(s)....769
      Installing The Drive Chain(s)....770
    AXLES AND BEARINGS....772
      Removing The Axle(s) And Bearings....772
      Assembly Of The Axle....774
      Installing The Axle(s) And Bearings....774
    CHAINCASE FLUID....777
      Replacing Chaincase Fluid....777
  MAIN FRAME....779
    OPERATOR CAB....781
      Raising The Operator Cab....781
      Lowering The Operator Cab....782
      Jumper Start Switch....782
      Removing The Operator Cab....783
      Installing The Operator Cab....783
    LIFT ARMS....784
      Removing The Lift Arms....784
      Installing The Lift Arms....785
    BOB–TACH....786
      Removing The Bob–Tach....786
      Disassembly Of The Bob–Tach....787
      Assembly Of The Bob–Tach....789
      Installing The Bob–Tach....790
    REAR DOOR....791
      Removing The Rear Door....791
    FUEL TANK....792
      Removing The Fuel Tank....792
      Installing The Fuel Tank....792
    REAR WINDOW....793
      Installing Rear Window....793
  ELECTRICAL SYSTEM....795
    ELECTRICAL SCHEMATICS....798
    TROUBLESHOOTING....811
    ELECTRICAL SYSTEM....812
      Electrical Circuitry....812
      Safety Procedures For The Batteries....812
      Precautions For The Alternator....813
    BATTERY....814
      Removing The Battery....814
      Checking The Battery....815
      Installing The Battery....815
    OPERATOR CAB WIRE HARNESS....816
      Removing The Wire Harness....816
      Installing The Wire Harness....817
    ENGINE WIRE HARNESS....817
    ALTERNATOR SYSTEM (440)....818
      Replacing The Stator....819
    ALTERNATOR SYSTEM (443)....820
      Adjusting The Alternator....820
      Checking The Alternator (443) (Early Models)....820
      Removing The Alternator....821
      Repairing The Alternator (Early Models)....822
      Install The Alternator....824
    ALTERNATOR (Melroe)....825
      Alternator Output Test (New Style)....825
      Rectifier (Diode) Test (New Style)....825
      Alternator Regulator Test (New Style)....826
      Disassembly And Inspection (New Style)....827
      Stator Continuity Test (New Style)....827
      Stator Ground Test (New Style)....827
      Rotor Continuity Test (New Style)....828
      Rotor Ground Test (New Style)....828
      Rectifier Continuity (Diode) Test (New Style)....828
      Assembly (New Style)....829
    STARTER (440)....830
      Checking The Starter (440)....830
      Removing The Starter....831
      Repairing The Starter....832
      Installing The Starter....833
    STARTER (443)....834
      Checking The Starter (443)....834
      Removing The Starter....834
      Repairing The Starter ....835
      Installing The Starter....837
    ALTERNATOR (Motorola)....838
      Belt Tension....838
      Troubleshooting The Alternator....838
      Checking The Alternator Output....839
      Removal And Installation....840
      Disassembly And Assembly....840
  ENGINE SERVICE....847
    ENGINE SERVICE - KOHLER (440)....849
      TROUBLESHOOTING....851
      ENGINE & ATTACHING PARTS....853
        Removing The Engine (Early Model)....853
        Installing The Engine....857
        Removing The Engine (Later Model)....857
        Oil Cooler Removal....861
        Engine Muffler Removal....861
        Engine Muffler Installation....862
      IGNITION SYSTEM....863
        Spark Plugs....863
        Breaker Points....863
        Condenser....864
        Ignition Coil....864
        Static Ignition Timing....864
        Timing Light....865
        Valve & Tappet Clearance....866
        Compression Test....866
      CARBURETOR AND GOVERNOR....867
        Carburetor Adjustment On The Engine....867
          Main Fuel Adjustment....867
          Idle Fuel Adjustment....867
          Idle Speed Setting....868
          Shutdown Control Solenoid....868
        Reconditioning the Carburetor....869
          Disassembly....869
          Assembly....869
        Governor and Adjustment....870
          Adjustments....870
        Carburetor....871
        Adjusting the Carburetor....871
        Throttle Shaft....873
        Choke Shaft....873
        Float Level....874
      RECONDITIONING THE ENGINE....875
        Engine Disassembly....875
        Cylinder Head....877
        Cylinder Barrels....878
        Cylinder Bore....878
        Valves....878
        Valve Guide....878
        Valve Seat Inserts....878
        Valve Springs....878
        Piston And Piston Rings....879
        Crankshaft And Connecting Rods....879
        Connecting Rods....879
        Governor Inspection....880
        Oil Pump Inspection....880
        Assembling The Engine....880
    ENGINE SERVICE - KOHLER (443)....889
      TROUBLESHOOTING....891
      FUEL SYSTEM....893
        Replacing The Fuel Filter....893
        Removing The Air From The Fuel System....893
        Fuel Injection Pump....894
        Checking The Injection Pump....894
        Removing Injection Pump....895
          Installation....896
        Timing The Fuel Injection Pump....896
        Fuel Injector Nozzles....897
        Nozzle Removal....897
        Checking Fuel Injector Nozzles....898
        Nozzle Installation....898
        Checking Glow Plugs....899
        Engine Compression Test....899
      ENGINE & ATTACHING PARTS....900
        Removing The Engine....900
        Installing The Engine....905
        Oil Cooler & Shrouding....906
          Removal....906
          Installation....906
        Engine Radiator Removal....907
        Engine Radiator Installation....908
        Engine Blower Fan & Shrouding....909
          Installation....909
        Fan Blower & Water Pump Belt....910
          Adjustment....910
        Engine Flywheel Removal....910
        Engine Flywheel Installation....910
      CYLINDER HEAD....911
        Removing The Cylinder Head....911
        Disassembly Of The Cylinder Head....913
        Servicing The Cylinder Head....914
        Assembly Of The Cylinder Head....916
        Installing The Cylinder Head....916
      REPAIRING THE ENGINE....918
        Removing The Gear Case....918
        Removing The Timing Gear, Camshaft & Oil Pump....920
        Removing Pistons & Crankshaft....922
        Servicing The Timing Gear And Camshaft....924
        Servicing The Connecting Rods And Pistons....926
        Servicing The Crankshaft....927
        Servicing The Cylinder Liners....929
        Servicing The Oil Pump....930
        Servicing The Water Pump....930
      ASSEMBLY OF THE ENGINE....931
        Installing The Crankshaft....931
        Installing The Pistons....931
        Installing The Camshaft And Timing Gears....932
        Installing The Gearcase Cover....934
  TECHNICAL DATA....935
    440 LOADER SPECIFICATIONS....937
      LOADER DIMENSIONS....937
      OPERATIONS & PERFORMANCE....937
      ENGINE....937
      HYDRAULIC SYSTEM....938
      ELECTRICAL....938
      DRIVE SYSTEM....938
      CAPACITIES....938
      TIRES....938
    ENGINE SPECIFICATIONS – 440 (KOHLER)....939
      Engine (General)....939
      Cylinder Bore....939
      Crankshaft....939
      Camshaft....939
      Connecting Rod....939
      Piston, Pin & Rings....939
      Valves, Guides & Tappet....939
      Oil Pump....940
      Engine Torque....940
    443 LOADER SPECIFICATIONS....941
      LOADER DIMENSIONS....941
      OPERATIONS & PERFORMANCE....941
      ENGINE....941
      HYDRAULIC SYSTEM....942
      ELECTRICAL....942
      DRIVE SYSTEM....942
      CAPACITIES....942
      TIRES....942
    ENGINE SPECIFICATIONS – 443 (KUBOTA)....943
      Fuel Injector Nozzles....943
      Fuel Injection Pump....943
      Cylinder Head....943
      Valves....943
      Valve Springs....943
      Rocker Arms....943
      Camshaft....943
      Cylinders....944
      Piston Rings....944
      Pistons....944
      Crankshaft....944
      Oil Pump....944
      Thermostat....944
      Engine Torque....945
      Crankshaft Re–Grind Data....946
  SPECIFICATIONS....947
    TORQUE SPECIFICATIONS....949
      Engine Group – 440 Loader....949
      Engine Group – 443 Loader....950
      Fuel System Group....952
      Steering Controls & Panel Group....953
      Bob–Tach & Lift Arm Group....954
      Seat Bar & Pedal Group....955
      Brake, Chaincase & Axle Group....956
      Hydraulic Group (Auxiliary Hydraulic–Optional)....957
      Operator Cab, Main Frame & Rear Door Group....958
      Hydrostatic Group – 440 Loader....959
      Hydrostatic Group – 443 Loader....960
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....961
    DECIMAL AND MILLIMETER EQUIVALENTS....962
    U.S. TO METRIC CONVERSION....962
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS....963
  SERVICE MANUAL REVISIONS....965
    440-1....965
    440-2....967
6570155 (4-97) - 440B Operation & Maintenance Manual....969
  OPERATOR SAFETY WARNINGS....971
  CONTENTS....972
    REFERENCE INFORMATION....972
  FOREWORD....974
    SERIAL NUMBER LOCATIONS....976
      Loader Serial Number....976
      Engine Serial Number....976
    DELIVERY REPORT....976
    BOBCAT LOADER IDENTIFICATION....977
  SAFETY....978
    SAFETY INSTRUCTIONS....980
      Safety Is The Operator's Responsibility....980
      Before Operating The Bobcat Loader....981
      Safe Operation Needs A Qualified Operator....981
      Fire Prevention....982
    MACHINE SIGNS (DECALS)....983
  OPERATING INSTRUCTIONS....986
    OPERATING INSTRUCTIONS....988
    GETTING ON AND OFF THE LOADER....988
    GETTING READY FOR OPERATION....988
    SAFETY SIGNS (DECALS)....989
    LEARNING THE CONTROLS....990
    KEY SWITCH....990
    FUSE (IGNITION)....990
    CHOKE CONTROL....990
    ENGINE SPEED CONTROL....990
    PARKING BRAKE....990
    STEERING LEVERS....991
    HYDRAULIC CONTROLS....992
      Foot Pedals....992
      Auxiliary Lever (Optional)....992
    BEFORE STARTING THE ENGINE....993
    STARTING THE ENGINE....994
      Cold Temperature Starting....995
      Warming The Hydrostatic Transmission....995
    ATTACHMENTS & BUCKETS....996
      Bucket Or Fork Installation....997
      Bucket Or Fork Removal....997
    OPERATING PROCEDURES....998
      Filling The Bucket....999
      Emptying The Bucket....999
      Digging Into The Ground....1000
      Backfilling....1000
    STOPPING THE ENGINE AND PARKING THE LOADER....1001
    SINGLE POINT LIFT....1001
    TRANSPORTING THE BOBCAT LOADER....1001
  PREVENTIVE MAINTENANCE....1002
    MAINTENANCE SAFETY....1003
    SERVICE SCHEDULE....1004
    LIFT ARM SUPPORT DEVICE....1005
    OPERATOR CAB (ROPS & FOPS)....1005
      Raising The Operator Cab....1006
      Lowering The Operator Cab....1006
      Seat Bar System....1007
      Seat Bar Inspection....1007
      Seat Bar Maintenance....1007
    REAR DOOR....1008
    AIR CLEANER SYSTEM....1008
    FUEL SYSTEM....1009
      Filling The Fuel System....1009
      Fuel Filter....1009
    ENGINE LUBRICATION SYSTEM....1010
      Engine Oil Replacement....1010
    ENGINE COOLING SYSTEM....1011
    ELECTRICAL SYSTEM....1012
      Battery Replacement....1012
      Electrical System Service....1012
      Using An Extra Battery (Jump Starting)....1012
      Hourmeter....1013
    HYDRAULIC/HYDROSTATIC SYSTEM....1014
      Checking / Adding Fluid To Reservoir....1014
      Replacement Of The Hydraulic Filter....1015
      Removing The Hydraulic / Hydrostatic Fluid....1015
    SPARK ARRESTOR MUFFLER....1016
      Cleaning The Spark Arrestor Muffler....1016
    FINAL DRIVE TRANSMISSION (CHAINCASE)....1017
      Chaincase Fluid Level....1017
    TIRE MAINTENANCE....1017
      Tire Rotation....1017
      Tire Installation On Rim....1017
      Tire Pressure....1017
      Wheel Nuts....1017
    LUBRICATION OF THE BOBCAT LOADER....1018
    PARKING BRAKE ADJUSTMENT....1019
    PIVOT PINS....1019
  TROUBLESHOOTING....1020
    TROUBLESHOOTING....1022
    Troubleshooting The Engine....1022
    Troubleshooting The Hydraulic System....1023
    Troubleshooting The Hydrostatic System....1024
  MACHINE SIGN TRANSLATIONS....1026
    IMPORTANT (6560573)....1028
    WARNING - 6579511....1029
    SERVICE SCHEDULE - 6567875....1030
    WARNING - 6579510....1032
    WARNING - 6579628....1033
    DANGER - 6579639....1033
    WARNING - 6577754....1033
    DANGER - 6579509....1033
  SPECIFICATIONS....1034
    LOADER SPECIFICATIONS....1036
      Loader Dimensions....1036
      Operation & Performance....1036
      Engine....1036
      Hydraulic System....1037
      Electrical....1037
      Drive System....1037
      Capactities....1037
      Tires....1037
    MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES....1038
    ADDITIONAL PUBLICATIONS....1039
  WARRANTY....1040
6570160 (06–12) - 440B Service Manual....1042
  MAINTENANCE SAFETY....1044
  CONTENTS....1046
    FOREWORD....1046
    SAFETY INSTRUCTIONS....1048
      SAFETY IS YOUR RESPONSIBILITY....1048
      BEFORE YOU OPERATE THE BOBCAT LOADER....1048
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR....1049
    FIRE PREVENTION....1049
    SERIAL NUMBER LOCATIONS....1050
      LOADER SERIAL NUMBER....1050
      ENGINE SERIAL NUMBER LOCATION....1050
    DELIVERY REPORT....1050
    BOBCAT LOADER IDENTIFICATION....1051
  PREVENTIVE MAINTENANCE....1052
    SERVICE SCHEDULE....1054
    PREVENTIVE MAINTENANCE....1055
    LIFTING AND BLOCKING THE FELLER BUNCHER....1055
      Procedure....1055
    TRANSPORTING THE LOADER....1056
      Procedure....1056
    LIFT ARM STOP....1057
      Procedure....1057
    OPERATOR CAB....1058
      Seat Bar System....1058
      Seat Bar Inspection....1058
      Seat Bar Maintenance....1059
      Raising the Operator Cab....1060
      Lowering the Operator Cab....1060
    USING AND EXTRA BATTERY (JUMP START)....1061
      Procedure....1061
  HYDRAULIC SYSTEM....1062
    HYDRAULIC / HYDROSTATIC FLOW CHART....1064
    HYDRAULIC SYSTEM....1070
    TROUBLESHOOTING....1070
    HYDRAULIC SYSTEM INFORMATION....1071
      Flare Connections....1071
      Straight Thread O–ring Fitting....1071
      Tubelines and Hoses....1071
    LIFT CYLINDER....1072
      Checking the Lift Cylinder(s)....1072
      Removal and Installation....1073
    TILT CYLINDER....1074
      Checking the Tilt Cylinder....1074
      Removal and Installation....1074
    HYDRAULIC CYLINDER REPAIR....1075
      Disassembly....1075
      Assembly....1077
    HYDRAULIC CONTROL VALVE....1080
      Checking the Main Relief Valve....1080
      Removal and Installation....1081
      Disassembly and Assembly....1083
      Inspection....1084
    HYDRAULIC PUMP....1085
      Checking Output of Hydraulic Pump....1085
      Removal and Installation....1087
      Disassembly and Assembly....1088
      Inspection....1090
    HYDRAULIC/HYDROSTATIC FLUID RESERVOIR....1091
      Removing Fluid from Reservoir....1091
      Removal and Installation....1091
    CONTROL PEDALS....1092
      Removal and Installation....1092
    PEDAL LOCK LINKAGE....1093
      Removal and Installation....1093
  HYDROSTATIC SYSTEM....1094
    TROUBLESHOOTING....1096
    HYDROSTATIC SYSTEM INFORMATION....1097
      High Pressure Relief Replenishing Valves Function....1097
    FRONT PANEL....1098
      Removal and Installation....1098
    STEERING LEVERS....1099
      Removal and Installation....1099
      Disassembly and Assembly....1100
      Neutral Adjustment....1100
    PINTLE ARMS....1102
      Removal and Installation....1102
      Disassembly and Assembly....1103
    HYDROSTATIC MOTOR....1104
      Removal and Installation....1104
      Disassembly and Assembly....1106
      Inspection....1111
      Start Up Procedure....1111
      Timing the Hydrostatic Motor....1112
    HYDROSTATIC PUMP....1113
      Checking Charge Pressure....1113
      Removal and Installation....1114
      Disassembly and Assembly....1116
      Inspection....1120
      Start Up Procedure....1121
    DRIVE BELT & TENSION PULLEY....1122
      Tension Pulley Removal and Installation....1122
      Drive Belt Replacement In Loader Removal and Installation....1123
    PORT BLOCK....1124
      Charge Pressure Relief Valve Removal and Installation....1124
      Cold Weather By–Pass Valve Removal and Installation....1124
    TOWING THE BOBCAT LOADER....1125
      Procedure....1125
  DRIVE SYSTEM....1126
    PARKING BRAKE....1128
      Adjustment....1128
      Removal and Installation....1128
      Calipers and Bushings....1129
    AXLE, AXLE SEAL AND BEARINGS....1131
      Removal....1131
      Installation....1133
    DRIVE CHAINS....1136
      Removal....1136
      Installation....1136
      Removal and Installation....1138
  MAIN FRAME....1140
    OPERATOR CAB....1142
      Removal and Installation....1142
    SEAT BAR....1143
      Removal and Installation....1143
    REAR DOOR....1144
      Removal and Installation....1144
    LIFT ARMS....1145
      Removal and Installation....1145
    BUCKETS AND ATTACHMENTS....1146
      Removal....1146
      Installation....1146
    FUEL TANK....1147
      Removal and Installation....1147
  ELECTRICAL SYSTEM....1148
    ELECTRICAL SCHEMATICS....1151
    ELECTRICAL SYSTEM INFORMATION....1154
      Description....1154
    TROUBLESHOOTING....1154
    BATTERY....1155
      Checking the Battery....1155
      Removal and Installation....1155
    ALTERNATOR....1156
      Description....1156
      Checking Alternator Circuit....1157
      Replacement of the Stator....1157
    STARTER....1158
      Checking the Starter....1158
      Removal and Installation....1158
      Disassembly and Assembly....1159
  ENGINE SERVICE....1162
    TROUBLESHOOTING....1164
    ENGINE COMPRESSION....1165
      Checking....1165
    CARBURETOR AND GOVERNOR....1166
      Carburetor Adjustment....1166
      Carburetor Removal and Installation....1167
      Carburetor Disassembly and Assembly....1167
      Governor Adjustment....1168
    CARBURETOR (Fixed Main Jet)....1169
      Description....1169
      Adjusting the Carburetor....1169
      Disassembly and Assembly....1170
      Throttle Shaft....1171
      Choke Shaft....1171
      Float Level....1172
    FUEL PUMP....1172
      Removal & Installation....1172
    IGNITION SYSTEM....1173
      Igintion System Information....1173
      Troubleshooting....1173
      Ignition System Tester....1174
      Spark Plugs....1174
      Ignition Module....1174
    CRANKCASE VACUUM....1175
      Manometer Tube....1175
      Vacuum Test....1175
    ENGINE....1176
      Removal and Installation....1176
    ENGINE MUFFLER....1180
      Removal and Installation....1180
    RECONDITIONING THE ENGINE....1181
      Disassembly....1181
      Assembly....1183
    CYLINDER HEAD....1191
      Checking....1191
    CYLINDER BARRELS....1191
      Checking....1191
    VALVES (Engine S/N 1917809295 & Below)....1192
      VALVE GUIDES....1192
        Removal and Installation....1192
      Checking....1192
      VALVE SEAT INSERTS (Engine S/N 1917809295 & Below)....1192
        Removal  and Installation....1192
      VALVE SPRINGS....1192
        Checking....1192
    VALVES (Engine S/N 1917809296 & Above)....1194
      Checking....1194
      VALVE SEAT INSERTS (Engine S/N 1917809296 & Above)....1194
        Removal and Installation....1194
    PISTON AND PISTON RINGS....1195
      Checking....1195
    CRANKSHAFT AND CONNECTING RODS....1196
      Checking....1196
    GOVERNOR AND OIL PUMP....1196
      Governor Inspection....1196
      Oil Pump Inspection....1196
  TECHNICAL DATA....1198
    LOADER SPECIFICATIONS....1200
      OPERATIONS & PERFORMANCE....1200
      ENGINE....1200
      LOADER HYDRAULICS....1201
      ELECTRICAL....1201
      DRIVE SYSTEM....1201
      CAPACITIES....1201
      TIRES....1201
    ENGINE SPECIFICATIONS....1202
      Engine (General)....1202
      Cylinder Bore....1202
      Crankshaft....1202
      Camshaft....1202
      Connecting Rod....1202
      Piston, Pin & Rings....1202
      Valves, Guides & Tappets....1202
      Oil Pump....1203
      Engine Torque....1203
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....1204
      Hydraulic/Hydrostatic Fluid....1204
    DECIMAL AND MILLIMETER EQUIVALENTS....1205
    U.S. TO METRIC CONVERSION....1205
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS....1206
  SERVICE MANUAL REVISIONS....1208
    FB-1....1208
    FB-2....1210
    440B/FB-3....1212
    440B/FB-4....1214
    440B/FB-5....1216
    440B/FB-6....1218
    440B/FB-7....1220
6570160 (1–87) - 440B Service Manual....1222
  MAINTENANCE SAFETY....1224
  CONTENTS....1226
    FOREWORD....1226
    SAFETY INSTRUCTIONS....1228
      SAFETY IS YOUR RESPONSIBILITY....1228
      BEFORE YOU OPERATE THE BOBCAT LOADER....1228
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR....1229
    FIRE PREVENTION....1229
    SERIAL NUMBER LOCATIONS....1230
      LOADER SERIAL NUMBER....1230
      ENGINE SERIAL NUMBER LOCATION....1230
    DELIVERY REPORT....1230
    BOBCAT LOADER IDENTIFICATION....1231
  PREVENTIVE MAINTENANCE....1232
    SERVICE SCHEDULE....1234
    PREVENTIVE MAINTENANCE....1235
    LIFTING AND BLOCKING THE FELLER BUNCHER....1235
      Procedure....1235
    TRANSPORTING THE LOADER....1236
      Procedure....1236
    LIFT ARM STOP....1237
      Procedure....1237
    OPERATOR CAB....1238
      Seat Bar System....1238
      Seat Bar Inspection....1238
      Seat Bar Maintenance....1239
      Raising the Operator Cab....1240
      Lowering the Operator Cab....1240
    USING AND EXTRA BATTERY (JUMP START)....1241
      Procedure....1241
  HYDRAULIC SYSTEM....1242
    HYDRAULIC / HYDROSTATIC FLOW CHART....1244
    HYDRAULIC SYSTEM....1250
    TROUBLESHOOTING....1250
    HYDRAULIC SYSTEM INFORMATION....1251
      Flare Connections....1251
      Straight Thread O–ring Fitting....1251
      Tubelines and Hoses....1251
    LIFT CYLINDER....1252
      Checking the Lift Cylinder(s)....1252
      Removal and Installation....1253
    TILT CYLINDER....1254
      Checking the Tilt Cylinder....1254
      Removal and Installation....1254
    HYDRAULIC CYLINDER REPAIR....1255
      Disassembly....1255
      Assembly....1257
    HYDRAULIC CONTROL VALVE....1260
      Checking the Main Relief Valve....1260
      Removal and Installation....1261
      Disassembly and Assembly....1263
      Inspection....1264
    HYDRAULIC PUMP....1265
      Checking Output of Hydraulic Pump....1265
      Removal and Installation....1267
      Disassembly and Assembly....1268
      Inspection....1270
    HYDRAULIC/HYDROSTATIC FLUID RESERVOIR....1271
      Removing Fluid from Reservoir....1271
      Removal and Installation....1271
    CONTROL PEDALS....1272
      Removal and Installation....1272
    PEDAL LOCK LINKAGE....1273
      Removal and Installation....1273
  HYDROSTATIC SYSTEM....1274
    TROUBLESHOOTING....1276
    HYDROSTATIC SYSTEM INFORMATION....1277
      High Pressure Relief Replenishing Valves Function....1277
    FRONT PANEL....1278
      Removal and Installation....1278
    STEERING LEVERS....1279
      Removal and Installation....1279
      Disassembly and Assembly....1280
      Neutral Adjustment....1280
    PINTLE ARMS....1282
      Removal and Installation....1282
      Disassembly and Assembly....1283
    HYDROSTATIC MOTOR....1284
      Removal and Installation....1284
      Disassembly and Assembly....1286
      Inspection....1291
      Start Up Procedure....1291
      Timing the Hydrostatic Motor....1292
    HYDROSTATIC PUMP....1293
      Checking Charge Pressure....1293
      Removal and Installation....1294
      Disassembly and Assembly....1296
      Inspection....1300
      Start Up Procedure....1301
    DRIVE BELT & TENSION PULLEY....1302
      Tension Pulley Removal and Installation....1302
      Drive Belt Replacement In Loader Removal and Installation....1303
    PORT BLOCK....1304
      Charge Pressure Relief Valve Removal and Installation....1304
      Cold Weather By–Pass Valve Removal and Installation....1304
    TOWING THE BOBCAT LOADER....1305
      Procedure....1305
  DRIVE SYSTEM....1306
    PARKING BRAKE....1308
      Adjustment....1308
      Removal and Installation....1308
      Calipers and Bushings....1309
    AXLE, AXLE SEAL AND BEARINGS....1311
      Removal....1311
      Installation....1313
    DRIVE CHAINS....1316
      Removal....1316
      Installation....1316
      Removal and Installation....1318
  MAIN FRAME....1320
    OPERATOR CAB....1322
      Removal and Installation....1322
    SEAT BAR....1323
      Removal and Installation....1323
    REAR DOOR....1324
      Removal and Installation....1324
    LIFT ARMS....1325
      Removal and Installation....1325
    BUCKETS AND ATTACHMENTS....1326
      Removal....1326
      Installation....1326
    FUEL TANK....1327
      Removal and Installation....1327
  ELECTRICAL SYSTEM....1328
    ELECTRICAL SCHEMATICS....1331
    ELECTRICAL SYSTEM INFORMATION....1334
      Description....1334
    TROUBLESHOOTING....1334
    BATTERY....1335
      Checking the Battery....1335
      Removal and Installation....1335
    ALTERNATOR....1336
      Description....1336
      Checking Alternator Circuit....1337
      Replacement of the Stator....1337
    STARTER....1338
      Checking the Starter....1338
      Removal and Installation....1338
      Disassembly and Assembly....1339
  ENGINE SERVICE....1342
    TROUBLESHOOTING....1344
    ENGINE COMPRESSION....1345
      Checking....1345
    CARBURETOR AND GOVERNOR....1346
      Carburetor Adjustment....1346
      Carburetor Removal and Installation....1347
      Carburetor Disassembly and Assembly....1347
      Governor Adjustment....1348
    CARBURETOR (Fixed Main Jet)....1349
      Description....1349
      Adjusting the Carburetor....1349
      Disassembly and Assembly....1350
      Throttle Shaft....1351
      Choke Shaft....1351
      Float Level....1352
    FUEL PUMP....1352
      Removal & Installation....1352
    IGNITION SYSTEM....1353
      Igintion System Information....1353
      Troubleshooting....1353
      Ignition System Tester....1354
      Spark Plugs....1354
      Ignition Module....1354
    CRANKCASE VACUUM....1355
      Manometer Tube....1355
      Vacuum Test....1355
    ENGINE....1356
      Removal and Installation....1356
    ENGINE MUFFLER....1360
      Removal and Installation....1360
    RECONDITIONING THE ENGINE....1361
      Disassembly....1361
      Assembly....1363
    CYLINDER HEAD....1371
      Checking....1371
    CYLINDER BARRELS....1371
      Checking....1371
    VALVES (Engine S/N 1917809295 & Below)....1372
      VALVE GUIDES....1372
        Removal and Installation....1372
      Checking....1372
      VALVE SEAT INSERTS (Engine S/N 1917809295 & Below)....1372
        Removal  and Installation....1372
      VALVE SPRINGS....1372
        Checking....1372
    VALVES (Engine S/N 1917809296 & Above)....1374
      Checking....1374
      VALVE SEAT INSERTS (Engine S/N 1917809296 & Above)....1374
        Removal and Installation....1374
    PISTON AND PISTON RINGS....1375
      Checking....1375
    CRANKSHAFT AND CONNECTING RODS....1376
      Checking....1376
    GOVERNOR AND OIL PUMP....1376
      Governor Inspection....1376
      Oil Pump Inspection....1376
  TECHNICAL DATA....1378
    LOADER SPECIFICATIONS....1380
      OPERATIONS & PERFORMANCE....1380
      ENGINE....1380
      LOADER HYDRAULICS....1381
      ELECTRICAL....1381
      DRIVE SYSTEM....1381
      CAPACITIES....1381
      TIRES....1381
    ENGINE SPECIFICATIONS....1382
      Engine (General)....1382
      Cylinder Bore....1382
      Crankshaft....1382
      Camshaft....1382
      Connecting Rod....1382
      Piston, Pin & Rings....1382
      Valves, Guides & Tappets....1382
      Oil Pump....1383
      Engine Torque....1383
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....1384
      Hydraulic/Hydrostatic Fluid....1384
    DECIMAL AND MILLIMETER EQUIVALENTS....1385
    U.S. TO METRIC CONVERSION....1385
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS....1386
  SERVICE MANUAL REVISIONS....1388
    FB-1....1388
    FB-2....1390
    440B/FB-3....1392
    440B/FB-4....1394
    440B/FB-5....1396
    440B/FB-6....1398
6722481 (3-99) - 443B Operation & Maintenance Manual....1400
  OPERATOR SAFETY WARNINGS....1401
  CONTENTS....1402
    REFERENCE INFORMATION....1402
  FOREWORD....1404
    SERIAL NUMBER LOCATIONS....1406
    LOADER SERIAL NUMBER....1406
    ENGINE SERIAL NUMBER....1406
    DELIVERY REPORT....1406
    BOBCAT LOADER IDENTIFICATION....1407
  SAFETY....1408
    SAFETY INSTRUCTIONS....1410
      SAFETY IS THE OPERATOR’S RESPONSIBILITY....1410
      BEFORE OPERATING THE BOBCAT LOADER....1411
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR*....1411
    FIRE PREVENTION....1412
    MACHINE SIGNS (DECALS)....1413
  OPERATING INSTRUCTIONS....1416
    DASH PANEL....1418
    ENGINE SPEED CONTROL....1418
    ENGINE STOP CONTROL....1418
    PARKING BRAKE....1419
    STEERING LEVERS....1420
    HYDRAULIC CONTROLS....1421
      Foot Pedals (Hydraulic)....1421
      Lift Arm Operation....1421
      Tilt Operation (Bucket)....1421
      Auxiliary Hydraulics Operation (Optional)....1422
    DAILY INSPECTION....1423
    SEAT BAR RESTRAINT SYSTEM....1424
    GETTING READY FOR OPERATION....1425
    STARTING THE ENGINE....1427
      Normal Starting Condition ....1427
      Cold Temperature Starting Condition....1429
      Warming The Hydraulic/Hydrostatic System....1429
    ATTACHMENTS AND BUCKETS....1430
      Installation And Removal (Pivot Pin Type)....1431
      Installation And Removal (Bob–Tach Type)....1432
    OPERATING PROCEDURES....1433
      Filling The Bucket....1434
      Emptying The Bucket....1434
      Digging Into The Ground....1435
      Leveling The Ground (Using Lift Arms In Float Position)....1436
      Backfilling....1436
    PARKING THE BOBCAT LOADER....1437
    TRANSPORTING THE BOBCAT LOADER....1437
    LIFTING THE BOBCAT LOADER....1438
    TOWING THE LOADER....1438
  PREVENTIVE MAINTENANCE....1440
    MAINTENANCE SAFETY....1441
    SERVICE SCHEDULE....1442
    LIFT ARM SUPPORT DEVICE....1443
    OPERATOR CAB (ROPS & FOPS)....1443
      Raising The Operator Cab....1444
      Lowering The Operator Cab....1444
    AIR CLEANER SERVICE....1445
    FUEL SYSTEM....1447
      Filling The Fuel Tank....1447
      Fuel Filter....1447
      Removing Air From The Fuel System....1448
    ENGINE LUBRICATION SYSTEM....1449
      Replacing Oil And Filter....1449
    COOLANT SYSTEM....1450
      Checking The Coolant Level....1450
      Removing The Coolant....1450
    ALTERNATOR BELT....1451
      Adjustment....1451
    ELECTRICAL SYSTEM....1452
      Description....1452
      Electrical System Service....1452
      Using A Booster Battery (Jump Starting)....1452
      Battery Removal And Installation....1453
    SPARK ARRESTOR MUFFLER....1454
    HYDRAULIC/HYDROSTATIC SYSTEM....1455
      Checking And Adding Fluid....1455
      Hydraulic Filter Element Replacement....1456
      Removing The Hydraulic/Hydrostatic Fluid....1456
    FINAL DRIVE TRANSMISSION (CHAINCASE)....1456
    TIRE MAINTENANCE....1457
      Wheel Nuts....1457
      Tire Rotation....1457
      Tire Inflation....1457
    LUBRICATION OF THE BOBCAT LOADER....1458
    BOB–TACH (Optional)....1459
    PIVOT PINS....1460
    BRAKE PEDAL ADJUSTMENT....1460
    SEAT BAR RESTRAINT SYSTEM....1461
      Seat Bar Inspection....1461
      Seat Bar Maintenance....1461
  TROUBLESHOOTING....1462
    TROUBLESHOOTING THE ENGINE....1464
    TROUBLESHOOTING THE HYDRAULIC SYSTEM....1465
    TROUBLESHOOTING THE DRIVE SYSTEM....1466
  MAJOR PARTS....1468
    MAIN FRAME....1470
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM....1471
    BRAKES, CHAINCASE & AXLE....1472
    HYDRAULIC SYSTEM....1473
    HYDROSTATIC SYSTEM....1474
    STEERING CONTROLS....1475
    ROPS ELECTRICAL SYSTEM....1476
    ENGINE ELECTRICAL SYSTEM....1477
    ENGINE & ATTACHING PARTS....1478
  MACHINE SIGN TRANSLATIONS....1480
    IMPORTANT - 6560573....1482
    WARNING - 6579511....1483
    SERVICE SCHEDULE - 6567875....1484
    WARNING - 6579510....1486
    WARNING - 6579528....1487
    DANGER - 6579639....1487
    DANGER - 6579509....1487
  SPECIFICATIONS....1488
    LOADER DIMENSIONS....1490
    OPERATION & PERFORMANCE....1490
    ENGINE....1490
    HYDRAULIC SYSTEM....1491
    ELECTRICAL....1491
    DRIVE SYSTEM....1491
    CAPACITIES....1491
    TIRES....1491
    MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES....1492
    ADDITIONAL PUBLICATIONS....1493
  WARRANTY....1494
6724163 (9-98) - 453 Operation & Maintenance Manual....1496
  OPERATOR SAFETY WARNING....1497
  CONTENTS....1498
    REFERENCE INFORMATION....1498
    MELROE COMPANY IS ISO 9001 CERTIFIED....1499
    REGULAR MAINTENANCE ITEMS....1499
  FOREWORD....1500
    SERIAL NUMBER LOCATIONS....1502
    LOADER SERIAL NUMBER....1502
    ENGINE SERIAL NUMBER....1502
    DELIVERY REPORT....1502
    BOBCAT SKID STEER LOADER IDENTIFICATION....1503
    OPTIONS AND ACCESSORIES....1504
  SAFETY....1506
    SAFETY INSTRUCTIONS....1508
      Safety Is The Operator's Responsibility....1508
      Before Operating The Bobcat Loader....1509
      Safe Operation Needs A Qualified Operator....1509
    FIRE PREVENTION....1510
    MACHINE SIGNS (DECALS)....1511
  OPERATING INSTRUCTIONS....1514
    INSTRUMENT PANEL....1516
    ENGINE SPEED CONTROL....1516
    ENGINE STOP CONTROL....1516
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....1517
      Seat Sensor Override (if Equipped)....1517
      Lift Arm By-Pass Control....1517
      Traction Lock Override....1518
    PARKING BRAKE....1518
    STEERING LEVERS....1519
    STOPPING THE BOBCAT LOADER....1519
    SEAT BAR RESTRAINT SYSTEM....1520
    HYDRAULIC CONTROLS....1521
      Foot Pedals....1521
      Lift Arm Operation....1521
      Lift Arm Float Position....1521
      Tilt Operation....1521
      Bucket Position Valve Operation (Optional)....1521
      Auxiliary Hydraulics (Option Or Field Accessory)....1522
      Quick Couplers (Flush Face)....1522
    DAILY INSPECTION....1524
    GETTING READY FOR OPERATION....1525
    STARTING THE ENGINE....1527
      Normal Starting Condition....1528
      Cold Temperature Starting Condition....1529
      Warming The Hydraulic / Hydrostatic Fluid....1529
    STOPPING THE ENGINE....1529
    ATTACHMENTS AND BUCKETS....1530
      Installation And Removal (Standard)....1530
      Installation And Removal (Bob-Tach - Option Or Field Accessory)....1531
    OPERATING PROCEDURES....1532
      Filling The Bucket....1533
      Emptying The Bucket....1533
      Digging Into The Ground....1534
      Leveling The Ground (Using Lift Arms In Float Position)....1535
      Backfilling....1535
    PARKING THE BOBCAT LOADER....1536
    LIFTING THE BOBCAT LOADER....1536
    TRANSPORTING THE BOBCAT LOADER....1537
    TOWING THE BOBCAT LOADER....1537
    STOPPING THE BOBCAT LOADER....1537
  PREVENTIVE MAINTENANCE....1538
    MAINTENANCE SAFETY....1539
    SERVICE SCHEDULE....1540
    LIFT ARM SUPPORT DEVICE....1541
      Engaging The Lift Arm Support Device....1541
      Disengaging The Lift Arm Support Device....1541
    REAR DOOR....1542
    OPERATOR CAB....1543
      Emergency Exit....1543
      Lowering The Operator Cab....1544
    SEAT BAR RESTRAINT SYSTEM ....1545
      Seat Bar Inspection....1545
      Seat Bar Maintenance....1545
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....1546
      Inspecting The BICS™ System Controller (Engine STOPPED - Key ON)....1546
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)....1546
      Inspecting The Traction Lock (Engine RUNNING)....1546
      Inspecting The Lift Arm By-Pass Control....1546
      Maintenance....1546
    AIR CLEANER SERVICE....1547
    FUEL SYSTEM....1548
      Fuel Specifications....1548
      Filling The Fuel Tank....1548
      Fuel Filter....1548
      Removing Air From The Fuel System....1549
    ENGINE LUBRICATION SYSTEM....1550
      Replacing Oil And Filter....1550
      Oil Chart....1550
    COOLING SYSTEM....1551
      Checking The Coolant Level....1551
      Propylene Glycol....1551
      Cleaning The Cooling System....1551
      Removing Coolant From The Cooling System....1551
    ALTERNATOR BELT ADJUSTMENT....1552
    ELECTRICAL SYSTEM....1552
      Description....1552
      Fuse Location....1552
      Electrical System Service....1552
      Using A Booster Battery (Jump Starting)....1553
      Battery Removal And Installation....1553
    SPARK ARRESTOR MUFFLER....1554
    HYDRAULIC / HYDROSTATIC SYSTEM....1555
      Checking And Adding Fluid....1555
      Replacement Of The Hydraulic / Hydrostatic Filter Element....1556
      Removing The Hydraulic / Hydrostatic Fluid....1556
    FINAL DRIVE TRANSMISSION (CHAINCASE)....1557
      Checking And Adding Oil....1557
    AUXILIARY CONTROL LOCKBOLT....1557
    TIRE MAINTENANCE....1557
      Wheel Nuts....1557
      Tire Rotation....1557
      Tire Inflation....1557
    LUBRICATION OF THE BOBCAT LOADER....1558
    BOB-TACH....1559
    PIVOT PINS....1559
  TROUBLESHOOTING....1560
    TROUBLESHOOTING THE ENGINE....1562
    TROUBLESHOOTING THE HYDRAULIC SYSTEM....1563
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM....1564
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....1565
  MACHINE SIGN TRANSLATIONS....1566
    IMPORTANT - 6560573....1568
    WARNING - 6579511....1569
    SERVICE SCHEDULE - 6708212....1570
    WARNING - 6579510....1572
    WARNING - 6579528....1573
    DANGER - 6702302....1573
    WARNING - 6577754....1573
    DANGER - 6702301....1573
  SPECIFICATIONS....1574
    PERFORMANCE....1576
    CONTROLS....1576
    ENGINE....1576
    HYDRAULIC SYSTEM....1577
    ELECTRICAL....1577
    DRIVE SYSTEM....1577
    CAPACITIES....1577
    TIRES....1577
    FLOOR PRESSURE....1577
    MELROE COMPANY APPROVED ATTACHEMENTS AND ACCESSORIES....1578
    ADDITIONAL PUBLICATIONS....1579
  WARRANTY....1580
6724207 (9-98) - 450 Operation & Maintenance Manual....1582
  OPERATOR SAFETY WARNINGS....1584
  CONTENTS....1586
    REFERENCE INFORMATION....1586
    MELROE COMPANY IS ISO 9001 CERTIFIED....1587
    REGULAR MAINTENACE ITEMS....1587
  FOREWORD....1588
    SERIAL NUMBER LOCATIONS....1590
    LOADER SERIAL NUMBER....1590
    ENGINE SERIAL NUMBER....1590
    DELIVERY REPORT....1590
    BOBCAT SKID STEER LOADER IDENTIFICATION....1591
    OPTION AND ACCESSORIES....1592
  SAFETY....1594
    SAFETY INSTRUCTIONS....1596
      Safety Is The Operator's Responsibility....1596
      Before Operating The Bobcat Loader....1597
      Safe Operation Needs A Qualified Operator....1597
    FIRE PREVENTION....1598
    MACHINE SIGNS (DECALS)....1599
  OPERATING INSTRUCTIONS....1602
    INSTRUMENT PANEL....1604
    ENGINE SPEED CONTROL....1604
    ENGINE CHOKE CONTROL....1604
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....1605
      Lift Arm By-Pass Control....1605
      Traction Lock Override....1606
      Seat Sensor Override (If Equipped)....1606
    PARKING BRAKE....1606
    STEERING LEVERS....1607
    STOPPING THE BOBCAT LOADER....1607
    SEAT BAR RESTRAINT SYSTEM....1608
    HYDRAULIC CONTROLS....1609
      Foot Pedals....1609
      Lift Arm Operation....1609
      Lift Arm Float Position....1609
      Tilt Operation....1609
      Auxiliary  Hydraulics (If Equipped)....1610
        Quick Couplers (Flush Face)....1610
        Auxiliary Hydraulics Operation....1611
        Auxiliary Hydraulics Continuous Operation....1611
    DAILY INSPECTION....1612
    GETTING READY FOR OPERATION....1613
    STARTING THE ENGINE....1615
      Normal Starting....1615
      Cold Temperature Starting....1617
      Warming The Hydraulic / Hydrostatic System....1617
    STOPPING THE ENGINE....1617
    ATTACHMENTS AND BUCKETS....1618
      Installation And Removal (Without Bob-Tach)....1618
      Installation And Removal (With Bob-Tach)....1619
    OPERATING PROCEDURES....1620
      Filling The Bucket....1621
      Emptying The Bucket....1621
      Digging Into The Ground....1622
      Leveling The Ground (Using Lift Arms In Float Position)....1623
      Backfilling....1623
    PARKING THE BOBCAT LOADER....1623
    TRANSPORTING THE BOBCAT LOADER....1624
    STOPPING THE BOBCAT LOADER....1624
    LIFTING THE LOADER....1625
    TOWING THE LOADER....1625
  PREVENTIVE MAINTENANCE....1626
    MAINTENANCE SAFETY....1627
    SERVICE SCHEDULE....1628
    LIFT ARM SUPPORT DEVICE....1629
      Engaging The Lift Arm Support Device....1629
      Disengaging The Lift Arm Support Device....1630
    OPERATOR CAB....1631
      Raising The Operator Cab....1631
      Lowering The Operator cab....1632
      Emergency Exit....1633
    SEAT BAR RESTRAINT SYSTEM....1634
      Seat Bar Inspection....1634
      Seat Bar Maintenance....1634
      Foot Pedal Clean Out....1634
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....1635
      Inspecting The BICS™ System Controller (Engine STOPPED - Key ON)....1635
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)....1635
      Inspecting The Traction Lock (Engine RUNNING)....1635
      Inspecting The Lift Arm Bypass Control....1635
      Maintenance....1635
    REAR DOOR....1636
    AIR CLEANER SERVICE....1637
    FUEL SYSTEM....1638
      Filling The Fuel Tank....1638
      Fuel Filter....1638
    ENGINE LUBRICATION SYSTEM....1639
      Replacing Oil And Filter....1639
    ENGINE COOLING SYSTEM....1640
      Cleaning The Cooling System....1640
    ELECTRICAL SYSTEM....1641
      Removing And Installing The Battery....1641
      Servicing The Electrical System....1641
      Using An Extra Battery (Jump Starting)....1641
      Fuse Location....1642
    SPARK ARRESTOR MUFFLER....1643
      Cleaning The Spark Arrestor Muffler....1643
    HYDRAULIC / HYDROSTATIC SYSTEM....1644
      Checking And Adding Fluid....1644
      Replacing The Hydraulic / Hydrostatic Filter....1645
      Replacing The Hydraulic / Hydrostatic Fluid....1645
    FINAL DRIVE TRANSMISSION (CHAINCASE)....1646
      Checking and Adding Oil....1646
    AUXILIARY CONTROL LOCKBOLT....1646
    TIRE MAINTENANCE....1647
      Wheel Nuts....1647
      Tire Rotation....1647
      Tire Inflation....1647
    LUBRICATING THE LOADER....1648
    PIVOT PINS....1650
    BOB-TACH (Option Or Field Accessory)....1650
  SYSTEM ANALYSIS....1652
    TROUBLESHOOTING....1654
      Troubleshooting The Engine....1654
      Troubleshooting The Hydraulic System....1655
      Troubleshooting The Hydrostatic System....1656
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....1657
      Troubleshooting Chart....1657
      Seat Sensor Override Only....1657
  MACHINE SIGN TRANSLATIONS....1658
    IMPORTANT - 6560573....1660
    WARNING - 6579511....1661
    WARNING - 6579510....1662
    SERVICE SCHEDULE -6708212 ....1663
    WARNING - 6579528 ....1665
    DANGER - 6702302 ....1665
    WARNING - 6577754....1665
    DANGER - 6702301 ....1665
  SPECIFICATIONS....1666
    LOADER SPECIFICATIONS....1668
      Performance....1668
      Controls....1668
      Engine....1668
      Hydraulic System....1669
      Electrical....1669
      Drive System....1669
      Capacities....1669
      Tires....1669
      Floor Pressure....1669
    MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES....1670
    ADDITIONAL PUBLICATIONS....1671
  WARRANTY....1672
6724259 (06–12) - 450, 453 Service Manual....1674
  MAINTENANCE SAFETY....1676
  ALPHABETICAL INDEX....1678
  CONTENTS....1680
    FOREWORD....1681
    SAFETY INSTRUCTIONS....1684
    SERIAL NUMBER LOCATIONS....1686
    LOADER SERIAL NUMBER....1686
    ENGINE SERIAL NUMBER....1686
    DELIVERY REPORT....1686
    BOBCAT SKID STEER LOADER IDENTIFICATION....1687
    OPTIONS AND ACCESSORIES....1688
  PREVENTIVE MAINTENANCE....1690
    SERVICE SCHEDULE....1692
    LIFTING AND BLOCKING THE LOADER....1693
      Procedure....1693
    TRANSPORTING THE LOADER....1694
      Procedure....1694
    LIFTING THE LOADER....1695
      Single Point Lift....1695
    TOWING THE LOADER....1695
    LIFT ARM SUPPORT DEVICE....1696
      Engaging The Lift Arm Support Device....1696
      Disengaging The Lift Arm Support Device....1697
    OPERATOR CAB....1698
      Description....1698
      Emergency Exit....1698
      Raising The Operator Cab....1698
      Lowering The Operator Cab....1699
    SEAT BAR RESTRAINT SYSTEM....1700
      Seat Bar Inspection....1700
      Seat Bar Maintenance....1700
      Foot Pedal Clean Out....1700
    AIR CLEANER SERVICE....1701
      450 Loader....1701
      453 Loader....1702
    FUEL SYSTEM....1703
      450 Loader....1703
        Fuel Specifications....1703
        Filling The Fuel Tank....1703
        Fuel Filter....1703
      453 Loader....1704
        Fuel Specifications....1704
        Filling the Fuel Tank....1704
        Fuel Filter....1704
        Removing Air From The Fuel System....1705
    ENGINE LUBRICATION SYSTEM....1706
      450 Loader....1706
        Replacing Oil And Filter....1706
      453 Loader....1707
        Replacing Oil And Filter....1707
    ENGINE COOLING SYSTEM....1708
      450 Loader....1708
        Cleaning The Cooling System....1708
      453 Loader....1709
        Checking The Coolant Level....1709
        Cleaning The Cooling System....1709
        Removing Coolant From The Cooling System....1709
    ALTERNATOR BELT ADJUSTMENT (453)....1710
    ELECTRICAL SYSTEM....1710
      Description....1710
    PIVOT PINS....1710
    SPARK ARRESTOR MUFFLER....1711
      Cleaning The Spark Arrestor Muffler....1711
    HYDRAULIC/HYDROSTATIC SYSTEM....1712
      Checking And Adding Fluid....1712
      Replacing The Hydraulic/Hydrostatic Filter Element....1713
      Removing The Hydraulic/Hydrostatic Fluid....1713
    FINAL DRIVE TRANSMISSION (CHAINCASE)....1714
      Checking And Adding Oil....1714
    AUXILIARY CONTROL LOCKBOLT....1714
    TIRE MAINTENANCE....1714
      Wheel Nuts....1714
      Tire Rotation....1714
      Tire Inflation....1714
    LUBRICATING THE LOADER....1715
    BOB–TACH....1716
    REMOTE START SWITCH....1717
      Procedure....1718
  HYDRAULIC SYSTEM....1720
    HYDRAULIC / HYDROSTATIC SCHEMATICS....1722
    TROUBLESHOOTING....1726
    HYDRAULIC SYSTEM INFORMATION....1727
      Tighten Procedures....1727
    LIFT CYLINDER(S)....1728
      Removal and Installation....1728
      Checking The Lift Cylinder For Internal Leakage....1729
    TILT CYLINDER....1730
      Removal And Installation....1730
      Checking The Tilt Cylinder For Internal Leakage....1731
    HYDRAULIC CYLINDERS....1732
      Disassembly And Assembly....1732
      Lift Cylinder Identification....1734
    LIFT ARM BY–PASS BLOCK....1735
      Removal And Installation....1735
      Disassembly And Assembly....1736
    HYDRAULIC CONTROL VALVE....1738
      Checking The Main Relief Valve....1738
      Main Relief Valve Removal And Installation....1739
      Main Relief Valve Adjustment....1739
      Removal And Installation....1740
      Identification Chart....1741
      Disassembly And Assembly....1742
      Load Check Valve....1742
      Main Relief Valve....1742
      Anti–Cavitation Valve....1743
      Rubber Boot....1744
      Lift Spool Detent....1745
      Tilt Centering Spring....1749
      Auxiliary Spool Detent....1749
      Spool Seal Installation....1750
    HYDRAULIC PUMP....1751
      Checking The Output Of The Hydraulic Pump....1751
      Removal And Installation....1752
      Disassembly And Assembly....1754
      Parts Identification....1756
    HYDRAULIC RESERVOIR....1757
      Removal And Installation....1757
    HYDRAULIC FILTER BLOCK....1758
      Removal And Installation....1758
      Disassembly And Assembly....1758
        450 Filter Block....1758
        453 Filter Block....1759
    PEDAL INTERLOCK LINKAGE....1760
      Removal And Installation....1760
    CONTROL PEDALS....1760
      Removal And Installation....1760
      Pedal Adjustment....1760
  HYDROSTATIC SYSTEM....1762
    TROUBLESHOOTING....1764
    HYDROSTATIC SYSTEM INFORMATION....1765
      Replenishing Valve Function....1765
    CONTROL SHIELD AND STEERING LEVER PANELS....1766
      Removal And Installation....1766
    STEERING LEVERS AND STEERING LEVER PANELS ....1767
      Removal And Installation....1767
    STEERING LEVERS....1767
      Removal And Installation....1767
      Disassembly And Assembly....1768
    STEERING LINKAGE....1769
      Adjustment....1769
      Pintle Arm Removal And Installation....1770
      Pintle Arm Disassembly And Assembly....1770
    DRIVE BELT....1771
      Removal And Installation....1771
        450 Loader....1771
        453 Loader....1771
    HYDR0STATIC PUMP....1772
      Checking Charge Pressure....1772
      Removal And Installation....1773
        450 Loader....1773
        453 Loader....1774
      Parts Identification....1776
      Disassembly And Assembly....1777
      Inspection....1780
    TENSION PULLEY AND SPRING....1783
    Removal And Installation....1783
    HYDROSTATIC MOTOR....1785
      Removal And Installation....1785
      Parts Identification....1786
      Disassembly....1787
      Inspection....1791
      Assembly....1792
  DRIVE SYSTEM....1796
    PARKING BRAKE PEDAL....1798
      Removal And Installation....1798
      Disassembly And Assembly....1798
    CHAINCASE FLUID....1799
      Removing Oil From The Chaincase....1799
    CHAINCASE COVER....1799
      Removal And Installation....1799
      Disassembly And Assembly....1799
    PARKING BRAKE DISC....1800
      Removal And Installation....1800
    AXLE HUB....1801
      Removal And Installation....1801
    AXLE SEAL....1802
      Removal And Installation....1802
    AXLE, BEARINGS, AND SPROCKET....1803
      Removing The Axle....1803
      Removing And Installing The Axle Bearing....1804
      Removing The Bearing Races....1805
      Installing The Bearing Races....1806
      Installing The Inner Bearing And Axle Sprocket....1806
    DRIVE CHAINS....1807
      Removal And Installation....1807
  MAIN FRAME....1808
    SEAT BAR....1810
      Gas Spring Removal And Installation....1810
      Compressing The Gas Spring....1811
      Seat Bar Removal And Installation....1812
      Assembly....1814
    OPERATOR CAB....1815
      Removal And Installation....1815
    OPERATOR CAB GAS CYLINDER....1817
      Removal And Installation....1817
    OPERATOR SEAT....1818
      Removal And Installation....1818
    BOB–TACH....1820
      Removal....1820
      Installation....1821
      Seal Removal And Installation....1822
      Lever And Wedge Removal....1822
      Lever And Wedge Installation....1824
    LIFT ARMS....1826
      Removal And Installation....1826
    FUEL TANK....1829
      Removal And Installation....1829
    REAR WINDOW....1830
      Removal And Installation....1830
    REAR DOOR....1831
      Exhaust Pipe Removal And Installation....1831
      Removal And Installation....1831
  ELECTRICAL SYSTEM....1832
    ELECTRICAL SCHEMATICS....1834
    TROUBLESHOOTING....1858
      Chart....1858
    ELECTRICAL SYSTEM INFORMATION....1859
      Description....1859
      Fuse Location....1859
      Relay Switches Location - 453 Only....1859
    BATTERY....1860
      Removal And Installation....1860
      Maintenance....1861
    ALTERNATOR (450)....1862
      Checking The Alternator Circuit (450)....1862
      Replacing The Stator....1863
    ALTERNATOR (453)....1864
      Removal And Installation....1864
      Adjusting The Alternator Belt....1864
      Alternator Output Test....1865
      Alternator Regulator Test....1866
      Disassembly and Inspection – Parts Identification....1867
      Stator Continuity Test....1867
      Stator Ground Test....1867
      Rotor Continuity Test....1868
      Rotor Ground Test....1868
      Rectifier Continuity (Diode) Test....1868
      Assembly....1869
    STARTER (453)....1870
      Removal And Installation....1870
      Checking The Starter....1870
      Parts Identification....1871
      Disassembly, Assembly And Inspection....1872
    STARTER (450)....1875
      Checking The Starter....1875
      Removal And Installation....1875
      Disassembly, Assembly And Inspection....1876
    INSTRUMENT PANEL....1878
      Removal And Installation....1878
    FRONT LIGHTS (OPTIONAL)....1879
      Removal And Installation....1879
    REAR LIGHT (OPTIONAL)....1880
      Removal And Installation....1880
  ENGINE SERVICE....1882
    ENGINE SERVICE (450)....1884
      TROUBLESHOOTING....1886
      IGNITION SYSTEM....1888
        Spark Plugs....1888
        Ignition Module Air Gap....1888
        Testing Ignition Module Primary....1889
        Testing Ignition Module Secondary....1889
        Valve & Tappet Clearance....1890
        Compression Test....1890
      CARBURETOR AND GOVERNOR....1891
        Carburetor Adjustment On The Engine....1891
        Main Fuel Adjustment ....1891
        Idle Fuel Adjustment....1891
        Idle Speed Setting....1892
        Shutdown Control Solenoid....1892
        Governor And Adjustment....1893
        Disassembly And Assembly....1893
      ENGINE....1897
        Removal And Installation....1897
        Muffler Removal And Installation....1900
        Intake Manifold Removal And Installation....1901
        Breather and Valve Cover Removal And Installation....1902
        Fuel Pump Removal And Installation....1902
      ENGINE DISASSEMBLY....1903
        Flywheel Removal And Installation....1903
        Stator Removal and Installation....1903
        Cylinder Head Removal....1904
        Cylinder Barrel Removal....1905
        Cylinder Barrel Inspection And Resizing....1906
        Valve Removal And Installation....1907
        Valve Guide Removal And Installation....1907
        Valve Seat Insert Removal....1908
        Valve Seat Insert Installation....1908
        Valve Details....1909
        Piston And Piston Rings....1910
        Closure Plate....1912
        Crankcase Halves....1912
        Camshaft Removal....1913
        Crankshaft Removal....1913
        Connecting Rod Removal....1914
        Governor Gear And Cross Shaft Removal....1915
        Oil Pickup Removal....1915
        OIl Pump Removal....1916
      ENGINE ASSEMBLY....1917
        Oil Pump Installation....1917
        Cross Shaft And Governor Shaft Installation....1919
        Connecting Rod Installation....1920
        Crankshaft And Bearing Installation....1920
        Tappets And Camshaft Installation....1922
        Sealing The Crankcase....1923
        Recommended Sealants....1924
        Installing Camshaft Bore Plug....1924
        Installing Crankcase Halves....1925
        Front And Rear Seal Installation....1925
        Filter Adapter Installation....1926
        Installing Oil Pressure Relief Valve And Closure Plate....1926
        Piston Installation....1927
        Setting Valve To Tappet Clearance....1928
        Cylinder Head Installation....1929
    ENGINE SERVICE 453 (KUBOTA)....1930
      TROUBLESHOOTING....1932
      FUEL SYSTEM....1934
        Replacing The Fuel Filter....1934
        Removing The Air From The Fuel System....1934
        Fuel Injection Pump....1935
        Checking The Injection Pump....1935
        Removing The Injection Pump....1936
        Installing The Injection Pump....1937
        Timing The Injection Pump....1937
        Fuel Injector Nozzles....1938
        Removing The Fuel Injector Nozzle....1938
        Checking Fuel Injector Nozzles....1939
        Installing The Fuel Injector Nozzle....1939
        Checking Glow Plugs....1940
        Engine Compression Test....1940
      OIL COOLER & SHROUDING....1941
        Removal And Installation....1941
      RADIATOR....1941
        Removal And Installation....1941
      ENGINE SPEED CONTROL....1942
        Adjustment....1942
        Removal And Installation....1942
      ENGINE....1943
        Removal And Installation....1943
      FLYWHEEL....1948
        Removal And Installation....1948
      FAN....1949
        Removal And Installation....1949
      CYLINDER HEAD....1950
        Removing The Cylinder Head....1950
        Disassembly Of The Cylinder Head....1952
        Servicing The Cylinder Head....1953
        Assembly Of The Cylinder Head....1955
        Installing The Cylinder Head....1955
      REPAIRING THE ENGINE....1957
        Removing The Gearcase....1957
        Removing The Timing Gear, Camshaft & Oil Pump....1959
        Removing Pistons & Crankshaft....1961
        Servicing The Timing Gear And Camshaft....1963
        Servicing The Connecting Rods And Pistons....1965
        Servicing The Crankshaft....1966
        Servicing The Cylinder Liners....1968
        Servicing The Oil Pump....1969
        Servicing The Water Pump....1969
      ASSEMBLY OF THE ENGINE....1970
        Installing The Crankshaft....1970
        Installing The Pistons....1970
        Installing The Camshaft And Timing Gears....1971
        Installing The Gearcase Cover....1973
  SYSTEMS ANALYSIS....1974
    BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM)....1976
      Inspecting The BICS™ System Controller (Engine STOPPED – Key ON)....1976
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)....1976
      Inspecting The Traction Lock (Engine Running)....1976
      Inspecting The Lift Arm By–Pass Control....1976
      Maintenance....1976
      Troubleshoot Chart....1977
      Troubleshooting Guide....1978
        BICS CONTROLLER....1978
        TRACTION LOCK....1979
        SEAT SENSOR....1980
        SEAT BAR SENSOR....1981
        LIFT LOCK BYPASS VALVE....1982
    BICS™ SYSTEM CONTROLLER....1983
      Removal And Installation....1983
      Controller Test....1984
    SEAT BAR SENSOR....1985
      Removal And Installation....1985
      Seat Bar Sensor Test....1986
    SEAT SENSOR....1987
      Removal And Installation....1987
      Seat Sensor Test....1988
    TRACTION LOCK....1989
      Removal And Installation....1989
    LIFT ARM BY–PASS BLOCK....1990
      Removal And Installation....1990
    LIFT AND TILT LOCK BY–PASS VALVE....1991
      Disassembly And Assembly....1991
  SPECIFICATIONS....1994
    450 LOADER SPECIFICATIONS ....1996
      PERFORMANCE....1996
      CONTROLS....1996
      ENGINE....1996
      HYDRAULIC SYSTEM....1997
      ELECTRICAL....1997
      DRIVE SYSTEM....1997
      CAPACITIES....1997
      TIRES....1997
    ENGINE SPECIFICATIONS – 450 (KOHLER)....1998
      Engine (General)....1998
      Cylinder Bore....1998
      Crankshaft....1998
      Camshaft....1998
      Connecting Rod....1998
      Piston, Pin & Rings....1998
      Valves, Guides & Tappet....1998
      Oil Pump....1999
      Engine Torque....1999
    453 LOADER SPECIFICATIONS....2000
      PERFORMANCE....2000
      CONTROLS....2000
      ENGINE....2000
      HYDRAULIC SYSTEM....2001
      ELECTRICAL....2001
      DRIVE SYSTEM....2001
      CAPACITIES....2001
      TIRES....2001
    ENGINE SPECIFICATIONS – 453 (KUBOTA)....2002
      Fuel Injector Nozzles....2002
      Fuel Injection Pump....2002
      Cylinder Head....2002
      Valves....2002
      Valve Springs....2002
      Rocker Arms....2002
      Camshaft....2002
      Cylinders....2003
      Piston Rings....2003
      Pistons....2003
      Crankshaft....2003
      Oil Pump....2003
      Thermostat....2003
      Crankshaft Re–Grind Data....2004
      Engine Torque....2005
    TORQUE SPECIFICATIONS FOR BOLTS....2006
      Torque For General SAE Bolts....2006
      Torque For General Metric Bolts....2007
    HYDRAULIC CONNECTION SPECIFICATIONS....2008
      O–ring Face Seal Connection....2008
      Straight Thread O–ring Fitting....2008
      Tubelines And Hoses....2008
      Flare Fitting....2008
      O–ring Flare Fitting....2009
      Port Seal Fitting....2011
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....2012
      Specifications....2012
    DECIMAL AND MILLIMETER EQUIVALENTS....2013
    U.S. TO METRIC CONVERSION....2013
    GLOSSARY OF HYDRAULIC SYMBOLS....2014
  SERVICE MANUAL REVISIONS....2016
    450/453-1....2016
    450/453-2....2018
    450/453-3....2020
    450/453-4....2022
    450/453-5....2024
    450/453-6....2026
6724259 (1–96) - 450, 453 Service Manual....2028
  MAINTENANCE SAFETY....2030
  ALPHABETICAL INDEX....2032
  CONTENTS....2034
    FOREWORD....2035
    SAFETY INSTRUCTIONS....2038
    SERIAL NUMBER LOCATIONS....2040
    LOADER SERIAL NUMBER....2040
    ENGINE SERIAL NUMBER....2040
    DELIVERY REPORT....2040
    BOBCAT SKID STEER LOADER IDENTIFICATION....2041
    OPTIONS AND ACCESSORIES....2042
  PREVENTIVE MAINTENANCE....2044
    SERVICE SCHEDULE....2046
    LIFTING AND BLOCKING THE LOADER....2047
      Procedure....2047
    TRANSPORTING THE LOADER....2048
      Procedure....2048
    LIFTING THE LOADER....2049
      Single Point Lift....2049
    TOWING THE LOADER....2049
    LIFT ARM SUPPORT DEVICE....2050
      Engaging The Lift Arm Support Device....2050
      Disengaging The Lift Arm Support Device....2051
    OPERATOR CAB....2052
      Description....2052
      Emergency Exit....2052
      Raising The Operator Cab....2052
      Lowering The Operator Cab....2053
    SEAT BAR RESTRAINT SYSTEM....2054
      Seat Bar Inspection....2054
      Seat Bar Maintenance....2054
      Foot Pedal Clean Out....2054
    AIR CLEANER SERVICE....2055
      450 Loader....2055
      453 Loader....2056
    FUEL SYSTEM....2057
      450 Loader....2057
        Fuel Specifications....2057
        Filling The Fuel Tank....2057
        Fuel Filter....2057
      453 Loader....2058
        Fuel Specifications....2058
        Filling the Fuel Tank....2058
        Fuel Filter....2058
        Removing Air From The Fuel System....2059
    ENGINE LUBRICATION SYSTEM....2060
      450 Loader....2060
        Replacing Oil And Filter....2060
      453 Loader....2061
        Replacing Oil And Filter....2061
    ENGINE COOLING SYSTEM....2062
      450 Loader....2062
        Cleaning The Cooling System....2062
      453 Loader....2063
        Checking The Coolant Level....2063
        Cleaning The Cooling System....2063
        Removing Coolant From The Cooling System....2063
    ALTERNATOR BELT ADJUSTMENT (453)....2064
    ELECTRICAL SYSTEM....2064
      Description....2064
    PIVOT PINS....2064
    SPARK ARRESTOR MUFFLER....2065
      Cleaning The Spark Arrestor Muffler....2065
    HYDRAULIC/HYDROSTATIC SYSTEM....2066
      Checking And Adding Fluid....2066
      Replacing The Hydraulic/Hydrostatic Filter Element....2067
      Removing The Hydraulic/Hydrostatic Fluid....2067
    FINAL DRIVE TRANSMISSION (CHAINCASE)....2068
      Checking And Adding Oil....2068
    AUXILIARY CONTROL LOCKBOLT....2068
    TIRE MAINTENANCE....2068
      Wheel Nuts....2068
      Tire Rotation....2068
      Tire Inflation....2068
    LUBRICATING THE LOADER....2069
    BOB–TACH....2070
    REMOTE START SWITCH....2071
      Procedure....2072
  HYDRAULIC SYSTEM....2074
    HYDRAULIC / HYDROSTATIC SCHEMATICS....2076
    TROUBLESHOOTING....2080
    HYDRAULIC SYSTEM INFORMATION....2081
      Tighten Procedures....2081
    LIFT CYLINDER(S)....2082
      Removal and Installation....2082
      Checking The Lift Cylinder For Internal Leakage....2083
    TILT CYLINDER....2084
      Removal And Installation....2084
      Checking The Tilt Cylinder For Internal Leakage....2085
    HYDRAULIC CYLINDERS....2086
      Disassembly And Assembly....2086
      Lift Cylinder Identification....2088
    LIFT ARM BY–PASS BLOCK....2089
      Removal And Installation....2089
      Disassembly And Assembly....2090
    HYDRAULIC CONTROL VALVE....2092
      Checking The Main Relief Valve....2092
      Main Relief Valve Removal And Installation....2093
      Main Relief Valve Adjustment....2093
      Removal And Installation....2094
      Identification Chart....2095
      Disassembly And Assembly....2096
      Load Check Valve....2096
      Main Relief Valve....2096
      Anti–Cavitation Valve....2097
      Rubber Boot....2098
      Lift Spool Detent....2099
      Tilt Centering Spring....2103
      Auxiliary Spool Detent....2103
      Spool Seal Installation....2104
    HYDRAULIC PUMP....2105
      Checking The Output Of The Hydraulic Pump....2105
      Removal And Installation....2106
      Disassembly And Assembly....2108
      Parts Identification....2110
    HYDRAULIC RESERVOIR....2111
      Removal And Installation....2111
    HYDRAULIC FILTER BLOCK....2112
      Removal And Installation....2112
      Disassembly And Assembly....2112
        450 Filter Block....2112
        453 Filter Block....2113
    PEDAL INTERLOCK LINKAGE....2114
      Removal And Installation....2114
    CONTROL PEDALS....2114
      Removal And Installation....2114
      Pedal Adjustment....2114
  HYDROSTATIC SYSTEM....2116
    TROUBLESHOOTING....2118
    HYDROSTATIC SYSTEM INFORMATION....2119
      Replenishing Valve Function....2119
    CONTROL SHIELD AND STEERING LEVER PANELS....2120
      Removal And Installation....2120
    STEERING LEVERS AND STEERING LEVER PANELS ....2121
      Removal And Installation....2121
    STEERING LEVERS....2121
      Removal And Installation....2121
      Disassembly And Assembly....2122
    STEERING LINKAGE....2123
      Adjustment....2123
      Pintle Arm Removal And Installation....2124
      Pintle Arm Disassembly And Assembly....2124
    DRIVE BELT....2125
      Removal And Installation....2125
        450 Loader....2125
        453 Loader....2125
    HYDR0STATIC PUMP....2126
      Checking Charge Pressure....2126
      Removal And Installation....2127
        450 Loader....2127
        453 Loader....2128
      Parts Identification....2130
      Disassembly And Assembly....2131
      Inspection....2134
    TENSION PULLEY AND SPRING....2137
    Removal And Installation....2137
    HYDROSTATIC MOTOR....2139
      Removal And Installation....2139
      Parts Identification....2140
      Disassembly....2141
      Inspection....2145
      Assembly....2146
  DRIVE SYSTEM....2150
    PARKING BRAKE PEDAL....2152
      Removal And Installation....2152
      Disassembly And Assembly....2152
    CHAINCASE FLUID....2153
      Removing Oil From The Chaincase....2153
    CHAINCASE COVER....2153
      Removal And Installation....2153
      Disassembly And Assembly....2153
    PARKING BRAKE DISC....2154
      Removal And Installation....2154
    AXLE HUB....2155
      Removal And Installation....2155
    AXLE SEAL....2156
      Removal And Installation....2156
    AXLE, BEARINGS, AND SPROCKET....2157
      Removing The Axle....2157
      Removing And Installing The Axle Bearing....2158
      Removing The Bearing Races....2159
      Installing The Bearing Races....2160
      Installing The Inner Bearing And Axle Sprocket....2160
    DRIVE CHAINS....2161
      Removal And Installation....2161
  MAIN FRAME....2162
    SEAT BAR....2164
      Gas Spring Removal And Installation....2164
      Compressing The Gas Spring....2165
      Seat Bar Removal And Installation....2166
      Assembly....2168
    OPERATOR CAB....2169
      Removal And Installation....2169
    OPERATOR CAB GAS CYLINDER....2171
      Removal And Installation....2171
    OPERATOR SEAT....2172
      Removal And Installation....2172
    BOB–TACH....2174
      Removal....2174
      Installation....2175
      Seal Removal And Installation....2176
      Lever And Wedge Removal....2176
      Lever And Wedge Installation....2178
    LIFT ARMS....2180
      Removal And Installation....2180
    FUEL TANK....2183
      Removal And Installation....2183
    REAR WINDOW....2184
      Removal And Installation....2184
    REAR DOOR....2185
      Exhaust Pipe Removal And Installation....2185
      Removal And Installation....2185
  ELECTRICAL SYSTEM....2186
    ELECTRICAL SCHEMATICS....2188
    TROUBLESHOOTING....2210
      Chart....2210
    ELECTRICAL SYSTEM INFORMATION....2211
      Description....2211
      Fuse Location....2211
      Relay Switches Location - 453 Only....2211
    BATTERY....2212
      Removal And Installation....2212
      Maintenance....2213
    ALTERNATOR (450)....2214
      Checking The Alternator Circuit (450)....2214
      Replacing The Stator....2215
    ALTERNATOR (453)....2216
      Removal And Installation....2216
      Adjusting The Alternator Belt....2216
      Alternator Output Test....2217
      Alternator Regulator Test....2218
      Disassembly and Inspection – Parts Identification....2219
      Stator Continuity Test....2219
      Stator Ground Test....2219
      Rotor Continuity Test....2220
      Rotor Ground Test....2220
      Rectifier Continuity (Diode) Test....2220
      Assembly....2221
    STARTER (453)....2222
      Removal And Installation....2222
      Checking The Starter....2222
      Parts Identification....2223
      Disassembly, Assembly And Inspection....2224
    STARTER (450)....2227
      Checking The Starter....2227
      Removal And Installation....2227
      Disassembly, Assembly And Inspection....2228
    INSTRUMENT PANEL....2230
      Removal And Installation....2230
    FRONT LIGHTS (OPTIONAL)....2231
      Removal And Installation....2231
    REAR LIGHT (OPTIONAL)....2232
      Removal And Installation....2232
  ENGINE SERVICE....2234
    ENGINE SERVICE (450)....2236
      TROUBLESHOOTING....2238
      IGNITION SYSTEM....2240
        Spark Plugs....2240
        Ignition Module Air Gap....2240
        Testing Ignition Module Primary....2241
        Testing Ignition Module Secondary....2241
        Valve & Tappet Clearance....2242
        Compression Test....2242
      CARBURETOR AND GOVERNOR....2243
        Carburetor Adjustment On The Engine....2243
        Main Fuel Adjustment ....2243
        Idle Fuel Adjustment....2243
        Idle Speed Setting....2244
        Shutdown Control Solenoid....2244
        Governor And Adjustment....2245
        Disassembly And Assembly....2245
      ENGINE....2249
        Removal And Installation....2249
        Muffler Removal And Installation....2252
        Intake Manifold Removal And Installation....2253
        Breather and Valve Cover Removal And Installation....2254
        Fuel Pump Removal And Installation....2254
      ENGINE DISASSEMBLY....2255
        Flywheel Removal And Installation....2255
        Stator Removal and Installation....2255
        Cylinder Head Removal....2256
        Cylinder Barrel Removal....2257
        Cylinder Barrel Inspection And Resizing....2258
        Valve Removal And Installation....2259
        Valve Guide Removal And Installation....2259
        Valve Seat Insert Removal....2260
        Valve Seat Insert Installation....2260
        Valve Details....2261
        Piston And Piston Rings....2262
        Closure Plate....2264
        Crankcase Halves....2264
        Camshaft Removal....2265
        Crankshaft Removal....2265
        Connecting Rod Removal....2266
        Governor Gear And Cross Shaft Removal....2267
        Oil Pickup Removal....2267
        OIl Pump Removal....2268
      ENGINE ASSEMBLY....2269
        Oil Pump Installation....2269
        Cross Shaft And Governor Shaft Installation....2271
        Connecting Rod Installation....2272
        Crankshaft And Bearing Installation....2272
        Tappets And Camshaft Installation....2274
        Sealing The Crankcase....2275
        Recommended Sealants....2276
        Installing Camshaft Bore Plug....2276
        Installing Crankcase Halves....2277
        Front And Rear Seal Installation....2277
        Filter Adapter Installation....2278
        Installing Oil Pressure Relief Valve And Closure Plate....2278
        Piston Installation....2279
        Setting Valve To Tappet Clearance....2280
        Cylinder Head Installation....2281
    ENGINE SERVICE 453 (KUBOTA)....2282
      TROUBLESHOOTING....2284
      FUEL SYSTEM....2286
        Replacing The Fuel Filter....2286
        Removing The Air From The Fuel System....2286
        Fuel Injection Pump....2287
        Checking The Injection Pump....2287
        Removing The Injection Pump....2288
        Installing The Injection Pump....2289
        Timing The Injection Pump....2289
        Fuel Injector Nozzles....2290
        Removing The Fuel Injector Nozzle....2290
        Checking Fuel Injector Nozzles....2291
        Installing The Fuel Injector Nozzle....2291
        Checking Glow Plugs....2292
        Engine Compression Test....2292
      OIL COOLER & SHROUDING....2293
        Removal And Installation....2293
      RADIATOR....2293
        Removal And Installation....2293
      ENGINE SPEED CONTROL....2294
        Adjustment....2294
        Removal And Installation....2294
      ENGINE....2295
        Removal And Installation....2295
      FLYWHEEL....2300
        Removal And Installation....2300
      FAN....2301
        Removal And Installation....2301
      CYLINDER HEAD....2302
        Removing The Cylinder Head....2302
        Disassembly Of The Cylinder Head....2304
        Servicing The Cylinder Head....2305
        Assembly Of The Cylinder Head....2307
        Installing The Cylinder Head....2307
      REPAIRING THE ENGINE....2309
        Removing The Gearcase....2309
        Removing The Timing Gear, Camshaft & Oil Pump....2311
        Removing Pistons & Crankshaft....2313
        Servicing The Timing Gear And Camshaft....2315
        Servicing The Connecting Rods And Pistons....2317
        Servicing The Crankshaft....2318
        Servicing The Cylinder Liners....2320
        Servicing The Oil Pump....2321
        Servicing The Water Pump....2321
      ASSEMBLY OF THE ENGINE....2322
        Installing The Crankshaft....2322
        Installing The Pistons....2322
        Installing The Camshaft And Timing Gears....2323
        Installing The Gearcase Cover....2325
  SYSTEMS ANALYSIS....2326
    BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM)....2328
      Inspecting The BICS™ System Controller (Engine STOPPED – Key ON)....2328
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)....2328
      Inspecting The Traction Lock (Engine Running)....2328
      Inspecting The Lift Arm By–Pass Control....2328
      Maintenance....2328
      Troubleshoot Chart....2329
      Troubleshooting Guide....2330
        BICS CONTROLLER....2330
        TRACTION LOCK....2331
        SEAT SENSOR....2332
        SEAT BAR SENSOR....2333
        LIFT LOCK BYPASS VALVE....2334
    BICS™ SYSTEM CONTROLLER....2335
      Removal And Installation....2335
      Controller Test....2336
    SEAT BAR SENSOR....2337
      Removal And Installation....2337
      Seat Bar Sensor Test....2338
    SEAT SENSOR....2339
      Removal And Installation....2339
      Seat Sensor Test....2340
    TRACTION LOCK....2341
      Removal And Installation....2341
    LIFT ARM BY–PASS BLOCK....2342
      Removal And Installation....2342
    LIFT AND TILT LOCK BY–PASS VALVE....2343
      Disassembly And Assembly....2343
  SPECIFICATIONS....2346
    450 LOADER SPECIFICATIONS ....2348
      PERFORMANCE....2348
      CONTROLS....2348
      ENGINE....2348
      HYDRAULIC SYSTEM....2349
      ELECTRICAL....2349
      DRIVE SYSTEM....2349
      CAPACITIES....2349
      TIRES....2349
    ENGINE SPECIFICATIONS – 450 (KOHLER)....2350
      Engine (General)....2350
      Cylinder Bore....2350
      Crankshaft....2350
      Camshaft....2350
      Connecting Rod....2350
      Piston, Pin & Rings....2350
      Valves, Guides & Tappet....2350
      Oil Pump....2351
      Engine Torque....2351
    453 LOADER SPECIFICATIONS....2352
      PERFORMANCE....2352
      CONTROLS....2352
      ENGINE....2352
      HYDRAULIC SYSTEM....2353
      ELECTRICAL....2353
      DRIVE SYSTEM....2353
      CAPACITIES....2353
      TIRES....2353
    ENGINE SPECIFICATIONS – 453 (KUBOTA)....2354
      Fuel Injector Nozzles....2354
      Fuel Injection Pump....2354
      Cylinder Head....2354
      Valves....2354
      Valve Springs....2354
      Rocker Arms....2354
      Camshaft....2354
      Cylinders....2355
      Piston Rings....2355
      Pistons....2355
      Crankshaft....2355
      Oil Pump....2355
      Thermostat....2355
      Crankshaft Re–Grind Data....2356
      Engine Torque....2357
    TORQUE SPECIFICATIONS FOR BOLTS....2358
      Torque For General SAE Bolts....2358
      Torque For General Metric Bolts....2359
    HYDRAULIC CONNECTION SPECIFICATIONS....2360
      O–ring Face Seal Connection....2360
      Straight Thread O–ring Fitting....2360
      Tubelines And Hoses....2360
      Flare Fitting....2360
      O–ring Flare Fitting....2361
      Port Seal Fitting....2363
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....2364
      Specifications....2364
    DECIMAL AND MILLIMETER EQUIVALENTS....2365
    U.S. TO METRIC CONVERSION....2365
    GLOSSARY OF HYDRAULIC SYMBOLS....2366
  SERVICE MANUAL REVISIONS....2368
    450/453-1....2368
    450/453-2....2370
    450/453-3....2372
    450/453-4....2374
    450/453-5....2376
6900326 (11-98) - 453 Operation & Maintenance Manual....2378
  OPERATOR SAFETY WARNINGS....2380
  CONTENTS....2382
    REFERENCE INFORMATION....2382
    MELROE COMPANY IS ISO 9001 CERTIFIED....2383
    REGULAR MAINTENANCE ITEMS....2383
  FOREWORD....2384
    SERIAL NUMBER LOCATIONS....2386
    LOADER SERIAL NUMBER....2386
    ENGINE SERIAL NUMBER....2386
    DELIVERY REPORT....2386
    BOBCAT SKID STEER LOADER IDENTIFICATION....2387
    OPTIONS AND ACCESSORIES....2388
  SAFETY....2390
    SAFETY INSTRUCTIONS....2392
      Safety Is The Operator's Responsibility....2392
      Before Operating The Bobcat Loader....2393
      Safe Operation Needs A Qualified Operator....2393
    FIRE PREVENTION....2394
    MACHINE SIGNS (DECALS)....2395
  OPERATING INSTRUCTIONS....2398
    INSTRUMENT PANEL....2400
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....2401
      Lift Arm By-Pass Control....2401
      Traction Lock Override....2402
      Seat Sensor Override (If Equipped)....2402
    ENGINE SPEED CONTROL....2402
    PARKING BRAKE....2403
    STEERING LEVERS....2404
    STOPPING THE BOBCAT LOADER....2404
    SEAT BAR RESTRAINT SYSTEM....2405
    HYDRAULIC CONTROLS....2406
      Foot Pedals....2406
      Lift Arm Operation....2406
      Lift Arm Float Position....2406
      Tilt operation....2406
      Bucket Position Valve Operation (If Equipped)....2406
      Auxiliary Hydraulics (If Equipped)....2407
        Quick Couplers....2407
      Auxiliary Hydraulic Continuous Operation....2408
      Relieving Hydraulic Pressure....2408
    DAILY INSPECTION....2409
    GETTING READY FOR OPERATION....2410
    STARTING THE ENGINE....2412
      Normal Starting....2412
      Cold Temperature Starting....2414
      Warming The Hydraulic / Hydrostatic System....2414
    STOPPING THE ENGINE....2414
    ATTACHMENTS AND BUCKETS....2415
      Installation And Removal (Without Bob-Tach)....2415
      Installation And Removal (With Bob-Tach)....2416
      Removing The Bucket Or Attachment....2417
    OPERATING PROCEDURE....2418
      Filling The Bucket....2419
      Emptying The Bucket....2419
      Digging Into The Ground....2420
      Leveling The Ground (Using Lift Arms In Float Position)....2421
      Backfilling....2421
    PARKING THE BOBCAT LOADER....2421
    TRANSPORTING THE BOBCAT LOADER....2422
    STOPPING THE BOBCAT LOADER....2422
    LIFTING THE LOADER....2423
    TOWING THE LOADER....2423
  PREVENTIVE MAINTENANCE....2424
    MAINTENANCE SAFETY....2425
    SERVICE SCHEDULE....2426
    LIFT ARM SUPPORT DEVICE....2427
      Installing The Lift Arm Support Device....2427
      Removing The Lift Arm Support Device....2428
    OPERATOR CAB....2429
      Raising The Operator Cab....2429
      Lowering The Operator Cab....2430
      Emergency Exit....2431
    SEAT BAR RESTRAINT SYSTEM....2432
      Seat Bar Inspection....2432
      Seat Bar Maintenance....2432
      Foot Pedal Clean Out....2432
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....2433
      Inspecting The BICS™ System Controller (Engine STOPPED - Key ON)....2433
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)....2433
      Inspecting The Traction Lock (Engine RUNNING)....2433
      Inspecting The Lift Arm By-Pass Control....2433
      Maintenance....2433
    REAR DOOR....2434
    AIR CLEANER SERVICE....2435
    FUEL SYSTEM....2436
      Fuel Specifications....2436
      Filling The Fuel Tank....2436
      Fuel Filter....2437
      Removing Air From The Fuel System....2438
    ENGINE LUBRICATION SYSTEM....2439
      Replacing Oil And Filter....2439
      Oil Chart....2439
    COOLING SYSTEM....2440
      Checking The Coolant Level....2440
      Propylene Glycol....2440
      Cleaning The Cooling System....2440
    ALTERNATOR BELT ADJUSTMENT....2441
    ELECTRICAL SYSTEM....2441
      Description....2441
      Fuse Location....2441
      Electrical System Service....2441
      Battery Removal And Installation....2442
      Using A Booster Battery (Jump Starting)....2443
    HYDRAULIC / HYDROSTATIC SYSTEM....2444
      Checking And Adding Fluid....2444
      Replacing The Hydraulic / Hydrostatic Filter Element....2445
      Removing The Hydraulic / Hysrostatic Fluid....2445
    SPARK ARRESTOR MUFFLER....2446
    TIRE MAINTENANCE....2447
      Wheel Nuts....2447
      Tire Rotation....2447
      Tire Inflation....2447
    FINAL DRIVE TRANSMISSION (CHAINCASE)....2448
      Checking And Adding Oil....2448
    AUXILIARY CONTROL LOCKBOLT....2448
    LUBRICATING THE LOADER....2449
    PIVOT PINS....2451
    BOB-TACH....2451
      Inspection And Maintenance....2451
  SYSTEMS ANALYSIS....2452
    TROUBLESHOOTING THE ENGINE....2454
    TROUBLESHOOTING THE HYDRAULIC SYSTEM....2455
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM....2456
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....2457
      Troubleshooting Chart....2457
  MACHINE SIGN TRANSLATIONS....2458
    IMPORTANT - 6560573....2460
    WARNING - 6579511....2461
    SERVICE SCHEDULE - 6708212....2462
    WARNING - 6579510....2464
    WARNING - 6579528....2465
    DANGER - 6702302....2465
    WARNING - 6577754....2465
    DANGER - 6702301....2465
  SPECIFICATIONS....2466
    PERFORMANCE....2468
    CONTROLS....2468
    ENGINE....2468
    HYDRAULIC SYSTEM....2469
    ELECTRICAL....2469
    DRIVE SYSTEM....2469
    CAPACITIES....2469
    TIRES....2469
    FLOOR PRESSURE....2469
    MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES....2470
    ADDITIONAL PUBLICATIONS....2471
  WARRANTY....2472
6900363 (5–97) - 453 Service Manual....2474
  MAINTENANCE SAFETY....2476
  ALPHABETICAL INDEX....2478
  CONTENTS....2480
    FOREWORD....2481
    SAFETY INSTRUCTIONS....2484
    SERIAL NUMBER LOCATIONS....2486
    LOADER SERIAL NUMBER....2486
    ENGINE SERIAL NUMBER....2486
    DELIVERY REPORT....2486
    BOBCAT SKID STEER LOADER IDENTIFICATION....2487
  PREVENTIVE MAINTENANCE....2488
    SERVICE SCHEDULE....2490
    LIFTING AND BLOCKING THE LOADER....2491
      Procedure....2491
    TRANSPORTING THE LOADER....2492
      Procedure....2492
    TOWING THE LOADER....2493
      Procedure....2493
    LIFT ARM SUPPORT DEVICE....2494
      Engaging The Lift Arm Support Device....2494
      Disengaging The Lift Arm Support Device....2495
    OPERATOR CAB....2496
      Description....2496
      Raising The Operator Cab....2496
      Lowering The Operator Cab....2497
      Emergency Exit....2498
    SEAT BAR RESTRAINT SYSTEM....2499
      Description....2499
      Inspectng The Seat Bar....2499
      Maintaining The Seat Bar....2499
    AIR CLEANER SERVICE....2500
      Replacing Filter Element....2500
    FUEL SYSTEM....2501
      Fuel Specifications....2501
      Filling The Fuel Tank....2501
      Fuel Filter....2502
      Removing Air From The Fuel System....2503
    ENGINE LUBRICATION SYSTEM....2504
      Checking Engine Oil....2504
      Oil Chart....2504
      Replacing Oil and Filter ....2504
    ENGINE COOLING SYSTEM....2505
      Checking The Coolant Level....2505
      Cleaning The Cooling System....2505
      Replacing the Coolant....2505
    ALTERNATOR BELT....2506
      Adjusting The Alternator Belt....2506
    HYDRAULIC/HYDROSTATIC SYSTEM....2507
      Checking And Adding Fluid....2507
      Hydraulic/Hydrostatic Filter Replacement....2508
      Replacing The Hydraulic/Hydrostatic Fluid....2508
    SPARK ARRESTOR MUFFLER....2509
      Cleaning Procedure....2509
    TIRE MAINTENANCE....2510
      Wheel Nuts....2510
      Tire Rotation....2510
      Tire Inflation....2510
    FINAL DRIVE TRANSMISSION (CHAINCASE)....2511
      Checking And Adding Oil....2511
    AUXILIARY CONTROL LOCKBOLT....2511
    LUBRICATING THE LOADER....2512
      Procedure....2512
    PIVOT PINS....2514
    BOB–TACH....2514
      Inspection And Maintenance....2514
    REMOTE START SWITCH....2515
      Procedure....2515
  HYDRAULIC SYSTEM....2518
    HYDRAULIC SYSTEM INFORMATION....2520
    HYDRAULIC / HYDROSTATIC SCHEMATICS....2524
    TROUBLESHOOTING....2532
      Chart....2532
    LIFT CYLINDER(S)....2533
      Checking The Lift Cylinders....2533
      Removal And Installation....2534
    TILT CYLINDER....2536
      Checking The Tilt Cylinder....2536
      Removal And Installation....2537
    HYDRAULIC CYLINDERS....2538
      Lift Cylinder Parts Identification....2538
      Tilt Cylinder Parts Identification....2538
      Disassembly And Assembly....2539
    BICS™ BLOCK VALVE....2541
      Removal And Installation....2541
      Disassembly And Assembly....2542
    MAIN RELIEF VALVE....2545
      Checking The Main Relief Valve....2545
      Checking The Main Relief Valve With Auxiliaries....2546
      Removal And Installation....2547
      Main Relief Valve Adjustment....2547
    HYDRAULIC CONTROL VALVE....2548
      Removal And Installation....2548
      Identification Chart....2549
      Disassembly And Assembly....2550
      Load Check Valve....2550
      Main Relief Valve....2550
      Anti–Cavitation Valve....2551
      Rubber Boot....2551
      Lift Spool Detent....2552
      Tilt Centering Spring....2556
      Auxiliary Spool Detent....2556
      Spool Seal Installation....2557
    HYDRAULIC PUMP....2558
      Checking The Output Of The Hydraulic Pump....2558
      Removal And Installation....2559
      Parts Identification....2561
      Disassembly And Assembly....2562
    HYDRAULIC RESERVOIR....2564
      Removal And Installation....2564
    HYDRAULIC FILTER BLOCK....2565
      Removal And Installation....2565
      Block Disassembly And Assembly....2566
    PEDAL INTERLOCK LINKAGE....2567
      Removal And Installation....2567
    CONTROL PEDALS....2567
      Removal and Installation....2567
      Pedal Adjustment....2567
  HYDROSTATIC SYSTEM....2568
    TROUBLESHOOTING....2570
      Chart....2570
    HYDROSTATIC SYSTEM INFORMATION....2571
      Replenishing Valve Function....2571
    CONTROL SHIELD AND STEERING LEVER PANELS....2572
      Removal And Installation....2572
    STEERING LEVERS....2573
      Removal And Installation....2573
      Disassembly And Assembly....2574
    STEERING LINKAGE....2575
      Adjustment....2575
      Pintle Arm Removal And Installation....2576
      Pintle Arm Disassembly And Assembly....2576
    HYDROSTATIC MOTOR....2577
      Removal And Installation....2577
      Parts Identification....2578
      Disassembly....2579
      Inspection....2583
      Assembly....2584
    DRIVE BELT....2588
      Removal And Installation....2588
    CHARGE PRESSURE....2589
      Checking....2589
    HYDROSTATIC PUMP....2590
      Parts Identification....2590
      Removal And Installation....2591
      Disassembly And Assembly....2593
      Inspection....2596
    TENSION PULLEY AND SPRING....2599
      Removal And Installation....2599
  DRIVE SYSTEM....2602
    PARKING BRAKE PEDAL....2604
      Removal And Installation....2604
      Disassembly And Assembly....2604
    CHAINCASE FLUID....2605
      Removing Oil From The Chaincase....2605
    CHAINCASE COVER....2605
      Removal And Installation....2605
      Disassembly And Assembly....2605
    PARKING BRAKE DISC....2606
      Removal And Installation....2606
    AXLE HUB....2607
      Removal And Installation....2607
    AXLE SEAL....2608
      Removal And Installation....2608
    AXLE, BEARINGS, AND SPROCKET....2609
      Removing The Axle....2609
      Removing And Installing The Axle Bearing....2610
      Removing The Bearing Races....2611
      Installing The Bearing Races....2612
      Installing The Inner Bearing And Axle Sprocket....2612
    DRIVE CHAIN....2613
    Removal And Installation....2613
  MAIN FRAME....2614
    SEAT BAR....2616
      Removal And Installation....2616
      Assembly....2619
    OPERATOR CAB....2620
      Removal And Installation....2620
    OPERATOR CAB GAS CYLINDER....2622
      Removal And Installation....2622
    OPERATOR SEAT....2623
      Removal And Installation....2623
    BOB–TACH....2625
      Removal....2625
      Installation....2626
      Seal Removal And Installation....2627
      Lever And Wedge Removal....2627
      Lever And Wedge Installation....2629
    LIFT ARMS....2631
      Removal And Installation....2631
    FUEL TANK....2634
      Removal And Installation....2634
    REAR WINDOW....2635
      Removal And Installation....2635
    REAR DOOR....2636
      Exhaust Pipe Removal And Installation....2636
      Removal And Installation....2636
  ELECTRICAL SYSTEM....2638
    ELECTRICAL SCHEMATICS....2640
    TROUBLESHOOTING....2644
      Chart....2644
    ELECTRICAL SYSTEM INFORMATION....2645
      Description....2645
      Fuse Location....2645
      Relay Switches Location....2645
    BATTERY....2646
      Removal And Installation....2646
      Servicing The Electrical System....2647
      Using A Booster Battery (Jump Starting)....2648
    ALTERNATOR....2649
      Removal And Installation....2649
      Adjusting The Alternator Belt....2649
      Alternator Belt Removal And Installation....2650
      Description....2652
      Tests....2652
      Alternator Output Test....2652
      Full Field Test....2653
      Alternator Regulator Test....2653
      Alternator Regulator Test With Voltmeter....2653
    STARTER....2654
      Removal And Installation....2654
      Checking The Starter In The Loader....2654
      Parts Identification....2655
      Disassembly....2656
      Inspection And Repair....2661
      No Load Test....2664
      Assembly....2665
    INSTRUMENT PANEL....2672
      Removal And Installation....2672
    FRONT LIGHTS (OPTIONAL)....2673
      Removal And Installation....2673
    REAR LIGHT (OPTIONAL)....2674
      Removal And Installation....2674
  ENGINE SERVICE....2676
    TROUBLESHOOTING....2678
      Chart....2678
    ENGINE SPEED CONTROL....2680
      Adjustment....2680
      Removal And Installation....2680
    RADIATOR....2681
      Removal And Installation....2681
    RADIATOR MOUNTING BRACKET....2681
      Removal And Installation....2681
    FAN....2682
      Removal And Installation....2682
    FLYWHEEL....2683
      Removal And Installation....2683
    ENGINE MOUNTING BRACKET....2683
      Removal And Installation....2683
    VALVE CLEARANCE....2684
      Ajustment....2684
    FUEL INJECTION PUMP....2685
      Checking The Injection Pump....2685
      Removal....2686
      Installation....2687
      Timing Procedure....2687
    FUEL INJECTOR NOZZLES....2688
      Checking....2688
      Removal....2689
      Installation....2689
    GLOW PLUGS....2690
      Checking....2690
    ENGINE COMPRESSION TEST....2690
      Procedure....2690
    ENGINE....2691
      Removal And Installation....2691
    CYLINDER HEAD....2697
      Removal And Installation....2697
      Inspection....2698
      Top Clearance....2698
    ROCKER ARM AND SHAFT....2699
      Checking....2699
    VALVE AND VALVE SPRINGS....2700
      Valve Removal....2700
      Checking Valve Spring....2700
    VALVE GUIDE, VALVE AND VALVE SEAT....2701
      Checking The Valve Guide....2701
      Reconditioning The Valve And Valve Seat....2702
    TIMING GEARCASE COVER....2703
      Removal And Installation....2703
    IDLER GEAR AND CAMSHAFT....2705
      Removal And Installation....2705
      Servicing The Idler Gear And Shaft....2707
    TIMING GEARS....2707
      Checking Backlash....2707
    FUEL CAMSHAFT....2708
      Removal And Installation....2708
      Governor....2708
    CRANKSHAFT GEAR....2709
      Removal And Installation....2709
    OIL PUMP....2709
      Removal And Installation....2709
      Oil Pump Service....2709
      Checking Engine Oil Pressure....2710
      Relief Valve....2710
    PISTON AND CONNECTING ROD....2711
      Removal And Installation....2711
      Servicing The Piston And Connecting Rod....2712
      Connecting Rod Alignment....2714
    CRANKSHAFT AND BEARINGS....2715
      Removal And Installation....2715
      Inspection Of Crankshaft And Bearings....2716
    CYLINDER  BORE....2719
      Inspection....2719
    HYDRAULIC OIL COOLER AND SHROUDING....2720
      Removal And Installation....2720
    THERMOSTAT....2721
      Removal And Installation....2721
    WATER PUMP....2722
      Removal And Installation....2722
      Disassembly And Assembly....2722
  SYSTEMS ANALYSIS....2724
    BICS™ (With Press To Operate Button)....2726
      Inspecting The BICS™ Controller (Engine STOPPED – Key ON)....2726
      Inspecting The Seat Bar Sensor (Engine RUNNING)....2726
      Inspecting The Traction Lock (Engine RUNNING)....2726
      Inspecting The Lift Arm By–Pass Control....2726
      Troubleshooting Chart....2727
      Inspecting The BICSTM Controller (Engine STOPPED – Key ON)....2728
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)....2728
      Inspecting The Traction Lock (Engine Running)....2728
      Inspecting The Lift Arm By–Pass Control....2728
      Maintenance....2728
      Troubleshoot Chart....2729
    BICS™ SYSTEM CONTROLLER....2730
      Troubleshooting Guide....2730
      Removal And Installation....2731
    SEAT BAR SENSOR....2732
      Troubleshooting Guide....2732
      Seat Bar Sensor Test....2733
      Removal And Installation....2734
      BICS™ Controller Seat Bar Sensor Circuit Test....2735
    SEAT SENSOR....2736
      Troubleshooting Guide....2736
      Seat Sensor Test....2737
      Removal And Installation....2738
      BICS™ Controller Seat Sensor Circuit Test....2739
    TRACTION LOCK....2740
      Troubleshooting Guide....2740
      Removal And Installation....2741
  SPECIFICATIONS....2742
    SKID STEER LOADER SPECIFICATIONS....2744
      PERFORMANCE....2744
      CONTROLS....2744
      ENGINE....2744
      HYDRAULIC SYSTEM....2745
      ELECTRICAL....2745
      DRIVE SYSTEM....2745
      CAPACITIES....2745
      TIRES....2745
      FLOOR PRESSURE....2745
    ENGINE SPECIFICATIONS....2746
      Engine....2746
      Fuel Injector Nozzles....2746
      Fuel Injection Pump....2746
      Cylinder Head....2746
      Valves....2746
      Valve Springs....2746
      Rocker Arms....2746
      Camshaft....2747
      Cylinders....2747
      Piston Rings....2747
      Pistons....2747
      Crankshaft....2747
      Oil Pump....2748
      Thermostat....2748
      ENGINE BOLT TORQUE....2749
      Re–Grinding The Crankshaft....2750
    TORQUE SPECIFICATIONS FOR BOLTS....2751
      Torque For General SAE Bolts....2751
      Torque For General Metric Bolts....2752
    HYDRAULIC CONNECTION SPECIFICATIONS....2753
      O–ring Face Seal Connection....2753
      Straight Thread O–ring Fitting....2753
      Tubelines And Hoses....2753
      Flare Fitting....2753
      O–ring Flare Fitting....2754
      Port Seal Fitting....2756
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....2757
      Specifications....2757
    DECIMAL AND MILLIMETER EQUIVALENTS....2758
    U.S. TO METRIC CONVERSION....2758
  SERVICE MANUAL REVISIONS....2760
    453-1....2760
    453-2....2762
    453-3....2764
    453-4....2766
6900363 (6–12) - 453 Service Manual....2768
  MAINTENANCE SAFETY....2770
  ALPHABETICAL INDEX....2772
  CONTENTS....2774
    FOREWORD....2775
    SAFETY INSTRUCTIONS....2778
    SERIAL NUMBER LOCATIONS....2780
    LOADER SERIAL NUMBER....2780
    ENGINE SERIAL NUMBER....2780
    DELIVERY REPORT....2780
    BOBCAT SKID STEER LOADER IDENTIFICATION....2781
  PREVENTIVE MAINTENANCE....2782
    SERVICE SCHEDULE....2784
    LIFTING AND BLOCKING THE LOADER....2785
      Procedure....2785
    TRANSPORTING THE LOADER....2786
      Procedure....2786
    TOWING THE LOADER....2787
      Procedure....2787
    LIFT ARM SUPPORT DEVICE....2788
      Engaging The Lift Arm Support Device....2788
      Disengaging The Lift Arm Support Device....2789
    OPERATOR CAB....2790
      Description....2790
      Raising The Operator Cab....2790
      Lowering The Operator Cab....2791
      Emergency Exit....2792
    SEAT BAR RESTRAINT SYSTEM....2793
      Description....2793
      Inspectng The Seat Bar....2793
      Maintaining The Seat Bar....2793
    AIR CLEANER SERVICE....2794
      Replacing Filter Element....2794
    FUEL SYSTEM....2795
      Fuel Specifications....2795
      Filling The Fuel Tank....2795
      Fuel Filter....2796
      Removing Air From The Fuel System....2797
    ENGINE LUBRICATION SYSTEM....2798
      Checking Engine Oil....2798
      Oil Chart....2798
      Replacing Oil and Filter ....2798
    ENGINE COOLING SYSTEM....2799
      Checking The Coolant Level....2799
      Cleaning The Cooling System....2799
      Replacing the Coolant....2799
    ALTERNATOR BELT....2800
      Adjusting The Alternator Belt....2800
    HYDRAULIC/HYDROSTATIC SYSTEM....2801
      Checking And Adding Fluid....2801
      Hydraulic/Hydrostatic Filter Replacement....2802
      Replacing The Hydraulic/Hydrostatic Fluid....2802
    SPARK ARRESTOR MUFFLER....2803
      Cleaning Procedure....2803
    TIRE MAINTENANCE....2804
      Wheel Nuts....2804
      Tire Rotation....2804
      Tire Inflation....2804
    FINAL DRIVE TRANSMISSION (CHAINCASE)....2805
      Checking And Adding Oil....2805
    AUXILIARY CONTROL LOCKBOLT....2805
    LUBRICATING THE LOADER....2806
      Procedure....2806
    PIVOT PINS....2808
    BOB–TACH....2808
      Inspection And Maintenance....2808
    REMOTE START SWITCH....2809
      Procedure....2809
  HYDRAULIC SYSTEM....2812
    HYDRAULIC SYSTEM INFORMATION....2814
    HYDRAULIC / HYDROSTATIC SCHEMATICS....2818
    TROUBLESHOOTING....2826
      Chart....2826
    LIFT CYLINDER(S)....2827
      Checking The Lift Cylinders....2827
      Removal And Installation....2828
    TILT CYLINDER....2830
      Checking The Tilt Cylinder....2830
      Removal And Installation....2831
    HYDRAULIC CYLINDERS....2832
      Lift Cylinder Parts Identification....2832
      Tilt Cylinder Parts Identification....2832
      Disassembly And Assembly....2833
    BICS™ BLOCK VALVE....2835
      Removal And Installation....2835
      Disassembly And Assembly....2836
    MAIN RELIEF VALVE....2839
      Checking The Main Relief Valve....2839
      Checking The Main Relief Valve With Auxiliaries....2840
      Removal And Installation....2841
      Main Relief Valve Adjustment....2841
    HYDRAULIC CONTROL VALVE....2842
      Removal And Installation....2842
      Identification Chart....2843
      Disassembly And Assembly....2844
      Load Check Valve....2844
      Main Relief Valve....2844
      Anti–Cavitation Valve....2845
      Rubber Boot....2845
      Lift Spool Detent....2846
      Tilt Centering Spring....2850
      Auxiliary Spool Detent....2850
      Spool Seal Installation....2851
    HYDRAULIC PUMP....2852
      Checking The Output Of The Hydraulic Pump....2852
      Removal And Installation....2853
      Parts Identification....2855
      Disassembly And Assembly....2856
    HYDRAULIC RESERVOIR....2858
      Removal And Installation....2858
    HYDRAULIC FILTER BLOCK....2859
      Removal And Installation....2859
      Block Disassembly And Assembly....2860
    PEDAL INTERLOCK LINKAGE....2861
      Removal And Installation....2861
    CONTROL PEDALS....2861
      Removal and Installation....2861
      Pedal Adjustment....2861
  HYDROSTATIC SYSTEM....2862
    TROUBLESHOOTING....2864
      Chart....2864
    HYDROSTATIC SYSTEM INFORMATION....2865
      Replenishing Valve Function....2865
    CONTROL SHIELD AND STEERING LEVER PANELS....2866
      Removal And Installation....2866
    STEERING LEVERS....2867
      Removal And Installation....2867
      Disassembly And Assembly....2868
    STEERING LINKAGE....2869
      Adjustment....2869
      Pintle Arm Removal And Installation....2870
      Pintle Arm Disassembly And Assembly....2870
    HYDROSTATIC MOTOR....2871
      Removal And Installation....2871
      Parts Identification....2872
      Disassembly....2873
      Inspection....2877
      Assembly....2878
    DRIVE BELT....2882
      Removal And Installation....2882
    CHARGE PRESSURE....2883
      Checking....2883
    HYDROSTATIC PUMP....2884
      Parts Identification....2884
      Removal And Installation....2885
      Disassembly And Assembly....2887
      Inspection....2890
    TENSION PULLEY AND SPRING....2893
      Removal And Installation....2893
  DRIVE SYSTEM....2896
    PARKING BRAKE PEDAL....2898
      Removal And Installation....2898
      Disassembly And Assembly....2898
    CHAINCASE FLUID....2899
      Removing Oil From The Chaincase....2899
    CHAINCASE COVER....2899
      Removal And Installation....2899
      Disassembly And Assembly....2899
    PARKING BRAKE DISC....2900
      Removal And Installation....2900
    AXLE HUB....2901
      Removal And Installation....2901
    AXLE SEAL....2902
      Removal And Installation....2902
    AXLE, BEARINGS, AND SPROCKET....2903
      Removing The Axle....2903
      Removing And Installing The Axle Bearing....2904
      Removing The Bearing Races....2905
      Installing The Bearing Races....2906
      Installing The Inner Bearing And Axle Sprocket....2906
    DRIVE CHAIN....2907
    Removal And Installation....2907
  MAIN FRAME....2908
    SEAT BAR....2910
      Removal And Installation....2910
      Assembly....2913
    OPERATOR CAB....2914
      Removal And Installation....2914
    OPERATOR CAB GAS CYLINDER....2916
      Removal And Installation....2916
    OPERATOR SEAT....2917
      Removal And Installation....2917
    BOB–TACH....2919
      Removal....2919
      Installation....2920
      Seal Removal And Installation....2921
      Lever And Wedge Removal....2921
      Lever And Wedge Installation....2923
    LIFT ARMS....2925
      Removal And Installation....2925
    FUEL TANK....2928
      Removal And Installation....2928
    REAR WINDOW....2929
      Removal And Installation....2929
    REAR DOOR....2930
      Exhaust Pipe Removal And Installation....2930
      Removal And Installation....2930
  ELECTRICAL SYSTEM....2932
    ELECTRICAL SCHEMATICS....2934
    TROUBLESHOOTING....2938
      Chart....2938
    ELECTRICAL SYSTEM INFORMATION....2939
      Description....2939
      Fuse Location....2939
      Relay Switches Location....2939
    BATTERY....2940
      Removal And Installation....2940
      Servicing The Electrical System....2941
      Using A Booster Battery (Jump Starting)....2942
    ALTERNATOR....2943
      Removal And Installation....2943
      Adjusting The Alternator Belt....2943
      Alternator Belt Removal And Installation....2944
      Description....2946
      Tests....2946
      Alternator Output Test....2946
      Full Field Test....2947
      Alternator Regulator Test....2947
      Alternator Regulator Test With Voltmeter....2947
    STARTER....2948
      Removal And Installation....2948
      Checking The Starter In The Loader....2948
      Parts Identification....2949
      Disassembly....2950
      Inspection And Repair....2955
      No Load Test....2958
      Assembly....2959
    INSTRUMENT PANEL....2966
      Removal And Installation....2966
    FRONT LIGHTS (OPTIONAL)....2967
      Removal And Installation....2967
    REAR LIGHT (OPTIONAL)....2968
      Removal And Installation....2968
  ENGINE SERVICE....2970
    TROUBLESHOOTING....2972
      Chart....2972
    ENGINE SPEED CONTROL....2974
      Adjustment....2974
      Removal And Installation....2974
    RADIATOR....2975
      Removal And Installation....2975
    RADIATOR MOUNTING BRACKET....2975
      Removal And Installation....2975
    FAN....2976
      Removal And Installation....2976
    FLYWHEEL....2977
      Removal And Installation....2977
    ENGINE MOUNTING BRACKET....2977
      Removal And Installation....2977
    VALVE CLEARANCE....2978
      Ajustment....2978
    FUEL INJECTION PUMP....2979
      Checking The Injection Pump....2979
      Removal....2980
      Installation....2981
      Timing Procedure....2981
    FUEL INJECTOR NOZZLES....2982
      Checking....2982
      Removal....2983
      Installation....2983
    GLOW PLUGS....2984
      Checking....2984
    ENGINE COMPRESSION TEST....2984
      Procedure....2984
    ENGINE....2985
      Removal And Installation....2985
    CYLINDER HEAD....2991
      Removal And Installation....2991
      Inspection....2992
      Top Clearance....2992
    ROCKER ARM AND SHAFT....2993
      Checking....2993
    VALVE AND VALVE SPRINGS....2994
      Valve Removal....2994
      Checking Valve Spring....2994
    VALVE GUIDE, VALVE AND VALVE SEAT....2995
      Checking The Valve Guide....2995
      Reconditioning The Valve And Valve Seat....2996
    TIMING GEARCASE COVER....2997
      Removal And Installation....2997
    IDLER GEAR AND CAMSHAFT....2999
      Removal And Installation....2999
      Servicing The Idler Gear And Shaft....3001
    TIMING GEARS....3001
      Checking Backlash....3001
    FUEL CAMSHAFT....3002
      Removal And Installation....3002
      Governor....3002
    CRANKSHAFT GEAR....3003
      Removal And Installation....3003
    OIL PUMP....3003
      Removal And Installation....3003
      Oil Pump Service....3003
      Checking Engine Oil Pressure....3004
      Relief Valve....3004
    PISTON AND CONNECTING ROD....3005
      Removal And Installation....3005
      Servicing The Piston And Connecting Rod....3006
      Connecting Rod Alignment....3008
    CRANKSHAFT AND BEARINGS....3009
      Removal And Installation....3009
      Inspection Of Crankshaft And Bearings....3010
    CYLINDER  BORE....3013
      Inspection....3013
    HYDRAULIC OIL COOLER AND SHROUDING....3014
      Removal And Installation....3014
    THERMOSTAT....3015
      Removal And Installation....3015
    WATER PUMP....3016
      Removal And Installation....3016
      Disassembly And Assembly....3016
  SYSTEMS ANALYSIS....3018
    BICS™ (With Press To Operate Button)....3020
      Inspecting The BICS™ Controller (Engine STOPPED – Key ON)....3020
      Inspecting The Seat Bar Sensor (Engine RUNNING)....3020
      Inspecting The Traction Lock (Engine RUNNING)....3020
      Inspecting The Lift Arm By–Pass Control....3020
      Troubleshooting Chart....3021
      Inspecting The BICSTM Controller (Engine STOPPED – Key ON)....3022
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)....3022
      Inspecting The Traction Lock (Engine Running)....3022
      Inspecting The Lift Arm By–Pass Control....3022
      Maintenance....3022
      Troubleshoot Chart....3023
    BICS™ SYSTEM CONTROLLER....3024
      Troubleshooting Guide....3024
      Removal And Installation....3025
    SEAT BAR SENSOR....3026
      Troubleshooting Guide....3026
      Seat Bar Sensor Test....3027
      Removal And Installation....3028
      BICS™ Controller Seat Bar Sensor Circuit Test....3029
    SEAT SENSOR....3030
      Troubleshooting Guide....3030
      Seat Sensor Test....3031
      Removal And Installation....3032
      BICS™ Controller Seat Sensor Circuit Test....3033
    TRACTION LOCK....3034
      Troubleshooting Guide....3034
      Removal And Installation....3035
  SPECIFICATIONS....3036
    SKID STEER LOADER SPECIFICATIONS....3038
      PERFORMANCE....3038
      CONTROLS....3038
      ENGINE....3038
      HYDRAULIC SYSTEM....3039
      ELECTRICAL....3039
      DRIVE SYSTEM....3039
      CAPACITIES....3039
      TIRES....3039
      FLOOR PRESSURE....3039
    ENGINE SPECIFICATIONS....3040
      Engine....3040
      Fuel Injector Nozzles....3040
      Fuel Injection Pump....3040
      Cylinder Head....3040
      Valves....3040
      Valve Springs....3040
      Rocker Arms....3040
      Camshaft....3041
      Cylinders....3041
      Piston Rings....3041
      Pistons....3041
      Crankshaft....3041
      Oil Pump....3042
      Thermostat....3042
      ENGINE BOLT TORQUE....3043
      Re–Grinding The Crankshaft....3044
    TORQUE SPECIFICATIONS FOR BOLTS....3045
      Torque For General SAE Bolts....3045
      Torque For General Metric Bolts....3046
    HYDRAULIC CONNECTION SPECIFICATIONS....3047
      O–ring Face Seal Connection....3047
      Straight Thread O–ring Fitting....3047
      Tubelines And Hoses....3047
      Flare Fitting....3047
      O–ring Flare Fitting....3048
      Port Seal Fitting....3050
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....3051
      Specifications....3051
    DECIMAL AND MILLIMETER EQUIVALENTS....3052
    U.S. TO METRIC CONVERSION....3052
  SERVICE MANUAL REVISIONS....3054
    453-1....3054
    453-2....3056
    453-3....3058
    453-4....3060
    453-5....3062
6900784 (10-04) - 453 Operation & Maintenance Manual....3064
  OPERATOR SAFETY WARNINGS....3066
  CONTENTS....3068
  FOREWORD....3070
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....3072
    REGULAR MAINTENANCE ITEMS....3072
    MOTOR OIL....3072
    SERIAL NUMBER LOCATIONS....3074
    LOADER SERIAL NUMBER....3074
    ENGINE SERIAL NUMBER....3074
    DELIVERY REPORT....3074
    BOBCAT SKID STEER LOADER IDENTIFICATION....3075
    OPTIONS AND ACCESSORIES....3076
      Tires....3076
      Operator Cab....3076
      Hydraulics....3076
      Other....3076
  SAFETY....3078
    SAFETY INSTRUCTIONS....3080
      Before Operation....3080
      Safe Operation Is The Operator’s Responsibility....3081
      Safe Operation Needs A Qualified Operator....3081
      Fire Prevention....3082
    MACHINE SIGNS (DECALS)....3083
  OPERATING INSTRUCTIONS....3086
    INSTRUMENT PANEL....3088
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....3089
      Lift Arm By-Pass Control....3089
      Traction Lock Override....3090
    ENGINE SPEED CONTROL....3090
    PARKING BRAKE....3091
    STEERING LEVERS....3092
    STOPPING THE BOBCAT LOADER....3092
    SEAT BAR RESTRAINT SYSTEM....3093
    HYDRAULIC CONTROLS....3094
      Foot Pedals....3094
      Bucket Position Valve Operation (If Equipped)....3095
      Auxiliary Hydraulics (If Equipped)....3095
      Quick Couplers....3096
      Auxiliary Hydraulic Continuous Operation....3097
      Relievng Hydraulic Pressure....3097
    DAILY INSPECTION....3098
    GETTING READY FOR OPERATION....3099
    STARTING THE ENGINE....3100
      Normal Starting....3100
      Cold Temperature Starting....3102
      Warming The Hydraulic/Hydrostatic System....3102
    STOPPING THE ENGINE....3102
    ATTACHMENTS AND BUCKETS....3103
      Installation And Removal (Without Bob-Tach)....3103
      Installation And Removal (With Bob-Tach)....3104
      Removing The Bucket Or Attachment....3105
    OPERATING PROCEDURE....3106
      Filling The Bucket....3107
      Emptying The Bucket....3108
      Digging Into The Ground....3108
      Leveling The Ground (Using Lift Arms In Float Position)....3109
      Backfilling....3109
    PARKING THE BOBCAT LOADER....3110
    TRANSPORTING THE BOBCAT LOADER....3111
    LIFTING THE LOADER....3112
    TOWING THE LOADER....3112
  PREVENTIVE MAINTENANCE....3114
    MAINTENANCE SAFETY....3116
    SERVICE SCHEDULE....3118
    LIFT ARM SUPPORT DEVICE....3119
      Engaging The Lift Arm Support Device....3119
      Disengaging The Lift Arm Support Device....3120
    OPERATOR CAB....3121
      Raising The Operator Cab....3121
      Lowering The Operator Cab....3122
      Emergency Exit....3122
    SEAT BAR RESTRAINT SYSTEM....3123
      Seat Bar Inspection....3123
      Seat Bar Maintenance....3124
      Foot Pedal Clean Out....3124
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....3125
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)....3125
      Inspecting The Seat Bar Sensor (Engine RUNNING)....3125
      Inspecting The Traction Lock (Engine RUNNING)....3125
      Inspecting The Lift Arm By-Pass Control....3125
    REAR DOOR....3126
    AIR CLEANER SERVICE....3126
    FUEL SYSTEM....3127
      Fuel Specifications....3127
      Filling The Fuel Tank....3128
      Fuel Filter....3128
      Removing Air From The Fuel System....3129
    ENGINE LUBRICATION SYSTEM....3130
      Oil Chart....3130
      Replacing Oil And Filter....3130
    COOLING SYSTEM....3131
      Checking The Coolant Level....3131
      Propylene Glycol....3131
      Cleaning The Cooling System....3131
      Removing Coolant From The Cooling System....3131
    ALTERNATOR BELT ADJUSTMENT....3132
    ELECTRICAL SYSTEM....3133
      Description....3133
      Fuse Location....3133
      Electrical System Service....3133
      Battery Removal And Installation....3133
      Using A Booster Battery (Jump Starting)....3134
    HYDRAULIC/HYDROSTATIC SYSTEM....3135
      Checking And Adding Fluid....3135
      Replacing The Hydraulic/Hydrostatic Filter Element....3135
      Removing The Hydraulic/Hydrostatic Fluid....3136
    SPARK ARRESTOR MUFFLER....3137
    TIRE MAINTENANCE....3138
      Wheel Nuts....3138
      Tire Rotation....3138
      Tire Inflation....3138
    FINAL DRIVE TRANSMISSION (CHAINCASE)....3139
      Checking And Adding Oil....3139
    AUXILIARY CONTROL LOCKBOLT....3139
    LUBRICATING THE LOADER....3140
    PIVOT PINS....3141
    BOB-TACH....3142
      Inspection And Maintenance....3142
  SYSTEM SETUP & ANALYSIS....3144
    TROUBLESHOOTING....3146
    TROUBLESHOOTING THE ENGINE....3146
    TROUBLESHOOTING THE HYDRAULIC SYSTEM....3147
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM....3147
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....3148
  MACHINE SIGN TRANSLATIONS....3150
    SERVICE SCHEDULE (6708212)....3152
    WARNING (6579510)....3154
    WARNING (6702255)....3155
    WARNING (6710358)....3155
    DANGER (6702301)....3156
    DANGER (6702302)....3156
    WARNING (6717343)....3158
    WARNING (6577754)....3158
    IMPORTANT (6560573)....3158
    LIFT ARM SUPPORT DEVICE (6711659)....3158
    WARNING (6579511)....3160
  SPECIFICATIONS....3162
    SKID STEER LOADER....3164
    SPECIFICATIONS....3164
      Performance....3164
      Controls....3165
      Engine....3165
      Hydraulic System....3166
      Electrical....3166
      Drive System....3167
      Capacities....3167
      Tires....3167
      Floor Pressure....3167
    BOBCAT APPROVED ATTACHMENTS & ACCESSORIES....3168
    BUCKET DESCRIPTIONS....3168
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....3169
  WARRANTY....3170
6901800 (5-07) - 442 Operation & Maintenance Manual....3172
  OPERATOR SAFETY WARNINGS....3174
  CONTENTS....3176
  FOREWORD....3178
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....3180
    REGULAR MAINTENANCE ITEMS....3180
    MOTOR OIL....3180
    SERIAL NUMBER LOCATIONS....3182
      Excavator Serial Number....3182
      Engine Serial Number....3182
    DELIVERY REPORT....3183
    BOBCAT EXCAVATOR IDENTIFICATION....3184
    FEATURES AND ACCESSORIES....3185
      Standard Items....3185
      Options and Accessories....3185
      Other....3185
    BOBCAT APPROVED ATTACHMENTS & ACCESSORIES....3185
    BUCKETS AND ATTACHMENTS AVAILABLE....3185
  SAFETY....3186
    SAFETY INSTRUCTIONS....3188
      Before Operation....3188
      Safe Operation Is The Operator’s Responsibility....3189
      Safe Operation Needs A Qualified Operator....3189
      Fire Prevention....3190
    MACHINE SIGNS (DECALS)....3191
  OPERATING INSTRUCTIONS....3194
    INSTRUMENTS AND CONSOLES....3196
      Left Console....3196
      Right Console....3197
    OPERATOR CAB....3200
      Description....3200
      Entering And Exiting The Excavator....3200
      Raising And Lowering The Left Console....3200
      Emergency Exit....3201
      Cab Door....3201
      Front Window....3202
      Front Window Ventilation....3203
      Top Window....3204
      Wiper/Washer Fluid Reservoir....3204
      Operation And Maintenance Manual Compartment (Early Models)....3204
      Heating, Air Conditioning And Ventilation (Early Models)....3205
      Heating, Air Conditioning And Ventilation (Later Models)....3206
    STEERING LEVERS/FOOT PEDALS....3207
      Forward And Reverse Travel....3207
      Turning....3207
    HYDRAULIC CONTROLS....3209
      ISO Control Pattern....3209
      Standard Control Pattern....3210
      Quick Couplers....3211
      Relieving Hydraulic Pressure....3214
      Auxiliary Hydraulics....3215
      Upperstructure Slew Brake....3216
      Auxiliary Hydraulic Flow Control (S/N 522311001 & Above)....3216
      Auxiliary Hydraulic Flow Control (S/N 528611001 & Above and S/N 528911001 & Above)....3217
    BLADE CONTROL LEVER....3218
      Operation....3218
    BOOM SWING PEDAL....3219
      Operation....3219
    DAILY INSPECTION....3220
    PRE-STARTING PROCEDURE....3222
    STARTING THE ENGINE....3225
      Key Switch....3225
      Cold Temperature Starting Procedure....3226
    OPERATING PROCEDURE....3227
      Operating On Public Roads....3227
      Lifting A Load....3227
      Excavating....3228
      Boom Offset....3230
      Backfilling....3231
      Driving The Excavator....3231
      Operating On Slopes....3232
      Operating In Water....3234
    PARKING THE EXCAVATOR....3234
    TRANSPORTING THE EXCAVATOR....3235
    LIFTING THE EXCAVATOR....3236
    ATTACHMENTS....3237
      Bucket And Ripper Tooth Installation....3237
      Bucket And Ripper Tooth Removal....3238
      Tilt Bucket Installation....3239
      Tilt Bucket Removal....3240
      Tilt Bucket Operation....3241
      Clamshell Bucket Installation....3242
      Clamshell Bucket Removal....3245
      Clamshell Bucket Operation....3246
      Lifting The Clamshell Bucket....3248
      Fastening The Clamshell Bucket To The Transport Vehicle....3249
      Manual Spring Loaded Coupler Installation....3250
      Manual Spring Loaded Coupler Removal....3251
      Manual Spring Loaded Coupler Attachment Installation....3252
      Manual Spring Loaded Coupler Attachment Removal....3254
  PREVENTIVE MAINTENANCE....3256
    MAINTENANCE SAFETY....3258
    SERVICE SCHEDULE....3260
    REAR COVER....3261
      Opening And Closing The Rear Cover....3261
    RIGHT SIDE COVER....3261
      Opening And Closing The Right Side Cover....3261
    AIR CLEANER....3262
      Daily Check....3262
      Replacing The Filters....3262
    FRESH AIR FILTER....3264
      Removal And Installation (S/N 522311001 & Above)....3264
      Removal And Installation (S/N 528611001 & Above and S/N 528911001 & Above)....3264
    FUEL SYSTEM....3265
      Fuel Specifications....3265
      Filling The Fuel Tank....3265
      Removing Water From The Pre-Filter (S/N 522311001 & Above)....3266
      Pre-Filter Removal (S/N 522311001 & Above)....3267
      Pre-Filter Installation (S/N 522311001 & Above)....3269
      Pre-Filter Removal And Installation (S/N 528611001 & Above and S/N 528911001 & Above)....3270
      Fuel Filter Removal And Installation....3270
      Draining The Fuel Tank....3271
    ENGINE LUBRICATION SYSTEM....3272
      Checking Engine Oil....3272
      Oil Chart....3272
      Replacing Oil And Filter....3273
    COOLING SYSTEM....3275
      Cleaning The Cooling System....3275
      Checking Coolant Level (S/N 522311001 & Above)....3275
      Replacing The Coolant (S/N 522311001 & Above)....3276
    ELECTRICAL SYSTEM....3278
      Description....3278
      Fuse And Relay Location (S/N 522311001 & Above)....3278
      Fuse And Relay Location (S/N 528611001 & Above and S/N 528911001 & Above)....3281
      Using A Booster Battery (Jump Starting)....3284
      Removing And Installing The Battery....3286
    ALTERNATOR BELT....3288
      Adjusting Belt Tension....3288
    FAN / FUEL PUMP BELT (S/N 522311001 & Above)....3288
      Adjusting Belt Tension....3288
    AIR CONDITIONING COMPRESSOR BELT (S/N 528611001 & Above and S/N 528911001 & Above)....3289
      Adjusting Belt Tension....3289
    HYDRAULIC SYSTEM....3290
      Checking And Adding Hydraulic Oil....3290
      Replacing The Hydraulic Oil....3291
      Hydraulic Filter Removal (S/N 522311001 & Above)....3292
      Hydraulic Filter Installation (S/N 522311001 & Above)....3293
      Hydraulic Filter Removal (S/N 528611001 & Above and S/N 528911001 & Above)....3294
      Hydraulic Filter Installation (S/N 528611001 & Above and S/N 528911001 & Above)....3295
      Diagnostic Couplers (S/N 522311001 & Above)....3297
      Diagnostic Couplers (S/N 528611001 & Above and S/N 528911001 & Above)....3297
    TRACK TENSION....3298
      Rubber Track Clearance....3298
      Steel Track Clearance....3300
      Adjustment....3301
    TRAVEL MOTOR....3303
      Checking Oil Level....3303
      Draining The Travel Motor....3303
    LUBRICATING THE EXCAVATOR....3304
    LUBRICATING THE ATTACHMENTS....3308
      Tilt Bucket Lubrication....3308
      Clamshell Bucket Lubrication....3309
  MACHINE SIGN TRANSLATIONS....3310
    WARNING (6813577)....3312
    LIFT CHART (6813628)....3313
    SERVICE SCHEDULE (6814224)....3316
    WARNING (6807776)....3319
    WARNING (6813581, 6813576, 6804233)....3322
    UNDERCARRIAGE COMPONENTS (6589129)....3323
    COOLANT (6811054)....3323
    MECHANICAL SPRING LOADED COUPLER (7130241)....3324
  SPECIFICATIONS....3328
    SPECIFICATIONS....3330
      Excavator Machine Dimensions....3330
      Performance Specifications....3331
      Controls....3331
      Engine (S/N 522311001 & Above)....3331
      Engine (S/N 528611001 & Above and S/N 528911001 & Above)....3331
      Hydraulic System (S/N 522311001 & Above)....3332
      Hydraulic System (S/N 528611001 & Above and S/N 528911001& Above)....3332
      Hydraulic Cylinders....3332
      Hydraulic Cycle Times....3332
      Drive System....3333
      Undercarriage....3333
      Track....3333
      Electrical System....3333
    FUEL, COOLANT AND LUBRICANTS....3334
      Chart (S/N 522311001 & Above)....3334
      Chart (S/N 528611001 & Above and S/N 528911001 & Above)....3335
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....3336
6901801 (5-10) - 442 Service Manual....3340
  MAINTENANCE SAFETY....3342
  ALPHABETICAL INDEX....3344
  CONTENTS....3346
    FOREWORD....3348
    SAFETY INSTRUCTIONS....3350
    FIRE PREVENTION....3352
      Maintenance....3352
      Operation....3352
      Electrical....3352
      Hydraulic System....3352
      Fueling....3352
      Starting....3352
      Spark Arrestor Exhaust System....3352
      Welding And Grinding....3353
      Fire Extinguishers....3353
    SERIAL NUMBER LOCATIONS....3354
      Excavator Serial Number....3354
      Engine Serial Number....3354
    DELIVERY REPORT....3355
    BOBCAT EXCAVATOR IDENTIFICATION....3356
  SAFETY & MAINTENANCE....3358
    LIFTING AND BLOCKING THE EXCAVATOR....3362
      Procedure....3362
    LIFTING THE EXCAVATOR....3364
      Procedure....3364
    OPERATOR CAB....3366
      Description....3366
      Entering And Exiting The Excavator....3366
      Raising And Lowering The Left Console....3366
      Emergency Exit....3367
    TRANSPORTING THE EXCAVATOR....3368
    REAR COVER....3370
      Opening And Closing The Rear Cover....3370
    RIGHT SIDE COVER....3372
      Opening And Closing The Right Side Cover....3372
    SERVICE SCHEDULE....3374
    AIR CLEANER....3376
      Daily Check....3376
      Replacing The Filters....3376
    FRESH AIR FILTER (S/N 522311001 & ABOVE)....3380
      Removal And Installation....3380
    FRESH AIR FILTER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....3382
      Removal And Installation....3382
    COOLING SYSTEM....3384
      Cleaning The Cooling System....3384
      Checking Coolant Level (S/N 522311001 & Above)....3384
      Replacing The Coolant (S/N 522311001 & Above)....3385
    FUEL SYSTEM....3388
      Fuel Specifications....3388
      Filling The Fuel Tank....3388
      Removing Water From The Pre-Filter (S/N 522311001 & Above)....3389
      Pre-Filter Removal (S/N 522311001 & Above)....3390
      Pre-Filter Installation (S/N 522311001 & Above)....3391
      Pre-Filter Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above)....3393
      Fuel Filter Removal And Installation....3394
      Draining The Fuel Tank....3395
    ENGINE LUBRICATION SYSTEM....3396
      Checking Engine Oil....3396
      Replacing Oil And Filter....3397
    HYDRAULIC SYSTEM....3400
      Checking And Adding Hydraulic Oil....3400
      Replacing The Hydraulic Oil....3401
      Hydraulic Filter Removal (S/N 522311001 & Above)....3402
      Hydraulic Filter Installation (S/N 522311001 & Above)....3403
      Hydraulic Filter Removal (S/N 528911001 & Above And S/N 528611001 & Above)....3405
      Hydraulic Filter Installation (S/N 528911001 & Above And S/N 528611001 & Above)....3406
      Diagnostic Couplers (S/N 522311001 & Above)....3408
      Diagnostic Couplers (S/N 528911001 & Above And S/N 528611001 & Above)....3409
    LUBRICATION OF THE EXCAVATOR....3410
    TRAVEL MOTOR....3414
      Checking Oil Level....3414
      Draining The Travel Motor....3414
    ALTERNATOR BELT....3416
      Adjusting Belt Tension....3416
    FAN/FUEL PUMP BELT....3418
      Adjusting Belt Tension (S/N 522311001 & Above)....3418
    AIR CONDITIONING COMPRESSOR BELT (S/N 522311001 & ABOVE)....3420
      Adjusting Belt Tension....3420
    AIR CONDITIONING COMPRESSOR BELT (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....3422
      Adjusting Belt Tension....3422
    CAB TILT PROCEDURE....3424
      Installing The Cab Tilt Hinges....3424
      Tilting The Cab....3425
  HYDRAULIC SYSTEM....3432
    HYDRAULIC / HYDROSTATIC SCHEMATICS....3440
    HYDRAULIC SYSTEM INFORMATION....3444
      Troubleshooting Chart....3444
      Description....3449
    BOOM CYLINDER....3452
      Testing....3452
      Removal And Installation....3454
      Parts Identification....3458
      Disassembly....3459
      Assembly....3464
    ARM CYLINDER....3470
      Testing....3470
      Removal And Installation....3470
      Parts Identification....3474
      Disassembly....3475
      Assembly....3480
    BOOM OFFSET CYLINDER....3486
      Testing....3486
      Removal And Installation....3489
      Parts Identification....3493
      Disassembly....3494
      Assembly....3498
    BUCKET CYLINDER....3506
      Testing....3506
      Removal And Installation....3506
      Parts Identification....3510
      Disassembly....3511
      Assembly....3515
    BLADE CYLINDER....3522
      Testing....3522
      Removal And Installation....3523
      Parts Identification....3525
      Disassembly....3526
      Assembly....3531
    RELIEF VALVES....3538
      Description....3538
      Testing The Three Spool Control Valve Main Relief Valve....3539
      Adjusting The Three Spool Control Valve Main Relief Valve....3539
    PORT RELIEF VALVES....3540
      Adjustment Procedure....3540
    PRESSURE REDUCING VALVE (S/N 528911001 & ABOVE AND 528611001 & ABOVE)....3542
      Description....3542
      Testing....3542
      Adjustment....3543
    PRESSURE REDUCING VALVE (S/N 522311001 & ABOVE)....3544
      Description....3544
      Testing....3544
      Adjustment....3545
    DUMP VALVE....3546
      Description....3546
      Testing....3546
      Adjustment....3546
      Removal And Installation....3547
      Parts Identification....3548
      Disassembly And Assembly....3549
    SIX SPOOL HYDRAULIC CONTROL VALVE....3554
      Removal And Installation....3554
      Control Valve Identification....3558
      Disassembly And Assembly....3559
      Left Travel And Right Travel Valve Section Disassembly And Assembly....3562
      Boom, Arm, Bucket And Auxiliary Valve Section Disassembly And Assembly....3565
      Inlet Valve Section Disassembly And Assembly....3570
    THREE SPOOL HYDRAULIC CONTROL VALVE....3572
      Removal And Installation....3572
      Parts Identification....3574
      Disassembly And Assembly....3575
      Boom Offset And Blade Valve Section Disassembly And Assembly....3577
      Inlet/Upperstructure Swing Valve Section Disassembly And Assembly....3581
    HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE)....3586
      Hydraulic Pump Work Sheet....3586
      Testing Information....3589
      Pump Testing....3591
      Load Sense Relief Valve Adjustment....3594
      Removal And Installation....3600
      Coupler Removal And Installation....3603
      Torque Limiter Valve Parts Identification....3604
      Torque Limiter Valve Removal and Installation....3605
      Torque Limiter Valve Disassembly....3606
      Torque Limiter Valve Assembly....3610
      Initial Torque Limiter Valve Setting....3614
      Pump Control Parts Identification....3616
      Pump Control Removal And Installation....3617
      Pump Control Disassembly And Assembly....3618
      Parts Identification....3623
      Disassembly....3624
      Assembly....3633
    HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE)....3644
      Removal And Installation....3644
      Parts Identification....3645
      Disassembly....3646
      Assembly....3655
    HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....3664
      Hydraulic Pump Work Sheet....3664
      Testing Information....3667
      Pump Testing....3668
      Load Sense Relief Valve Adjustment....3671
      Removal And Installation....3676
      Coupler Removal And Installation....3678
      Torque Limiter Valve Parts Identification....3679
      Torque Limiter Valve Removal and Installation....3680
      Torque Limiter Valve Disassembly....3681
      Torque Limiter Valve Assembly....3685
      Initial Torque Limiter Valve Setting....3689
      Pump Control Parts Identification....3691
      Pump Control Removal And Installation....3692
      Pump Control Disassembly And Assembly....3693
      Parts Identification....3698
      Disassembly....3699
      Assembly....3708
    HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....3718
      Removal And Installation....3718
      Parts Identification....3720
      Disassembly....3721
      Assembly....3724
    ACCUMULATOR (S/N 522311001 & ABOVE)....3728
      Description....3728
      Removal And Installation....3728
    ACCUMULATOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....3730
      Description....3730
      Removal And Installation....3730
    TRAVEL MOTOR....3732
      Removal And Installation....3732
      Parts Identification....3733
      Disassembly....3734
      Assembly....3751
    SWIVEL JOINT....3770
      Removal And Installation....3770
      Parts Identification....3772
      Disassembly And Assembly....3773
    SWING MOTOR....3776
      Removal And Installation....3776
      Parts Identification....3778
      Disassembly....3779
      Assembly....3785
    SWING MOTOR DRIVE CARRIER....3792
      Removal And Installation....3792
      Parts Identification....3794
      Disassembly....3795
      Assembly....3804
    SWING BRAKE VALVE....3818
      Removal And Installation....3818
      Parts Identification....3819
      Disassembly And Assembly....3820
    SWING BRAKE RELEASE VALVE....3822
      Removal And Installation....3822
    SWING BRAKE RELEASE VALVE (CONT’D)....3823
      Parts Identification....3823
      Disassembly And Assembly....3824
    JOYSTICK CONTROL PATTERN SELECTOR VALVE....3826
      Removal And Installation....3826
      Parts Identification....3827
      Disassembly And Assembly....3828
    JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 522311001 & ABOVE)....3830
      Removal And Installation....3830
      Parts Identification....3831
      Disassembly And Assembly....3832
    JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....3834
      Removal And Installation....3834
      Parts Identification....3836
      Disassembly And Assembly....3837
    RIGHT CONTROL LEVER (JOYSTICK)....3842
      Testing....3842
      Handle Removal And Installation....3843
      Removal And Installation....3844
      Parts Identification....3846
      Disassembly And Assembly....3847
    LEFT CONTROL LEVER (JOYSTICK)....3852
      Testing....3852
      Handle Removal And Installation....3853
      Removal And Installation....3854
      Parts Identification....3856
      Disassembly and Assembly....3857
    TRAVEL LEVER/FOOT PEDAL VALVE....3862
      Left Travel Lever/Foot Pedal Valve Removal And Installation....3862
      Right Travel Lever/Foot Pedal Valve Removal And Installation....3863
      Parts Identification....3865
      Disassembly And Assembly....3866
    HYDRAULIC FILTER MOUNT....3870
      Removal And Installation....3870
    HYDRAULIC RESERVOIR....3872
      Removal And Installation....3872
    OIL COOLER....3878
      Description....3878
    SECONDARY FRONT AUXILIARY VALVE....3880
      Removal And Installation....3880
      Parts Identification....3881
      Disassembly And Assembly....3882
    HYDRAULIC BREAKER APPLICATION VALVE (S/N 522311001 & ABOVE)....3886
      Removal And Installation....3886
      Parts Identification....3887
      Disassembly And Assembly....3888
    AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/ N 522311001 & ABOVE)....3890
      Removal And Installation....3890
      Parts Identification....3891
      Disassembly And Assembly....3892
    AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....3894
      Removal And Installation....3894
      Parts Identification....3895
      Disassembly And Assembly....3896
    BLADE VALVE....3900
      Removal And Installation....3900
      Parts Identification....3901
      Disassembly And Assembly....3902
    BLADE FLOAT VALVE....3906
      Removal And Installation....3906
      Parts Identification....3907
      Disassembly And Assembly....3908
    BOOM OFFSET VALVE....3912
      Removal And Installation....3912
      Parts Identification....3913
      Disassembly And Assembly....3914
    BOOM LOAD HOLDING VALVE....3920
      Removal And Installation....3920
      Parts Identification....3921
      Disassembly....3922
      Assembly....3929
    OIL TEMPERATURE REGULATOR....3936
      Description....3936
      Removal And Installation....3936
    AUXILIARY HYDRAULICS SELECTOR VALVE....3938
      Removal And Installation....3938
    HYDRAULIC PISTON PUMP DRIVE COUPLER....3940
      Removal And Installation....3940
  UNDERCARRIAGE....3942
    BLADE....3944
      Removal And Installation....3944
    TRACKS....3946
      Track Lug Height....3946
      Rubber Track Clearance....3947
      Steel Track Clearance....3948
      Track Adjustment....3949
      Rubber Track Removal And Installation....3951
    TRACK FRAME....3954
      Disassembly And Assembly....3954
      Drive Sprocket Removal And Installation....3958
    TRACK IDLER....3960
      Parts Identification....3960
      Disassembly....3961
      Assembly....3964
    UPPER TRACK ROLLER....3970
      Parts Identification....3970
      Disassembly....3971
      Assembly....3973
    LOWER TRACK ROLLER....3978
      Parts Identification....3978
      Disassembly....3979
      Assembly....3982
    GREASE CYLINDER....3988
      Parts Identification....3988
      Disassembly....3989
      Assembly....3990
    TRACK DAMAGE IDENTIFICATION....3992
      Cutting Of Steel Cords....3992
      Abrasion Of Embedded Metals....3993
      Separation Of Embedded Metals....3994
      Separation Of Embedded Metals Due To Corrosion....3995
      Cuts On The Lug Side Rubber....3996
      Cracks On The Lug Side Rubber Due To Fatigue....3997
      Lug Abrasion....3998
      Cracks And Cuts On The Lug Side Rubber....3999
      Abrasion Of The Track Roller Side....4000
      Cuts On The Edges Of Track Roller Side....4001
  UPPERSTRUCTURE & SWING SECTION....4004
    UPPERSTRUCTURE....4006
      Removal And Installation....4006
      Swing Bearing Removal And Installation....4011
    CAB....4014
      Removal And Installation....4014
      Door Removal And Installation....4021
      Front Window Removal And Installation....4022
      Front Window Disassembly And Assembly (S/N 522311001 & Above)....4027
      Front Window Gas Strut Removal And Installation....4030
      Front Window Pivot Frame Removal And Installation....4031
      Lower Front Widow Removal And Installation....4032
      Door, Left Side, Right Side And Rear Window Removal....4033
      Door, Left Side, Right Side And Rear Window Installation....4034
      Cab Visor Removal And Installation....4036
      Top Window Removal And Installation....4037
    SEAT AND SEAT MOUNT....4038
      Removal And Installation....4038
    RIGHT CONSOLE....4040
      Description....4040
    LEFT CONSOLE....4042
      Removal And Installation....4042
      Disassembly And Assembly....4047
      Console Lockout Switch Removal And Installation....4049
    ENGINE SPEED CONTROL....4050
      Removal And Installation....4050
      Disassembly And Assembly....4052
    CONTROL LEVERS....4054
      Description....4054
    FUEL TANK....4056
      Removal And Installation....4056
    HORN....4060
      Removal And Installation....4060
    SWING FRAME....4062
      Removal And Installation....4062
      Bushing Removal And Installation....4066
    FLOOR MAT....4068
      Removal And Installation....4068
    BOOM....4070
      Removal And Installation....4070
      Bushing Removal And Installation....4077
    ARM....4078
      Removal And Installation....4078
      Bushing Removal And Installation....4081
    BUCKET....4082
      Removal And Installation....4082
    REAR COVER....4084
      Removal And Installation....4084
    RIGHT SIDE COVER....4086
      Removal And Installation....4086
    COUNTERWEIGHT....4090
      Removal And Installation....4090
  ELECTRICAL SYSTEM & ANALYSIS....4094
    ELECTRICAL SCHEMATICS....4096
    ELECTRICAL SYSTEM INFORMATION....4105
      Troubleshooting Chart....4105
      Description....4106
      Fuse And Relay Location (S/N 522311001 & Above)....4107
      Fuse And Relay Location (S/N 528911001 & Above And S/N 528611001 & Above)....4109
    BATTERY....4113
      Servicing....4113
      Removal And Installation....4114
      Using A Booster Battery (Jump Starting)....4116
    ALTERNATOR....4119
      Removal And Installation (S/N 522311001 & Above)....4119
      Removal And Installation (S/N 528911001 & Above And 528611001 & Above)....4121
      Parts Identification....4123
      Alternator Identification....4124
      Charging System Check....4125
      Rectifier Continuity (Diode) Test....4127
      Disassembly....4129
      Stator Continuity Test....4135
      Stator Ground Test....4135
      Rotor Continuity Test....4135
      Rotor Ground Test....4136
      Capacitor Continuity Test....4136
      Assembly....4137
    STARTER....4145
      Removal And Installation (S/N 522311001 & Above)....4145
      Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above)....4146
      Parts Identification (All Models)....4147
      Disassembly (All Models)....4148
      Inspection And Repair (All Models)....4156
      Assembly (All Models)....4158
    STARTER (S/N 528911001 & ABOVE & S/N 528611001 & ABOVE)....4169
      Removal And Installation....4169
    FRONT CAB LIGHT....4171
      Removal And Installation....4171
      Disassembly And Assembly....4172
    TWO SPEED SWITCH....4175
      Removal And Installation....4175
    FUEL LEVEL SENDER....4177
      Removal And Installation....4177
    WIPER MOTOR....4179
      Removal And Installation....4179
    BATTERY DISCONNECT SWITCH....4181
      Removal And Installation....4181
    INSTRUMENT PANEL....4183
      Removal And Installation....4183
      E-Prom Information....4184
  ENGINE SERVICE....4185
    TROUBLESHOOTING....4189
      Chart....4189
    MUFFLER (S/N 522311001 & ABOVE)....4191
      Removal And Installation....4191
    MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....4195
      Removal And Installation....4195
    AIR CLEANER....4197
      Removal And Installation....4197
    RADIATOR/OIL COOLER (S/N 522311001 & ABOVE)....4199
      Removal And Installation....4199
    RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....4207
      Removal And Installation....4207
      Hydraulic Check Valve Removal And Installation....4211
      Hydraulic Check Valve Disassembly And Assembly....4212
    ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE)....4213
      Engine Compression Checking....4213
      Checking the Glow Plugs....4215
      Glow Plug Removal And Installation....4216
      Fuel Shutoff Solenoid Checking....4217
      Fuel Shutoff Solenoid Removal And Installation....4218
      Fuel Injection Pump Removal....4219
      Fuel Injection Pump Timing....4221
      Fuel Injection Pump Installation....4227
      Fuel Injector, Checking....4230
      Fuel Injector Disassembly....4231
      Fuel Injector Assembly....4233
      Valve Clearance Adjustment....4235
      Thermostat....4236
    ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....4237
      Engine Compression Checking....4237
      Checking the Manifold Heater....4239
      Manifold Heater Removal And Installation....4240
      Fuel Shutoff Solenoid Checking....4241
      Fuel Shutoff Solenoid Removal And Installation....4242
      Fuel Injection Pump Removal....4243
      Fuel Injection Pump Timing....4245
      Fuel Injection Pump Installation....4246
      Fuel Injector Removal And Installation....4249
      Fuel Injector Removal And Installation (Cont’d)....4250
      Fuel Injector, Checking....4250
      Fuel Injector Disassembly....4251
      Fuel Injector Assembly....4253
      Timing Belt Inspection....4255
      Timing Belt Removal....4256
      Timing Belt Installation....4258
      Valve Clearance Adjustment....4264
      Valve Timing, Checking....4265
      Thermostat, Oil Pressure Control Valves & Heater Connections....4267
      Aneroid Device....4270
    ENGINE (S/N 522311001 & ABOVE)....4273
      Removal And Installation....4273
    ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....4283
      Removal And Installation....4283
    FLYWHEEL (S/N 522311001 & ABOVE)....4289
      Removal And Installation....4289
      Flywheel Ring Gear....4290
    FLYWHEEL (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....4291
      Removal And Installation....4291
      Flywheel Ring Gear....4292
    RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE)....4293
      Deutz Engine Tools Identification Chart....4293
      Disassembly....4294
      Assembly....4301
      Cylinder, Checking....4339
      Camshaft Bearing, Checking....4340
      Camshaft Bearing, Removal And Installation....4341
      Balancing Shaft Bearing, Checking (If Equipped)....4342
      Balancing Shaft Bearing, Removal And Installation....4343
      Control Rod Guide Bushing Installation....4344
      Rear Cover Seal Removal And Installation....4346
      Rear Cover Seal Removal And Installation (Cont’d)....4347
      Crankshaft, Checking....4348
      Connecting Rod, Checking....4350
      Piston, Checking....4353
      Piston Pin, Checking....4354
      Piston Rings Installation....4355
      Piston Installation On The Connecting Rod....4356
      Cylinder Head Disassembly....4357
      Valves, Checking....4358
      Valve Clearance Adjustment....4359
      Cylinder Head Assembly....4360
      Rocker Arm And Bracket, Checking....4361
      Front Cover Disassembly....4362
      Front Cover Assembly....4363
      Turbo Charger Removal and Installation....4364
    RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....4367
      Deutz Engine Tools Identification Chart....4367
      Disassembly....4368
      Assembly....4375
      Cylinder, Checking....4394
      Camshaft Bearing, Checking....4395
      Camshaft Bearing, Removal And Installation....4396
      Control Rod Guide Bushing Removal....4397
      Control Rod Guide Bushing Installation....4399
      Rear Cover Seal Removal And Installation....4404
      Crankshaft, Checking....4405
      Connecting Rod, Checking....4407
      Piston, Checking....4410
      Piston Pin, Checking....4411
      Piston Rings Installation....4412
      Piston Installation On The Connecting Rod....4413
      Cylinder Head Disassembly....4414
      Valves, Checking....4415
      Valve Clearance Adjustment....4416
      Cylinder Head Assembly....4417
      Rocker Arm And Bracket, Checking....4419
      Front Cover Disassembly....4420
      Front Cover Assembly....4426
      Turbo Charger Removal and Installation....4436
      Crankshaft Gear Mounting Bolt Torque Procedure....4438
  HEATING, VENTILATION, AIR CONDITIONING....4441
    EVAPORATOR/HEATER UNIT (S/N 522311001 & ABOVE)....4445
      Removal And Installation....4445
    EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE)....4447
      Removal And Installation....4447
      Disassembly And Assembly....4451
    HEATER/AC FAN....4457
      Removal And Installation....4457
      Resistor Removal And Installation....4459
    HEATER VALVE....4461
      Removal And Installation....4461
    AIR CONDITIONING SYSTEM FLOW....4464
      Principles....4464
      Chart....4465
    COMPONENTS (S/N 522311001 & ABOVE)....4467
      Identification....4467
    COMPONENTS (S/N 528911001 & ABOVE AND 52864001 & ABOVE)....4469
      Identification....4469
    SAFETY....4473
      Safety Equipment....4473
    REGULAR MAINTENANCE....4475
      Heater Air Filter....4475
      Air Conditioning Compressor Belt....4475
      Cleaning The Condenser....4476
    BASIC TROUBLESHOOTING....4477
      Poor A/C Performance....4477
      Compressor Drive Belt Inspection....4478
      Cleaning The A/C Evaporator Coil & Heater Coil (S/N 522311001 & Above)....4478
      Cleaning The A/C Evaporator Coil And Heater Coil (S/N 528911001 & Above And 528611001 & Above)....4479
      Checking The Electrical System....4481
      Engine Coolant Bypassing The Heater Valve....4490
    GENERAL AIR CONDITIONING SERVICE GUIDELINES....4493
      Compressor Oil....4493
      Compressor Oil Check....4493
      Component Replacement And Refrigeration Leaks....4495
    SYSTEM TROUBLESHOOTING CHART....4497
      Blower Motor Does Not Operate....4497
      Gauge Pressure Related Troubleshooting....4498
    TEMPERATURE/PRESSURE....4501
      Chart....4501
    AIR CONDITIONING SERVICE....4503
      Chart....4503
    SYSTEM CHARGING AND RECLAMATION....4505
      Reclamation Procedure....4505
    COMPRESSOR (S/N 522311001 & ABOVE)....4509
      Removal And Installation....4509
    COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....4511
      Removal And Installation....4511
      Parts Identification....4512
      Compressor Clutch Disassembly And Assembly....4513
    CONDENSER (S/N 522311001 & ABOVE)....4517
      Removal And Installation....4517
    CONDENSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....4519
      Removal And Installation....4519
    RECEIVER/DRYER (S/N 522311001 & ABOVE)....4521
      Removal And Installation....4521
    RECEIVER/DRYER (S/N 528911001 & ABOVE AND 528611001 & ABOVE))....4523
      Removal And Installation....4523
    PRESSURE SWITCH (S/N 522311001 & ABOVE)....4525
      Removal And Installation....4525
    PRESSURE SWITCH (S/N 528911001 & ABOVE AND 528611001 & ABOVE)....4527
      Removal And Installation....4527
    HEATER COIL/EVAPORATOR....4529
      Removal And Installation....4529
    THERMOSTAT....4531
      Removal And Installation....4531
    EXPANSION VALVE....4533
      Removal And Installation....4533
    UPGRADED AIR CONDITIONING SYSTEM....4535
      Evaporator Unit Removal And Installation....4535
      Disassembly And Assembly....4538
      Thermostat Removal And Installation....4541
      Evaporator Removal And Installation....4541
      Fan Removal And Installation....4542
      Switch Removal And Installation....4542
  SPECIFICATIONS....4543
    HYDRAULIC EXCAVATOR SPECIFICATIONS....4545
      Machine Dimensions....4545
      Performance....4546
      Controls....4546
      Engine (S/N 522311001 & Above)....4546
      Engine (S/N 528911001 & Above And S/N 528611001 & Above)....4547
      Electrical....4547
      Hydraulic System (S/N 522311001 & Above)....4547
      Hydraulic System (S/N 528911001 & Above And S/N 528611001 & Above)....4548
      Hydraulic Cycle Times....4548
      Swing System....4548
      Hydraulic Cylinders....4548
      Drive System....4549
      Brakes....4549
      Undercarriage....4549
      Track....4549
      Capacities (S/N 522311001 & Above)....4550
      Capacities (S/N 528911001 & Above And S/N 528611001 & Above)....4550
      Digging Force....4550
    ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE)....4551
      General....4551
      Fuel System....4551
      Valve, Valve Guide and Seat Insert....4552
      Piston And Rings....4553
      Connecting Rod....4554
      Cylinder Head and Block....4554
      Crankshaft And Main Bearings....4555
      Camshaft And Bearings....4556
      Oil Pump....4556
      Governor....4556
      Engine Balancing Shaft And Bearings....4556
    ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....4557
      General....4557
      Fuel System....4557
      Valve, Valve Guide and Seat Insert....4558
      Piston And Rings....4559
      Connecting Rod....4560
      Cylinder Head and Block....4560
      Crankshaft And Main Bearings....4561
      Camshaft And Bearings....4562
      Oil Pump....4562
    ENGINE BOLT TORQUE (S/N 522311001 & ABOVE)....4563
      Specifications....4563
    ENGINE BOLT TORQUE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)....4567
      Specifications....4567
    EXCAVATOR BOLT TORQUE....4571
      Specifications....4571
    TORQUE SPECIFICATIONS FOR BOLTS....4573
      Torque For General SAE Bolts....4573
      Torque For General Metric Bolts....4573
    HYDRAULIC FLUID SPECIFICATIONS....4575
      Specifications....4575
    FUEL, COOLANT AND LUBRICANTS....4577
      Chart (S/N 522311001 & Above)....4577
      Chart (S/N 528911001 & Above And S/N 528611001 & Above)....4579
    CONVERSIONS....4581
      Decimal And Millimeter Equivalents....4581
      U.S. To Metric Conversion....4582
  SERVICE MANUAL REVISIONS....4583
    SMR-1....4583
    SMR-2....4585
    SMR-3....4587
    SMR-4....4589
    SMR-5....4591
    SMR-6....4593
    SMR-7....4595
    SMR-8....4597
6987203 (5-09) - 442 Compact Excavator Operation & Maintenance Manual....4599
  CONTENTS....4603
  FOREWORD....4605
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....4607
    REGULAR MAINTENANCE ITEMS....4607
    ENGINE OIL....4607
    SERIAL NUMBER LOCATIONS....4609
      Excavator Serial Number....4609
      Engine Serial Number....4609
    DELIVERY REPORT....4609
    EXCAVATOR IDENTIFICATION....4610
    FEATURES, ACCESSORIES AND ATTACHMENTS....4611
      Standard Items....4611
      Options and Accessories....4611
      Attachments....4611
      Buckets Available....4611
      Falling Object Guards (FOGS)....4612
      Special Applications Kit....4612
      Special Applications Kit Inspection And Maintenance....4612
  SAFETY & TRAINING RESOURCES....4613
    SAFETY INSTRUCTIONS....4615
      Before Operation....4615
      Safe Operation Is The Operator’s Responsibility....4616
      Safe Operation Needs A Qualified Operator....4616
      Avoid Silica Dust....4617
    FIRE PREVENTION....4617
      Maintenance....4617
      Operation....4617
      Electrical....4617
      Hydraulic System....4618
      Fueling....4618
      Starting....4618
      Spark Arrestor Exhaust System....4618
      Welding And Grinding....4618
      Fire Extinguishers....4618
    MACHINE SIGNS (DECALS)....4619
    PUBLICATIONS AND TRAINING MATERIALS....4621
  OPERATING INSTRUCTIONS....4623
    INSTRUMENTS AND CONSOLES....4625
      Left Console....4625
      Right Console....4626
      Raising And Lowering The Left Console....4628
    OPERATOR CAB....4629
      Description....4629
      Cab Door....4629
      Front Window....4630
      Front Window Ventilation....4631
      Right Side Windows....4632
      Wiper/Washer Fluid Reservoir....4632
      Heating, Ventilation And Air Conditioning Duct....4633
    TRAVEL CONTROLS....4634
      Description....4634
      Forward And Reverse Travel....4634
      Turning....4634
    EMERGENCY EXIT....4636
      Right Side Window....4636
      Front Window....4636
    MOTION ALARM SYSTEM (IF EQUIPPED)....4637
      Operation....4637
    HYDRAULIC CONTROLS....4638
      Description....4638
      Standard Control Pattern....4638
      ISO Control Pattern....4639
      Quick Couplers....4640
      Auxiliary Hydraulics....4643
      Relieving Hydraulic Pressure....4644
      Upperstructure Slew Brake....4645
    BLADE CONTROL LEVER....4646
      Operation....4646
    BOOM SWING PEDAL....4646
      Operation....4646
    DAILY INSPECTION....4647
      Daily Inspection And Maintenance....4648
    PRE-STARTING PROCEDURE....4649
      Operation And Maintenance Manual And Operator’s Handbook Locations....4649
      Entering And Exiting The Excavator....4649
      Seat Adjustment....4650
      Seat Belt Adjustment....4651
      Control Console....4652
    STARTING THE ENGINE....4653
      Key Switch....4653
      Cold Temperature Starting Procedure....4654
    STOPPING THE ENGINE AND LEAVING THE EXCAVATOR....4655
      Procedure....4655
    ATTACHMENTS....4656
      Bucket And Ripper Tooth Installation....4656
      Bucket And Ripper Tooth Removal....4657
      Tilt Bucket Installation....4658
      Tilt Bucket Removal....4659
      Tilt Bucket Operation....4660
      Clamshell Bucket Installation....4661
      Clamshell Bucket Removal....4664
      Clamshell Bucket Operation....4665
      Lifting The Clamshell Bucket....4667
      Fastening The Clamshell Bucket To The Transport Vehicle....4668
      Manual Spring Loaded Coupler Installation....4669
      Manual Spring Loaded Coupler Removal....4670
      Manual Spring Loaded Coupler Attachment Installation....4671
      Manual Spring Loaded Coupler Attachment Removal....4673
    OPERATING PROCEDURE....4674
      Inspect The Work Area....4674
      Lowering The Work Equipment (Engine STOPPED)....4674
      Operating On Public Roads....4674
      Lifting A Load....4675
      Excavating....4676
      Boom Swing....4678
      Backfilling....4679
      Driving The Excavator....4679
      Operating On Slopes....4680
      Operating In Water....4682
    TOWING THE EXCAVATOR....4682
      Procedure....4682
    LIFTING THE EXCAVATOR....4683
      Procedure....4683
    TRANSPORTING THE EXCAVATOR ON A TRAILER....4684
      Loading And Unloading....4684
      Fastening....4684
  PREVENTIVE MAINTENANCE....4685
    SERVICE SCHEDULE....4689
      Chart....4689
    CONTROL CONSOLE LOCKOUTS....4690
      Inspection And Maintenance....4690
    SEAT BELT....4691
      Inspection And Maintenance....4691
    MOTION ALARM SYSTEM (IF EQUIPPED)....4692
      Description....4692
      Inspecting....4692
      Adjustment....4692
    REAR COVER....4694
      Opening And Closing....4694
    RIGHT SIDE COVER....4694
      Opening And Closing....4694
    AIR CLEANER SERVICE....4695
      Daily Check....4695
      Replacing Filter Elements....4695
    FRESH AIR FILTER....4697
      Removal And Installation....4697
    FUEL SYSTEM....4698
      Fuel Specifications....4698
      Biodiesel Blend Fuel....4698
      Filling The Fuel Tank....4699
      Pre-Filter Removal And Installation (If Equipped)....4699
      Fuel Filter Removal And Installation....4700
      Draining The Fuel Tank....4701
    ENGINE LUBRICATION SYSTEM....4702
      Checking Engine Oil....4702
      Oil Chart....4702
      Removing And Replacing Oil And Filter....4703
    ENGINE COOLING SYSTEM....4705
      Cleaning....4705
      Checking Level....4705
      Removing And Replacing Coolant....4706
    ELECTRICAL SYSTEM....4708
      Description....4708
      Fuse And Relay Location....4709
      Using A Booster Battery (Jump Starting)....4711
      Removing And Installing Battery....4713
    ALTERNATOR BELT....4715
      Adjusting Belt Tension....4715
    FAN BELT....4715
      Adjusting Belt Tension....4715
    AIR CONDITIONING COMPRESSOR BELT....4716
      Adjusting Belt Tension....4716
    HYDRAULIC SYSTEM....4717
      Checking And Adding Hydraulic Oil....4717
      Replacing The Hydraulic Oil....4718
      Hydraulic Filter Removal....4719
      Hydraulic Filter Installation....4720
      Diagnostic Couplers....4721
    TRACK TENSION....4722
      Rubber Track Clearance....4722
      Steel Track Clearance....4724
      Adjustment....4725
    TRAVEL MOTOR....4727
      Checking Oil Level....4727
      Draining The Travel Motor....4727
    LUBRICATING THE EXCAVATOR....4728
      Lubrication Locations....4728
    LUBRICATING THE ATTACHMENTS....4732
      Tilt Bucket Lubrication....4732
      Clamshell Bucket Lubrication....4733
    EXCAVATOR STORAGE AND RETURN TO SERVICE....4734
      Storage....4734
      Return to Service....4734
  MACHINE SIGN TRANSLATIONS....4735
    WARNING (6813577)....4737
    LIFT CHART (6813628)....4738
    SERVICE SCHEDULE (6814224)....4741
    WARNING (6807776)....4744
    WARNING (6813581, 6813576, 6804233)....4747
    UNDERCARRIAGE COMPONENTS (6589129)....4748
    COOLANT (6811054)....4748
    MECHANICAL SPRING LOADED COUPLER (7130241)....4749
  SPECIFICATIONS....4751
    SPECIFICATIONS....4753
      Excavator Machine Dimensions....4753
      Performance Specifications....4754
      Controls....4754
      Engine....4754
      Hydraulic System....4755
      Hydraulic Cylinders....4755
      Hydraulic Cycle Times....4756
      Electrical System....4756
      Drive System....4756
      Undercarriage....4756
      Capacities....4756
      Tracks....4757
  WARRANTY....4759
    WARRANTY....4761
  ALPHABETICAL INDEX....4763
6987204 (5-10) - 442 Compact Excavator Service Manual....4765
  MAINTENANCE SAFETY....4767
  ALPHABETICAL INDEX....4769
  CONTENTS....4771
    FOREWORD....4772
    SAFETY INSTRUCTIONS....4774
    FIRE PREVENTION....4776
      Maintenance....4776
      Operation....4776
      Electrical....4776
      Hydraulic System....4776
      Fueling....4776
      Starting....4776
      Spark Arrestor Exhaust System....4776
      Welding And Grinding....4777
      Fire Extinguishers....4777
    SERIAL NUMBER LOCATIONS....4778
      Excavator Serial Number....4778
      Engine Serial Number....4778
    DELIVERY REPORT....4779
  SAFETY AND MAINTENANCE....4781
    LIFTING AND BLOCKING THE EXCAVATOR....4783
      Procedure....4783
    LIFTING THE EXCAVATOR....4785
      Procedure....4785
    OPERATOR CAB....4787
      Description....4787
      Entering And Exiting The Excavator....4787
      Raising And Lowering The Left Console....4787
      Emergency Exit....4788
    TRANSPORTING THE EXCAVATOR....4789
    REAR COVER....4791
      Opening And Closing The Rear Cover....4791
    RIGHT SIDE COVER....4793
      Opening And Closing The Right Side Cover....4793
    SERVICE SCHEDULE....4795
    AIR CLEANER....4797
      Daily Check....4797
      Replacing The Filters....4797
    FRESH AIR FILTER....4799
      Removal And Installation....4799
    COOLING SYSTEM....4801
      Cleaning The Cooling System....4801
      Checking Coolant Level....4801
      Replacing The Coolant....4802
    FUEL SYSTEM....4805
      Fuel Specifications....4805
      Filling The Fuel Tank....4805
      Pre-Filter Removal And Installation....4806
      Fuel Filter Removal And Installation....4806
      Draining The Fuel Tank....4806
    ENGINE LUBRICATION SYSTEM....4809
      Checking Engine Oil....4809
      Oil Chart....4809
      Replacing Oil And Filter....4809
    HYDRAULIC SYSTEM....4811
      Checking And Adding Hydraulic Oil....4811
      Replacing The Hydraulic Oil....4812
      Hydraulic Filter Removal....4813
      Hydraulic Filter Installation....4814
      Diagnostic Couplers....4816
    LUBRICATION OF THE EXCAVATOR....4817
    TRAVEL MOTOR....4821
      Checking Oil Level....4821
      Draining The Travel Motor....4821
    ALTERNATOR BELT....4823
      Adjusting Belt Tension....4823
    FAN/FUEL PUMP BELT....4825
      Adjusting Belt Tension....4825
    AIR CONDITIONING COMPRESSOR BELT....4827
      Adjusting Belt Tension....4827
    CAB TILT PROCEDURE....4829
      Installing The Cab Tilt Hinges....4829
      Tilting The Cab....4830
  HYDRAULIC SYSTEM....4837
    HYDRAULIC / HYDROSTATIC SCHEMATICS....4843
    HYDRAULIC SYSTEM INFORMATION....4845
      Troubleshooting Chart....4845
      Description....4850
    BOOM CYLINDER....4853
      Testing....4853
      Removal And Installation....4855
      Parts Identification....4859
      Disassembly....4860
      Assembly....4865
    ARM CYLINDER....4871
      Testing....4871
      Removal And Installation....4871
      Parts Identification....4875
      Disassembly....4876
      Assembly....4881
    BOOM OFFSET CYLINDER....4887
      Testing....4887
    BOOM OFFSET CYLINDER....4890
      Removal And Installation....4890
      Parts Identification....4894
      Disassembly....4895
      Assembly....4899
    BUCKET CYLINDER....4907
      Testing....4907
      Removal And Installation....4907
      Parts Identification....4911
      Disassembly....4912
      Assembly....4916
    BLADE CYLINDER....4923
      Testing....4923
      Removal And Installation....4924
      Parts Identification....4926
      Disassembly....4927
      Assembly....4932
    RELIEF VALVES....4939
      Description....4939
      Testing The Three Spool Control Valve Main Relief Valve....4940
      Adjusting The Three Spool Control Valve Main Relief Valve....4940
    PORT RELIEF VALVES....4941
      Adjustment Procedure....4941
    PRESSURE REDUCING VALVE....4943
      Description....4943
      Testing....4943
      Adjustment....4944
    DUMP VALVE....4945
      Description....4945
      Testing....4945
      Adjustment....4945
      Removal And Installation....4946
      Parts Identification....4947
      Disassembly And Assembly....4948
    SIX SPOOL HYDRAULIC CONTROL VALVE....4953
      Removal And Installation....4953
      Control Valve Identification....4957
      Disassembly And Assembly....4958
      Left Travel And Right Travel Valve Section Disassembly And Assembly....4961
      Boom, Arm, Bucket And Auxiliary Valve Section Disassembly And Assembly....4964
      Inlet Valve Section Disassembly And Assembly....4969
    THREE SPOOL HYDRAULIC CONTROL VALVE....4971
      Removal And Installation....4971
      Parts Identification....4973
      Disassembly And Assembly....4974
      Boom Offset And Blade Valve Section Disassembly And Assembly....4976
      Inlet/Upperstructure Swing Valve Section Disassembly And Assembly....4980
    HYDRAULIC PISTON PUMP....4985
      Hydraulic Pump Work Sheet....4985
      Testing Information....4988
      Pump Testing....4989
      Load Sense Relief Valve Adjustment....4992
      Removal And Installation....4997
      Coupler Removal And Installation....4999
      Torque Limiter Valve Parts Identification....5000
      Torque Limiter Valve Removal and Installation....5001
      Torque Limiter Valve Disassembly....5002
      Torque Limiter Valve Assembly....5006
      Initial Torque Limiter Valve Setting....5010
      Pump Control Parts Identification....5012
      Pump Control Removal And Installation....5013
      Pump Control Disassembly And Assembly....5014
      Parts Identification....5019
      Disassembly....5020
      Assembly....5029
    HYDRAULIC GEAR PUMP....5039
      Removal And Installation....5039
      Parts Identification....5041
      Disassembly....5042
      Assembly....5045
    ACCUMULATOR....5049
      Description....5049
      Removal And Installation....5049
    TRAVEL MOTOR....5051
      Removal And Installation....5051
      Parts Identification....5052
      Disassembly....5053
      Assembly....5070
    SWIVEL JOINT....5089
      Removal And Installation....5089
      Parts Identification....5091
      Disassembly And Assembly....5092
    SWING MOTOR....5095
      Removal And Installation....5095
      Parts Identification....5097
      Disassembly....5098
      Assembly....5104
    SWING MOTOR DRIVE CARRIER....5111
      Removal And Installation....5111
      Parts Identification....5113
      Disassembly....5114
      Assembly....5123
    SWING BRAKE VALVE....5137
      Removal And Installation....5137
      Parts Identification....5138
      Disassembly And Assembly....5139
    SWING BRAKE RELEASE VALVE....5141
      Removal And Installation....5141
    SWING BRAKE RELEASE VALVE (CONT’D)....5142
      Parts Identification....5142
      Disassembly And Assembly....5143
    JOYSTICK CONTROL PATTERN SELECTOR VALVE....5145
      Removal And Installation....5145
      Parts Identification....5146
      Disassembly And Assembly....5147
    JOYSTICK LOCKOUT/TWO SPEED VALVE....5149
      Removal And Installation....5149
      Parts Identification....5151
      Disassembly And Assembly....5152
    RIGHT CONTROL LEVER (JOYSTICK)....5157
      Testing....5157
      Handle Removal And Installation....5158
      Removal And Installation....5159
      Parts Identification....5161
      Disassembly And Assembly....5162
    LEFT CONTROL LEVER (JOYSTICK)....5167
      Testing....5167
      Handle Removal And Installation....5168
      Removal And Installation....5169
      Parts Identification....5171
      Disassembly and Assembly....5172
    TRAVEL LEVER/FOOT PEDAL VALVE....5177
      Left Travel Lever/Foot Pedal Valve Removal And Installation....5177
      Right Travel Lever/Foot Pedal Valve Removal And Installation....5178
      Parts Identification....5180
      Disassembly And Assembly....5181
    HYDRAULIC FILTER MOUNT....5185
      Removal And Installation....5185
    HYDRAULIC RESERVOIR....5187
      Removal And Installation....5187
    OIL COOLER....5193
      Description....5193
    SECONDARY FRONT AUXILIARY VALVE....5195
      Removal And Installation....5195
      Parts Identification....5196
      Disassembly And Assembly....5197
    AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE....5201
      Removal And Installation....5201
    AUXILIARY HYDRAULIC FLOW CONTROL/HYDRAULIC BREAKER APPLICATION VALVE (CONT’D)....5202
      Parts Identification....5202
      Disassembly And Assembly....5203
    BLADE VALVE....5207
      Removal And Installation....5207
      Parts Identification....5208
      Disassembly And Assembly....5209
    BLADE FLOAT VALVE....5213
      Removal And Installation....5213
      Parts Identification....5214
      Disassembly And Assembly....5215
    BOOM OFFSET VALVE....5219
      Removal And Installation....5219
      Parts Identification....5220
      Disassembly And Assembly....5221
    BOOM LOAD HOLDING VALVE....5227
      Removal And Installation....5227
      Parts Identification....5228
      Disassembly....5229
      Assembly....5236
    OIL TEMPERATURE REGULATOR....5243
      Description....5243
      Removal And Installation....5243
    AUXILIARY HYDRAULICS SELECTOR VALVE....5245
      Removal And Installation....5245
    HYDRAULIC PISTON PUMP DRIVE COUPLER....5247
      Removal And Installation....5247
  UNDERCARRIAGE....5249
    BLADE....5251
      Removal And Installation....5251
    TRACKS....5253
      Track Lug Height....5253
      Rubber Track Clearance....5254
      Steel Track Clearance....5255
      Track Adjustment....5256
      Rubber Track Removal And Installation....5258
    TRACK FRAME....5261
      Disassembly And Assembly....5261
      Drive Sprocket Removal And Installation....5264
    TRACK IDLER....5265
      Parts Identification....5265
      Disassembly....5266
      Assembly....5270
    UPPER TRACK ROLLER....5277
      Parts Identification....5277
      Disassembly....5278
      Assembly....5280
    LOWER TRACK ROLLER....5285
      Parts Identification....5285
      Disassembly....5286
      Assembly....5289
    GREASE CYLINDER....5295
      Parts Identification....5295
      Disassembly....5296
      Assembly....5297
    TRACK DAMAGE IDENTIFICATION....5299
      Cutting Of Steel Cords....5299
      Abrasion Of Embedded Metals....5300
      Separation Of Embedded Metals....5301
      Separation Of Embedded Metals Due To Corrosion....5302
      Cuts On The Lug Side Rubber....5303
      Cracks On The Lug Side Rubber Due To Fatigue....5304
      Lug Abrasion....5305
      Cracks And Cuts On The Lug Side Rubber....5306
      Abrasion Of The Track Roller Side....5307
      Cuts On The Edges Of Track Roller Side....5308
  UPPERSTRUCTURE & SWING SECTION....5311
    UPPERSTRUCTURE....5313
      Removal And Installation....5313
      Swing Bearing Removal And Installation....5318
    CAB....5321
      Removal And Installation....5321
      Door Removal And Installation....5327
      Front Window Removal And Installation....5328
      Front Window Gas Strut Removal And Installation....5333
      Front Window Pivot Frame Removal And Installation....5334
      Lower Front Widow Removal And Installation....5335
      Door, Left Side, Right Side And Rear Window Removal....5336
      Door, Left Side, Right Side And Rear Window Installation....5337
      Cab Visor Removal And Installation....5339
      Top Window Removal And Installation....5340
    SEAT AND SEAT MOUNT....5341
      Removal And Installation....5341
    RIGHT CONSOLE....5343
      Description....5343
    LEFT CONSOLE....5345
      Removal And Installation....5345
      Disassembly And Assembly....5350
      Console Lockout Switch Removal And Installation....5352
    ENGINE SPEED CONTROL....5353
      Removal And Installation....5353
      Disassembly And Assembly....5355
    CONTROL LEVERS....5357
      Description....5357
    FUEL TANK....5359
      Removal And Installation....5359
    HORN....5363
      Removal And Installation....5363
    SWING FRAME....5365
      Removal And Installation....5365
      Bushing Removal And Installation....5369
    FLOOR MAT....5371
      Removal And Installation....5371
    BOOM....5373
      Removal And Installation....5373
      Bushing Removal And Installation....5380
    ARM....5381
      Removal And Installation....5381
      Bushing Removal And Installation....5384
    BUCKET....5385
      Removal And Installation....5385
    REAR COVER....5387
      Removal And Installation....5387
    RIGHT SIDE COVER....5389
      Removal And Installation....5389
    COUNTERWEIGHT....5393
      Removal And Installation....5393
  ELECTRICAL SYSTEM AND ANALYSIS....5397
    ELECTRICAL SCHEMATICS....5399
    ELECTRICAL SYSTEM INFORMATION....5404
      Troubleshooting Chart....5404
      Description....5405
      Fuse And Relay Location....5406
    BATTERY....5410
      Servicing....5410
      Removal And Installation....5411
      Using A Booster Battery (Jump Starting)....5413
    ALTERNATOR....5416
      Removal And Installation....5416
      Parts Identification....5418
      Alternator Identification....5419
      Charging System Check....5419
      Rectifier Continuity (Diode) Test....5421
      Disassembly....5423
      Stator Continuity Test....5429
      Stator Ground Test....5429
      Rotor Continuity Test....5429
      Rotor Ground Test....5430
      Capacitor Continuity Test....5430
      Assembly....5431
    STARTER....5438
      Removal And Installation....5438
      Parts Identification....5439
      Disassembly....5440
      Inspection And Repair....5448
      Assembly....5450
    FRONT CAB LIGHT....5460
      Removal And Installation....5460
      Disassembly And Assembly....5461
    TWO SPEED SWITCH....5464
      Removal And Installation....5464
    FUEL LEVEL SENDER....5466
      Removal And Installation....5466
    WIPER MOTOR....5468
      Removal And Installation....5468
    BATTERY DISCONNECT SWITCH....5470
      Removal And Installation....5470
    INSTRUMENT PANEL....5472
      Removal And Installation....5472
      E-Prom Information....5473
    OIL TEMPERATURE COMPONENTS....5474
      Sensor Testing....5474
      Gauge Testing....5474
  ENGINE SERVICE....5476
    TROUBLESHOOTING....5478
      Chart....5478
    MUFFLER....5480
      Removal And Installation....5480
    AIR CLEANER....5482
      Removal And Installation....5482
    RADIATOR/OIL COOLER....5484
      Removal And Installation....5484
    ENGINE COMPONENTS AND TESTING....5492
      Engine Compression Checking....5492
      Checking The Manifold Heater....5494
      Manifold Heater Removal And Installation....5495
      Fuel Shutoff Solenoid Checking....5496
      Fuel Shutoff Solenoid Removal And Installation....5497
      Fuel Injection Pump Removal....5498
      Fuel Injection Pump Timing....5500
      Fuel Injection Pump Installation....5501
      Fuel Injector Removal And Installation....5504
      Fuel Injector, Checking....5505
      Fuel Injector Disassembly....5506
      Fuel Injector Assembly....5507
      Timing Belt Inspection....5509
      Timing Belt Removal....5510
      Timing Belt Installation....5512
      Valve Clearance Adjustment....5518
      Valve Timing, Checking....5519
      Aneroid Device....5521
    ENGINE....5526
      Removal And Installation....5526
    FLYWHEEL....5532
      Removal And Installation....5532
      Flywheel Ring Gear....5533
    RECONDITIONING THE ENGINE....5534
      Deutz Engine Tools Identification Chart....5534
      Disassembly....5535
      Assembly....5542
      Cylinder, Checking....5560
      Camshaft Bearing, Checking....5561
      Camshaft Bearing, Removal And Installation....5562
      Control Rod Guide Bushing Removal....5563
      Control Rod Guide Bushing Installation....5565
      Rear Cover Seal Removal And Installation....5570
      Crankshaft, Checking....5572
      Connecting Rod, Checking....5574
      Piston, Checking....5577
      Piston Pin, Checking....5578
      Piston Rings Installation....5579
      Piston Installation On The Connecting Rod....5580
      Cylinder Head Disassembly....5581
      Valves, Checking....5582
      Valve Clearance Adjustment....5583
      Cylinder Head Assembly....5584
      Rocker Arm And Bracket, Checking....5586
      Front Cover Disassembly....5587
      Front Cover Assembly....5593
      Turbo Charger Removal and Installation....5603
      Crankshaft Gear Mounting Bolt Torque Procedure....5606
  HEATING, VENTILATION, AIR CONDITIONING....5608
    EVAPORATOR UNIT....5610
      Removal And Installation....5610
      Disassembly And Assembly....5613
      Evaporator Removal And Installation....5615
      Fan Removal And Installation....5616
      Switch Removal And Installation....5616
    HEATER UNIT....5618
      Removal And Installation....5618
      Disassembly And Assembly....5622
    HEATER FAN....5628
      Removal And Installation....5628
      Resistor Removal And Installation....5630
    AIR CONDITIONING FAN....5632
      Removal And Installation....5632
      Switch Removal And Installation....5632
    HEATER VALVE....5634
      Removal And Installation....5634
    AIR CONDITIONING SYSTEM FLOW....5637
      Principles....5637
      Chart....5638
    COMPONENTS....5640
      Identification....5640
    SAFETY....5644
      Safety Equipment....5644
    REGULAR MAINTENANCE....5646
      Heater Air Filter....5646
      Air Conditioning Compressor Belt....5646
      Cleaning The Condenser....5647
    BASIC TROUBLESHOOTING....5648
      Poor A/C Performance....5648
      Compressor Drive Belt Inspection....5649
      Cleaning The Heater Coil....5650
      Cleaning The A/C Evaporator Coil....5650
      Checking The Electrical System....5651
      Engine Coolant Bypassing The Heater Valve....5660
    GENERAL AIR CONDITIONING SERVICE GUIDELINES....5662
      Compressor Oil....5662
      Compressor Oil Check....5662
      Component Replacement And Refrigeration Leaks....5664
    SYSTEM TROUBLESHOOTING CHART....5666
      Blower Motor....5666
      Gauge Pressure Related Troubleshooting....5667
    TEMPERATURE/PRESSURE....5670
      Chart....5670
    AIR CONDITIONING SERVICE....5672
      Chart....5672
    SYSTEM CHARGING AND RECLAMATION....5674
      Reclamation Procedure....5674
    COMPRESSOR....5678
      Removal And Installation....5678
      Compressor Clutch Disassembly And Assembly....5679
    CONDENSOR....5682
      Removal And Installation....5682
    RECEIVER/DRYER....5684
      Removal And Installation....5684
    PRESSURE SWITCH....5686
      Removal And Installation....5686
    HEATER COIL....5688
      Removal And Installation....5688
    THERMOSTAT....5690
      Removal And Installation....5690
  SPECIFICATIONS....5692
    HYDRAULIC EXCAVATOR SPECIFICATIONS....5694
      Excavator Machine Dimensions....5694
      Performance....5695
      Controls....5695
      Engine....5695
      Electrical....5696
      Hydraulic System....5696
      Hydraulic Cycle Times....5696
      Swing System....5696
      Hydraulic Cylinders....5697
      Drive System....5697
      Brake....5697
      Undercarriage....5697
      Track....5697
      Capacities....5697
    ENGINE SPECIFICATIONS....5698
      General....5698
      Fuel System....5698
      Valve, Valve Guide And Seat Insert....5698
      Piston And Rings....5699
      Connecting Rod....5699
      Cylinder Head And Block....5699
      Crankshaft And Main Bearings....5700
      Camshaft And Bearings....5700
      Oil Pump....5700
      Governor....5700
    ENGINE BOLT TORQUE....5702
      Specifications....5702
    EXCAVATOR BOLT TORQUE....5704
      Specifications....5704
    TORQUE SPECIFICATIONS FOR BOLTS....5706
      Torque For General SAE Bolts....5706
      Torque For General Metric Bolts....5706
    HYDRAULIC FLUID SPECIFICATIONS....5708
      Specifications....5708
    FUEL, COOLANT AND LUBRICANTS....5710
      Chart....5710
    CONVERSIONS....5712
      Decimal And Millimeter Equivalents....5712
      U.S. To Metric Conversion....5713
  SERVICE MANUAL REVISION....5714
    Revision No: 442 - 1....5714