CONTENTS FOREWORD . SAFETY INSTRUCTIONS - ‘SERIAL NUMBER LOCATIONS . . DELIVERY REPORT oo... BOBCAT LOADER IDENTIFICATION PREVENTIVE MAINTENANCE vill i HYDRAULIC SYSTEM . . 24 HYDROSTATIC SYSTEM . 34 DRIVE SYSTEM .... a4 MAIN FRAME... 5-4 ELECTRICAL SYSTEM a ENGINE SERVICE 7A ‘SPECIFICATIONS Revised Aug. 97 NN LUA Nort HYDRAULIC Sia Tacs Sia NL Sr) aaa ort Sia) ENGINE Salers SPECIFICATIONS 843 Loader Service Manual\ &. g a. 843 Loader Revised Aug. 97 ii Service Manualstarting procedure, daily checks, etc. FOREWORD ‘This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, ‘A general inspection ofthe following items must be made after the loader has had service or repair 1. Check that the ROPS/FOPS (Including sidescreens) Is in good Condition and is not moditie 4 2. Check that ROPS mounting hardware is tightened and is Melroe approved. 3. The seat belt must be correctly installed, functional and in good condition, 4. The seat bar and pedal interlocks must be correctly adjuste 4, clean and lubricated. 5._ Machine signs must be legible and in the correct location. 6. _Stooring levers and foot pedals must retum fo neutral 7. Check for correct function of the work lights. 8. The parking brake must {unetion correctly. Added Aug. 97 9. Enclosure door latches must ‘open and close freely. 10. Bob—Tach linkages must y and be in good wedges _ and function correct conditio 11. Safely treads must in good condition. 42. Check for correct function of indicator lamps (Optional on some models), 18. Check hydraulic fluid level, engine cil level and fuel supply. 14. Inspector uo, ior hydraulic fia leks a 18. Lubricate the loader. 46. Check the condition of the battery and cables, BIN 4 ie e¢/ iS ae 843 Loader Service Manual17. Inspect the ait cleaner for daimago or leaks. Check the condo of the element. 18. Check the electrical charging system. 19. Check ties for wear and pressure. 20. Inspect for loose or broken ants or connections. 21, Operate the loader and check all functions. 22. Check for any fold ‘modification not completed. 23. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machin © is returned to the custom or. Recommend to the owner that all Necessary corrections be made before the machine is retumed to service. ‘Added Aug. 97 843 Loader Service ManualSAFETY INSTRUCTIONS The following publications provide information on the safe use and maintenance of the loader and attachments: ‘+The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition. ‘The Operation & Maintenance Manual deliverad with the loader gives operating information as well as routine maintenance and service procedures. Itisa partof ine loader and must stay with the machine when itis sold. Replacement ‘Operation & Maintenance manuals can be rdeed from your Bobcat loader dealer. * The loader has a plastic Operator's Handbook fastened to the operator cab. Its brie! instructions are convenient to the ator. The handbook is available from your dealer in an English edition or one of the following languages: French. jerman, Italian, Dutch & spanish. ‘+ The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information. ‘© The Service Manual and Parts Manual are available trom your dealer for use by mechanics to do shop-type service and repair work, ‘* The Skid-Steer Loader Operator training Course is available through your local Bobcat dealer, This course in intended to provide rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version. ‘© The Bobcat Skid-Steer Loader Safety Video is available trom your Bobcat Dealer. IMPORTANT This notice identifies procedures which must be followed to avoid damage to the machine. 843 Loader ‘Added Aug. 97 v ManualFIRE PREVENTION ‘The loader has several components that are at high temperature under normal operating conditions. The primary source of high | lures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks. Flammable debris leaves, straw, etc.) must be removed regulary. I tlammable debris is allowed to accumulate, it vilincrease the fire hazard. The loader must be cleaned as often as necessary to avoid this accumulation. Flammable debris in the engine compartment isa fre hazard when the loader is parked with a hot engine. ‘The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the ‘muffler and the exhaust gases are still hot. * Donot use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases. ‘© The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating. ‘© Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any amaged part. ‘© Check fuel and hydraulic tubes, hoses and fitings for damage and leakage. Never use open flame or bare skin to'check {for leaks. Tighten or replace any pars that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for Cleaning parts. Use commercial nonflammable solvents. * Do not use ether or starting fluids on this engine. It has glow plugs. These starting aids can cause explosion and injure you or bystanders. '* Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a tire extinguisher near the loader when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced. '© Stop the engine and let & coo! before adding fuel. No smoking! ‘© Use the procedure in the Operation & Maintenance Manual for connecting the battery. ‘© Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor mutler. © Know where fire extinguishers and first aid kits are located and how to use them. AA fire extinguisher is available from your Bobcat dealer. The fire extinguisher can be installed in the location shown (Al. ‘8106-0396 843 Loader wi Service Manual‘SERIAL NUMBER LOCATIONS Always use the serial number of the loader when requesting service information or when ordering pars. Early or later models (identification made by serial ‘number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation. LOADER SERIAL NUMBER ‘The loader serial number plate is located on the inside of the left upright, above the gril [A]. Explanation of loader Serial Number: 200K 0000 Production Sequence (Series) ModeVEngine Version ENGINE SERIAL NUMBER Perkins (4.154) ‘The engine serial number is on the left side of the engine block, above the fuel injection pump [B] Perkins TK200 (4.154) ‘The engine serial number is on the left side of the engine block, above the fuel injection pump [8] leuzu 4JB1-PKO1 ‘The engine serial number is located on the fuel injection ump side and at the rear of the engine block [C], DELIVERY REPORT ‘The Delivery Report must be filed out by the dealer and signed by the owner or operator when the Bobcat loader isdovefed An explanation the farm musi be gen to the owner. Make sure itis filed out completely [0] ‘Added Aug. 97 Perkins 4.154 Perkins TK200 ( 843 Loader Service ManualBOBCAT LOADER IDENTIFICATION FRONT LIGHTS SEAT BAR i i} \ GRAB | e HANDLES. H : ie OPERATOR STEERING di j Fi SEAT LEVER ! SEAT BELT =k ® fj = TILT CYLINDER = quick 1 COUPLERS + BUCKET Fa SAFETY TREAD BUCKET STEPS REAR LIGHT (Opt) ——pof OPERATOR CAB . (ROPS & FOPS) UPRIGHT, LIFT ARM REAR GRILL LIFT ARM ‘SUPPORT DEVICE LIFT CYLINDER GS TIRES* + TIRES Flotation tres are shown, THE Bobcat loader is based-equipped with standard tres. f +t BUCKET - Several different buckets and other attachments are available for the Bobcat loader. ‘ © ROPS, FOPS — Roll-Over Protective Structure, Falling Object Protective Structure, per SAE J1040 and SAE 'J1043. The Bobeat loader is base-equipped with a standard operator cab as shown. REAR DOOR 807377 Boorees > 843 Loader Added Aug. 97 vill Service ManualPREVENTIVE MAINTENANCE LIFT ARM STOP Procedure LIFTING AND BLOCKING THE LOADER Procedure... 2-0... cee e ee OPERATOR CAB Lowering the Operator Cab. Raising the Operator Cab Seat Bar Inspection Seat Bar Maintenance Seat Bar System REMOTE START SWITCH Procedure SERVICE SCHEDULE Chart... TRANSPORTING THE LOADER Procedure USING AND EXTRA BATTERY (JUMP START) Procedure cara PUN 843 Loader Service Manual3 Re iat 5‘SERVICE SCHEDULE “The service schedule isa guide fr correct maintenance of the Bobcat loader that must be done regularly. Always use these service intervals uniess very hot, cald, dusty or corrosive operating conditions make it necessary to increase the frequency of service. Failure to do so will cause damage to the loader or the engine. Instructions are necessary before operating or servicing machine. Read Operstor’s ‘Manual, Handbook and signs (decals) on machine. Follow warnings and instructions 7N EP V ANT IN (eg isthe manvals when making repairs, adjusiments or servicing, Check for corect function after adjustments, repairs or service. Failure to follow instructions can cause injury oF death. Reeser aris Pein ITEM SERVICE REQUIRED f-10| s0 | 100 | 250 | 00 | 000] Engine Oi ‘Cheek the oll level and add oll as needed! Engine Air Cleaner TEmaty the dust cup Replace the outer fiter element only when | the ted ting shows in the indicator window. Check for leaks and damaged components. Engine Cooling System | Clean debris from shrouds and grils. Check coolant level in the recovery tank and add as needed. Tes Check for damaged es ond correct ar pesnire Seat Bak and Seat Bar] Check te condition of seat be Check he sat br for comet Safety Signs Decals) | Check for damaged signs Decals Replace damaged signs | = (Decal) ond sgns Decale that are notin the covet cation, [i Tift Arm and BabTach | Add grease tothe fitings until exre grease shows PuorAteab Zngine Ful Filer Femave water fom fier : Operator Cab Check the fastening bolts washers and ruta Check the Sonston ofthe cals Wheel Nuts eCheck for loose wheel nuts Tighten tocorect owes |_| Engine Oil ond Fer |. Replace the ol and the engin ol ier. eatery Check the water level Check batery cables Tor coreson Check the the battery cables are tighe Creek covers Taras Fa Whines | Chock the Ted evel and add as needed. Check fr darnage : nd Hoses an leake ond replace os needea i | Alternator Drive Belt Check the tension and adjust as needed. : Chaincase ‘Check the fluid level and add as needed. . | Controls and Brakes ‘Check operation and adjust as needed. 3 Spark Arvestor Muffler | Remove the pig and clean the sparc chamber a ‘Seat Bar ‘Grease pivot as needed. : Steering ShaW Powe | Grease two (2) ftings. Ade ovo steeng ahah Hydraulic and Hydrostatic | Replace filter elements. 7 "ers, Toit Grease tives GY Tags wih coneet pease Engine Ful Fite [eeplece the iter element. Fyerauleydrosaic” Replace breather can Teservo Breather Cap Chaincase Replace the fluid. _ ae : yeraule Fuld Resewek | Replace the hydraule Tad E + Check wheel nut torque every 8 hours for the frst 24 hours of operation. © ‘Also replace hydrastatic filter element when the transmission warning ight stays on for five (5) minutes after the hydrostatic fluid is at operating temperature. 843 Loader Service ManualPREVENTIVE MAINTENANCE A 7 WEG (ey Instructions are necessary before operating or servicing ‘machine. Read Operator's Manual, Handbook and signs (decals) on machine. Follow warnings and instructions In the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, ropairs or service. Failure to follow instructions can cause injury or death w.2002:1288 LIFTING AND BLOCKING THE BOBCAT LOADER B Procedure Always park the loader on a | 7 WGC) ut jackstands under the front axles and rear comers of frame before raising the operator cab, raising the lift ‘arms or when the engine is running for service. Failure 10 use jackstands can allow the machine to fall or move and eause injury or death. w20171208 3 HN : Put floor jack under the rear of the loader. Lift the rear of the loader and install jackstends Put floor jack under the front of the foader Lift the front of the loader and put jackstands under the axle tubes NOTE: Make sure the jackstands do not touch the tires. ‘843 Loader Service Manual * Revised Feb. 87‘TRANSPORTING THE BOBCAT LOADER Procedure 7 WEG (ey Steel loading ramps are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps may break and cause personal injury. ‘Aloader with an empty bucket orno attachment must be driven backwards onto the transport vehicle [A] Lower the lift arms and bucket to the transport vehicle. Stop the engine. Engage the parking brake. Fasten chains to the uprights as shown Fasten chains to the front 2s shown []. c 843 Loader Service ManualFT ARM STOP Procedure ‘One person must stay in the operator cab with the seat belt fastened and the seat bar lowered, while the second person, installs the stop over the rod of one lift cylinder Start the engine and reise the lift arms Have a second person install the lift arm stop over the rad of cone lift cylinder ‘The lift atm stop must be tight egainst the cylinder rod. Lower the lift arms until the stop is held between the lift arm and the lift cylinder A WARNING Eye and body protection is required when welding or grinding, Wear approved goggles, helmet and clothing Failure to wear eye and body protection can result in serious injury. ‘843 Loader Service MenualOPERATOR CAB “The loader has en operator cab (ROPS and FOPS) as standard ‘equipment. The ROPS and FOPS protect the operator from roll cover and falling objects Never modify operator cab by welding, grinding. ding holes or adding attachments unless instructed to do so bby Melroe Company. Changes to cab can cause loss of ‘operator protection from rollover and faling objects, and result in injury or death. w.2069:1205 cases 8.6980 ‘Check with your desler ifthe operator cab has been damaged. “The operator eab fastening bolts and nuts must be tight [A ‘Seat Bar System “The seat bar system has a pivoting seat bar with arm rests and thas spring loaded latches forthe lift and tit control pedals. The ‘operator controls the use of the seat bar. The seat bar in the {down postion keeps the operator inthe seat and unlocks the foot pedals, When the seat bar is up the lft and tit pedals are Tocked in neutral position. Seat Bar Inspection Sit in the sest and fasten the seat belt snugly. Paull the seat bar all the way down and start the engin, Operate eech foot pedal to check both if arm and tt functions. Raise the lft arms until the bucket is about two feet (600 mm) off the ground. as. 843 Loader Service ManualOPERATOR CAB (Contd) Raise the seat bar. Ty to move each foot pedal. Pedals must be firmly locked in the neutral position. There must be no motion of the lft arms or tit (buckot] when the pedals are pushed. Pull the seat bar down, lower the lift arms all the way. Stop the engine. Engage the parking brake. Raiso the seat bar and operate the foot pedal tobe sure thatthe pedals are firmly locked in the neutral positon. Unfasten the seat belt. Seat Bar Maintenance Clean the debris or dirt from moving parts {]. Inspect the linkage bolts and nuts . The correct torque is 25-28 ftolbs. (94-38 Nm). Use general purpose grease to lubricate the seat bar pivot points at each side of the cab [A] lf seat bar systern does not function correctly, check for free movement of each linkage part. Check for excessive wear Adjust pedal control inkages (See Page 2—62 for correct, procedure). Replace parts that are worn, bent ot broken 7 A EI (e) ‘Seat bar system must lock the lift and tit control pedals in neutral when seat bar is up. Service the system if pedals do not lock correctly. Revised Feb. 87 4-6 243 Loader Service ManualOPERATOR CAB (Cont'd) Raising the Operator Cab ‘The cab can be raised or lowered with the lft arms up or down. Ir the lift arms are up, lift arm stop must be installed (See Page 14h ‘Stop the loader on a level surface. Stop the engine and engage the brake, Put jackstands under the rear of the loader. Disconnect the two front fasteners [A] It the lift arms are down, stand on the safety tread 8). It the lft arms are up, stand beside the loader {€) Slowly raise the cab unt it ie all the way up Blor ©). Lowering the Operator Cab Stand on the safety tread A or beside the loader [Eland slowly lower the operator cab. A WARNING Both sets of fasteners atthe front of the operator cab (ROPS) must be assembled as shown inthis Operator's ‘Manual. Failure to secure ROPS correctly can cause injury or death. w.2008-1208 Install the fasteners [lbefore opersting the loader. atUSING AN EXTRA BATTERY (JUMP START) Procede WET ey IF itis necessary to use an extra battery to start the engine, BE CAREFUL! There must be one person inthe operator's seat and one person to connect and disconnect the battery cables. Batteries contain acid which burns eyes and skin on ‘The extra battery must be the same voltage as the loader contact. Wear goggles and protective clothing and battery, rubber gloves to keep acid off body. Incase of acid contact, wash immediately with water 1, Tum the key switch to the “OFF position for several minutes and get medical attention. 2. Connect the first jumper cable tothe positive +) terminal ofthe extra battery (tem 1} and to the positive (+I terminal Keep arca. sports. flomes and lighted tobecco away of the battery (Item 21 [A}. from batteries. When “jumping” from an extra battery ‘make final connection (negative) at engine frame, NOTE: Never connect the negative (—) cable to the negative (negative) at eng (=) terminal of the battery. Do not jump start or charge a frozen battery. Warm battery to 60°F (16°C) before connecting toa charger 3. Connect the second jumper cable to the negative (—) Unplug charger before connecting or disconnecting terminal of the extra battery item 3) end to the engine cables at battery {item 4) () Battery gas can explode and cause serious injury. 4. Keep the jumper cebles away from moving parts. 5. Start the engine. 16. Immediately remove the negative (—) cable [Item 4) from the engine (A) 7. Remove the positive (+) cable from the starter ‘8 Remove the cables from the extra battery. IMPORTANT Damage to the alternator ean occur it Engine is operated with battery cables disconnected. Battery cables are connected when using a fast charger or when welding on the loader (Remove both cables from the battery) Extra battery cables (booster cables) are connected wrong. 12023-1265 eane7 843 Loader * Revised July 88 Service ManualREMOTE START SWITCH Procedure ‘The too! listed will be needed to do the following procedure: MEL-1138A — Remote Start Switch ‘The remote start switch is required when the operator cab is. in the raises position for service and the serviceman needs to start the engine. The wire harness must be separates at the operator cab and engine wiring harness connectors and the remote start switch connected [A]. This remote start switch is required when the serviceman is ‘adjusting the steering linkage or check the hydraulc/hydrostatic system, yee] Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use Jackstands can allow the machine to fall ‘or move and cause injury or death. w.2017-0286 * Revised July 88 fed 843 Loader Service Manuali BB \ bobcat