CONTENTS

PREVENTIVE
MAINTENANCE
'1"--.
FOREWORD .................................................... ::!¥: :;fir~ .
-.~ t SAFETY INSTRUCTIONS ......................................... J!f{j>c,
- ", " SERIAL NUMBER LOCATIONS ................................... .. . vii
DELIVERY REPORT .............................................. vii
BOBCAT LOADER IDENTIFiCATION ................................ viii HYDRAULIC
PREVENTIVE MAINTENANCE .............. " ... :' ....... .. ........ 1-1 SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . ... . ................ 2-1
HYDROSTATIC SYSTEM ......................................... 3-1
DRIVE SYSTEM ................................................. 4-1
MAIN FRAME ................... . ....................·............ 5-1 HYDROSTATIC
ELECTRICAL SySTEM ........................................... 6-1 SYSTEM
ENGINE SERVICE .................... ... .......... . ...... . ...... 7-1
SPECIFICATIONS ............................................... 8-1

DRIVE
SYSTEM

MAIN
FRAME

ELECTRICAL
SYSTEM

ENGINE
SERVICE

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SPECIFICATIONS
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Revised Aug. 97 843 Loader

. Service Manual
 ®

843 Loader
Revised Aug . 97 ii Service Manual
 FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat
loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions,
starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:

1. Check that the RaPS/FOPS 9. Enclosure door latches must

(Including sidescreens) is in good open and close freely.
condition and is not modi fie
d.

2. Check that RaPS mounting 1O. Bob-Tach wedges and

hardware is tightened and is Melroe linkages must function correctl
approved. y and be in good conditio
n.

3. The seat belt must be correctly 11. Safety treads must in good
installed, functional and in good condition.
condition.

4. The seat bar and pedal 12. Check for correct function of
interlocks must be correctly adjuste
d, clean and lubricated. r-:'\J indicator lamps (Optional on some
models).
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r;~
5. Machine signs must be legible 13. Check hydraulic fluid level,
and in the correct location. engine oil level and fuel supply.

! :~~~~::~':i~
"-'-'-"- ..
:i
._ -. __ " ."

6. Steering levers and foot pedals 14. Inspect for fuel, oil or hydraulic
must return to neutral. fluid leaks.

7. Check for correct function of 15. Lubricate the loader.

the work lights.

8. The parking brake must 16. Check the condition of the

function correctly. battery and cables.

®
843 Loader
Added Aug. 97 iii Service Manual
17. Inspect the air cleaner for
damage or leaks. Check the conditio
n of the element.

18. Check the electrical charging

system.

19. Check tires for wear and

pressure.

20. Inspect for loose or broken

parts or connections.

21. Operate the loader and check

all functions.

22. Check for any field

modification not completed.

23. Check for correct function of

the Bobcat Interlock Control System
(BICSTM) before the machin
e is returned to the custom
er.

Recommend to the owner that all

ti
necessary corrections be made before the
machine is retumed to service.

843 Loader
Added Aug. 97 iv Service Manual
SAFETY INSTRUCTIONS

The following publications provide information 0fI the safe use and maintenance of !he 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 sate operating condition.
• The Operation & Maintenance Manual delivered with the toadar gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must slay with the machine when it is sold. Replacement
Operation & Maintenance manuals can be (deed from yool' 6obcalloader dealer.

• The loader has a plastic Operator's Handbook fastened to the operator cab. lis brief instructions are convenient to the
operator. The handbook is available from your dealer in an English edition or one of the following languages: Franeh.
Getman, 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 lrom your dealer for use by mechanics 10 do shop- type service and
repair work.

• The Skid-Steer Loader Operator training Course is available through your local Bobcat dealer. This course in fntended
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 from your Bobcat Oealer.

IMPORTANT
This notice identifies procedures
which must be fo.lowed to avoid
damage to the machine.

Added Aug. 97
ARE PREVENTION
The loadet has several components that are at high temperature under' normal operating conditions. The Pflr'nary source of
high temperatures is the engine and exhaust system. The electrical system. if damaged or lnoorrectfy maintained. can be a
source of arcs or spatks.
Flammable debris (leaves, straw. etc.) must be (emoved regularly. If flammable debris Is allowed to accumulate, it vJiIf increase
the fire hazard. The loader must be cleaned as often as necessary to avoid this accumulation. Flan\mable debris In the engine
compartment is a fire hazard when the loader Is parked with a hot engine.
The sparkarrestOf' muffler Is designed to control the emission of hot particles from the engine and exhaust system. but the
muffler and the exhaust gases are stm hot.
• 00 not use the Bobcat loader where exhaust. arcs •.sparks or hot components can contact flammable ma.terial. explosive
dust or gases.
• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fir~
hazard and overheating.
• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any
damaged part.
• Check fuel and hydraulic tubes. hoses and fittings for damage and leakage. Never use open flame or bare skin to'check
lor leaks, Tighten or replace any parts that show leakage. Always clean nuid spills. 00 not use gasoitne or diesel fuet 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 fire extinguisher near the loader when welding. Have good ventilation when grinding or wekfing
painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.
• Stop the engine and let it cool before adding fuel. No smoking!
• Use the procedure in the Operation & Maintenance Manual for connecting the battery.
• Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler.
• Know where fire extinguishers and first aid kits are located and how to use them.

A tire extingUisher is available from your Bobcat dealer. The fire extinguisher can be installed in the location shown [AJ.

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S106-0398

Added Aug. 97 vi
SERIAL NUMBER LOCATIONS

Always use the serial number of the loader when

requesting service information or when ordering parts.
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 grill [A].

Explanation of loader Serial Number:

XXXXX

T I

ENGINE SERIAL NUMBER

Production Sequence (Series)

Model/Engine Version
Perkins 4.154

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 [B].

Isuzu 4JB1-PK01

The engine serial number is located on the fuel injection

pump side and at the rear of the engine block [C].

DELIVERY REPORT

The Delivery Report must be filled out by the dealer and

signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [0].
_==
=--
=--
~DEUVERY
--
=--
REPORT

.==~

843 Loader
Added Aug. 97 vii Service Manual
BOBCAT LOADER IDENTIFICATION

OPERATOR
JHH~~f:::j--r-- SEAT

REAR LIGHT (Opt.)

-+"~~iI,1~~~4-_0PERATOR CAB.
(ROPS & FOPS)

UPRIGHT

REAR GRILL
LIFT ARM
SUPPORT DEVICE

LIFT CYLINDER

REAR DOOR
8-07377
8-07484

* TIRES - Flotation tires are shown. THE Bobcat loader is based-equipped with standard tires.
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 Bobcat loader is base-equipped with a standard operator cab as shown.

843 Loader
Added Aug. 97 viii Service Manual
 PREVENTIVE MAINTENANCE
PREVENTIVE
Page MAINTENANCE
Number
LIFT ARM STOP
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 4

LIFTING AND BLOCKING THE LOADER

Procedure . . .......... . ........ . . ... . . ... . . " 1-2

OPERATOR CAB
Lowering the Operator Cab. . . . . . . . . . . . . . . . . . . . .. 1- 7
Raising the Operator Cab. . . . . . . . . . . . . . . . . . . . . . .. 1- 7
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 5
Seat Bar Maintenance. . . . . . . . . . . . . . . . . . . . . . . . .. 1- 6
Seat Bar System. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 5

REMOTE START SWITCH

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-9

SERV ICE SCHEDULE

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

TRANSPORTING THE LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

USING AND EXTRA BATTERY (J UMP START)

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 8

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843 Loader
::: Service Manual
 SERVICE SCHEDULE

The service schedule is a guide for correct maintenance of the Bobcat loader that must be done regularly. A lways use these service
intervals unless very hot, cold, dusty or corrosive operating conditions make it necessary to increase the frequency of service.
Failure to do so w ill cause damage to the loader or the engine.

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, repairs or service. Failure to follow instructions can cause
injury or death.
W·2003-1285

100 250 500 1000

Engine Oil
Engine Air Cleaner

Engine Cooling System

Seat Belt and Seat Bar

operation.
Safety Signs (Decals) Check for damaged signs (Decals). Replace damaged signs
(Decals) and signs (Decals) that are not in the correct location.
Lift Arm and Bob-Tach Add grease to the fittings until extra grease shows.

bolts, washers and nuts. Check the

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• Also replace hydrostatic filter element when the transmission warning light stays on for five (5) minutes after the hydrostatic
fluid is at operating temperature.

'" 843 loader

-1-1- Service Manual
PREVENTIVE MAINTENANCE
A

A WARNING
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,
repairs or service. Failure to follow instructions can
cause injury or death.
W-2003-1285

8-7023

LIFTING AND BLOCKING THE BOBCAT LOADER

Procedure

Always park the loader on a level surface.

A WARNING
Put jackstands under the front axles and rear corners
of frame before raising the operator cab, raising the lift
arms or when the engine is running for service. Failure
to use jackstands can allow the machine to fall or move
and cause injury or death.
W·2017-1285

Put floor jack under the rear of the loader.

Lift the rear of the loader and install jackstan~s lID.

I
Put floor jack under the front of the loader.

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
* Revised Feb. 87 -1-2- Service Manual
 TRANSPORTING THE BOBCAT LOADER

Procedure

A WARNING
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.
W·2058·1285

A loader with an empty bucket or no attachment must be driven

backwards onto the transport vehicle fAl.

Lower the lift arms and bucket to the transport vehicle.

Stop the engine. Engage the parking brake.

Fasten chains to the uprights as shown rru.

C·2563

Fasten chains to the front as shown ©.

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843 Loader
-1-3- Service Manual
LIFT ARM STOP

Procedure

One person must stay in the operator cab with the seat belt
A WARNING
fastened and the seat bar lowered, while the second person
installs the stop over the rod of one lift cylinder ~. 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
Start the engine and raise the lift arms. serious injury.
W·2009·1285

Have a second person install the lift arm stop over the rod of
one lift cylinder.

The lift arm stop must be tight against the cylinder rod.

Lower the lift arms until the stop is held between the lift arm
and the lift cylinder.

8·6581

843 Loader
·1-4· Service Manual
 OPERATOR CAB

The loader has an operator cab (ROPS and FOPS) as standard

equipment. The ROPS and FOPS protect the operator from roli -
over and falling objects.

A WARNING
Never modify operator cab by welding, grinding, drilling
holes or adding attachments unless instructed to do so
by Melroe Company. Changes to cab can cause loss of
operator protection from rollover and falling objects, and
result in injury or death.
W-2069·1285
C·2599
B-6940

Check with your dealer if the operator cab has been damaged.

The operator cab fastening bolts and nuts must be tight ~ .

Seat Bar System

The seat bar system has a pivoting seat bar with arm rests and
has spring loaded latches for the lift and tilt control pedals. The
operator controls the use of the seat bar. The seat bar in the
down position keeps the operator in the seat and unlocks the
foot pedals. When the seat bar is up, the lift and tilt pedals are
locked in neutral position.

Seat Bar Inspection

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Operate each foot pedal to check both lift arm and tilt functions.
Raise the lift arms until the bucket is about two feet (600 mm)
off the ground.

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843 Loader
-1-5- Service Manual
OPERATOR CAB (Cont'd)
JUUU
]000
Raise the seat bar. Try to move each foot pedal. Pedals must
be firmly locked in the neutral position. There must be no motion
of the lift arms or tilt (bucket) when the pedals are pushed.

Pull the seat bar down, lower the lift arms all the way.

Stop the engine. Engage the parking brake. Raise the seat bar
]
and operate the foot pedals to be sure that the pedals are firmly
locked in the neutral position. Unfasten the seat belt.

Seat Bar Maintenance

8·7387
Clean the debris or dirt from moving parts ~.

Inspect the linkage bolts and nuts. The correct torque is 25-28
ft.-Ibs. (34-38 Nm).

Use general purpose grease to lubricate the seat bar pivot points
at each side of the cab ~.

I
lf seat bar system does not function correctly, check for free
movement of each linkage part. Check for excessive wear.
Adjust pedal control linkages (See Page 2-62 for correct
procedure). Replace parts that are worn, bent or broken.

A WARNING
Seat bar system must lock the lift and tilt control pedals
in neutral when seat bar is up. Service the system if
pedals do not lock correctly.
W·2105·1285

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843 Loader
Revised Feb. 87 -1-6- Service Manual
OPERATOR CAB (Cont'd)

Raising the Operator Cab

The cab can be raised or lowered with the lift arms up or down.

If the lift arms are up, a lift arm stop must be installed {See Page
1-4\.

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 @.

If the lift arms are down, stand on the safety tread rID.

If the lift arms are up, stand beside the loader 1£] .

Slowly raise the cab until it is all the way up rID or 1£].
6 · 7465

Lowering the Operator Cab

Stand on the safety tread A or beside the loader I£]and slowly

lower the operator cab.

A WARNING
Both sets of fasteners at the front of the operator cab
(ROPS) must be assembled as shown in this Operator's
Manual. Failure to secure ROPS correctly can cause
injury or death.
W· 2005·1285

Install the fasteners @ before operating the loader.

6·7463

843 Loader
-1-7- Service Manual
USING AN EXTRA BATTERY (JUMP START)

Procedure

If it is necessary to use an extra battery to start the engine.

BE CAREFUL! There must be one person in the operator's seat
and one person to connect and disconnect the battery cables.
The extra battery must be the same voltage as the loader
battery .
1. Turn the key switch to the "OFF" position .
Connect the f irst jumper cable to the positive (+) terminal
of the extra battery (Item 1) and to the positive ( + ) terminal
of the battery (Item 2) fA].
NOTE: Never connect the negative (-) cable to the negative
(-) terminal of the battery.
3. Connect the second jumper cable to the negative (-)
terminal of the extra battery (Item 3) and to the engine
(Item 4) fA].
4. Keep the jumper cables away from moving parts.
A WARNING
Batteries contain acid which burns eyes and skin on
contact_ Wear goggles and protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water
for several minutes and get medical attention.
W-2065-1285
Keep arcs, sparks. flames and lighted tobacco away
from batteries. When "jumping" from an extra battery
make final connection (negative) at engine frame.
Do not jump start or charge a frozen battery. Warm
battery to 60°F (16°C) before connecting to a charger.
Unplug charger before connecting or disconnecting
cables at battery.
Battery gas can explode and cause serious injury.
W-2066-1285

5. Start the engine .

6. Immediately remove the negative {-I cable (Item 4) from

the engine fA] .

7. Remove the positive (+) cable from the starter.

8. Remove the cables from the extra battery.

IMPORTANT
Damage to the alternator can occur if:
Engine is operated with battery cables disconnected. '"
Battery cables are connected when using a fast charger
o~ when welding on the loader (Remove both cables
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from the battery). c

Extra battery cables (booster cables) are connected

wrong.
1-2023-1285

843 loader
* Revised July 88 -1-8- Service Manual
 REMOTE START SWITCH
*
Procedure

The tool 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 raised position for service and the serviceman needs to
start the engine. The wire harness must be separated at the
operator cab and engine wiring harness connectors and the
remote start switch connected IAI.

This remote start switch is required when the serviceman is

adjusting the steering linkage or check the hydraulic/hydrostatic
system.

8-9842

A WARNING
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

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843 loader
* Revised July 88 -1-9- Service Manual
 HYDRAULIC SYSTEM
Page
Number
BUCKET POSITION VALVE (S/N 15001 & Above)
Disassembly and Assembly ..................... . 2 - 49
Removal and Installation ........ ...... ......... . 2-49 HYDRAULIC
SYSTEM
HYDRAULIC CONTROL PEDALS (S/N 14999 & Below)
Adjustment. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. 2 - 60
Removal and Installation..... . ......... ...... ... 2 - 60

HYDRAULIC CONTROL PEDALS (S/N 15001 & Above)

Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-61
Removal and Installation...... . . . . . . . . . . . . . . . . .. 2-61

HYDRAULIC CONTROL VALVE (CESSNA)

Assembly .................................. . 2-29
Auxiliary Section ............ . . .. ............. . 2-27
Checking the Main Relief Valve .................. . 2-18
Disassembly ... . ............................ . 2-21
Inlet Section . ... ........... ...... ... . . . ..... . 2-22
Lift Section ... ............... . ....... . ... ... . 2-25
Main Relief Valve Removal and Installation .... .. .... . 2-19
Removal and Installation ....................... . 2-19
Tilt Section . . . . ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Valve Spool Bolt ............................. . 2-28

HYDRAULIC CONTROL VALVE (MELROE)

Centering Mechanism ............... . ......... . 2-38
Checking the Main Relief Valve .................. . 2-30
Detent Assembly ... ..... ... . ..... . .. . ...... . . . 2-35
Disassembly and Assembly ................ . .... . 2-33
Removal and Installation ..... . ........... ...... . 2 - 31

HYDRAULIC CYLINDER REPAIR

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2 -15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-13

HYDRAULIC FLU ID FILTER HOUSING (S/N 15001 & Above)

By-Pass Valve ... .......... ... ............... . 2-57
Removal and Installation ....................... . 2-57

HYDRAULIC/HYDROSTATIC RESERVOIR (SIN 21514 & Below)

Removal and Installation ... .. ..... . . ...... .... .. 2 - 58

HYDRAULIC PUMP (DOUBLE STAGE)

Checking the Output of the Hydraulic Pump ......... . 2-43
Disassembly and Assembly ...... .. ............. . 2-46
Inspection ....................... ..... ...... . 2-48
Removal and Installation ....................... . 2-44

HYDRAULIC PUMP (SINGLE STAGE)

Checking the Output of the Hydraulic Pump ......... . 2-39
Disassembly and Assembly ........ .. .. . . ....... . 2-40
Inspection .................................. . 2-42
Removal and Installation ...... ...... ........... . 2-40
Continued on Next Page
843 Loader
Service Manual
 HYDRAULIC SYSTEM (Cont'd)
Page
Number
HYDRAULIC SYSTEM INFORMATION
Flare Connections.. .. .......... . ............ .. 2-2
Straight Thread O-Ring Fitting. . . . . . . . . . . . . . . . . . .. 2-2
Tubelines and Hoses...... ... ...... . . . . . . . . . . .. 2- 2

LIFT CYLINDERS
Checking the Lift Cylinder(s). . . . . . . . . . . . . . . . . . . .. 2-3
Removal and Installation........ . ............... 2-3

PEDAL LOCK LINKAGE

Adjustment ........ . ................... . .... . 2-62

PORT BLOCK (SIN 14999 & Below)

40 Micron Filter (Bronze) ....................... . 2-51
Neutral By-Pass Valve ......................... . 2-52
Removal and Installation ....................... . 2-52

PORT BLOCK (SIN 15001 & Above)

Charge By-Pass ...... ... ........ ... .......... . 2-56
Cold Oil By-Pass ... .. ........... .. ...... .. ... . 2-56
Removal and Installation ................. . ..... . 2-55

TILT CYLINDER
Checking the Tilt Cylinder ...................... . 2-5
Removal and Installation ........... ... ... . ..... . 2-5
Rod End Seal ................................ . 2-6

TILT CYLINDER (CESSNA)

Assembly ........ . ....... .. ................ . 2-9
Disassembly ................................ . 2-7
TROUBLESHOOTING N

Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-1 '"

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843 loader
Service Manual
f' e f'

~ bobcat
HYDRAULIC I HYDROSTATIC FLOW CHART om RED- ...... HIgh .........
For Model
E,··~l BlUE - - - - - - Low Pr_ure
843 CS/N 11001 Thru 12999) ~ GJIEfN - - - - - Cue Oraln • Reservoir
AI Chart #6566716 [Printed NoYember 1988' ~ ORANGE - - • - CIwge Pranure

~5'S'SS"SS5S~

NOTE
Chart shows oi flow In Forward DrIve
PosItion and with Hydreullc Cylinders
Parti.lly Extended. For Hydraulic/
Hydroetetlc System Operation, refer to
Sheet 2 of til.. pubUcatJon.

xss:!\!SSss:s."x:;:,,:<S·\""'''\\\,,~USOS~

\\.'"SX, S5 S ""U\S."S:~5
t·l'llClJ
65881111IU-881 (.1 _
CSNet 'l of 21 _ .. u.s.A.
 ~boIxat
HYDRAULIC I HYDROSTATIC SYSTEM OPERATION
ToB. Used With
HYDRAULIC I HYDROSTATIC FLOW C~ART
for Modet
843 (SiN 11001 Thru 12999)
Chart :'6566716 (Printed November 1988.

==--::~~====~= CHART LEGEND =~==~====

eFLUlp itESERVOIR.. 4& ALTER By.pASS ••• 30 PSI (207 kPat

Cap.:. . . • . • . • •. 6.0 Gals. (22.7 l) 8 Oil COOLER
Working Cap.:. . . . . .. 3~·5-4·.O Gal. • PRESSURE SWITCH. • • .• 2.5-3.5 PSI
(13,2-15.1 U 117.3-24,1 kPa)
• HYDROSTATIC MOTOR••• 15 cu. in. • BY-PASS VALVE•.. , .. 180-200 PSI
(246 em 3 ) (1241·1379 kPa)
• HYDROSTATIC PUMP . , ACCUMULATOR. Nitrogen Precharge
• HIGH PRESSURE REUEF IJEPLE.NISHING 120 PSI (827 kPeJ tStaning at
VALVES, .•. 35OOP51 C24132'kPa) SIN 11936)
• HYDRAUUC PUIVIP•• ' , ••• 15.4 GPM
(5S;3lmin.) at 2720 RPM
e TEMPERATURE SWITCH, '" 210°f.
(99°C)
• PORT BLOCK
• "EUEF VALVE••••.••••• 43·57 PSI
. (296-393. kPa)
• ALTER . . . • • • . • . • . • • •• 40 Micron
• IIIT CYUNDER (Cushioned'
• UfT CYUNDERS
80RIACi:•.... 0.099" f2..51 mm) Dia.
S';' 11935 l. Below
ORIACE. • • •• 0.13S'· (3,51 mm) Diu.
Starting With SN 11936
• ~YDRAU4C CONTROL VALVE.
Selfoolevel
• MAIN REUEF. • • • • .• 2325·2500 PS.
(16030··17237 kPa) (Measured at Quiclc
Couplers)
• RESl'RICTOR (In Float and lower Position
Only)
• PORT REUEf (Uft SectionJ
3500 PSI (24132 kPa)
• AUXIlIARY QUICK COUPLERS
48 FJLTER, •••.•••••••••• , 10 Micron

65667US U f·80l (Sheet 2 Of 2~ P""ced lit U.S.A.

 ======= Oil FLOW EXPLANATION =~:-::-::==:=:==~
-
The nuid flows from the reservoir. to the inlet of the port block • • Reservoir fluid is
toined by the hydrostatic motor • case drain and the retum fluid from theoii coolf)f • .
This combined flow. supplies fluid to the hydraulic pump • •

The hydraulic pump. (a "gear" type) ,fo~ce$ the f'uJd totf1ehydrau.ic co~(ol valve • .
When all three spoofs are in ~t1a1. position, the fluid goes through the control varve. and
either to the reservoir. or to the port b10ck • • The hydraulic control valve • is.a three
section, parallel open center, closed port valve with a main relief valve" built into the
inlet section of the control valvee •

When one of the ~Is, is activate4, the fluid fJow is directed to either the base end or
the rod end of the cylinder(s)... Retum fluid from the other end of the
cylinder(sJ • • ~s back to the hydraulic control valve. and goes to the 40 micron
filter. in the port block • • The "tee fitting at the outletofthe' cOi'ltroJvalve • altows
U

ffuid to retum to either the by-pass valve. and:to the fluid reservoir. through a diffuser
or to the 40 micron filter. in the port block. during norma! operati~n. ~The Utes" fitting
also connects to an accumulator. which will provide 8 temporary charge ,pressure flow
when the lift and tilt cyfinders are being extended. Two sections on the control valva. can
be usecf at the same time if the main relief valve. is not open.

-The accumulator. is standard beginning with ser;al number 11936.

The by-pass valve. wilf open during cold weather or if thers is excessive fluid pressure.
The normal fluid flow through the 40 micron filter. , goes by the temperature switch. ,
and against the neutral charge by-pass valve • • The normal flow is through the "tee"
fitting between the temperature switch. and the charge by-passvalve. to the front
and the rear hydrostatic pumps • • The fluid ,flow is calted "charge pressure" and supplies
the hydrostatiC pumps. and the hydrostatic motors • with charge fluid. The charge
fluid is used by the pump arid motor, but as the charge pressure incteases. the charge
by-pass valve. win open to prevent excessive pressure built up.

The neutral charge fluid flows into each hydrostatic pump. and hydrostatic motor. to
cool, lubrica~e and replenish the fluid supptV which is lost through case ,drain. Hydrostatic
pumps • case drain flows into the inli!t side of the hydrauliC pump. tht:oughintemal
porting.

There 8fe two hydrostatic pumps. • and two hydrostatic motors • . One pump and one
motor work together as a pair to drive on one side of the loader. The other pump and motor
wotk as a pair to drive the opposite side of the loader.

When the hydrostatic pumps. , swashplate are angled in either direction. the hydrostatic
 to the hydrostatic m~tors • • Th~ ,~yC"!~slacic
pumps. force fluid, under hkJh pressure.
motors. tum and push the low pressure fluid back. to the hydrostatic pumps • lo'be
J
used a~ain. The hydrostatic motors. also contain a shuttle valve to allpwsome of the
fluid from ,the "drive loop" to go to the oil cooler. for cooling. The hydrostatic
pumps • center section contains four high pressure relief/replenishing va.lves • . Two
for e~ch side, one fe>r forward travel and one for reverse travel. The high pressure
repleniShing vahies • have a dual function. In neutral the varve can ridges ' . are pushed
off their' seats to allow' fluid ;'Iow from~he charge loop to the cool. lubricate and replenish
the pumps and the motors. When the swashpl,ates are angled, the Ouid is at a higher
pressure than the chargefluid~ this pressure: difference causes the high pressure replenishing
valves. to be forced against the seats. The high pressure repte,nfshing valves. also
act as a high pressure relief valve for the hydrostatic pumps • • in case of excessive
pressure being generated by the hydrostatic pumps • • The high pressure replenishing
valv~sc. will open allo.wing the "drive pressure-- to relieve into the charge loop to be
use~ again.

Excess charge pressurefJuid which is relie~ed over the charge bY'pass valve. is routed
to the "tee H and joins the hydrostatic rriQtor • case drain fluid arid flows to the oil
cooler • • The "teen fitting has a pressure switCh. that senses·~ drop in pressure of
the fluid which goes to the oil cooler • • Fluid from the oil cooler. flows through the
filter. which has a built in by-pass valve I) _The fluid then rIows into the inlet of the
port block and back to the hydraulic pump • •
 HYDRAULIC I HYDROSTATIC FLOW CHART I5DiI RED· - •• - • -
HIgh PMssure
For Model t-,,~I awE - - - - - -
Low Pre _ _

~ 843 (SIN 13001 Thru 14999) ~ GREEN - - - • - ea..

OnIIn • Reservoir
~ 0RANGf - - - - Charge P'ressIn
.. CWIIh Accumulator .IMI Charge Una Filterl
bobcxIt Chan #6566748lPrinted November 19881

NOTE
Chart shows 01 flow In F-.d Drive
PosiIIan ... with Hydraulc Cylnden
PartieDy Extended. For Hydraullcf
H1draetatic: Sywtem Opendlon. nd.. 10
Sheet 2 of this publJc:;dfOIt.

1-'."
E·1475
_ .. u.s.A.
_48nl-881 !Sheet 1 Df 2J

l,.. '--' ~
 ~bobcat
HVPR.AULIC I HY~DROSTATIC SYST'EM OPER'ATION
To Be Used With
HYDRAULIC I HYDROSTATIC FLOW CHART
FcWMode.
843 fS/N 13001 'Thru 14999)
CWith Accumulator and Charge Line Filter)
Chart II 6566748 (~nt.d Novelil'* 19881

===='!'====:==!::=~= CHART LEGEND ~==========

• FLU.D RESERVOIR. • OIL, COOlER

Cap.: ....•.... , 6.0 Gals. (22.7 l) • ORli=lCE RE~~CTOR;. ••••• 0.275"
Working Cap.: • . . • . .. 3.5-4.0 Gal. , i6;.99 mm) Dia.
(13.2·15.1 L) . . PRESSURE SWITCH. • • •• Z~,5·3.5 PSI
• HYDROSTATIC MOTOR, •• 15 cu. in. (17,3~24; 1 kPa)
" (246 cm 3 ,
• BY·PASS VAlVE•••••• UIO-200PSt
• HY~ROSrArICPUMP (1241-1379 kPa)
. . HIGH PRESSURE RatEF REPLENISHING
VALVES, ••• ~!)()O,psi (2~ 1~2 ~a)
• HYDRAUUC PUMP••.... 15,4 GPM
(58;3lmin.) at 2120 RPM
• TEMPERATURE SWITCH. 226-232°f.
(108-130 0 C)
• PORT BLOCK
• RELIEF VALVE •....•.••• ' 43~57 PSI
, (296-393 kPa)
• RLJ"ER ••••••••••••, ....... ~. , 3
' . OifFERENTIAL PRESSURE SWITCH.
19 psi C131" kPa)
' . TILT CYU",OER ICushioned)
• UFr CYUNOERS
• ,F,tLTER BY-PASS •. , 25 PSI (172 kPat
it:,MA1N RElIEF. . . . . .. 2125-2225 PSI
(14651-15341 tePa)
."QRlficE.,. ••• ,0;099-' (2.:51 mm) Dia.
" " •.;~!CJQIUlij BCJ8t and lower Position"
]),.fy)
• PORT REUEF fUft Sscdol'i)
,3~0() 'PSi 'C'2,.:r:$,2,kPa) ,
8t<HvDAAUU¢ 'C6'NrROl VALVE.
sait l!~~r '
• AwaU~RYQlJICK COUPlERS
• ACCUMULATOR

6166748 II t-88) (Sheet 2 Of 2) PrinIcd '" U.S.A.

======= OIL FLOW EXPLANATION
The fluid flows from the reservoir. to the intet ofthe port block • . Reservoir fluid is
joined by the hydrostatic motor. case drain and the rerum fluid from the oil cooler • .
This combined flow supplies fluid to the hydraulic pump • .

The hydraulic pump. (a "gear" type) forces the fluid to the hydraulic ~ontrol valve • .
When an three spoofs are in neutral position, the fluid goes through the control valve. and
either to the reservoir. or to the port block • . The hydraulic control valve. is a three
section, parallel open center, cJosed port valve with a main relief valve. built into the
inlet section.

When one of the spoots is activated, the fluid flow is directed to either the base end or
the rod end of the cylinder(s)... Return fluid from the other end of the
cylinder(s) 4& • goes back to the hydraulic control valve. and through the 3 micron
filter. and back to the port block • • The "tee" fitting at the outlet of the control
valve. allows fluid to return to either the by·pass valve. and to the fluid
reservoir. through a diffuser or through the 13 filter. and to the pan block. during
normal operation. -The '~tee" fitting also connects to an accumulator" which will provide
a temporary charge pressure flow when the lift and tilt cylinders are both being extended.
Two sections on the control valve. can be used at the same time if the main relief
valve. is not open.

The by-pass valve. will open during cold weather or if there is excessive fluid pressure.
The flow of fluid is through the 13 filter • • into the port block. , past the temperature
switch. and against the neutral charge by-pass valve • . The normal flow is through
the "tee" fitting between the temperature switch. and the charge bY--P8ss valve. to
the front and the rear hydrostatic pumps • . This fluid ftow is called "charge pressure"
and supplies the hydrostatic pumps" and the hydrostatic motors. with charge fluid.
The charge fluid is used by the pump and motor, but as the charge pressure increases,
the charge by-pass valve • will open to prevent excessive pressure build up.

The neulral charge fluid flows into each hydrostatic pump. and hydrostatic motor. to
cool, lubricate and replenish the fluid supplv which is lost through case drain. Case drain
from the hydrostatic pumps • flows into the inlet side of the hvdraulic pump. through
internal porting.

There are two hydrostatic pumps. and two hydrostatic motors • . One pump and one
motor work together asa pair to drivo one side of the loader. The other pump and motor
work as a pair to drive the opposite side of the loader.

When the swashplates. of the hydrostatic pumps. , are angled in either direction, the
hydrostatic pumps. force fluid, under high pressure, to the hydrostatic m.otors • . The
hydrostatic motors. tum and push the low pressure fluid back to the ,I!.V~.!WItatic
pumps 810 be used again. The hydrostatic motors 8.
, .
also contain a shunte valve to anow
some of the fluid from the drive loop to go t~ the oil cooter. for coating. The hydrostatic
pumps • center section contains four high pressure reUef/rep'enishing valves • . The~
are two for each side; one 'for forward travel and one for reverse tr~el The.high pressure
replenishing valves. have a dual function. In neutral the valve canridge~ • are pushed
off their seats to anow fluid flow from the charge loop to the coo'~ lubricate and replenish
the pumps and the motors .. When the swashplates are angled. the fluid is at a higher
pressure than the charge fluid, tt:Us pressure difference causes the high pressure replenishing
valves. to be forced against the seats. The high pre$SUre rep~nishing valves. also
act as a high pressure relief valve for the hydrostatic pumps • • in ca~e of excessive
pressure being generated by the hydrostatic pumps. . The high pressure replenishing
valves. Will open allowing the "drive pressure" to relieve into the charge loop to be
used again.

Excess emarge pressure fluid which is relieved over the charge by.pass valve. is routed
to the "tee" block and joins the hydrostatic motor. case drain fluid and flows to the
oft cooler • • The "tee" fitting has, pressure switch. that senses 8 drop in pressure
of the fluid which goes to the oil cooler • • Fluid from the oil cooler. flows into the
inlet of the port block. and back to the hydrautic pumP • .
r, n f'

~• bobcat
HYDRAULIC I HYDROSTATIC fLOW CHART WiI RED - - - - - - - High Pressure
For Model rz:i:] BWE - - - - - - low Pressure
'" 843 (SIN 15001 Thru 25999) :!m OREEN - - - - - c... Dr.n • ReseMlir
Chart #6570242 (Printed April 1986) ~ ORANOE - •.. Che,.. P r _
mii1 LT. ORANGE - HydreuBc Pump Charge

~
: .. ,......
::::0
.'- '

~: ,•• r· o• "

.............

tlI102G 11·IHII_O<II.... OI
IStInI 1 of 21 -..... ~.
E-l&08
 ~bobcat
HYDRAULIC I HYDROSTATIC SYSTEM OPERATION
. To Be Used With •
HYDRAULIC I HYDROSTATIC FLOW CHART
For Model
843 (SIN 16001 Thru 25999)
Chart II 6570242 (Printed Apftl1986.

========= CHART LEGEND ========~

• RESERVOIR, Cap.: ..••• 3.5-4.0 Gals. fa PRESSURE REUEF VALVE
113,2-15,1 L) . , UN-LoADING SPOOL
• TEMPERATURE SWITCH,. 225-232°F • FILTER. Hydraulic _• • • • •• 610 Microl
fl08-111°Ct • BY·PASS VALVE ••• 72 PSI (496 kPa
• COLD Oil BY-PASS VAlVE,.. 297 PSI • OIL COOLER
(2048 kPa)
• FILTER. Hydrostatic.. • •• #3 Efemen
• PORT BLOCK fa DIAGNOSTIC COUPLER
• CHARGE ay..PASS VALVE,. •• 110 PSI . . PRESSURE SWITCH. Differential
(758 kPat SIN 15001-20991 - 19 PSI (131 kPaJ
• OR_FICE. .• Motor Case Drain 0.217"' Starting WI SIN 20992 - 40 PSI {276 kPa
15,51 mm) Cia. I> BY-PASS VALVE.
• HYDROSTATIC MOTOR SIN 15001-20991 - 25 PSI (172 kPa:
OP9ESSURE SWITCH (Dual Function). StartingW/SJN 20992 - SO PSI (345kPa
Hourmeter Starts @ 19-23 PSI (132·158 . . DEFUSER
kPat Waming Ught Turns off @ 17-21 PSI . . SCREEN. • . . . •• _. • • • .• 100 Mest
(118·144 kPa)
I) BREATHER CAP _. _. . . • •• 5 Micror
• HYDRAUUC PUMP. Gear lYpe
8. Charge Pump, 11.5 GPM (43,5 Umin.) • HYDROSTATIC PUMPS
@ 2700 RPM @ 1050 PSI (7239 kPa] • HIGH PRESSURE REUEF VALVES
b. Hydraulic Pump. 16.1 GPM (60.9 Umin.) 3500 PSI (24133 kPa
@ 2700 RPM @ 1050 PS"I (7239 kPal
• HYDRAULIC AUXILIARY UNES
• LIFT CYUNDERS
• TILT CY~NDERS
• LOAD CHECK VALVES (Four)
• ANn-CAVITAnON CHECK VALVE
eORIACE
• MAIN REUEF VALVE,. 2250-2400 PSI
(15514-16548 kPa)
• PORT RELIEF VALVE ••••. ' 3500 PSI
(24132 kPa)
• HYORAUUC CONTROL VALVE
.. BUCKET posmON VALVE
• FlOW-CONTROL SPOOL
• CHECK VALVe
657024211-86) Revi-tod I"-aet «Sheet 2 Of 2) P,intcd In US.A
 Oil FLOW EXPLANATION

The fluid reservoir. is fiUed bV removing the breather cap. and ,filling ·fluid through the
100 mesh screen • •

Hydraulic fluid flows from the reservoir. and enters the inlet port of the tandem (2
sections) gear pump • .

The larger section Oft of the tandem pump suppUes pressure to the. inlet of the hydraulic
control valve • • The pump pressure is controlled bV the main relief valve • • The control
valve. is a four~ction, open center, closed port. series type valve. When all foUf' Spools
are in neutral position, the fluid. goes through the control valve. and either to th. hydraulic
filter fa or to the bucket position valve • •

The lift section and tilt section of the control valve • w~ together to pOSition the bucket
as the lift arms of the loader are b~fng r.aised. When th(;l lift ,arms are being raised. the
hydraulic pump . . now is directed to the base end of the lift cylinders • • The fluid from
the rod end of the lift cylinders. retums into the bucket position valve • and is directed
to the center of the 'ftf:JwooQOfltrol spool • • The flow-control spool. has an oriftce at each
end. Fifty nine ~nt (59~) of the fluid flow is directed to the base end of the tilt
cylinder • • Forty one ~f'cent (41%) of the fluid ,is directed throogh the opposite end of
the now-control spoo1 • and to the return port of the control valve .. lift section.

The fifty nine percent (59%. of the fluid flow from the flow-eontrol spool • is against
the un-Ioading'spool. and a check valve ED. An increase in ffuid pressure causes the
check valve. to open which allOws the frow of the fluid to the base end of the tilt
cylinder • • The fluid from the rod end of the tilt c;:ytinder • is contained by the un..foading
spool. until the tilt CYlinder base end • pressure is high enough to open the un..foading
spool. and ailow the rod end fluid to return into the control vafve • • The pressure relief
valve. is to relief fluid from the base end of the tilt cylinder. if the bucket is fully tolled
out and lift cylinders. are still extending.

The fluid flOViS from the charge pump • • either to the 0;1 cooler. or to the cooler by-
pass V~.tve • will ~~n when the, flu.l~ temperature is fOw or if there .5 excessive fluid
pressure. The 6ujd~1Qws th~ugh'~~Qil coole~ ... then through the hydrostatic filter" and
into the four-way Cioss fitting. TJle, f!uit;f fl9wsPast the pressure switCh. to the ch8rge
by-pass valve • • The pressure switch. has a dual function.. itStarts the hourmeter and
turns the warning light ofr.

Nannal flow of fluid is through the four~wav cross fitting to the front and rear hydrostatic
pumps • • This fruid flow is called "charge pressure" aod supplies the hydrostatic
pumps. and the hydrostatic motors. with charge fluid. The charge fluid is used by tho
pump and motor, but as the charge pressure increases. the charge by-pass valve. will
open to prevent e)Ccessive pressure build up.

The charge fluid flows into each pump • and motor. to coot, lubricate· and replenish
the fluid supply which is lost through case dram. Case drain from the pumps. flows into
the inlet side of the hydraulic pump. through internal porting.

There are two hydrostatic pumps. and two hydrostatic motors • . One pump and one
motor work together as a pair to drive one side of the loader. The other pump and motor
work as a pair to drive the opposite side of the loader.

The the swash plates of the hydrostatic pumps. are angled in either direction. the
pumps. fOlce fluid, under pressure. to the motors • • The motors. tum and push the
low pressure fluid back to the pumps. to be used again. The motors. contain a shuttfe
valve which allows some fluid from the "drive loop" to go to the port block. and back
to the reservoir • • The hydrostatic pumps. contain four high pressure refief/repienishJng
valves • • There are two valves. for drive on each side of the loader. one for forward
travel and one for reverse travel. The high pressUle reUef/repienishing valve. have a dual
function. In neutral the valve cartridges. are pushed off their seats to allow fluid flow
from the charge loop to cool. lubricate and replenish the pumps and motors. In forward
or reverse (when the swashplates are angled), the fluid has a higher pressure than charge
fluid. Th;s pressure difference forces one of tho high pressure replenishing valves (one per
pump) • against the seat. Tho high pressure replenishing valves ED also act as a high
pressure relief valve for the hydrostatic pumps.. The high pressure replenishing
valves. will open allowing the ··drive pressure" to relieve into the charge loop to be used
again if excessive pressure is generated by the pumps • •

E)Ccess charge pressure fluid which is relieved over the charge by-pass valve. goes through
the port block • and joins the hydrostatic motors. case drain Huid and flows to the
reservoir. through the defusser • . Fluid from the cofd oir by-pass valve. flows into
the port block. and back to the reservoir • •

Both the hydrawlC filter fa and the hydrostatic filter" have a by-pass valves. The hvdraulic
filter. has a 72 PSI (496 kPa) by-pass valve • • The hydrostatic filter. has a 25 PSI
(172 kPaJ (SIN 15001-20991) or 50 PSt (345 kPa) (Starting at SIN 20992) by-pass
valve . . and also contains a pressure differentia' switch • which indicates the condition
of the filter.

The diagnostic coupler fI provides a quick access for checking the charge pressure.
 HYDRAULIC I HYDROSTATIC FlOW CHART . . RED - - - - - - - High Pressure

J!t
For Modal fk'::"
BLUE - _ •••• Low Pr-..e
843 (SJN 26001 TI'II'u 29825) !BIll
'bobcat Ch1lJtI6670562 (Prihted May 1989'
GREEN·· - • - Calla Drain & Reservoir
~ ORANGE - - - - Charge Pressure
. . LT. ORANGE - BueIud Position Ruid Flow

NOTE
Chan shows 01 now In ~ard Drive
PosIdDn and with Hydraulic Cylinclen
Par1lallr Extended. Fer Rr4r-lIci
HydlOltadc: System Operalion. refer to ~l1i ,f' . i' f 'I, . ;! , M='~""""lf
ShMt 2 of tills publcalion.

115105&2 tNII! lSI-' 1 of!1 _InU,s.A, MC-10U

l, '-' '--'
 ~bobalt
HYDRAULIC I HYDROSTATIC SYSTEM OPERATION
To Be Used With
HYDRAUUC I HYDROSTATIC FLOW CHART
FOfMocieI
843 (SIN 26()01 Thru 2992&)
CUrt #6570552 (Printed May 1989)

================~ CHART LEGEND ~=~==========

• R~SERVOIR" Ca~:. • • •• 3.5-4.0 Gals. • PRESSURE RElEF VALVE

(13,2-15.1 l) • UN4.OADING SPOOL
• TEMPERATURE SWITCH... 226-232°F • fiLTER, Hydraulic. • • • • •• '10 Micron
(108-111 OCt • BY-PASS VALVE. •• 72 PSI (496 kPa)
• COLD FWID SV.pASS VALVE. 297 PSI
(2048 kPa)
e OIL CopLER
"fllJ'ER. Hydrostatic. • • •. 113 Element
e·PORTBLDCK
• DIAGNOSTIC CoUPLER
• CHARGE av-PASS VALVE,. .• 110 PSI • PRESSURE SWITCH. Differential
(758 kPa)
SIN 15001-209~1 - 19 PSI (131 lcPa)
• ORIFICE. •• Motor Case Drain 0.217" Starting WI SIN 20992 - 40 PSI (276 kPa)
(5,51 mmt Oia.
• BY·PASS VALVE_
• HYDROSTATIC MOTOR SIN 16001·20991 - 25 PSI (172 !cPa,
• PRESSURE SWI1CH (Dual Function), Starting WI SIN 20992 - 60PSf (345·1cPa)
Hourmeter Starts @ 19-23 PSI (131-159
kPalWamingUghtTurnsoff@ 17·21 PSt • DJFRlSER
(117-145 kPa) • SCREEN ••••••••••••• ~ 100 Mesh
• BREATHER CAP......... 5 Micron
• HYDRAULIC PUMP, Gear Type
8. Charge Pump. 11.5 GPM (43,5 Umln.) • HYDROSTAnC PUMPS
• 2700 RPM @ 1050 PSI (7240 Wa) • HIGH PRESSURE RELIEf VALVES
h Hydraulic Pump, 16.1 GPM (6G.9l/min.) 3500 PSI (24133 kPa)
@ 2700 RPM @ 1060 PSI (7240 kPa) • STEERING SERVO VAlVE (21
• HYDRAUUC AUXlUARY UNES
• LIFT CYLINDERS
.TUCYUNDER
• lOAD CHECK VALVES ,Four)
• ANTI-CAVITA1l0N CHECK VALVE
.OlUFtce
• MAIN RBJEF VALVE.. 2260.2400 PSI
(15514-16548 kPa)
• PORT RBJEF VALVE. • • • •• 3500 PSt
(24133 kPa)
• HYDRAUUC CONTROL VALVE
• BUCKET POsmON VA"VE
• FLOW-CONTROL SPOOL
• CHECK VALVE

6510552 f5.891 (Sheel 2 Of 2)

 OIL FLOW EXPLANATION .....-:""-=-:::-:""""======
J
sections) gear pump • • The larger section .It
Hydraulic fluid (lows from the reservoir. and enters the inlet port of the tandem C2
of the tandem pump supplies pressure
to the inlet of the hydraulic control vafve • • The pump pressure is controlled by the main
relief valve • • The control valve. is a four·section. open center. closed port. series
type valve. When all four spools are in neutral position, the fluid goes through the control
valve. and to the hydraulic filter • .

The lift section and tilt section of the control valve. work together to position ahe bucket
as the tift arms of the loader are being raised. When the lift arms are being raised. the
hydraulic pump" flow is directed 10 the base end of the lift cylinders • • The fluid from
the rod end of the lift cvHnders • returns into the bucket position valve • and is directed
to the center of theftow-control spoolS. The flow-control spoof. has an orifice at
each end. Forty one percent (41 %) of the fluid flow is dirocted through tho opposite end
of the flow-control spool. and to the return port of the control valve. lift section.

Fifty nine percent 159%J of the fluid flow from the flow-control spool. is against the
un-loading spool. and a check valve. _An increase in fluid pressure causes the check
valve. to open which allows the flow of the fluid to the base end of the tilt cylinder • •
The fluid from the rod end of the tilt cylinder. is contained by the un-loading spool I) until
the tilt cylinder" base end pressure is high enough to open the un-loading spool. and
allow the rod end fluid to return to the control valve • • The pressure relief valve fI is
to relieve fluid from the base end of the tilt cylinder. if the bucket is fully rolled out and
the lift cylinders. are still being extended.

The fluid from the charge pump section • • flows to either the oil cooler ED or to the
cooler by-pass valve • • The cooler by-pass valve" will open when the fluid temperature
is low (cold) or if there is excessive fluid pressure. The fluid flows through the oil cooter" •
then through the hydrostatic filter. and into the four·way cross fitting. The fluid flows
past the pressure switch. to the charge bY'pass valve • • The pressure switch. has
a dual function. it starts the hounneter and turns the waming light off.

Normal flow of fluid is through the four-way cross fitting to the front and rear hydrostatic
pumps" • and also supplies fluid to actuate the steering servo controls • • This fluid
flow is called charge pressure fluid. The charge fluid flows into each pump. and
motor. to cool. lubricate and replenish the fluid supply which is lost through case drain.
Case drain from the pumps. flows into the inlet side of the hydraulic pump. through
intemal paning. The return fluid from the steering servos. flows to the port block • .

There are two hydrostatic pumps. and two hydrostatic motors • • One pump and one
motor work together as a pair to drive one sjde of the loader. The other pump and motor
work as a pair to drive the opposite side of the loader.
 The swash plates of the hydrostatic pumps. are angled by the steering servo .v.alves... in
eit~r direction t the pumps. force fluid. under -pressure. to the motors.. The
motors. tum and push the low pressure fluid back to Ihe pumps. to be used again.
The motors. contain a shuttfe va1ve whk:h anows some fluid 'rom the drive loop to go
to the port block. and back to the resel'VQir • • The hydrostatic pumps • contain four
high pressure relief/replenishing valves • • There are two valves ED for dr:ve on each side
of the loader: one for forward travel and one for reverse travel. The higfl pressure
relief/replenishing .valves • have a dual function. Tho vatve cartridges. are· pushed off
their seats to anow fluid flow from the charge loop to cool, lubricate and replenish the
pumps and motors. In forward Or reverse (when tho swash plates are angled), the fluid
has a higher pressure than charge fluid. This pressure difference forces the high pressure
rep1enishin9 valves. onto the seat. The high preSsure replenishing valve" will open
allowing the drive pressure to r~tieve into the charge loop to be used again if e~cessive
pressure is gemJrated bV the pumps • •

Exeess charge pressure fluid which is relieved over the charge by·pass valve. goes
through the port block. and jojns the hydrosta~ic motors. case drain and flows to the
reservoir. through the diffuser • • Fluid from the cold oil by-pass valve. flows into
the port block. and back to th8 reservoir. under conditions of cold fluid or excess flow.

The hydraulic filter • ~$S a ~·pass valves to protect the system if the fi1ter element
becomes pfugged. The hydrostatic filter. has a by-pass valve and a pressure differential
switch" which indicates the condition of the fille, element.

The diagnostic coupler. provides a quiCk access for checking the charge pressure in
the system.
n f' n
HYDRAUUC I HYD'ROSTATIC FLOW CHART mil RED - - - - - - - High " - e
~ For Model K::l 8WE------ Law~
~ 843 (SIN 29926 ... Above) !;.o:. GREEN - - - - - c.. DnIn • . . - - . .
.. bobcat Chart #8720178 (Printed May 1989) l'S.'SS1 ORANGE- - - - a.ge ..........
c:;:] LT. ORANGE - BucIaIt ~ RuId Flow

IoIC·1al
_ .. u.s.A.
812111181&-881 Ilhet 1 of 21
 ~bobd
HYDRAULIC I HYDROSTATIC SYSTEM OPERATION
To. U~ \'lith
HYDRAUUC I HYDROSTATIC FLOW CHART
for Model
843 (SIN 29$26 It Above)
tharti6720178 CPrinte4 May 1989)

=======:;:!!!~======== CHART LEGEND ======================

• RESERVOIR. Cap.:. • • •• 3~5w4.0 Gals. • UN-LOADING SPOOL
(13~2-15.1 l) • FI1Jl;R, HVdrau1ic. • • • • •• 110 Micron
• TEMPERATURE SWITCH.. 225-232°F • BY-PASS VALVE. •• 72 PSI (496 kPa)
n08-111°CJ • OIL COOLER
• COJ,.D fWID BY-PASS VALVE, 297 PSI • FlLTER_ Hydrostatic. • • •• 13 Element
(2048 kPa)
• DiAGNOSTIC couPLER
• PORT BLOCK • PRESSURE SWITCH. Differential
• hHARGE BY-PASS VALVE•••• 110 PSI
•
(758 kPa)
ORIFICE. •• Motor Case Drain 0.217"
*'
•
40 PSI (276 1cPa)
BY-PASS VALVE. •• 50 PSI (345 kPa)
DiffuSER
(6,51 mm) Dia.
o "V[)fI(JSTAnc MOTOR •
•
SCREEN.. • • • • • • • • • • •• 100 Mesh
BREATHER CAP ••••• _ • •• 5 Micron
• PRE$.SURE SWITCH ,(Dual Fu~).
Hourme~r Starts @ 19-23 P$l (131-159 • H.YDROSTATIC PUMPS
kPa) W~ light bns off @l17...21 PSt • HIGH' PRESSURE REUEF VALVES
(117-145 kPaJ 3500 PSI (24133 kPa)
• HYDRA~UC POI!IP. Gear Type ED STEERING SERVO VALVE (2)
8. Charge'Purftp. i1.5 GPM (43,S Umin.t
@ 2700 RPM @ 1050 PSI (7240 kPa)
h H~ulic Pump, 16.1 GPM (60,9 L/min.t
@2700, RPM@) 1050 PSI (7240 Wat
• HYDRAUUC AUXILIARY UNES
• liFT evUN'DERS '
• TILT CYUNDER
• LOAD CHECK VALVES (Four)
• ANTl-cAVITATION CHECK VALVE
.ORi~
• MAIN REUEF VALVE. • 2250-2400 PSI
f15514-16548 kPa)
• PORT ReUEF VALVE •••••• 3500 PSI
(24133 kPa)
• HYDRAUUC-CONTROL VALVE
• BUCKET POSITION VALVE
• FLOW-CONTROL SPOOL
• FlOW ADJUSTMENT VALVE

,Sheet 2 Of 2) Printed .. u.s.A.

 OIL FLOW EXPLANATION

Hydrauic fluid Hows from the re~rvOlr. and enters the "tel port of the tandem (2
sections. ge,arpump • • The, lar:g~,r ~~c"tjon " cj, the tandem pump supplies pressure
to the inlet'of thehydr~u~c,¢on~1 valw • • The p,ump pressure is contro1led by the main
relia'valve • • The control valve • is a r()ur-sec:tion~open center, close$l pOrt, series type
valve. When an four spools are 1n neutral position, the fluid goes through the control
valve • and to the hydraulic titter • •

The lift section and tiJt section of the control valve • work together to position the bucket
as the lift arms, of the loader, al'& being raised. When the lift arms Ii" being raised- the
hydraulic pump . . fluid flow is directed to the base ~ of the lift cyrlRders • • The fluid
from the 'rod end of the rift cylinders. returns to the bucket position valve.,. and is
directad to the center of the fIow-contro1 spool • • The flow-control spool .·and
of
acf'JUstable metering orifice • split 'ibiS flow. Fifty-nine ,percent (59;(.) the flUid flow is
directed over the metering orifice,. to '-wi; the bucket. Foriv-one perCent (41%) of the
fluid is directed dlroUgh 'ibeoi'lflce in the" 8ow~ntrOl.sPooi . ' and on to the return port
of the contrQi valve (6ft section) • •

Fifty nine. percent (59". of the fluid "ow from the flow-coratrol spool. and metering
orifice. sPool' ••
is against the un.foading The un-Ioading spool moves to·allow extension
of the tt1t cylinder. as the fift cyrmders • raise the rift arms.

The fluid from the charge. pump section . . flows to either the oil cooler • or to the
cooler by-pass valve • • The ~ler by-pass valve. wi. open when the fluid temperatUre
is low (cold) or if there is excessive fluid pressure. Theflukf flows throUgh the oil cooJer • ~
then through the hydrostatic filter . . ~ into the four-way etoss filting. The fluid flows
past the pressure switch. to the charge by.pass valve • • The pJeSs,ure switch. has
a duat function, it starts the hourmeter and turns the waming,light off.

Normal flow of fluid is through the four-way cross fitting to the front and rear hydrostatic
pumps. , and also supplies fluid to actuate the steering servo controls • • This fluid
flow is called charge pressure fluid. The charge fluid flows into each pump" and
motor. to ~1; lubricate and reph.!nishthe fluid supply which is lost through case drain.
Case drain from the pumps. flows into 'the Intet Side of the hydraulic pump • through
interl\,~t portin,g. The ~orn ~d from the steering servos. flows to t~e port block • •

There:ar. two hydrostatic:pumps • and two hydrostatic,motors • • One pump and one
motOr work: tog~her as a pak to drive one side of the loader. The other pump and motor
work as a.pair to drive the opposite side of the loader.

The swaSh plates of the hydrostatic pumps. are angled bv the steering servo valves. in
either direction, the pumps . • forte fluid~ under pressure. to the· motors • • The motors
• tum and push the low pressure fluid back to the pumps. to be used again. The motors
.~tain a shuttle valve which allC)Ws some fluid from the drive loop to 99 tc)..the port
blOCk. and back to the reservoir • • The hVdrosta~ pumps. c()ntain four high pressUre
reUeffreplenishiJ\g valves • • Ther:e:are two valves'" fo~ dri~ on each side of the loader:
one 'or forward travel ·and one for reverse travel. The high pressure relieflr~p'enishing
valves. have a dual function. The· va'wcartridges • are pushed off their seats t~'allow
fluid flow from the charge loop to cool. lubricate and reptenishthe p~ps and motors.
in forward or'~rse (when the :$wash piatesare angled). the fluid haaa higher pressure
than charge Huitt. This pressure difference forces the high pressure replenishing
valves • onto the seat. The high pressure replenishing valve. will· open allowing the
drive pt'8$s'ure to relieve into the charge loop to be used again if excessive pressure is
generated by the PUmps • •

Excess~ pressure fluid \Vhich is relieved over the charge by-pass valve • goes through
the port block·.• and joins the hydrostatic motors. case drain and flows to the
reserwir • through the diffuser •• Auid f,omthe cold oil t)y-pass valve • 'flows into
the port block. and back to the reservoir. under conditions of cold fluid or excess flow.

The hydrauUc ~Iter • has a by-pass valve. to protect the system if the filter element
become$ plugged. The hYdrostatic filter • has 8 by-pass valve • and a pressure differential
switch. which indicates the cOndition of the filter element.

The diagnostic coupler. provides a quick access for checking the Charge pressure in the
system.
 HYDRAULIC I HYDROSTATIC FLOW CHART IliiB R£D - - - - - - - High Pressure
AND WIRING DIAGRAM Ii: !',~4 BUJE - - - - - - law Prassure
For Model i!D GREEN - - - - - Case Drain aReservoir
m:!!.'I
\at' 843 HIGH HORSEPOWER HYDRAULICS ORANGE - - • - Charge ...........
C!!:'ii] IT. ORANGE· Bucket FOeition Fluid Row
~ COPTIONAL)
• bobcat Chart #6570916 4Printad May 1989)

NOTE
Chart shows fluid flow In Forward DriVB
Posidon and with HydndIc CyBnders
PardaIy &tended.

• THE LATER PRODUCTION WADER WITH HIGH

HORSEPOWER HVDAAUUC$IOPrION. MAY IE
DIFFERENT THAN THE EARLY PRODUCOON
LOADERS. AS USTED BB.OW:
• Orifice. could be in either location shown on me
<:hart. but not in both .
• E!def1)81 relief wMt W8$ replaced by inW,.,.,rtelief
lIall/& . . In· the $O.d cap ~f the hydraulic pump.
Case drain hose was added from the hydrostatic
pump. to the hydraulic re&efVOir. and the
internal port between the hydraulic pump and
hydrostatic pumps was removed on later production
loaders.

MCIZ59

_ .. WI.A. NC·,U4
'57'01116 16-891 tsa-1tJ12)

l, ~ '-'
 HYDRAULIC I HYDROSTATIC SYSTEM OPERATIONS
To Be Used With
HYDRAUUC I HYDROSTATIC FIDW CHART AND WIRI~~ DIAGRAM
For Model
843 HIGH HORSEPOWER HYDRAUUCS (OPTIONAL)
Chart 66570916 (Printed September 1990)
~=~==~~======= CHART LEGEND =====~====~

• RESERVOIR, Capacity:.. 3.5-4.0 Gals. • ·ORIFICE••••• 0.024" (0.61 mmJ Dia.

(13,2-15,1 LJ
• TEMPERATURE SWITCH,.. 225-232°F
(100·111 0 C)
• COLD FWID sy.;PASS VALVE, 291 PSI
(2048 kPa)
• PORrBLOCK
• CHARGE BY-PASS VALVE.. •• 110 PSt
'(758 kPa).
• ORIFICE. •• Motor Case Drain 0.217';
(5~5 nvn) Diameter
• HYDROSTAnC MOTOR
• PRESSURE $WffCH CDual Function'"
HOUfmeter Starts 0 19·23 PSI f132-158
kPa) Warning light Nms off @ 17-21
PSI (118-144 kPaJ
• HYDRAUUC PUMP. Gear Type - Rated
@ 2700 RPM @ 1050 PSI (7239 kPa)
a. Hydraulic Pump. 16.2 GPM (61,3l/min.J
b. Charge Pump, 10.8 GPM (40,9 L/min.t
Co Auxiliary Hydraulic Pump, 6.9 GPM
(28,1 Urin .•
d. -Relief Valve, 3000 PSI (20685 kPal
• AUXlUARV COUPLER, Case Fluid Drain
• AUXILIARY COUPLERS, •.•..••• High
Horsepower Flow
• nLT CYUNDBl
I) lIFT CYUNDERS
• LOAD CHECK VALVES, ••••••••.•• 3
• ANTI-CAVITATION VALVE
• AUXIUARY QUICK COUPLERS
• HYDRAULIC CONTROL VALVE
. . SOLENOID VALVE. •• High Horsepower
Control
. , PORT RE1EF VALVE. • ••••• 3500 PSI
(24132 kPa)
MAIN RElIEF VALVE CBecUJcaf Con1roIIedJ,
•
Norma' Operation; 2200 PSI (15159 Id'ai
High Horsepower Operation; 3000 PSI
(20685 !cPa,
80RIRCE
• ELECrRICA" SELECTOR VALVE
• -RELIEF VALVE. 3000 PSI (20685 tePa)
• UN-WADING SPOQL
. , FLOW CONTROL SPOOL
• BUCKET POSITION VALVE
• fLOW ADJUSTMENT VALVE
• FILTER.......... Hydraulic 114 Element
• 8Y~S VALVE, •••• 72 PS, (496 kPa)
eOILCOOLER
• FlIl'ER. . •••.• Hydrostatic 113 Element
eDIAGNOS11C coUtuR
• PRESSURE SWITCH, Differential 40 PSI
(276 kPaJ
• BY-PASS VALVE, .•.• 60 PSI (345 kPa)
• BREATHER CAP. •••••••••• 5 Micron
• SCREEN.................. 100 Mesh
• DIffUSER
• STEERING SERVO CONTROL
• HYDROSTATIC PUMPS
• HIGH PRESSURE REUS: VALVES. 3500
PSI (24133 kPa)

6!i70,,1t t8-801 ISh••t 2 Of 2t

 WI~E ~.AGQM LEGEND WIRING DIAGRAM
PARIS LEQEND--
MO.'. COLOR GAUGE
120
SOl
0raIiC~16
~ 16
rn Harness Ce.ectur
soIiA Black 16 00 Swilda
50S Black 16 00 Solenoid Copilector&
SOY a~ 16
54E Dk-Crean 16 ~ GfOIIIUI
S4EA :Dk.·Green 16
S4FDk.Creen 16
S4G Dk.C~ 16

C,HECK'NG 8t ADJUSTING MAIN RELiEf

VALVE (DUAL PRESSURE,

1. Uft and block tho loader. High Pressure.

2. Coooect the hydraulic: tesler '0 the quick

couplers.

.•-and.·.
3. Disconnect the ele~ttical connectors

4. Start ahe engino. Chock the main relie'

valve • pressure.

5. Eflgage the high flow hydrouUc:s sW}lch • •

NO're If the pronute relief setting Is adjusted.

it wit eHuct the standard roUef pres~o.
Alwaysadjuat the high rwessuro ....ing .irst.

6. If odjustment is needed. loosen the jam nut and

adjust the high flow relief valve pnmuro by
turning in to inctuse pressure or out to docrease
pressure. The correct setting is 2950-3030 PSI
(20340-21030 kPa).
Adjustment
7. Disengage the high flow hydraulics. SlOP the
engine. tighten the jam nUllO 35 ftAbs. «47 Nml
torque. MC·J253

8. Remove the access plug or 'oosen the jam nut

on the main relief vahle • •
9. Start the engine. Use an aRen wrench and turn
the screw in to inCrease pressure Of out to
decrease pre~sure. Tho cor~ecC setting is
2150 2250 PSt (14824.15514 kPa).
4
n. To che~ the relief valve In the hydraulic
pump e end section: connect the hydraulic
tester into the outlet line of tht pump e c
.BV
restrie1ing the flc)w, with the hvdraullc leSter, tho
pressure should be 3000 PSI (20685 kPat at the

relief vatve ad .
10. S'(OP th4: engine. Install the 8CC4!$$ plug or tighten
lhe lam nul. DiscorUlect me hydf8uUc tester.
f' ~ f'

~ RED - - - - - - - High Pre....

•
rri:.l BlUE - - - - - - 1Dw Preaure
c:::J GREEN - - - - - Cae Drain • R..wir
~ ORANGE---- C...... p,....-.
c:::J LT. ORANGE - au. . I"oIition fluid Row
• bobcat
~,.
i~~~~

~JI 1$ r
'"I~~
(
\
\ ,-,
,_.
' r"
.
l
, -L-o
.
• -"'1\ ~lf'1
<1\..
.........
'v-

- )
1 '
.

" {1,,1\c ........

~_:::Z::==.:a ~ =I.'
_... !.,.JI I':J.-==;=:::':--'-~-.-'-.~-
I . ;;=~. ~;;;;'""=';
r
J
""",,'. -,,' -~, ... ,

1122~ ",921 ,....-', of 21

_In u.s.A.
 ~babc1at
HYDRAULIC I HYDROSTATIC ,YSTEM OPEIiATrONS
To Be Used With
HYDRAULIC I HYDROSTATIC FLOW CHART AND WIRING DIAGRAM
For Model
843H lWith Pilot Operated Main Relief)
Chart #6722306 (Printed September 1992)

========= CHART LEGEND =========

• RESERVOIR. Cap.: .. _ •. 3.5-4.0 Gels.
(13#2·15,1 l)
• SCREEN••••••••••••••.• 60 Mesh
• BREATHER CAP... . . . . . .• 5 Micron
• DIFFUSER
• TEMPERATURE SWlTCH~. 225-232°F.
(1ao-l11°C.)
• COLD flUID BY·PASS VALVE. 297 PSI
(2048 kPa)
• PORT BLOCK
. . CHARGE BY-PASS VALVE. 18().200 PSI
11241·1379 kPa)
• ORIACE.. .. Motor Case Drain 0.217"
(5.5 mmJ Diameter
• HYDROSTAnC MOTOR
.. HYDRAUliC PUMP.. Gear Type·Rated
@ 2700 RPM
s. Hydrau&c Pum~ 16.2 GPM (61.3 Umin.)
b. Charge Pump, 10.8 GPM (40,9 Llmin.)
c. Auxiliary Hydraulic Pump.
6.9 GPM (26,1 Umin.)
• PRESSURE SWITCH (Dual Function)~
Hourmeter Starts @ 19-23 PSI
(131-159 kPaI: Warning Ught Tums
Off @ 17-21 PSI (117-145 kPa)
• REUEF VALVE. 3000 PSI (20685 kPa)
• HIGH PRESSURE RElIEFJREPlENISHING
VALVES (41••. 3500 PSI (24133 kPa~
• HYDROSTATIC PUMPS
. . AUXIUARY COUPlER.. •• Case Drain
• AUXtUARY QUICK COUPLERS
• AUXIUARY COUPlERS.. • • . • •• High
Horsepower Row
• TILT CYLINDER
• UFT CYLINDERS
• STEERING SERVO CONTROL
• HYORAUUC CONTROL VALVE
• ORIFICE, ••• 0.024" CO,61 mm) Dis.
• SOLENOID VALVE.. High Horsepower
s. Forward Row Ruid Control (High flow)
b. Reverse Row Auid Control (low RDw)
. . ANTI-CAVJTATION VALVE
• LOADER CHECK VALVES,. • • • • • •• 3
• ORIFICE
• MAtN REUEF VALVE, Pilot Operated
Norma' Operation;
2260-2400 PSI (15514·16648 kPa)
High Flow Control;
3000 PSI (20686 kPa)
" PORT RELIEF VALVE.. • • •• 3500 PSI
r24133 kPa)
• El.ECTRICAL SELECTOR VALVE
. . UN-lOAD.NG SPOOL I PRESS. REUEF
VALVE
. . flOW CONTROL SPOOL
G FLOW ADJUSTMENT VALVE
• CHECK VALVE
. . BUCKET POSmON VALVE
• FILTER,. • • • • •• Hydraulic 14 Bement
. . BY·PASS VALVE,. •• 72 PSI (496 kPaJ
• OIL COOLER
. . FtIl"ER.. . • •• Hydrostatic 13 Bement
• DIAGNOSTIC COUPLER
• PRESSURE SWITCH,. • • •• Differential
40 PSI (276 kPaJ
tiD BY-PASS VAlVE.. •• 50 PSI (345 kPa)

612230549·9.2) (Sheet 2 Of 2) PtinlCld In uSA.

 WiRE i.ECEND PARIS LEGEND
~ NO!s
120
COLOR
Orang_",,"_
GAUGE
,.
16
; l!1 HarndS C....ctor

SORA Black II ~ Switdt

50s Black 16 [!] Ground
SOy Black 11
&OW Black 16 ~ Solenoid Conn.dar (Forward Flow,
54E Dk.Green 16
5 .........' Connector (Reverse Flow)
54EA
S4EB
Dk.Green
Ilk. CreelllYeUow
16
16
l!1
S4G Ok. Green 16 f!I Ele~ical SeiadOr Valve, Connecter

CHECKING " ADJUS'l"WG MAIN ilEUEF

VALVE (DUAL PRESsURE)
1. Lift 8& block the Joader.
2. Con"'ect~he hydraulic tester to the quick
coUplers.. AU tests are done with
engine speed at fuii RPM.
3. Start the en~ine. Check m.8in rftr,pf valve
presstn. The ~ p~ure fo[therow
setting is 2250-2400 PSt "6514-16548
kPBJ. '
4. Engage lhe uhigh pressure'# function Be
die,c~ the hiQh fl.~,w pressl¥e. The co~
presSure for the high setting is 3000 PSt
(20685 kPa).
is
NOTE: If adjustment M~ary • adjust 6. When the low pressure setting is COfTeCt.
the 'o w
pr~ setting before
adjusting the high preaure setting.
the next step is to set the high pres~ure
adjustment Of the marn ,r;efief valve •
use the following procedure:
S. Stop the engine. To adjust the' low
pressure on the main relielvahie • • use a. Stop the,engil1e..Disconnect the pi1~t
thefoJlowing .procedure: 'hose"& ~ni'Ove the ad8J)ter.
b. Use '8 1/4" ·allen' wrenCh (fternlt, to
a. Disconnect the p~t hose at remove p,~s;trna~hpin:(ltem 2. in'uli~1 it
the adapter fitting. bottoms ou~;§ainst the shoulder
b. ~~e high pressure adjustment stop (.Item 3t IIJ.
housing (Item 1)' I&J • c. Turn the adjustil')9 guide (Item 4) in
c. Use a 1/4" allen wrench (Item 2J to to increa~ or out to decrease the
tum the adjusting'screw (Item 3) in presSure fi] .•One turn is :eq~1 to
to increase or . out to decrease appro~imatety ~90 PSI .2Q~9k~)~
pressure .[6J. O~tum is equal to d. Install the ~dap~r& c,onnect~ pIlot
approximately 490 PSI (3379 kPaJ. hose.
d. Install th~high pressure ad;u,stment e. $trJi1 the engine. Engage the Uhigh
ho,usy,9,&:8d~Pte(._c::onnect the.pHo1 horsepower f ' function and check. for
hos& ~ .
the coriect· pressure. Repeat the
& start i~,e,"'9i"'" and, c"eck the proceddure until· the pressure setting
. pje$s,~r•. s~~ira_g.Repeat ~he is correct.
p'i'oeedure unitil the pressure setting
is correct.
=======FLUID FLOW EXPLANATION=======

Hydraulic fluid flows from the reservoir. and enters the inlet port of the triple (3 section)
gear pump • • The larger section. 8 of the pump supplies fiow to the inlet of the hydrautic
control valve • . The pump pressure is controlled by the main relief valve «I. The control
valve. is a four-section, open center, closed port. series type valve. wtaen aU four spools
are in neutral position. the fluid goes through the control valve fa and to the hydraulic
filter • •

When the lift arms are raised, the hydraulic pump • a fluid flow is directed to the base
end of the lift cylinders • • The fluid from the rod end of the Jift cylinders • returns to
the bucket position vald and is directed to the center of the flow-control spoof ED . The
flow-control spool ED and flow adjustment valve. direct this flow. A percentage of the
fluid is directed over the flow adjustment valve . , to position the bucket. The rest of the
fluid is directed through the orifice in the flow-control spool. and onto the return port
of the control valve. Clift sectiont.

The fluid flow from the flow-control spool. and flow adjustment valve. are against
the un-loading spool/pressure retlef valve.. The un-loading spool/pressure relief
valve. moves to allow extension of the tilt cylinder. as the lift cylinders. raise the
lift arms.

The un-loading spool/pressure relief valve. is to relief fluid from the base end of the tilt
cylinder. if the bucket is fullv rolled out and the lift cylinders. are still extending.

The fluid from the charge pump. b flows to the four-way cross fitting and is called "charge
pressure fluid". The fluid flows to the oil cooler" or oil cooler by-pass valve • • The oil
cooler by-pass valva. will open when the fluid temperature is cold or if there is excessive
fluid pressure. The fluid flows through the oil cooler" • then through the hydrostatic
filter. and past the pressure switch. to supply the front and rear hydrostatic
pump. with charge pressure and on to the charge by-pass valve • • The pressure
switch. has a dual function, it starts the hourmeter and turns the warning light off. The
charge pressure fluid flows into each pump. and motor. to cool, lubricate and replenish
the fluid supply which has been lost through case drain. Also fluid from the four·way cross
fining supplies fluid to actuate the steering servo controls. and the electrical
solenoids. for high horsepower operation. The return fluid from tho steering servo
controls. and electrical solenoids. flows to the port block • •

There are two hydrostatic pumps. and two hydrostatic motors • • One pump and one
motor work together as a pair to drive one side of the loader. The other pump and motor
work as 8 pair to drive the opposite side of the loader.

The sw~sh plates of the hydrostatic pumps. are angled by the steering servo
controls • in either direction. the pumps. force fluld. under pressure. to the motors • .
The motors. tum and push the 'ow pressure fluid back to the pumps. to be used again.
The motors. contain a shuttle velve which allows some fluid from the drive loop to go
to the port block. and back to the reservoir • • The hydrostatic pumps. contain four
high pressure relief/replenishing valves • • There are two valves. for drive on each side
of the loader: one for forward travel and one for reverse travel. The high pressure
relief/replenishing valves. have a dual function. The valve cartridges. are pushed off
their seats to allow fluid flow from the charge loop to cool. lubricate and replenish the
 pumps. and motors • • In forward or reverse (when the sw.ash plates are angled), the
fluid has a higher pressure the charge fluid. This pressure difference forces the high pressure
replenishing valVe. onto ~e seat. The high pressure reptenishing valve • wiU open
anowing the drive pressure to refieve into the charge '~p to be used again·if excessive
pressure is generated by the pumps.••

Excess charge pressure fluid Which is relieved over the charge bv-PBSS valve • goes through
the Port block. and joins the hydrostatic motors. case drain and ffows to the reservoir
through the diffuser.. Ffuid from the cO,d oil by-pass valve. flows into the port
block. and back to the reservoir • under conditions of cold fluid or ~cess f'ow.

The hydraulic fjl~r • has a by-pass wrve • to protect the system it the filter element
becomes plugged. The hydrostatic filter. has 8 by·pass valve • to protect the system
if the filter element becomes plugged and a pressure differential switch. which indicates
the condition of the filter element.

The diagnostic coupler. provides a quick access for checking the charge presswe in the
system.

HIGH FLOW OPERAnON

Turning the switch III lION" for high flow operation will activate the following functions:
It wig energize the electrical solenoid . " , and the electrical setector ~Ive • • When the
electricar solenoid • a is energized the charge pressure wltl shift the control valve
spoof. to allow the fluid f'ow from the hydraulic pump. a to flow to the electrical
selector valve • where the fluid joins with the flliid from ~ 8Uxjfiary hydraulic pump. c.
This flUid than flows to the lJigh flow quick coupler. at the front of the loader. The retum
fluid flows to the control valve. and to the hydraulic filter • • Case drain fluid (Example:
Planer) wiU return through the coupler It and back to the port brock. to join the ffuid
going to the reservoir • •

When the higb ~ operation is engaged; it will engage the pilot operated main retief
valve. which will Increase the relief pressure to 3000 Psi (20685 kPa). The relief
valve • in the auxiUary hydraulic pump. C and main relief vatve • will open to ..elieve
excessive p~ssure.

The fluid from the auxiliary hydraufic pump. C when not in Uti!e, flows to the electrical
selector valve. and returns to. the hydrauUc filter • •

Turning the switch III "REV" for reverse operation will active the electrical solenoid. b
and 'shift the controt valve spool • to aUow fluid flC)W from the hydraulc pump. a to
ffow to the high trow coupler . . . The return fruid goes to the control wive. end to the
hydraulic filter • • The electrical selector valve. hi not energi2ed iothis function.
 HYDRAULIC I HYDROSTATIC FLOW CHART
~ AND WIRING DIAGRAM
~ For Model
*,' bobcat 843H (SIN 50450 • Above)
Chart #8720946 (Printed September 1991)
G!I! RED - - - - - - - High Pressure
(,.~.I BlUE - - - - - - Low '"'--a
~ GREEN - - - - - ea..Drain • Res_lr
~ ORANGE - - - - Charge '"'-t'e
!iiifJ LT. ORANGE - IIuc*8t POaitIon FUel Row

~G

l-G_. .well»

-e

~m

"" I~.

57_'S-ell ca-t' at 21 _ir>u.&A.

'-' ~ l,
 HYDRAULIC I HYDROSTATIC SYSTEM OPERATIONS
-bobd
To Be USed WIth
HYDRAULIC I HYDROSTATIC FLOW CHART AND WIRING DIAGRAM
For Modef
843" (SIN 60460 a Above)
Chart '6720945 (Ptlnted Sept.,ber 1991)

.
====~,~============ CHART LEGEND ::==--======
• RESERVOIR, Cap.:. • • •• 3.5-4.0 Gals. • HYORAUUCCONTROL VALVE
(13,2-15~1 l) • ORIFICE. ••• 0.024'· (0,61 mmJ Cia.
• SCREEN.. • • • • • • • • • • • • •• 60 Mesh e SOLENOID VALVE.. High Horsepower
• BREATHER CAP.. . . • • . . •• 5 Micron a. forward Flow Fluid COntrollH"agh Flow)
• DIFFUSER b. Revenae Row Fluid Control (LDw flow)
• TEMPERATURE SWITCH... 225-232°F. • ANTI-CAVITAnON VALVE .
(100-l11 o e.) • LOADER CHECK VALVES.. • . . • • •• 3
• COLD FWiD ev-PASS VALVE, 297 PSI • ORIFICE
(2048 kPaJ • MAIN REUS: VALVE. (Bectrical ~Ied)
• PORT BLOCK Normal Operation;
• CHARGE BY·PASS VALVE, 180-200 PS' 2200-2300 PSI C15159-15859 kPa)
"241-1319 kPa) High Row Control;
• ORJAC~. •. Motor Case Drain 0.217" 3000 PSI (20685 kPa)
(5.5 mm) Diameter • PORT REUEF VALVE.. • • •• 3500 PSI
• HYDROSTATIC MOTOR (24133 kPa)
• HYDRAUUC PUM~ - Gear Tvpe-Ra~ed • ELECTRICAL SEL£CTOR VALVE
@ 2700 RPM • UN·lOADING SPOOL/PRESS. RWEF
a. HydratiUc Pum~ 16.2 GPM (61,3 Umin.J VALVE
b. Charge Pump, 10.8 GPM C40.9l/min.) • FlOW CONTROL SPOOL
c. Auxiliary Hydraulic Pump, • FlOW ADJUSTMENT VALVE
6.9 GPM (26.1 Umin.)
• CHECK VALVE
• PR£SSU~E SWITCH (Dual function), • BUCKET POSmON VALVE
Hourmeter Starts @ 19·23 PSI
• FlLl"ER.. • • • • •• Hydraulic 14 gement
(131-159 kPa); Warning tight Tums
• BY·PASS VAlVE. • •• 72 PSI (496 kPa)
Off @ 17-21 PSI (117-145 kPa)
• OIL COOLER
• REUEF VALVE, 3000 PSI (20685 kPa)
• Flt:rER.. • . •• Hydrostatic 13 Bement
• HIGH PRESSURE RBJEFJREPLENISHING
VALVES (4)... 3500 PSI (24133 kPa) • DIAGNOsnC COUPLER
• HYDROSfAnC PUMPS • PRESSURE SWITCH, • • • •• Differential
40 PSI (278 kPa)
• AUXILIARY COUPLER.. •• Case Drain
• BY·PASS VALVE, .• , 50 PSt (345 kPa)
• AUXfUARY QUICK COUPLERS
• AUXlUARY COUPLERS.. . • • • •• H!gh
Horsepower Row
• Till" CVUNDER
• UFT CVUNDERS
• STEERING SERVO CONTROL
(Sheet 2 Of 2)
 WIRE LEGEND PARIS LEGEND
NO!s COLOR GAUGE a Hamess CoIInedor' -
12GA
SOR
Ora....elWhlte
Slade
16
16
EI Switch
SORA Btack 16 II SoJenefd Connectors
50S Black 16 a. Forward fluid Flow
SOY aaack 16 It. Reverse Fluid Flaw
sow Biack 16
54E DIe. Cnten 16 lEI Ground
54EA Ok. Green 16
S4EB Lt. CreenlYellclw 16
S4F Ok•.cr.- 16
S4C Ok.Creen 16

CHECKING It ADJUSnNG MAIN ReliEF

vALve (OOAL PRESSUREt AdjUSlment
1. Uft 8& block the toader.
High Pressure
2. Connect the hydraulic tester to the quick Adjustment
couplers • •

3. Disconnect the electrical connectors

&. and lib.
4. Start the engine. Check the main relief
valVe ED pressure.

Engage the high flow hydraulic system

•
5.

NOTE: If the high presswe relief setting is

adjusted. it will effect the standard
reHef pressure. Always adjust the
high pressure setting first.

6. 11 adjustment is needed, loosen tJ"ae jam

nut and adjust the high flow relief valve
/
HighPr...... Screw
pressure by turning in to increase Adjustment
pressure or out to decrease pressure. The
MC-t2S3
correct setting is 2950·3050 PSI
(20340~21030 kPa).
10. Stop the engine. Install the access plug
7. Disengage the high flow hydrauIios. Stop or tighten the jam nut. Disconnect the
the engiile. Tighten the jam nut to 35 ft.· hydraufic tester.
Ibs. (47 Nm) torque.
11. To check the relief valve. in the
8. Remove the aCCf)SS plug or loosen the hydraulic pump end section: connect the
jam nut on the main relief valve . , • hydraunc tester into the outlet of the
pump • c. BV restricting the flow, with
9. Start the engine. Use an allen wrench and
the hydrauf,c tester# the pressure should
tum the screw In to Increase or out to be 3000 PSI (20685 kPat at tho relief
decrease pressure. The correct setting is
21S()"2250 PSt (14824-t5514 kPa).
valve • .
 ===!!::::~=~~FLUID FLOW EXPLANATION==~====

Hydraulic fluid flows 'rom the reservoir. and enters the inlet port of the triple (3 section)
gear pump. ' The larger section. a of the pump supplies flow to the inlet of the hydraulic
control valve • • The pump pressure is controlled by the main relief valve • . The control
valve. is a four-section, open center, closed port, series type valve. When all four spools
are in neutral position, the fluid goes through the control valve • a.nd to the hydraulic
filter. '

When the lift arms arc raised, the hydraulic pump. a fluid flow is directed to the base
end of the Uh cylinders • • The fluid from the rod end of the lift cylinders. returns to
the bucket position valvae and is directed to the center of the flow-control spool • . The
flow-controf spool. and flow adjustment valve. direct this flow. A percentage of the
fluid is directed over the ffow adjustment valve. to position the bucket. The rest of the
fluid is directed through the orifice in the flow-control spool. and onto the relum port
of the control valve. (lift section).

The fluid flow from the flow-control spool • and flow adjustment valve . . are against
the un-loading spool/pressure relief valve.. The un-loading spool/pressure relief
valve. moves to allow extension of the tilt cylinder. as the lift cylinders. raise the
lift arms.

The un-loading spool/pressure relief valve. is to relief fluid from the base end of the tilt
cylinder. if the bucket is fully rolled out and the lift cylinders • are s1i1f extending.

The fluid from the charge pump. b flows to the four-way cross fitting and is called "charge
pressure fluid", The fluid flows to the oil cooler 8) or oil cooler by-pass valve • • The oil
cooler by·pass valve. will open when the fluid temperature is cold or if there is excessive
fluid pressure. The fluid flows through the oil cooler., then through the hydrostatic
filter. and past the pressure switch. to supply the front and rear hydrostatic
pump. with charge pressure and on to the charge by-pass valve • • The pressure
switch. has a dual function, it starts the hourmeter and turns the warning light off. The
charge pressure fluid flows into each pump. and motor. to cool, lubricate and replenish
the fluid supply which has been lost tlvough case drain, Also fluid from the four·wav cross
fitting supplies fluid to actuate the steering servo controls. and the electrical
solenoids. for high horsepower operation. The return fluid from the steering servo
controls. and electrical solenoids. flows to the port block • .

There are two hydrostatic pumps. and two hydrostatic motors I) . One pump and one
motor work together as a pair to drive one side of the loader. The other pump and motor
work as a pair to drive the opposite side of the loader.

The swash plates of the hydrostatic pumps. are angled by the steering servo
controls. in either direction, the pumps. force fluid. under pressure. to the motors • •
The motors. tum and push the low pressure fluid back to the pumps. to be used again.
The motors. contain a shuttle valve which allows some fluid from the drive loop to go
to the port block. and back to the reservoir 0 . The hydrostatic pumps. contain four
high pressure relief/replenishing varves • • There are two valves. for drive on each side
of the loader: one for forward travel and one for reverse travel. The high pressure
relief/replenishing valves • have a dual function. The valve cartridges • are pushed off
their seats to allow fluid flow from the charge loop to cool, lubricate and replenish the
pumps. and motors. _~n f.orward or reverse {when the swash plates are angled), the
a
fluid has higher ~ssure the charge fluid. This pressure diffe.eneeforces thehighpr~sure
replenishing "aiVe • onto the seat. The high pres!Nre r~plenishlng valve. will open
allowing ·the drive pressure to relieve into the charge loop· to be used again if excessive
pressure is generated by the ·pumps· • •

Excess charge pressure fluid which is relieved over the charge by-paSs valve .90es through
the port block. and joins the hydrostatic motors • case drain and flows to the reservoir
through the diffuser.. Fluid from tf1e cold oil by-pass valve • ftows into the port
block. indo back to the reservoir. under conditions of cold fluid or excess flow.
The hydraulic ·filter . . has a by-pass valve. to protect the system if the filter element
becomes plugged. The hydrostatic filter. has a by-pass valve. to protect the system
if the filter .element~eCOmes·plu9ged·and.a pressure differential switch. Which indicates
Ihe condition of the filter element.

The di~sticcoupler . , provides a quick aceess for checking the charge pressure in the
system.

HIGH FLOW OPERATION

Turning the switch. "ON" for high flow operation wiD activate the following functions:
it wJlJ energize the electrical soJenoid fa a, the main relief valve. and .the eleClFical selector
valve • • When the e!ectnc~lsolenoid. a is energized the charge pressure will shift the
control val"e spool .toallow the fluid ·fJowfrom the hydraulic pump. a to flow to the
etectrical se'ectoJ valve G where the fluid joins with the fluid from the auxiliary hydraulic
pump. c. This flukJ than flows to the high flow quick coupfer • at the front of the loader.
The return fiuid flows to the co~t,ol valve. and 10 the hydraulic filter • • Case drain
f'uid (Example: Planer) will return tf:troUgh the coupler 49
and back to the port block. to
join the fluid going to the reservoir. _

When the high flow operation is engaged; it also energized the main relie' valve . . which
will increase the retief pressure to 3000 PSI (20685 kPaJ. The relief valve. in the auxiliary
hydraulic pump. C and main relief valve • witt open to relieve excessive pressure.

The fluid from the auxiliary hydraulic pump ....C when not in use, fJows to the eleOlrical
serector valve. and returns to the hydraulic filter • .

Turning the switch II "REV'~ for reverse operation will active the electricat solenoid • b
and shift· the control w.lve spool til to allow fluid flow from the hydraulic pump. 8 to
flow to the high flow coupler • • The return fluid goes to the control valve. and 10 the
hydraulic filt~.r" _ The electrical selector valve 6) and the main relief vafve • are not
energized in this function.
 .-----~~-~-------~-.~------.-------------------~"--~..~--,---------,~,----------'

r-, f' f'

HYDRAULIC / HYDROSTATIC FLOW CHART IIDi RED------- High Pre.....

k?;ij BLUE------ ~~
I( ~
.. bobcat
For Model
8438
Chart #6720555 (Printed September 1992)
:s!l GREEN - - - - - c.. Dmh • "-"toir
~ ORANGE - - - - Charp .........
1mLT. ORANGE - BucIIIIt r..bIan RuId Row

?
T
~ tyl

l
~::e
NOTE
Chan showa oil flow in Forward
DrIve Po.I1lon end with Hydraulic
Cyllndert Partlaly Extended. For
Hydraulic/Hydrostatic System r.Pl. h 2.PP ..... , .. ~I

Opendion. ntfw to Sheet 201 thi$

publication.

872DH5.lI-421 (&Met 1 of 21 ,.... "'~ 1ft u.s.1I.

 ~babcxlt
HYDRAULIC I HYDROSTATIC SYSTEM O,PERATION
To Be Used With
HYDRAULIC I HYDROSTATIC FLOW CHART
For Model
8438
Chart '6720555 (Printed September 19921

============ CHART LEGEND ===========

• BREATHER CAP. •••. . . • •. 5 Micron • FLOW CONTROL SPOOL
• SCR~. •.•.••••••••• 100 Mesh • flOW ADJUSTMENT VALvE
• RESERVOIR, Capacity • CHECK VALVE
3.5-4.0 Gals. ('13.2-15.1 L) • BUCKET POSmON VALVE (OPr.1
eDEFUSER • HYDRAULIC FllJ'£R. ••••• 10 Micron
• TEMPERATURE SWitCH. 225-232° F. • BY-PASS. VALVE. •• 72 PSI (496 kPa)
n08-111° c.t fa HYDflOSTAnC FILTER. •• 13 Element
• COLD FWID BY-PASS VALVE. 8) DIAGNOSTIC COUPLER
297 PSI (2048 kPa)
• DIf=FER£NT1AL PRESSURE SWITCH.
• PORT BLOCK 40 PSI (276 kPat
o CHARGE BV-PASS VALVE.
110 PSI (758 kPa)
4) BY-PASS VALVE. •• 50 PSI (345 kPa)
eOILCQOLER
• ORIFICE. . .•• _ • •• Motor C8se Drain
• HVDROSfAnC PUMPS
0.217" (5,5 mmJ
• HIGH PRESSURE/REPLENISHING REUEF
•
•
HYDROSTATIC MOTOR
PRESSURE SWItCH (Dual Function)
VALVES. +... 3500 PSI (24133 kPat
Hourmeter Starts @ 19·23 PSI (131-159
kPa); Waming Ught rums Off @ 17-21
PSI (117-145 kPaI
• HYDRAUUC PUMP. ••••. Gear Tvpe
Rated @ 2700 RPM &
1050 PSI (7239 kPa)
8. Charge Pump, 115 GPM (43,5 Um;n.)
h Hydraulic Pump. 16.1 GPM (60.9) Llmin.J
49 TILT CYLINDER
• UFT CYLINDERS
• AUXlUARY QUICK COUPLERS COPT.)
• LOAD CHECK VALVES (3)
• ANTI~CAVITATION VAlVE
• HvDRAUUC CONTROL VALVE
.ORIACE
• MAIN REUEf VALVE.
2250-2400 PSI «15514-16558 kPa)
• PORT REUEF VALVE.
~500 PSI (24133 kPa)
• UN-LOADING SPOOL/PRESSURE
RELIEF VALVE
872055S C9-921 «Sheet 2 Of 21 Prirlb!d In U.s.A.
 ~~~~===~FLUID FLOW EXPLANAtION======~====

Hydraulic fluid flows from the re~nloir • to t~e inlit port ot the tandem 42 seCtion) gear
pump • • The larger section., of' ~e hv~rauUc pump suppii,s, pressure to the infe't of
the hydraulJccontrot valve • • The ~ppressure is co~1ed by ,the malt) r.,ief wive . . .
The con~ol valve. is, a three-section. open center, closed~, seri~ wpe~va~ When
all three spools a;ein neutral position, tf)e fluid g08sthrough the control valve. to', the
hydraulic filter • •

If one of the spools is activated, the fluid goes out the respective port to e;ther the base
end. or the rod end of ~ eylirid8f'{s) • • • As the fluid gees into one end of fhe
cylinder(s) • • the:nuid from the other si~~ ~f the cylinder-flows backkrto the control
varve •• ALSO'SEE BUCKET POSITIONING SYsTEM 'oPERf.no~ IOPTlONAL).
When the cylinder(s) • ' . reach the end of the stroke, the fJ1Jid reaches, the setting of
the main refref valve • , It will open and let the fluid by..pass the-hydraulic circuit fm..,atly)
and go back to the rese~ir • •

The fluid flows from the charge pump •• to either the oil cooler. or the cooler by-pass
valve • which will open when there is cold fluid or if there is e~ fluid pressure.
The fluidfloW8 through the oil coo1er • , then through the hydrostatic filter. 'and into
the four-way block. The fluid floWs past the pressure' ~witch. ~o tb~ charge by~pass
valve • • The pressure swjt~h e' it
has a dual function# s"tarts the" hOutmeter and turns
the warning light "OFF".

Normal f.ow of fluid. Is through the four-way block to the front and ...ear hydrostatic
pumps • • This fluid Oow is caKed "charge pressure'· and supplies the hydrostatic
pum~s • and hydrostatic 'motors. with charge fluid. The cha~ge fluid is us~ by the
pumps and motors#but as the charge pressure increases. the charge by-pass vatve. will
open to prevent ex~sive pressure build-up.

The charge fluid flows into each pumP. and motor. to COOl; lubricate and replenish
the fluid supply which is lost thr'?Ughcase drain. Case drain from the pumps. flows into
the· inlet side'of the hydraufic pump. through internal porting.

There,afa two hydrostatic pumps. and motors • • One pump and one motor work
toge~er as. pair to drive one side of the loader. The other pump :and motor work 'as a
pair to ,'drive the opposite side of the toader.

The sw,astlptates of the hYdrostatic pumps. are angled to either direction~ the
pump$ . . foree fluid, under pressure, to the motors • • The motors. tum and push the
Jaw pressure fluid back to the pumps. to be used again. the motors 49 contain a shuttl.
valve which allows somefluic;t from the "drive fOOp#l to go to the port block. and back
to the reservoir • .
The hydrostatic pumps. contain four high pressure relief/replenishing valves" • There
are two valves. for drive on each side of the loader.:. one for forward travel and one for
reverse travel. The high pressure relief/replenishing valves. havea dual function. In neutral
the valve cartridges ED afe pushed off their seats to allow fluid flow from the charge loop
to cool, lubricate and replenish the pumps. and motors • . In forward or reverse travel.
the fluid has a higher pressure than charge pressure fluid. This pressure difference forces
one of the high pressure replenishing valves. against the seat. The high pressure
replenishing valves. also act as a high pressure relief valve fOf the pumps • . The high
pressure replenishing valves (I wilt open allowing the "drive pressure" to relieve into the
charge loop to be used again if excessive pressure is generated by the pumps ••

Excess charge pressure flUid which is relieved over the charge by-pass valve. goes through
ahe port block. and joins the hydrostatic motors. case drain fluid and flows to the
reservoir. through tho defuser • . Ruid from the cold fluid by·pass valve. flows into
the port block • and back to the reservoir • •

Both the hY.drauric fdter 6) and hydrostatic filter. have a bv-pass • • • The hydrostatic
filter. also has a pressure differential switch. which indicates the cond'ltion of the filter.

The diagnostic coupler. provides a quick access for checking the charge pressure.

BUCKET POSITIONING SYSTEM OPERATION (OPnONAL)

The lift and tilt section of the control valve. work together to position the bucket as
the lift arms are being raised. When the lift arms are being raised, the hydraulic
pump 8' flow is directed to the base end of the Uft cylinders • • The fluid from the rod
end of the lift cylinders. returns to the bucket posltion valve. and is directed to the
center of the flow-control spool • • The flow-control spoOl. has an orifice at each end.
Some of the fluid flow is directed to the base end of the tilt cylinder. and the other portion
of the fluid is directed through the opposite end of the flow-control spool. to the return
port of the lift section of the control valve • .

The fluid flow from the flow-control spool. is against the un-loading spool. and flow
adjustment valve ... An increase in fluid pressure causes the fJow adjustment valve. to
open which alJows the flow of the fluid to the base end of the tilt cylinder • • The fluid
-trom the rod end of the tilt cylinder. is contained by the un-loading spool • and allows
the rod end fluid to retum into the control valve • • The pressure relief valve fa is to relief
fluid from the base end of the tilt cylinder. if the bucket is funV rolled out and the 11ft
cyIJnders • are still being extended.
I 1*'\

I·
I

I
I~
2 HYDRAULIC SYSTEM

TROUBLESHOOTING

The following troubleshooting chart is provided as an assistance in locating and

correcting problems which are most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel only.

PROBLEM CAUSE

The hydraulic system will not operate. 1,2,3,4

Slow hydraulic system action. 1, 3, 5, 6, 7

Hydraulic action is not smooth. 1, 5, 6, 7, 8

Lift arms go up slowly at full engine RPM. 1, 3, 5, 6, 7, 9, 10, 11

The lift arms or Bob;rach will move with the pedal in neutral position. 5, 10

The !ift arms come down with the pedal in the neutral position. 5. 11. 12. 13. 14

The bucket does not self-level. 15, 16, 17

The bucket will partially self-level. 15, 16

The bucket as no power to roll forward. 17

The bucket does not roll back. 16

KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.

2. The pedal linkage is disconnected.
3. The hydraulic pump has a defect.
4. The relief valve has a defect.
5. The pedal linkage is not adjusted correctly.
6. Relief valve is not at the correct pressure.
7. Suction leak on the inlet side of the hydraulic pump.
8. Fluid is cold.
9. Using the loader for more than its rated capacity.
10. Spool in the valve section is not centering or the centering spring is broken.
11. Internal leak at the lift cylinder(s).
12. External leak at the lift cylinder(s).
13. Port relief seal is leaking.
14. Load check has a defect in the valve section.
15. Check the flow divider.
16. Check the unloading spool.
17. Check the self-level relief.

843 Loader
-2-1- Service Manual
 HYDRAULIC SYSTEM INFORMATION Mark a Line on Nut
Flats of Both Nuts

Always keep hydraulic and hydrostatic parts clean. Tighten to Correct

Clean outside of all assembles before beginning repairs. Amount from Chart
Use plugs and caps to cover open ports. Dirt can quickly
damage the system.
1·2021·0284

,0\-1897

Flare Connections

Use the following procedure to tighten the flare fitting: l!!J

Wrench Size
Tube Size
Outside Die. Thread Size
Rotate No.
of Hex Flats
Tighten the nut until it makes contact with the seat. 5/S" 5/16" 1/2" - 20 2-1/2

Make a mark across the "flats" of both the male and female
11116" 3/S" 9116" - lS 2
parts of the connection IA]. 7/S" 1/2" 3/4" - 16 2

'"
1-1/4"
5/S"
3/4"
7/8" - 14
1·1/16" • 12
'-1/2 - 2
1
Use the chart to find the correct tightness needed [i].
1-3/S" 1" 1-5/16" • 12 3/4· 1
If the fitting leaks after tightening. disconnect it and inspect 2" 1·1/4" 1·5/S" - 12 3/4 - 1
the seat area for damage.
2·1/4" '·1/2" 1-7/S" - 12 1/2 - 3/4

Straight Thread O-ring Fitting

When installing this fitting. the O-ring must be first lubricated.

Loosen the jam nut. install the fitting into place, then tighten
the jam nut. Trghten the jam nut until it and the washer are tight
against the surface @.

Tubellnes and Hoses

Make replacement of tubelines which are bent or have become

flat. There will be a restriction of fluid flow, which will give a
slow hydraulic action and cause heat.
A·1852
Make replacement of hoses which show signs of wear. damage
or weather cracked rubber.

When installing tubelines or hoses, make sure you use two

wrenches when loosening and tighten them.

843 Loader
·2-2· Service Manual
LIFT CYLINDER

Checking the Lift Cylinderls)

Lower the lift arms. Stop the engine. Activate the lift pedal to
release the hydraulic pressure.

Open the rear door.

Disconnect the hose from the tubeline which comes from the
base end of the lift cylinder (right side) 00 (left side) [ru. Only
check one cylinder at a time.

Put a plug in the tubeline.

A WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes causing serious injury. Ruid leaks
under pressure may not be visible. Use a piece of
cardboard or wood to find leaks. Do not use your bare
hand. Wear safety goggles. If fluid enters skin or eyes.
get immediate medical attention.
W-2074-1285

Start the engine and push the top Itoe) of the lift pedal. If there
is any leakage from the open hose. remove the cylinder for repair.

Repeat this procedure to check the lift cylinder on the other side.

Removal and InstaRatlon

Raise the lift arms. Install jackstands under the Bob.:rach. Stop
the engine. Activate the lift pedal to release the hydraulic
pressure.

Remove the lock bolt at the rod end of the cylinder @.

Installation: Tighten the lock bolt to 8-10 ft.-Ibs_ (11-14 Nml 8-8495
torque.

Remove the rod end pin lID.

843 Loader
-2-3- Service Manual
LIFT CYLINDER ICont'dl

Remove the lock bolt at the base end pivot pin.

Remove the base end pivot pin IAJ.

Slide the cylinder forward a small amount. Disconnect the hoses

from the cylinder Ill·

Remove the lift cylinder from the loader.

See Page 2-13 for Hydraulic Cylinder Repair.

843 Loader
·2-4· ~p.rvir.p. Man"al
TILT CYLINDER

Checking the Tilt Cylinder

Remove the bucket. Roll the Bob.:rach fully backward. Stop the
engine. Activate the tilt pedal to release the hydraulic pressure.

Disconnect the hose which goes to the base end of the tilt
cylinder I!l.

Put a plug in the hose. Remove Hose from

~ __ Endof Tilt Cylinder

- - 8-2790

A -WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes causing serious injury. Fluid leaks
under pressure may not be visible. Use a piece of
\
cardboard or wood to find leaks. Do not use your bare
hand. Wear safety goggles. H fluid enters skin or eyes,
get immediate medical attention.
W·2074·1285

Start the engine and push the bottom (heel) of the tilt pedal.
\
If there is leakage from the open port. remove the tilt cylinder
\
for repair.

Removal and Installation

Remove the bucket or attachment. Roll the Bob.:rach fully

forward. Stop the engine. Push the tilt pedal to release the
hydraulic pressure.

Disconnect the hoses at the tiit cylinder [!].

Remove the lock bolt at the rod end pin ~.

Installation: Tighten the lock bolt to 8-10 ft.-Ibs. {11-14 Nml

torque.

Remove the rod end pin @.

=11!!!!!!!55!;;,~:a:a-" 8-4399

843 Loader
-2-5- Service Manual
TILT CYLINDER (Cont'dl

Remove the lock bolt at the base end pin @.

8·4402

Remove the pin at the base end of the tilt cylinder [!].

Remove the tilt cylinder from the loader.

See Page 2-7 for the Cessna tilt cylinder and Page 2-13 for
all the other tilt cylinders.

Rod End Seal

Remove the old seal at the rod end of the cylinder. Install a new
seal with the lip facing out @.

8-4405

Use two pieces of shim stock, to install the rod end of the
cylinder, so there is no damage to the seals @.

8·4406

843 Loader
-2-6- Service Manual
TILT CYLINDER (CESSNA)

The tools listed will be needed to do the following procedure:

MEL-1074 - D-ring Seal Hook

MEL-1033 - Rod Seal Installation Tool
MEL-1075 - Gland Nut Wrench
MEL-1010 - Seal Installation Tool

Disassembly

NOTE: If there is movement between the head and the snap

ring the complete cylinder must be replaced.
8·3919
Put the base end of the cylinder in a drain pan. Move the rod
in and out to remove the fluid from the cylinder barrel.

Put the base end of the cylinder in a vise.

Put a cap on the fitting litem 1) in the end cap ~.

Lift the retainer ring litem 2) out of the cylinder barrel ~.

Put a wrench on the fitting and turn the end cap

counterclockwise to remove the retainer ring I!].

Remove the cylinder end cap, piston and rod assembly from the
cylinder barrel [£l.

8·3897

Put the rod end of the rod in a vise. Remove the piston from
the rod ~.

843 Loader
-2-7- Service Manual
 TILT CYLINDER (CESSNA) (Cont'd)

, Remove the O-ring from the end of the rod IAJ·

Remove the cushion sleeve from the rod ~.

Remove the end cap from the rod.

B-3902

Remove the wiper seal [j].

B-3905

Remove the oil seal ~.

8-3911

Remove the O-ring litem 11 and back-up washer (Item 2) from

the end cap ~.

8·3912

843 Loader
-2-8- Service Manual
 TILT CYLINDER (CESSNA) (Cont'd)

Assembly

_ -Remove the teflon seal and the O-ring from the piston @.

Wash all the parts in clean solvent. Dry with air only_ Destroy
old seals and O-rings.

8·3689
8·3703

Install the piston on the tool ~.

Install the O-ring on the piston using the tool ~.

8·3675

Install the teflon seal over the tool and on the piston ~.

NOTE: To prevent damage to the teflon seal, do not tum it into

the piston groove.

Install the piston into the tapered end of the tool to get the teflon
seal to piston size diameter.

8-3677
8-3673

Install the oil seal in the end cap ~.

8·3899

843 Loader
-2-9- Service Manual
TILT CYLINDER (CESSNA) (Com'd)

Install the wiper seal, with the lip toward the outside of the end
cap !AI.

8·3907

Install the back-up washer (Item 1) and Coring (Item 21 on the

end cap I).

Put oil on the oil and wiper seal and install on the rod ~.

Install the cushion sleeve. with tapered end toward the end cap
~.

Instell the Coring on the end of the rod.

Remove the piston from the tool.

Install the piston on the shaft. with the recessed edge toward
the O-ring ~.

B·3902 B-3915

843 Loader
-2-10- Service Manual
TILT CYLINDER (CESSNA) (Cont'd)

Tighten the piston to 400-455 ft.-Ibs. (542-617 Nm) torque ~.

Lubricate the teflon seal and Q-ring.

Install the piston into the cylinder barrel and work the teflon seal
and O-ring past the slot in the barrel 00.

Install the rod and end cap assembly into the cylinder barrel ~.

8·3894

Install the end cap into the barrel, work the a-ring past the slot
~.

Rotate the end cap until the small hole in the end cap can be
seen in the slot.

8·3910

843 Loader
·2-11- Service Manual
TILT CYLINDER (CESSNAI (Cont'dl

Install the new retainer ring hook end (Item 1) into the hole in
the end cap ~.

Turn the end cap clockwise until the retainer ring is in the slot.

8·2604

Push down on the retainer ring and make sure it is seated

correctlv 00.

Push the cylinder rod in and out the full length. It must travel
freely through the full stroke.

8-3913

843 Loader
-2-12- Service Manual
 HYDRAULIC CYLINDER REPAIR

NOTE: The following procedure can be used for the lift and
tilt cylinders.

Disassembly

The tools listed will be needed to do the following procedure:

MEL-l074 - O-ring Seal Hook

MEL-l033 - Rod Seal Installation Tool
MEL-t075 - Gland Nut Wrench
MEL·1215 - Seal Installation Tool
MEL-1178 - Seal Installation Tool

Put the base end of the cylinder in a drain pan. Move the rod
in and out to remove the fluid from the cylinder barrel.

Put the base end of the cylinder in a vise. Remove the end cap
from the from the cylinder using the special tool I!].

Remove the rod with the end cap and piston from the cylinder
. barrel.

Put the rod end of the shaft in the vise and remove the nut lID.

Remove the piston from the rod @.

8·3683

Remove the end cap from the rod ~.

843 Loader
-2-13- Service Manual
HYDRAULIC CYLINDER REPAIR (Cont'd)

Remove the O-ring and back-up washer from the end cap @.

Remove the wiper seal from the end cap [!]-

Remove the oil seal from the end cap @.

Remove the teflon seal and O-ring from the piston @.

Wash all the parts in clean solvent. Dry with air onlv. Destroy
all the old seals and O-rings.

843 Loader
-2-14- Service M8IIuai
HYDRAULIC CYLINDER REPAIR (Cont'd)

Assembly

Inspect the parts for scratches, nickS', bent, etc. Replace the
parts as needed.

Install the piston on the tool @.

Install the O·ring on the piston using the tool ~.

8·3674
8·3675

Install the teflon seal over the tool and on the piston 00.
NOTE: To prevent damage to the teflon seal, do not turn it into
the piston groove.

Install the piston into the tapered end of the tool to get the teflon
seal to the piston size diameter.

Wait 5 minutes so that the teflon seal becomes the same size
as the piston.

Install the seal on the seal tool @.

Install the seal in the end cap @.

8-3702
8-3671

Install the wiper seal with the lip toward the outside of the end
cap@.

NOTE: The O-ring side of the oil seal goes toward the inside
of the cylinder.

843 Loader
-2-15- Service Manual
HYDRAULIC CYLINDER REPAIR (Cont'd)

Install the back-up washer and O-ring on the end cap ~-

B·3679
B-3681

Put oil on the wiper seal and install the end cap on the shaft 00·
NOTE: On tilt cyRnder with tapered sleeve, instan the sleeve
with the taper toward the eye end of the rod.

Remove the piston from the tool and install the piston on the
shaft ~.

NOTE: On tilt cylinder with tapered piston. instaft the piston

with the taper toward the eye end of the rod.

B-3692

Install the nut and tighten to the following torque @:

Lift Cylinder - 150-160 ft.-Ibs.

1203-217 Nm)

Tilt Cylinder (Tapered Sleeve) - 330-360 ft.-Ibs.

(447-488 Nm)

Tilt Cylinder (Tapered Piston) - 478-550 ft.-Ibs.

. 1638-745 Nm)

843 Loader
-2-16- Service Manual
HYDRAULIC CYLINDER REPAIR ICont'd)

Inspect the cylinder barrel bore for scratches.

Put oil on the seals, O-rings and end cap threads !A].
Install the assembly into the cylinder barrel,

B·3691

Tighten the end cap with the special tool I!J.

Push the cylinder rod in and out the full length of the cylinder
barrel. It must travel freely through the full stroke of the cylinder
with no binding,

843 Loader
~ .. pvl" .. MA""AI
 HYDRAULIC CONTROL VALVE (CESSNA I

Checking the Main Ref..f Valve

The tools listed will be needed to do the following procedure:

MEL-1238 - Hydraulic Tester

MEL·10006 - Hydraulic Test Kit

Stop the engine. Activate the right steering lever (auxiliary

hydraulics) to release the hydraulic pressure.

Lift and block the loader (See Page 1-2 for the correct
procedure).

Connect the hydraulic tester to the auxiliary Quick couplers IAJ.

IMPORTANT
The flow control tester must be in the fully open position
before you start the engine to perform test.
1·2024·0284

Start the engine and run at idle RPM.

Engage the right steering lever into detent position. Watch the
flow at the hydraulic tester ·to make Sure it is correct.

Increase the engine RPM to maximum. There should be 15.5

GPM (58,8 L/min.) free flow.

The correct pressure for the main relief valve is 2150-2400 PSI
(14824-16548 kPal.

If not, stop the engine.

Remove the main relief valve (See Page 2-19),

IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of all assemblies before begiming repairs.
Use plugs and caps to cover open ports. Dirt can quickly
damage the system.
1-2021.Q284

843 Loader
-2-18- Service Manual
HYDRAUUC CONTROL VALVE (CESSNA I (Cont'dl

Main Relief Valve Removal and Installation

Activate the hydraulic controls to release the hydraulic pressure.

Raise the operator cab (See Page 1-7 for the correct
procedurel.

Clean the area around the control valve.

Loosen the main relief valve IA].

Remove the main relief valve from the control valve 00.
Installation: When installing the main relief valve, always use
NEW O-rings.

Clean and inspect the main relief valve.

Repeat the procedure for checking the relief valve. If the

pressure is not correct, replace the main relief valve.

8-4373

Removal and Installation

Stop the engine. Activate the hydraulic controls to release the

hydraulic pressure.

Lift and block the loader (See Page 1-2 for the correct
procedure).

Raise the operator cab (See Page 1- 7 for the correct

procedure).

Remove the front panel (See Page 3-3 for the correct
. procedure).

Clean the area around the control valve. 8-4374

Remove the hose from the control valve which goes to the port
block ~.

Disconnect the pedal control linkage at the valve spool @.

8-4375

843 Loader
-2-19- Service Manual
HYDRAULIC CONTROL VALVE (CESSNA) (Cont'd)

Disconnect all the control linkage from the control valve IAJ·

8-4376

Disconnect all the tubelines from the control valve [!I.

Installation: When installing the tubelines, make sure the,

restrictor orifice is. located in the port [!I.

8-4377

Disconnect the linage at the throttle lever @ ..

..,

Remove the three bolts at the outside of the loader frame ~.

Installation: TIghten the bolts to 25-28 ft.-Ibs. (34-38 Nml

torque.

Remove the control valve from the loader.

8·4379

843 Loader
-2-20- Service Manual
HYDRAULIC CONTROL VALVE (CESSNA] (Cont'd]

Disassembly

IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of all assemblies before beginning repairs.
Use plugs and caps to cover open ports. Dirt can quickly
damage the system.
1·2021·0284

Mark each section of the control valve for identification for

correct assembly @.

Remove the control valve thru-bolts 00.

Remove the end section lID.

8-4290

Remove the auxiliary, lift and tilt sections IQ].

Remove all the O-rings and destroy them.

NOTE: Disassembly. repair and assembly must be done to one

valve section at a time.

8·4295

843 Loader
-2-21- Service Manual
HYDRAULIC CONTROL VALVE [CESSNA) [Cont'd)

Inlet Section

Remove the main relief valve @.

8·4296

Remove the O-ring, back-up washer and O-ring from the port
00,

8 .... 297

Remove the O-ring from the main relief valve @.

Clean and inspect the main relief valve and inlet section. Replace
the parts as needed.

8-4298

Installation: Make sure to install NEW O·rings and back-up

washer in the inlet section ~.

8·4300

843 Loader
-2-22- Service Manual
HYDRAULIC CONTROL VALVE (CESSNA) (Cont'd)

Tilt Section

Remove the bolts from the end cap IAJ.

Installation: Tighten the bolts to 10-13 ft.-Ibs. 114-17 Nml torque.

8-4301

Remove the end cap 00.

Remove the valve spool assembly 1£).

Installation: CAREFULLY install the spool from the rear of the

valve section to prevent damage to the D-rings.

Installation: Check the valve spool, it must move freely in the

bore. If not, rotate it 180°.

8-4305

Remove the D-ring from the valve spool ~.

Remove the D-rings from the valve spool bore @.

Installation: Always use NEW O-rings before installing the spool

assembly.

NOTE: DO NOT remove the spool bolt from the valve spool
unless the spring is broken. If the spool bolt is to be
removed ISee Page 2-28 for the correct procedure).

843 Loader
-2-23- Service Manual
HYDRAULIC CONTROL VALVE (CESSNA) (Cont'dl

Remove the plug for the load check valve @.

Remove the spring and poppet ~.

,
~O 1>4'"
Remove the plug for the check valve ~.

Remove the spring and poppet [!J.

, ,t>
8·4315

Remove the plug at the unloading valve 1£].

8-4317

Remove the spring and unloading valve @.

Clean and inspect all the parts.

Replace the parts as needed.

Remove and destroy all the O-rings.

Always use NEW O-rings when assembling the valve section.

8·4318

843 Loader
-2-24- Service Manual
HYDRAULIC CONTROL VALVE (CESSNA) (Cont'd)

Lift Section

Remove the bolts from the end cap I!].

Installation: Tighten the bolts to 10-13 ft.-Ibs. (14-17 Nml torque.

8-4320

Remove the end cap 00.

NOTE: When instaling the end cap, make sure the detent holds
the spool.

8·4321

Remove the valve spool assembly ~.

8-4322

Remove the a-ring from the valve spool IQ].

Installation: Check the valve spool so it operates freely in the

bore. If not, rotate the spool 180°.

Remove the a-rings at both ends of the valve spool bore in the
valve section.

NOTE: DO NOT remove the spool bolt from the valve spool
unless the spring is broken. If the bolt is to be removed.
(See Page 2-28 for the correct procedu~e),

8-4307

843 Loader
-2-25- Service Manual
HYDRAULIC CONTROL VALVE ICESSNA) (Cont'd)

Remove the port relief valve ~.

Remove the O-ring, back-up washer and O-ring ~.

000
8-4324
8·4326

Remove the plug at the load check valve 00·

Remove the spring and poppet 00·

fD ~0 1It-4329
8·4327

Remove the plug at the flow divider valve ~.

Remove the flow divider valve and O-ring ~.

8·6568
8-4331

Remove the self-level valve ~.

Remove the O-rings and back-up washers from the self-level

valve lID.

Clean and inspect all the parts. Replace the parts as needed.

,
Remove and destroy all the O'rings and back-up washers.

NOTE: Always use NEW O-rings and back-up washers when

assembling the valve section.

000- 8-4336
8-4338

843 Loader
-2-26- Service Manual
HYDRAULIC CONTROL VALVE (CESSNA I (Cont'dl J
Auxiliary Section

Remove the bolts from the end cap I!I.

Installation: Tighten the bolts to 10-13 ft.-Ibs. (14-17 Nml torque.

Remove the end cap.

NOTE: When instal&ng the end cap, make sure the detent hol~s
the spool.

8-4342

Remove the valve spool assembly [!].

Installation: Check the valve spool so it operates freely in the

bore. If not, rotate the spool 180°.

B-4345

Remove the O-ring from the valve spool @.

Remove the O-rings at both ends of the valve spool bore in the
section.

NOTE: DO NOT remove the spool bolt from the valve spool
unless the spring Is broken. If the bolt is removed See
Page 2-28 for the correct procedure.

8·4307

Remove the plug at the load check valve [Q).

Remove the spring and poppet [Q).

8-4347
8-4348

843 Loader
c .......:............... _ .. _1
 HYDRAUUC CONTROL VALVE (CESSNA) (Cont'd)

Remove the flow plug ~.

Clean and inspect all the parts. Replace the parts as needed.

Remove and destroy all the O-rings.

Always use NEW D-rings when assembling the auxiliary section.

Valve Spool Bolt

To remove the spool bolt. follow this procedure:

8·4350

IMPORTANT
Remove This
The spool bolt Is held tightly by Loc-tite. Failur. to heat
the spool wiU cause breakage of the spool bolt ..
or
1. Heat the spool where the spools bolt turns into the spool
to about 400 0 F 1205°CI Ill.
~
2. Use a deep socket and remove the spool bolt. Heat This Area to
4000F 1205°C) to Remove
Bolt 8-3508

3. Install a NEW D-ring (Item 11 on the spool ~.

4. Install the washer (Item 2), spring cap litem 3). spring (Item
4) and spring cap litem 5).

5. Put Loctite on the spool bolt (Item 6) and install it in the

spool [g.

8·4341

6. Tighten the spool bolt to 60-96 in.-Ibs. 16,8-10,8 Nm) torque

~.

Tighten to
60-96 In.-fbs. (6.8-10.8
Nml
Torque Only

8-3512

843 Loader
-2-28- Service Manual
HYDRAULIC CONTROL VALVE (CESSNA) (Cont'd)

Assembly

NOTE: Use vaseline or grease to hold the O-rings in their

correct location between each section when
assembling the valve sections.

Put the inlet section in the vise.

Install the auxiliary section (Item 1) IAJ.

InstaU the lift section (Item 21 IAJ.

Install the tilt section (Item 11 I!].

Install the end section (Item 1) ~.

Install the thru-bolts (Item 21 and finger tighten only.

Remove the control valve from the vise. Set the control valve
on a flat surface to make alignment of all the valve sections.

Tighten the bolts to 22 ft.-Ibs. (30 Nml torque @.

843 Loader
-2-29- Service Manual
 HYDRAULIC CONTROL VALVE (MELROE)

Checking the Main Relief Valve

The tools listed will be needed to do the following procedure:

MEL-1238 - HydrauliC Tester

MEL-l0006 - Hydraulic Test Kit

Stop the engine. Activate the right steering lever (auxiliary

hydraulics) to release the hydraulic pressure.

Lift and block the loader (See Page 1-2 for the correct
procedure).

Connect the hydraulic tester to the auxiliary quick couplers IAJ.

IMPORTANT
The flow control tester must be in the fu8y open position
before you start the engine to perform test.
1·2024-0284

Start the engine and run at idle RPM.

Engage the right steering lever into the detent position. Watch
the flow at the hydraulic tester to make sure it is correct.

Increase the engine RPM to maximum. There should be 15.5

GPM (58.8 Llmin.! free flow.

The correct pressure for the main relief valve is 2250-2400 PSI
115514-16548 kPa) measured at the quick couplers.

If not. stop the engine.

Replace or adjust the main relief valve (See Page 2-31).

IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of all assemblis before beginning repairs.
Use plugs and caps to cover open ports. Dirt can quickly
damage the system.
1-2021-0284

843 Loader
-2-30- Service Manual
HYDRAULIC CONTROL VALVE (MELROE) (Cont'd)

Main Relief Valve Removal and Installation

Move the hydraulic controls to release the hydraulic pressure.

Open the rear door. The main relief valve (Item 1) is located on
the rear of the control valve on the right side ~.

Clean the area around the main relief valve.

Using a deep socket and extension. remove the main relief

valve [iJ.

Installation: When installing the main relief valve. always use

NEW O-rings.

Clean and inspect the relief valve.

Repeat the procedure for checking the main relief valve. if the
pressure is not correct do the following procedure:

Remove the cap (Item 11 from the main relief valve ~. Using
an allen wrench. adjust the relief valve until the pressure is
correct.

Removal and InstaUation

NOTE: The 843B loader control valve is a 3 spool valve, but

I the procedure for removal and installation is the same.

Stop the engine. Move the hydraulic controls to release the

hydraulic pressure.

Lift and block the loader (See Page 1-2 for the correct
procedure).

Raise the operator cab (See Page 1-7 for the correct
procedure).

Clean the area around the control valve.

Remove the high pressure hoses from the hydrostatic

pumps @].

Disconnect the auxiliary linkage from the control valve spool

~.

843 Loader
Revised Sept. 90 -2-31- Service Manual
I HYDRAUUC CONTROL VALVE (MELAOEI (Cont'dl
1(; Disconnect the lift and tilt linkage from the control valve
spools ~.

Disconnect all the tubelines from the control valve [i] (g .

I
!

Disconnect the inlet and outlet hoses from the control

valve fi8.

Remove the mounting bolts from the control valve. Remove the
control valve from the loader.

Installation: Tighten the mounting bolts to 180-200 in.-Ibs.

(21-23 Nml torque.

843 Loader
-2-32- Service Manual
HYDRAULIC CONTROL VALVE (MELROEJ ICont'd)
INLET

Disassembly and Assembly

The 8438 control valve is a 3 spool valve. The 03 rear

auxUiary section is NOT there, but the procedure for
disassembly and assembly is the same.

Mark each spool and section for correct assembly.

Check the control valve layout before disassembly for correct

identification and location of the parts l!l.
OUTLET

At Lift Cylinder. Rod End 02 Tilt Spool

A2 Tilt Cylinder. Rod End 03 Rear Auxiliary Spool
A3 Rear AuxHiary 04 Front Auxiliary Spool
A4 Front AuxHiary Et Anti-Cavhatlon Valve
B1 Uft Cylindar. Base End E2 Plug
B2 Tilt Cylinder. Base End F1 Main Relet Valve
B3 Re. Audlary F2 Port Retlaf Valve
B4 Front Auxili.y F3 Anti·Cavitation Valve
C1 Uft Load Check F4 Plug
C2 Tilt Load Check G1 Lift Detent
C3 Re. Auxiliary. Load Check G2 Tilt Cantering Mechanism
C4 Front Auxiliary. Load Check G3 Ree. Awe. Cantering Mechanism
01 Uft Spool G4 Front AUld"ary Detent
B-6581

Remove the load check vaives (Item 1) from the four center ports
lID· I
b
I

B·6886

Remove the port relief valve from the lift section ~.

1. Relief Valve
Remove the O-rings and back-up washer. 2. O·ring
3. Back-Up Washer
Assembly: Always use NEW O-rings and back-up washer. 4. O·ring
Tighten to 35-40 ft.-Ibs. (47·54 Nml torque.

crqxp
0-0-0
E-1S09

843 Loader
Revised Sept. 90 -2-33- Service Manual
HYDRAULIC CONTROL VALVE (MELROE) (Cont'd)
1. Anti-Cavitation Valve
2. O-ring
Remove the anti-cavitation valves from the spool end of the lift
3. Back-Up Washer
section and base end of the tilt section.
4. O-ring
Remove the O-rings and back-up washer [AI.

Assembly: Always use NEW O-rings and back-up washer.

Tighten to 35-40 ft.-Ibs. (47-54 Nm) torque. cp CPcp~
Remove the plugs from the spool end and base end of the front
auxiliary section. 0-0-0--
E·1509

Remove the a-rings and back-up washer lID· 1. Plug

2. O-ring
Assembly: Always use NEW a-rings and back-up washer.
3. Back-Up Washer
Tighten to 35-40 ft.-Ibs. (47-54 Nm) torque.

cp <p~p
4. O-ring

-0-0-0--
E-1509

Remove the main relief valve from the control valve ~.

Remove the a-rings and back-up washers ~.

1.
Assembly: Always use NEW a-rings and back-up washers.
2.
3.
Tighten to 35-40 ftAbs. (47-54 Nm) torque.
4.
5.

8-6887
E-1509

Remove the screws which fasten the rubber boot retainer to

the valve~.

Assembly: TIghten the screws to 90-100 in.-Ibs. (10-11 Nm)

torque.

8·6888

843 Loader
-2-34- Service Manual
HYDRAULIC CONTROL VALVE (MELROE) (Cont'd)

Remove the retainer, rubber boot and bronze filter !AI.

1. Screw
Repeat this procedure for the other valve spools. 2. Rubber Boot
3.
4.
Detent Assembly 5.

The tool listed will be needed to do the following procedure: 6.

MEL-1278 - Detent Tool

The lift spool and the front auxiliary spool have a detent and
float position. Use the following procedure to disassemble and 8·6889
assemble the detent assembly for either the lift or auxiliary
spool.

The detent sleeves are not the same:

Uft detent has a inside depth of 1.160" (29,5 mm).

Auxiliary detent has a inside depth of 1.061" (26,9 mml.

Remove the snap ring and washer [i].

IRemove the screws securing the detent cap ~.

Assembly: Tighten the screws to 90-100 in.-Ibs. (10-11 Nm)

torque.

Remove the detent cap.

Remove the detent sleeve and detent balls and spring.

A WARNING
Wear safety glasses to prevent eye injury when .any of
the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W·2019·1285

Remove the centering spring bolt ~ .

NOTE: Carefully remove the centering spring bolt, because

there is spring pressure.

Remove the spool from the bore.

Remove the front and rear O-rings. 8·6894

843 loader
Revised Sept. 90 -2-35- Service Manual
HYDRAULIC CONTROL VALVE (MELROE) (Cont'd)

NOTE: It is not necessary to remove the spool from tha bore

completely on the counter-bored valve with a bushing
1Aj.

Bushing Quad-Ring

8-13345

Install a NEW O-ring in the groove at the front of the control

valva [j].

Install the valve spool into the control valve from the rear of
the control valve. Push the spool into the valve just far enough
so that the rear O-ring can be installed ~.

Install the NEW rear O-ring ~.

Push the valve spool back into the control valve until it is even
with the rear machined surface of the control valve.

843 Loader
-2-36- Service Manual
Revised Sept. 90
HYDRAULIC CONTROL VALVE (MELROE) (Cont'd)

Put the detent adapter into a vise.

Install the detent spring I!l.

Put grease on the jaws of the detent tool. Put the detent balls
on the jaws of the detent tool ~.

Hold the detent balls in position. Install the spring end cap over
the detent adapter ~.

Remove the detent adapter and spring cap assembly from the
vise.

Install the centering spring and the other spring cap on the spool
and tighten the adapter to 90-100 in.-Ibs. (10-11 Nm) torque.

Install the detent spring into the detent adapter ~.

843 loader
• Revised Sept. 90 -2-37- Service Manu"
 HYDRAUUC CONTROL VALVE (MELROE) (Cont'd)

Hold the detent balls in position with the detent tool and slide
the detent sleeve into position ~.

Install the detent cap. TlQhten the screw to 90-100 in.-Ibs. (1()'11
Nm) torque.

Install the washer and snap ring on the end of the detent sleeve.

Centering Mechanism

The tilt and rear auxiliary spool have a centering spring. Use
the following procedure to disassemble and assemble the center
mechanism for either spool.

Remove the screws securing the cap 00.

Assembly: Tighten the screws to 90-100 in.-Ibs. 11()'11 Nml
torque.

Remove the cap. Remove the centering spring bolt 19.

A WARNING
Wear safety glasses to prevent aye Injury when any of
the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine Is running.
• Tools are being used.
W-2019-1285

Assembly: Tighten the centering spring bolt to 9()'lOO in.-Ibs.

110-11 Nml torque.

NOTE: Carefully remove the centering spring bolt, because

there Is spring pressure. 8·6897

Remove the spring caps, spring and adapter ~ .

1. a-ring 4. Centering Spring
IRemove the spool and the front and rear a-rings from the bore. 2. Bushing
(Early Models)
5.
6.
Spring Cap
Adapter
'nstall the front O-ring in the groove. Install the valve spool into 3. Spring Cap 7. Bolt
the valve from the rear of the valve. Push the spool into the valve
just far enough so the rear a-ring can be installed.

Install the rear O-ring.

Push the spool back into the control valve until it is even with
the rear machined surface of the valve.

Install the centering mechanism.

843 Loader
Revised Sept. 90 -2-38- Service Manual
HYDRAULIC PUMP (SINGLE STAGE)

Checking the Output of the Hydraulic Pump

The tools listed will be needed to do the following procedure:

OEM-1238 - Hydraulic Tester

MEL-1000e - Hydraulic Test Kit

NOTE: Make sure that all the air is removed from the system
before beginning the test. Air In the system can give
an inaccurate test.

Lift and block the loader (See Page 1- 2 for the correct
procedure). 8-4381

Raise the operator cab (See Page 1- 7 for the correct

procedure).

Connect the jumper start switch (See Page 1-9 for the correct
procedure).

Disconnect the outlet hose at the bottom of the hydraulic

pump ~.

IMPORTANT
Connect the INLET hose of the tester to the outlet of the
pump Ii!.
Be careful when turning the flow control restrictor at
Connect the OUTLET of the tester to the hose which was the hydraulic tester. When the tester is connected this
removed from the hydraulic pump Ii!. way there is no relef valve in the system. DO NOT close
the flow restrictor, on the tester, all the way.
NOTE: Make sure that the restrictor valve on the tester is fuly
open.

Start the engine and run at idle RPM. Make sure the tester is
connected correctly. If no flow is indicated on the tester, the
hoses are connected wrong. Increase the engine RPM to full .
RPM*.

Warm the hydraulic fluid to 140°F (eOOC) by turning the

restrictor knob on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure.

Open the restrictor and record the free flow (GPM) at full RPM.

Use the right steering lever to put the auxiliary hydraulics into
the detent position. Record the highest pressure and flow at
full RPM.

The high pressure flow must be at least 80% of free flow.

%= HIGH PRESSURE FLOW (GPM-lPM) x 100

FREE FLOW (GPM-LPM)

A low percentage may indicate a failed hydraulic pump or it may

be caused by air in the system. Make sure that all the air is
removed from the system.

·Refer to the specifications (Section 8) for system relief

pressure and full RPM. The system relief pressure must be per
specification before the test is run.

8-4382

843 Loader
Revised Sept. 90 -2-39- Service Manual
 HYDRAULIC PUMP (SINGLE STAGE) (Cont'd)

Removal and Installation

IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of all assemblies before beginning repairs.
Use plugs and caps to cover open ports. Dirt can quickly
damage the system.
1·2021-0284

Remove the port block from the hydraulic pump (See Page
2 - 51 for the correct procedure).

Disconnect the outlet hose from the pump ~.

Remove the two mounting bolts 1iJ.

Installation: Tighten the bolts to 25 ft.·lbs. (34 Nm) torque.

Remove the hydraulic pump and the O'ring [9.

8-4416

Disassembly and Assembly

Put the pump in a vise.

Make a mark across the body for correct assembly.

Remove the bOlts from the pump IRI.

Assembly: TIghten the bolts to 23 ft.-Ibs. (31 Nm) torque.

843 Loader
·2-40· Service Manual
HYDRAULIC PUMP (SINGLE STAGE) (Cont'd)

Remove the pump housing ~.

Remove the a.ring.

Remove the idler and drive gears [!].

Remove the wear plate ~.

Remove the spring and steel ball from the pump housing [QJ.

aMPORTANT
Make sure to mark the port where the spring and steel
bal are removed. If the ball and spring are instaled in
the wrong port. damage will result to the c~te
hydrostatic pumps. Only one baD and spring must be
instaHed on the high pressure side of the pump or the
lower port as it Is attached to the hydrostatic pumps.

843 Loader
Service Manual
 HYDRAULIC PUMP (SINGLE STAGE) (Cont'd)

Remove the back-up gasket and diaphragm seal from the

housing !AI.

Inspection

Clean and dry the parts.

Inspect the drive gears 00.

Check the bearing points and seal area for rough surface and
wear.

If the shaft measures less than 0.685" (17.4 mm) at the bearing
point or the gear width is less than 0.924" -(23.5 mm). the gears
must be replaced.

Check the 1.0. of the bearings'in the front and back housing !£J.
If the bearings are more than 0.691" /17,5 mm), the housing
must be replaced (bearings are not available as a separate
items).

8-4429 8-4428

Oil grooves in the bearings at both housings must be in

alignment with the dowel pin hole and 180 0 apart. This put the
oil grooves closest to the correct dowel pin @.

Check the body gear area for wear [Q}.

Replace as needed.

8·4427 B-4430

843 Loader
-2-42- Service Manual
 HYDRAULIC PUMP (DOUBLE STAGE)
The hydraulic pump is a two stage (double gearl pump, each
section of the pump must be checked separately.
The tools listed will be needed to do the following procedure:

OEM-1238 - Hydraulic Tester

MEL-l0006 - Hydraulic Test Kit

Checking the Output of the Hydraulic Pump

NOTE: Make sure that all the air is removed from the sys1em
before begiMing the test. Air in the system can give
an inaccurate test.
Uft and block the loader (See Page 1-2 for the correct
procedure).
Raise the operator cab (See Page 1- 7 for the correct
procedure).
Connect the jumper start switch (See Page 1-9 for the correct
procedure). 8·9370
Small Section of the Pump Only: Disconnect the outlet hose
from the pump IAJ. Connect the inlet hose of the tester to the
outlet of the pump IAJ. Connect the outlet of the tester to the
hose which was removed from the pump [Al. Disconnect the
hose which goes to the port block (at the hydraulic pump). Put
plugs in the hose and the fitting on the pump.
Disconnect the hose which goes to the port block (on the
hydraulic pump). Plug the hose and the fitting on the hydraulic
pump.

Large Section of the Pump Only: Disconnect the outlet hose

from the pump 00. Connect the inlet hose of the tester to the
outlet of the pump [iJ. Connect the outlet of the tester to the
IMPORTANT
hose which was removed 00.

NOTE: Make sure thet the restrictor valve on the tester is fully Be careful when turning the flow control restrictor at
open. the hydraulic tester. When the tester is connected this
way there is no reUef valve In the system. DO NOT close
Start the engine and run at low RPM. Make sure that the tester the flow restrictor, on the tester, aU the way.
is connected correctly. If no flow is indicated on the tester, the
Ihoses are connected wrong.
Increase the engine speed to full RPM *. Warm the hydraulic fluid
to l40DF (60 0 CI by turning the restrictor knob on the tester
to about 1000 PSI (6895 kPaI. Do not exceed system relief
pressure.

Open the restrictor on the tester and record the free flow at
full RPM.

Small Section of the Pump Only: Turn the restrictor knob so

there is about 500 - 600 PSI (3448 - 4137 kPa). Record the
highest pressure (PSI) and flow (GPMI at full RPM.
Large Section of the Pump Only: Use the right steering lever
to engage the auxiliary hydraulics. Record the highest pressure
land flow at full RPM.
The highest pressure flow must be at least 80% of free flow.

%= HIGH PRESSURE FLOW (GPM·LPMl X 100

FREE FLOW (GPM-LPM)

A low percentage may indicate a failed hydrauliC pump. or it may

be caused by air in the system. Make sure that all the air is
removed form the system .
• Refer to the Specifications (Section 81 for system relief
pressure and full RPM. The system relief pressure must be per
_specifications before test is run.
8-9372

843 Loader
Revised Sept. 90 -2-43- Service Manual
 HYDRAULIC PUMP (DOUBLE STAGE) ICont'dl

Removal and Installation

Lift and block the loader (See Page l- 2 for the correct
procedurel.

Raise the lift arms and have a second person install a lift arm
stop (See Page 1-4 for the correct procedure I.

Stop the engine. Raise the operator cab (See Page 1- 7 for the
correct procedurel.

IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of aU assemblies before beginning repairs.
Use plugs and caps to cover open ports. Dirt can quickly
damage the system.
1·2021·0284

Disconnect the charge pressure hose at the front of the pump

[AI.

Disconnect the hose at the charge pressure sender ~.

Disconnect the charge tubeline at the charge pressure sender

@.

Disconnect the charge pressure tubeline from the hydrostatic

pump ~.

Remove the tubeline.

843 Loader
·2-44- Service Manual
HYDRAUliC PUMP (DOUBLE STAGEI (t.ont'dl J
Disconnect the hose from the rear section of the pump ~.

Remove the tee fitting at the front section 00.

Disconnect the inlet hose at the bottom fitting of the hydraulic

pump @.

Loosen the clamp at the inlet hose ~.

843 Loader
-2-45- Service Manual
 HYDRAULIC PUMP (DOUBLE STAGEI (Cont'dl

Remove the mounting bolts from the pump flange IAI.

Installation: Tighten the bolts to 25-28 ft.-Ibs. (34-38 Nml
torque.

Turn the pump so the inlet fitting at the bottom is to the side
and slide the pump from the hydrostatic pump I!J.

Disassembly and Assembly

Put the pump in the vise.

Put a mark across the body of the pump for correct assembly.

Loosen the through bolts @.

Assembly: Tighten the bolts to 25-28 ft.-Ibs. (34-38 Nml torque.

Remove the bolts from the pump lm.

843 Loader
-2-46- Service Manual
HYDRAULIC PUMP (DOUBLE STAGE) (Cont'd)

Separate the pump body from the end plate ~.

Remove the O·ring.

Remove the pressure plate at the gears 00.

Remove the large section from the pump @.

Remove the O-ring.

Remove the large idler gear ~.

843 Loader
-2-47- Service Manual
 HYDRAULIC PUMP (DOUBLE STAGE) (Com'd)

Remove the pump body with the drive gear and shaft.

Assembly: Make sure the round key (Item 1) is in position and

engages with the small drive gear slot @.

8·8823

Remove the pressure plate from the small gears [!).

8·8820

Remove the small section of the pump @.

Remove the O-ring.

Remove the small drive and idler gear ~.

Inspection

Clean and dry all the parts.

Inspect both drive gears and idler gears at bearing points and
seal area for rough surfaces and wear.

Check the bushings in the end housings.

Check the pressure plates for wear.

Always use new O-rings when assembling the hydraulic pump.

843 Loader
-2-48- Service Manual
BUCKET POSITION VALVE IS/N 15001 81 Above)

Removal and Installation

Stop the engine. Operate the hydraulic controls to release the

hydraulic pressure.

Open the rear door.

Disconnect all the tubelines at the bucket position valve ~.

Remove the bolts and nuts and remove the bucket position valve
00·
Installation: Put Loctite on the treads of the tube line fittings
before tightening.

Disassembly and Assembly

NOTE: Make sure to mark the plugs and valves for correct
assembly.

Remove the plug, O·ring • spring and spool ~.

I
I

6
• B-7993

On the other side, remove the plug and O-ring ~.

B-8022

843 Loader
-2-49- Service Manual
 BUCKET POSITION VALVE (SIN 15001 III Above)

Remove the plug. O-ring, spring and spool ~.

8-8059

On the other side. remove the plug and O-ring 00.

It
8-8041

Remove the flow divider plug and O-rings [g.

Clean and check all the parts for wear. replace as needed.

Always use new O-rings and back-up washers when assembling

the bucket position valve.

8-7992

843 Loader
-2-50- Service Manual
PORT BLOCK (SIN 14999 & Below)

40 Micron Filter (Bronze)

The tool listed will be needed to do the following procedure:

MEL-l177 - filter Removal Tool

Replace the bronze (40 micron) filter every 500 hours of loader
operation.

I
IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of aa assemblies before beginning repairs.
Use plugs and caps to cover open ports. Dirt can quickly
damage the system.
1·2021-0284

Raise the operator cab.

Disconnect the hose at the fitting ~.

Remove the fitting from the port block Ii).

Install the filter removal tool on the filter ~.

Remove the filter. spring and sleeve from the port block [QJ.

843 Loader
-2-51- Service Manual
 PORT BLOCK (SIN 14999 & Below) (Coot'd)

Remove the filter removal tool from the filter I!l.

NOTE: DO NOT remove the sleeve before removing the bronze
filter from the port block. Particles trapped by the filter
may drop and enter the system. Always check the port
block for debris and clean the bore.

Clean the filter and sleeve in clean solvent. use air pressure to
dry them.

Install the spring, filter and sleeve on the tool !AI.

8-5085

Install the assembly into the port block [!J.

Remove the tool. Install the fitting and connect the hose.

Neutral By-Pass Valva

Raise the operator cab.

Disconnect the hose from the fitting lID.

Remove the fitting.

Remove the spring and by-pass poppet from the port block IQ].

Clean the parts. Check the valve seat in the port block. Replace
the parts as needed.

Removal and Installation

Raise the operator cab.

Remove the hoses from the port block [Q).

843 Loader
-2-52- Service Manual
PORT BLOCK (SIN 14999 & Below) (Cont'd)

Disconnect the charge tubelines at the front of the port block

@I!l.

Disconnect the charge tubeline at the rear of the hydrostatic

pump ~.

Disconnect the charge tubeline at the front of the hydrostatic

pump (Q].

843 Loader
-2-53- Service Manual
 PORT BLOCK (SIN 14999 8r Below) ICont'dl

Disconnect the tubeline which goes to the hydraulic/hydrostatic

reservoir IAJ.

Remove the bracket from the port block (!].

Installation: Tighten the bolt to 25-28 ft.·lbs. (34·38 Nm) torque.

Remove the large bolt from the port block and remove the port
block from the hydraulic pump ~.

Clean all the parts in solvent. Use air pressure to dry them.

Always use NEW O-rings when assembling the port block.

,
843 Loader
·2-54· Service Manual
PORT BLOCK [SIN 15001 & Abovel

Removal and Installation

J
Raise the operator cab.

Remove the front and side panels ISee Page 3 - 9 for the correct
procedure).

Disconnect the wire at the temperature switch @.

Disconnect the fitting at the tubeline from the reservoir [!J.

Disconnect both hydraulic hoses ~.

Remove the mounting bolt.

Remove the port block from the loader [Q].

843 Loader
-2-55- Service Manual
PORT BLOCK (SIN 15001 8& Abovel (Cont'd)

Charge By-Pass

Remove the fitting 00·

Remove the poppet and spring [!I.

Install a NEW O-ring before installing the fitting.

Cold Oil By-Pass

Remove the fitting @.

Remove the poppet and spring [gJ.

Install a NEW O-ring before installing the fitting.

843 Loader
-2-56- Service Manual
HYDRAULIC FWID FILTER HOUSING (SIN 15001 & Above)

Removal and Installation

Raise the operator cab (See Page 1-7 for the correct
procedurel.

Disconnect and remove the throttle rod linkage at the throttle

lever.

Disconnect the tube line at the filter housing 00.

Remove the mounting bolt and nut [ru.

Pull the filter housing away from the loader frame.

Disconnect the hoses from the filter housing @.

By·Pass Valve

Remove the plug. spring and poppet @.

Clean all the parts.

Check the poppet and seat for scratches.

Replace the parts as needed.

Always use a NEW O-ring when installing the by-pass valve.

B·8582

843 Loader
-2-57- Service Manual
 HYDRAUUC/HYDROSTATIC RESERVOIR (SIN 21514 & Below)

Removal and Installation

Raise the operator cab (See Page 1-7 for the correct
procedurel.

Remove the screen at the filler neck at the reservoir.

Use a transfer pump and remove the fluid from the reservoir.

Remove the front. side panels and steering levers (See Page
3-3 for the correct procedure).

Remove the port block (See Page 2 - 551.

IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of aU assemb6es before beginning repairs.
Use plugs and caps to cover open .ports. Dirt can quickly
damage the system.
1-2021-0284

Disconnect the high pressure hoses at the hydrostatic motor

IAJ.

Disconnect the high pressure hoses at the hydrostatic pumps

and remove them from the loader [!).

Remove the dipstick and tube from the reservoir ~.

Remove the filler neck from the reservoir ~.

843 Loader
-2-58- Service Manual
HYDRAULIC/HYDROSTATIC RESERVOIR
IS/N 21514 " Below) ICont'd)

Loosen the clamp at the outlet hose for the reservoir I!l.
NOTE: It may be easier to disconnect and remove the hose
from the reservoir at the hydraulic pump. Tum the
hydrau6c pump about 90° so the hose comes off the
inlet fining at the hydraulic pump.

Remove the bolts at the holding strap I!J.

Slide the reservoir forward and to the side and remove it from
the loader ~.

843 Loader
-2-59· Service Manual
 HYDRAULIC CONTROLS PEDALS (SIN 14999 & Below)

Removal and Installation

Disconnect the linkage at the pedal [!J.

Remove the hair pins at the pivot pins ~.

Remove the pedal from the bracket.

Remove the bushing from the pedal, using a vise, install the new
bushing in the pedal ~.

Adjustment

Loosen the nuts at the mounting bracket ~.

Slide the mounting bracket backward or forward until there is

about 1-1/2" (38 mml under the rear edge of the pedal.

Tighten the nuts to 25-28 ft.-Ibs. (34-38 Nml torque.

843 Loader
-2-60- Service Manual
HYDRAULIC CONTROL PEDALS (SIN 15001 & Abovel

Removal and Installation

Remove the bolt and nut at the linkage ~.

Check the rubber bushing in the pedal for wear and replace as
needed.

Remove the two mounting bolts 00.

Remove the pedal from the loader @.

Adjustment

After installing the pedal. adjust the pedal so that there is

clearance under the rear of the pedal and the valve spool will
travel full stroke without the pedal hitting.

If the linkage bar is to be removed. disconnect it at the valve.

Pull it out through the front of the loader ~.

843 Loader
-2-61- Service Manual
PEDAL LOCK LINKAGE

Adjustment
=:.----~

Check the pedal lock linkage so it is free and lock the pedals
@. ·1
~-.-.---~.
f~ --... "---'
~--j-"--q
•...~4-p_

0·1548

Check that the tab goes into the slot at the lock 00.
If not. loosen the bolts (Item 1) and adjust the tab for
engagement 00.

Installation: Tighten the bolts to 25 ft.-Ibs. (34 Nml torque.

A WARNING
Adjust locking tabs on pedal control linkage so that 11ft
6--4043
and tilt control pedals .,e locked in neutral when se.t
bar is up.
W-21 04-1285

843 Loader
-2-62- Service Manual
 HYDROSTATIC SYSTEM

Page
Number

FRONT AND SIDE PANELS (SIN 19999 & Below)

Removal and Installation..... . . . . . . . . . . . . . . . . . . . 3-3

FRONT AND SIDE PANELS (ONE PIECE)

(SIN 20001 & Above) & 843B
Removal and Installation........................ 3-9

HYDROSTATIC FLUID FILTER HOUSING HYDROST ATIC

Removal and Installation........................ 3 - 53 SYSTEM

HYDROSTATIC MOTOR
Disassembly and Assembly ................•..... 3-37
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-41
Removal and Installation ....................... . 3-36
Timing the Hydrostatic Motor ....................• 3-42
High Pressure Hose Routing ..................... . 3-42

HYDROSTATIC PUMPS
Checking Charge Pressure ...•................... 3-44
Checking the High Pressure RelieflReplenishing Valves .. 3-42
Disassembly and Assembly ..................... . 3-45
Hydrostatic Pump Rear Mount. .................. . 3-52
Inspection .................................. . 3-50
Removal and Installation......... . ............. . 3-44
Tow Valves ................................. . 3-51

HYDROSTATIC SYSTEM INFORMATION

High Pressure RelieflReplenishing Valve Function. . . . . • 3- 2

PINTLE LEVER ARMS (SIN 26000 Thru 29869)

Removal and Installation.............. . . . . . . . . . • 3-25

SERVO CONTROL
Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . 3-24
Removal and Installation........................ 3-23

STEERING LEVERS (SIN 16191 & Below)

Removal and Installation ....................... . 3-4
Repairing the Steering Levers .................... . 3-5

STEERING LEVERS (SIN 16192 & Above) & 843B

Removal and Installation ....................... .' 3-12
Repairing the Steering Levers ........'. . . . . . ...... . 3-13

STEERING LINKAGE (SIN 16191 & Below)

Removal and Installation ....................... . 3-7
Repairing the Pintle Lever ....................... . 3-8
Steering Linkage Adjustment .................... . 3-6

STEERING LINKAGE (SIN 16192 Thru 25999) & 843B

Removal and Installation ....................... . 3-15
Repairing the Pintle Lever ....................... . 3-16
Steering Linkage Adjustment .................... . 3-14

843 Loader
Service Manual
Revised Sept. 90
 HYDROSTATIC SYSTEM

Page
Number

FRONT AND SIDE PANELS (SIN 19999 & Below)

Removal and Installation.. . ..................... 3- 3

I FRONT AND SIDE PANELS (ONE PIECE)

(SIN 20001 & Above) & 843B
Removal and Installation ... ..... . ............ . .. 3- 9

HYDROSTATIC FLUID FILTER HOUSING HYDROSTATIC

Removal and Installation. ... .... . ........... .. .. 3-53 SYSTEM

HYDROSTATIC MOTOR
Disassembly and Assembly ....... . .... .... ... . . . 3-37
Inspection ................. - _ ............... . 3-41
Removal and Installation ....................... . 3-36
Timing the Hydrostatic Motor .................... . 3-42
High Pressure Hose Routing ..................... . 3-42

HYDROSTATIC PUMPS
Checking Charge Pressure ...................... . 3-44
Checking the High Pressure RelieflReplenishing Valves .. 3-42
Disassembly and Assembly ..................... . 3-45
Hydrostatic Pump Rear Mount. .. _ ............... . 3-52
Inspection .................................. . 3-50
Removal and Installation ....................... . 3-44
Tow Valves ........ .. ... ... ............. ... . . 3-51

HYDROSTATIC SYSTEM INFORMATION

High Pressure RelieflReplenishing Valve Function. . . . . . 3-2

PINTLE LEVER ARMS (SIN 26000 Thru 29869)

Removal and Installation ..................... - .. 3-25 ..
'"
ill

SERVO CONTROL
Disassembly and Assembly .. ...... _............ . 3-24
Removal and Installation ....................... . 3-23

STEERING LEVERS (SIN 16191 & Below)

Removal and Installation ....................... . 3-4 ,
o
~

Repairing the Steering Levers .................... . 3-5 o

~
o
o
'"
I STEERING LEVERS (SIN 16192 & Above) & 843B
Removal and Installation ............. _ - - ....... : 3-12
Repairing the Steering Levers ........-... . ....... _ . 3-13

IST~~~~;I L!~~~~;t~~~~o~6.1~~ .~ .B.e~~~) ............. . 3-7

3-8
Repairing the Pintle Lever .. .... ............. .. .. .
Steering Linkage Adjustment .................... . 3- 6 8'
"S'
STEERING LINKAGE (SIN 16192 Thru 25999) & 843B
Removal and Installation . ...................... . 3-15
Repairing the Pintle Lever ........ . .............. . 3-16
Steering Linkage Adjustment .................... . 3-14

843 loader
Service Manual
Revised Sept. 90
 HYDROSTATIC SYSTEM (Cont'd)

Page
Number

STEERING LINKAGE (SIN 26000 Thru 29869)

Description ....... . ...... .. ........ . ........ . 3-17
Neutral Adjustment . .. . .. . . . . . . ...... ... ...... . 3-17
Steering Lever Centering Spring Mechanism . ... . .. .. . 3-19
Removal and Installation (Creep Mechanism) .. .. .. ... . 3-20

STEERING LINKAGE (SIN 29870 Thru 31863)

Creep Centering Spring Mechanism .. . . . .. . ..... . . . 3 - 29
Description . . . .. . . ..... . ... ... . . ... . . . . .. ... . 3 - 27
Neutral Adjustment . . .. ... .. ... .. .. . . .... .. .. . . 3-27
Pintle Arm ......... . ...... .. ......... . ...... . 3 - 29
Steering Lever Centering Spring Mechanism .. .. ..... . 3-29

STEERING LINKAGE (SIN 31864 & Above) ... . . . .. .. .. . 3-30

Hydrostat Centering Spring Adjustment ... ..... . ... . 3-31
Servo Control Unit Adjustment ... . . . ...... .. ..... . 3-32
Steering Lever Centering Spring Adjustment ......... . 3-33
Wheel RPM Adjustment (Left and Right) ... ... . . .... . 3-34

TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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,,

843 Loader
Revised Sept. 90 Service Manual
3 HYDROSTATIC SYSTEM

TROUBLESHOOTING

The following troubleshooting chart will help to locate and correct problems which
are most common. Many of the recommended procedures must be done by authorized
Bobcat Service Personnnel only.

PROBLEM CAUSE

No drive on one side, in one direction. 1, 2,3,4,5

No drive on one side in both directions. 2, 3, 5, 6, 7, 8

The loader does not move in a straight line. 2, 3, 4, 6, 8, 9, 10

The hydrostatic system is overheating. 4, 11, 12, 13, 14, 15

The oil light comes "ON". 16, 17, 18

KEY TO CORRECT THE CAUSE

1. The hydrostatic system has a fluid leak.

2. The steering linkage needs adjustment.
3. The high pressure replenishing valve(s) are defective.
4. The shuttle valve in the hydrostatic motor has a defect.
5. The balance plate in the hydrostatic motor seals is defective.
6. The hydrostatic pumps have a defect.
7. The final drive chain is broken.
8. The hydrostatic motor has a defect.
9. The tires do not have the correct air pressure.
10. The tires are not the same size.
11. The hydrostatic fluid is not at the correct level.
12. The oil cooler has a restriction.
13. The temperature switch is not operating correctly.
14. The control valve is not operating correctly.
15. The engine is not being operated at the correct RPM.
16. One of the switches is defective.
17. There is low charge pressure.
18. The relief valve has a defect.

843 Loader
Revised Sept. 90 -3-1- Service Manual
HYDROSTATIC SYSTEM INFORMATION

IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of all assemblies before beginning repairs.
Use plugs and caps to cover open ports. Dirt can quickly FUNCTION 1 Valve Moves for Charge
damage the system. Fluid Replacement

~
1·2021·0284 '

'1
"
High Pressure Relief/Replenishing Valves Function " ~ ~" . ... ~
The high pressure relief replenishing valves are used both in
forward and reverse travel ~.
FUNCTION 2 Valve Stays on Seat
The functions of the high pressure relief replenishing valves are
to Hold High Pressure

~
as follows:
~
j
for Drive
1. Give replacement fluid to the low pressure side of the
closed hydrostatic circuit (Function 11 ~. .::;;
...."-"-,·v", -,,~. '-:
,, ~

2. To keep the high pressure flow of fluid out of the low

pressure side of the closed hydrostatic circuit (Function 2)
~. Valve Release Very
FUNCTION 3 High Pressure to
3. They will also release very high pressure caused by overload Protect System C·2526
when traveling in a forward or reverse direction (Function
3) ~.

843 Loader
·3-2- Service Manual
FRONT ANO SIDE PANELS (SIN 19999 & Belowl

Removal and Installation

Raise the operator cab (See Page 1- 7 for the correct

procedure) .

Remove the bolts from the front of the panel ~.

Remove the front panel.

Remove the bolt from the foot rest (both sides) rm·

Remove the bolts and remove the side shields (both sides) ~.

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~

Remove the bolts from the steering lever shields (both sides)
rnJ·
Remove the shields from the steering levers.

843 Loader
-3-3- Service Manual
ISTEERING LEVERS (SIN 16191 & Below)

Removal and Installation

Disconnect the steering linkage from the steering levers ~ .

IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of all assemblies before beginning repairs.
Use plugs and caps to cover open ports. Dirt can quickly
damage the system.
1-2021-0284

Disconnect the charge tubelines from the port block 00.

Disconnect the auxiliary linkage from the right steering

lever @] .

Remove the nuts and bolts from the left side pivot bearing ~ .

Installation: Tighten the bolts to 25 - 28 ft.lbs. (34 - 38 Nml

torque.

843 Loader
Revised Sept. 90 -3 - 4- Service Manual
ISTEERING LEVERS (SIN 16191 & Belowl (Cont'd)

Remove the nuts and bolts from the right side pivot bearing ~.

Installation: Tighten the bolts to 25 - 28 ft.lbs. (34 - 38 Nm)

torque.

Remove the steering lever assembly from the loader lID.

Repairing the Steering levers

Remove the rubber bushings and the teflon bushings from the
steering levers.

Install new rubber bushings into the steering levers, using two
sockets and a vise [£).

Neoprene

~hing~~
n
Washer
~.
\

: 84387 8·4450

Install new teflon bushings into the steering levers U!i.

Check the pivot bearings and replace as needed.

843 loader N
m
Revised Sept. 90 -3-5- Service Manual N
o
o
I STEERING LINKAGE (SIN 16191 & Below) (Cont'd)
Steering Linkage Adjustment

Lift and block the loader (See Page 1- 2 for the correct
procedure).

Loosen the nuts from the pintle lever ~.

Loosen the nuts on the steering levers 00.

Connect the remote start switch.

Start the engine and run at a slow speed.

/ / B·4440

Move the left steering lever until the tires do not turn (neutral).
Adjust the rear pintle bar so that the bar is tight against both
lobes of the pintle lever and the transmission is still in neutral
[g.

Tighten the bolts on the pintle bar to 28 ft.lbs. (38 Nm) torque.

Move the left steering lever backward and forward and let the
transmission return to neutral. If the transmission does not go
back to neutral, repeat the adjustment.

Move the right steering lever until the tires do not move (neutral).
Adjust the front pintle bar so the bar is tight against the lobes
of the pintle lever and the transmission is still in neutral mi.

Tighten the bolts on the pintle bar to 28 ft.lbs. (38 Nm) torque.

Move the right steering lever backward and forward and let the
transmission return to neutral. If the transmission does not
return to neutral, repeat the adjustment.

Install new lock nuts on the steering linkage.

Tighten the bolts and nuts to 23 ft.lbs. (31 Nm) torque.

843 Loader
Revised Sept. 90 -3-6- Service Manual
I STEERING LINKAGE (SIN 16191 & Below) (Cont'd)

Removal and Installation

Raise the operator cab.

Disconnect the steering linkage from the steering levers and

pintle levers ~.

Disconnect the springs from the centering bar rru.

Slide the centering bar toward the rear and lift up and remove
it from the transmission [£].

Loosen the bolt on the pintle lever ~.

Installation: Install the key in the pintle shaft [j?J. Tighten the
pintle lever bolt to 18-20 ft.-Ibs. (24-27 Nm) torque.

843 Loader
Revised Sept. 90 -3-7- Service MantAJl
STEERING LINKAGE (SIN 16191 & Belowl (Cont'd)

Remove the guide, bushing and pintle lever fAl .

Installation: Adjust the steering linkage for neutral (See Page

3-6).

Repairing the Pintle Lever

Remove the bolts from the lobes on the pintle lever ~.

Installation: Tighten the bolt to 25-28 ft.-Ibs. (34-38 Nm) torque.

Remove the rubber bushing from the pintle lever.

Install new rubber bushing into the pintle lever !9.

8·4388

Press the rubber bushing into the pintle lever, using two sockets
and a vise IQ].

843 Loader
-3-8- Service Manual
I
FRONT AND SIDE PANEL (ONE PIECE) (SIN 20001 & Above)
& 843B

Removal and Installation

Raise the lift arms and have a second person install a lift arm
stop (See Page 1-4) for the correct procedurel.

Stop the engine.

Raise the operator cab (See Page 1- 7) for the correct

procedure).

Remove the nuts from the parking brake pedal ~.

Remove the brake pedal rru.

Remove the hydraulic foot pedals and linkage (See Page 2 - 60
or 2-61 for the correct procedure).

Remove the foot rest (both sides) @.

Disconnect the throttle linkage and remove the throttle lever

IQ].

843 Loader
Revised Sept. 90 -3-9- Service Manual
FRONT AND SIDE PANEL (ONE PIECE)

I (SIN 20001 & Above) & 8438 (Cont'd)

Remove the bolts from the bottom of the front panel (both
sides) ~.

Remove the hydrostatic motor cover (both sides) rnJ·

Now remove the bolts from the side of the loader frame and
side panel (both sides) [g.

Remove the hand grip by plugging the hole in the bottom of the
steering lever and using air pressure to remove the hand grip
(both sides) [Q].

843 loader
Revised Sept. 90 -3-10- Service Manual
I FRONT AND SIDE PANEL (ONE PIECE) (SIN 20001 & Above)
& 843B (Cont'd)

Lift and remove the front panel from the loader frame ~.

I Remove the steering levers (See Page 3-4 for the correct
procedure).

Remove the bolts and remove the side panel from the loader
frame 00.

'"'"

843 Loader
Revised Sept. 90 -3-11- Service Manual
STEERING LEVERS

843 (SIN 16192 thru 25999)

1
843 (Starting with SIN 34222)
843B

Removal and Installation

Remove the front panel (See Page 3-9).

Disconnect the steering linkage from the steering levers ~ .

Installation: Tighten the bolts and nuts to 23 ft.lbs. (31 Nm)

torque.

Disconnect the auxiliary linkage from the right steering

lever rn:J.

Remove the bolts and nuts from the pivot bearings [g.

Lift and remove the steering lever assembly from the loader [Q).

843 Loader
Revised Sept. 90 -3-12- Service Manual
STEERING LEVERS (Cont'd)

843 (SIN 16192 thru 25999)

843 (Starting with SIN 34222)
1
8438

Repairing the Steering Levers

Remove the rubber bushings and teflon bushings from the

steering levers.

Install new rubber bushings into the steering levers, using two
sockets and a vise ~. .

Install new teflon bushings when installing the two steering

assemblies together 00.

B·9312

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~

843 Loader
Revised Sept. 90 -3-13- Service Manual
STEERING LINKAGE

843 (SIN 16192 thru 25999)

1
843 (Starting with SIN 34222)
843B

Steering Linkage Adjustment

Lift and block the loader (See Page 1- 2 for the correct
procedure).

Raise the operator cab (See Page 1- 7 for the correct procedure.

I
Loosen the nuts and bolts connecting both pintle levers to the
steering levers ~.

Connect a remote start switch (See Page 1- 9 for the correct

procedure).

Loosen the bolts from the front bar ~.

I
Loosen the bolts from the rear bar.

Start the engine and run at idle.

Stand clear of the tires. Move the steering lever for the rear arm,

I
until the tires do not turn (neutral). Push the rear bar against
both lobes of the lever with transmission in neutral. Tighten the
rear bar bolts to 28 ftAbs. (38 Nm) torque.

I
Move the steering lever, for the front arm, until the tires do not
turn (neutral). Push the bar against both lobes of the lever with
the transmission in neutral [£].

Tighten the bolts at the pintle bar to 28 ft.-Ibs. (38 Nm)

torque ~.

Move both steering levers backward and forward and let the
transmission return to neutral. If the transmission does not
return to neutral, repeat the adjustment again.

Install new lock nuts onto the steering linkage and tighten to
23 ft.-Ibs. (31 Nm) torque.

843 Loader
Revised Sept. 90 -3-14- Service Manual
 STEERING LINKAGE (Cont'd)

843 (SIN 16192 thru 25999)

843 (Starting with SIN 34222)
1 843B

Removal and Installation

Raise the operator cab (See Page 1- 7 for the correct

procedure).

I Disconnect the steering linkage from both pintle levers ~ .

Installation: Install new lock nuts and tighten to 23 ft.lbs. (31
Nm) torque.

I Loosen the locknut on the centering spring bolt (Item 1) and

turn the bolt out of the rear bracket ~.

Installation: Turn the centering spring bolt (Item 1) into the rear
bracket until the spring measures (Item 2) 3.20" (81,3 mm) and
tighten the locknut ~.

Slide the centering bar toward the front and lift up and remove
it from the transmission [£J.

I Loosen the bolt on the pintle lever ~ .

Installation: Install the key in the pintle shaft. TIghten the pintle
lever bolt to 18 - 20 ft.lbs. (24 - 27 Nm) torque.

843 loader
Revised Sept. 90 -3-15- Service Manual
 STEERING LINKAGE (Cont'd)

843 (SIN 16192 thru 25999)

843 (Starting with SIN 34222)
/ 8438

Remove the guide, bushing and pintle lever ~.

Installation: Adjust the steering linkage for neutral (See Page

3-14).

Repairing the Pintle Lever

Remove the bolts from the lobes on the pintle lever IIJ.
Installation: Tighten the bolt to 25 - 28 ft.-Ibs. (34 - 38 Nm)
torque.

Remove the rubber bushing from the pintle lever.

8·4476

Install a new rubber bushing into the pintle lever ~ .

x
o
"

B·4388

Press the rubber bushing into the pintle lever, using two sockets
and a vise [QJ .

B·4471

843 Loader
Revised Sept. 90 -3-16- Service Manual
STEERING LINKAGE (SIN 26000 Thru 29869)

Description

A hydraulic servo control cylinder (Item 1) is used to stroke each

hydrostatic pump pintle lever [AJ. The hydraulic servos are
controlled by steering levers and the fluid to activate them
comes from the charge circuit [AJ.

The steering levers are centered by two centering spring

mechanisms (Item 2) ~. Neutral setting for the hydrostatic
pumps is achieved through the servo spool adjustment on the
centering spring mechanism (Item 3) for the pintle levers ~.

Neutral Adjustment

l
use the following procedure to adjust the hydrostatic pumps
to neutral:

1. Lift and block the loader (See Page 1- 2).

2. Raise the operator cab (See Page 1- 7).

3. Remove the bolt from the servo spool (Item 4) and steering
linkage (both sides) [AJ.

A WARNING
AVOID INJURY
Stay clear of the loader wheels. They will turn whenever
the pump is not centered.

4. Adjust one side at a time. Adjust the centering spring

mechanism for the steering lever so that there is no free
play. Loosen the two jam nuts (Item 1) and turn them in
or out 00. When there is no more free play in the centering
spring mechanism, lock the jam nuts together.

NOTE: If there is any free play il1 the centering spring

mechanism, the correct adju~ment of positive neutral
can not be obtained.

5. Position the steering lever by loosening the jam nut (Item

2) and turning the centering rod (Item 3) in or out of the
ball joint 00. When the steering lever is in a perpendicular
position, lock the jam nut (Item 2) 00. Check the centering
spring mechanism again to make sure that the adjustment
(no free play) has been maintained.

843 loader
Revised Sept. 90 -3-17- Service Manual
STEERING LINKAGE (SIN 26000 Thru 29869) (Cont'd)

6. To adjust the free play in the centering spring mechanism

of the pintle lever, loosen the jam nuts (Item 1) ~. Turn
the jam nuts until there is no free play and tighten the jam
nuts.

7. Loosen the jam nut from the connector end of the centering
spring rod of the pintle lever (Item 2) ~.

8. Connect the Remote Start Switch (See Page 1-9). Start

the engine and run at low idle.

A WARNING
AVOID INJURY
Stay clear of the loader wheels. They will tum whenever
the pump is not centered.

9. Adjust the wheel creep to neutral by turning the centering

rod (Item 3) in or out of the connector rod end ~.

NOTE: Always maintain at least 3/8" 19,5 mm) thread contact

in the rod end.

10. Check the neutral setting by hand stroking the servo spool
(Item 4) ~. Stroke the servo spool forward and backward
allowing it to return to neutral each time. Repeat this several
times. If wheel creep is still present, repeat Step 9.

11. Tighten the jam nut (Item 2) ~. Connect the steering

linkage to the servo spool.

12. Loosen the lock nut on the servo spool (Item 5) ~.

13. Turn the servo spool in or out to obtain servo neutral.

NOTE: The servo spool has a neutral band of approximately

0.10" (0,25 mm) in width. Tum the servo spool so that
it is positioned in the center of the neutral band.

14. Stroke the steering lever forward and backward letting it

return to neutral by itself several times. If the wheels do
not creep the adjustment is completed.

15. Tighten the jam nut (Item 5) on the servo spool ~.

16. Repeat the Steps 3 through 15 to adjust natural for the

other side of the loader.

843 loader
Revised Sept. 90 -3-18- Service Manual
I STEERING LINKAGE (SIN 16000 Thru 29869) (Cont'd)

NOTE: TORQUE All STEERING LINKAGE HARDWARE TO

GRADE 5 SPECIFICATIONS UNLESS OTHERWISE
SPECIFIED.

Steering lever Centering Spring Mechanism

To remove, install or repair the centering spring mechanism,

use the following procedure:

Remove the bolt and nut from the mounting bracket I!].

Remove the bolt and nut from the steering lever lID.

Remove the centering spring assembly [£J.

~
N
o

'"oo
~

Remove the lock nuts [Q].

Installation: Tighten the lock nuts to 16-20 ft.-Ibs. (22-27 Nm)

torque.

843 loader
-3-19- Service Manual
Revised Sept. 90
STEERING LINKAGE (SIN 26000 Thru 29869) (Cont'd)

Remove the spring rod and rod end assembly I!].

Remove the spring lID.

Remove the bushings [£J .

Check all parts for wear or damage and replace as needed.

Removal and Installation (Creep Mechanism)

Remove the bolt and nut from the pintle lever and spring rod
end [Q].

843 Loader
Revised Sept. 90 -3-20- Service Manual
STEERING LINKAGE (SIN 26000 Thru 29869) (Cont'd)

Remove the rod end washer ~ .

Remove the lock nuts lID.

Installation: Tighten the lock nuts to 16 - 20 ft.-Ibs. (22-27 Nm)
torque.

Remove the spring rod and rod end assembly ~.

Remove the centering spring and washers Iru.

843 Loader
Revised Sept. 90 -3-21- Service Manual
STEERING LINKAGE (SIN 26000 Thru 29869) (Cont'd)

Remove the bolts and nuts from the centering spring mounting
bracket ~.

Installation: Before tightening the bolts and nuts, install the

spring rod and align the rod end hole and the hole in the pintle
lever Iru.

Remove the centering spring mounting bracket [£J.

I
NOTE, The centering spring mechanism must be adjusted for
neutral after installation, See Page 3-17 for the
correct procdure.

843 Loader
Revised Sept. 90 -3-22- Service Manual
 SERVO CONTROL

Removal and Installation

I Remove the centering spring mechanism (Page 3-20).

Remove the bolt and nut from the piston rod end ~.

Disconnect the linkage from the spool end of the servo control
lID·
Installation: Tighten the bolt and nut to 25 ft.-Ibs. (34 Nm)
torque.

Disconnect both hoses from the servo control ~.

Remove the bolt and nut from the pintle arm and servo control
body [Q].

Installation: Tighten the bolt and nut to 100 - 110 ft.-Ibs. (136
- 149 Nm) torque.

843 loader
Revised SeDt. 90 -3-23- Service Manual
 SERVO CONTROL (Cont'd)

Remove the servo control and spacer (Item 1) [AJ.

I See Page 3-17 for neutral adjustment of the servo controls and
steering linkage.

Disassembly and Assembly

Use a snap ring plier, remove the snap ring from the housing
lID ·
Remove the rod and piston assembly lID.

B-8633 B-8632

Remove the cap from the servo housing. Use an allen wrench
and remove the plug ~.

Remove the spool from the housing [Q].

Clean and inspect all the parts for wear or damage. Replace
the parts as needed.

Always use new O-rings and seals when assembling the servo
control.

843 Loader
Revised Sept. 90 -3-24- Service Manual
PINTLE LEVER ARMS (SIN 26000 Thru 29869)

I
Removal and Installation

Remove the servo control (Page 3-231.

Remove the three screws from the pintle lever arm !Ai.
Installation: Tighten the screws to 60 - 65 in.-Ibs. (6,8 - 7,3
Nml torque. Re-torque several times until screws stay at 60
- 65 in.-Ibs. (6,8 - 7,3 Nml torque.

Install the three screws in the holes next to the ones they were
removed from lID.

Turn the screws in to remove the pintle lever arm from the hub
1£].

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o
'"
Remove the pintle lever arm ~.

843 Loader
Revised Sept. 90 -3-25- Service Manual
 PINTLE LEVER ARMS (SIN 26000 Thru 29869) (Cont'd)

Remove the hub from the pintle lever shaft @.

Installation: Use solvent to clean the pintle shaft & hub. Put
loctite (PIN 6649654) on the inside diameter of the hub. Make
sure the key is in the slot of the pintle lever shaft and the hub
is aligned [!J .

NOTE: Thread locking adhesive must cure at room

temperature for 8 hours without primer (or 3 hours with
primer (PIN 6649655).

\ ,

843 loader
Revised Sept. 90 -3-26- Service Manual
I STEERING LINKAGE (SIN 29870 Thru 31863)

Description

A hydraulic servo control cylinder (Item 1) is used to stroke each

hydrostatic pump pintle lever [AJ. The hydraulic servo system
is controlled by the steering levers and the fluid to activate them
comes from the charge circuit.

The steering levers are centered by two centering spring

mechanisms (Item 2) ~. Neutral setting for the hydrostatic
pumps is achieved through the servo spool adjustment with the
centering spring mechanism (Item 3) on the pintle levers ~.

Neutral Adjustment

Use the following procedure to adjust neutral on the hydrostatic

pumps:

1. lift and block the loader (Page 1- 2).

2. Raise the operator cab (Page 1- 7).

3. Disconnect the pintle arm steering linkage (both sidesl OO}.

INOTE: Adjust one side of the loader at a time.

4. Adjust the centering spring mechanism for the steering

lever so that there is no free play. Loosen the two jam nuts
and turn them in or out. When there is no more free play
in the centering spring mechanism, lock the jam nuts
against each other ~.

NOTE: If there is any free play in the centering spring

mechanism, the correct adjustment of positive neutral
can not be obtained.

843 Loader
Revised Sept. 90 -3-27- Service M,"ual
STEERING LINKAGE (SIN 29870 Thru 31863) (Cont'd)

5. Position the steering lever by loosening the jam nut (Item

1) and turning the centering rod (Item 2) in or out of the
clevis ~. When the steering lever is in a perpendicular
position, lock the jam nut. Check the centering spring
mechanism again to make sure that the adjustment (no free
play) has been maintained.

6. Connect the Remote Start Switch (Page 1-9). Start the

engine and run at low idle.

A WARNING
AVOID INJURY
Stay clear of the loader wheels. They will tum whenever
the pump is not centered.

r' Loosen the jam nut on the servo control spool. Turn the
spool in or out to find the neutral band in the servo control
cylinder rnJ. Tighten the jam nut.

8. Loosen the jam nut connector rod end. Turn the rod in or
out until the bolt is a frop fit in the pintle steering linkage
@J. Install and tighten the lock nut.

NOTE: Always maintain at least 3/8" (9,5 mm) thread contact

in the rod end.

843 Loader
Revised Sept. 90 -3-28- Service Manual
I STEERING UNKAGE (SIN 29870 Thru 31863) (Cont'd)
9. Make a final adjustment on the clevis threaded rod [!].
Tighten the clevis jam nut.

NOTE: The servo spool has a neutral band of approximately

0.10" (0,25 mm) in width. The steering lever centering
should position the spool near the center of this neutral
band when the pintle levers are positioned at absolute
neutral by their centering springs.

10. Stroke the steering lever forward and backward letting it

return to neutral by itself several times. If the wheels do
not creep the adjustment is correct.

11. Repeat the above steps to adjust neutral of the other pump.

Steering Lever Centering Spring Mechanism

I
The remove and disassemble the steering lever centering spring
mechanism, See Page 3-19 (SIN 2600 thru 29869) for the
procedure.

Creep Centering Spring Mechanism

I
To remove and disassemble the spring mechanism, See Page
3-20 (SIN 26000 thru 29869), the photo's may look different
but the procedure is the same lID.

Pintle Arm

I
To remove and install the hydrostatic pump pintle arm See Page
3-25 (SIN 26000 thru 29869), the photo's may be different
by the procedure is the same lID.

843 Loader
Revised Sept. 90 -3-29- Service Manual
 STEERING LINKAGE (SIN 31864-34221)

A WARNING
AVOID INJURY
Stay clear of the loader wheels. If the engine is running.
they will turn whenever the pump is not centered or
when the steering levers are moved.

This steering linkage adjustment procedure is for 843 loaders

(SIN 31864 & Above). with steering kits that have mechanical
stops for the steering lever centering spring mechanism.

Before making any adjustments to the loader. check for worn

or damaged parts and replace them if needed.

Lift and block the loader (See Page 1- 2 for the correct
procedure).

Raise the operator cab (See Page 1-7 for the correct
procedure).

Start the engine with the remote start switch and increase the
speed to 2750 RPM (See Page 1-9 for the correct procedure).

To determine if the loader needs to be adjusted do the following:

1. Put the steering lever in neutral position to see if the wheels

creep.

2. Take a forward and reverse wheel RPM reading with a digital

tachometer ~ .

Move one steering lever as far forward as possible to take the

forward wheel RPM reading.

Move the same lever as far back as possible to take a reverse

wheel RPM reading.

NOTE: The forward and reverse wheel speed should be

between 62 and 72 RPM with the engine running at
2750 RPM.

843 Loader

.,
""
-3-30- Service Manual
STEERING LINKAGE (SIN 31864·34221) (Cont'd)

Hydrostatic Pump Centering Spring Adjustment

Remove the bolt at connects the steering linkage bar to the

servo control spool ~.

Loosen the hydrostatic pump linkage bolt lID. DO NOT remove

the bolt.

Check for freeplay in the hydrostatic pump centering spring

mechanism ~.

NOTE: Freeplay will exist in the centering spring adjustment

rod (Item 1) if the adjusting nut is too loose, or in the
centering spring bushing if the adjusting nut is too tight
~.

o
,
N

,o
N
o
o
~

To remove the free play, adjust the hydrostatic pump centering '"'"
spring by loosening the jam nut (Item 1) and turning the
adjusting nut in or out [QJ .

Adjust the centering spring mechanism so there is no free play.

Tighten the jam nut after the adjustment is made.

Re·tighten the hydrostatic pump linkage bolt.

.
~
x

843 Loader
Revised April 96 -3-31- Service Manual
STEERING LINKAGE (SIN 31864-34221) (Cont'd)
A
Servo Control Unit Adjustment

Start the engine with the remote start switch and increase the
speed to 2750 RPM (See Page 1-9 for the correct procedurel.

Locate the neutral band (Item 1) on the servo control spool ~.

8-13257

Move the servo control spool back and forth several times to
find the width of the neutral band.

Position the spool in the center of the neutral band ~.

NOTE: Adjustment to the hydrostatic pump linkage rod (Item

1) is necessary only if wheel creep is present [g.

Loosen the hydrostatic pump linkage rod jam nut (Item 2) to

adjust the rod [g.

Lengthening the linkage rod will give reverse creep.

Adjust the rod to the mid point between forward and reverse
creep [Q] .

Tighten the jam nut.

NOTE: The mid point adjustment is a preliminary adjustment

and may need to be adjusted again. shorter or longer.

843 Loader
-3-32- Service Manual
Revised April 96
STEERING LINKAGE (SIN 31864-34221) (Cont'd)

Steering Lever Centering Spring Adjustment

Check for freeplay in the steering lever centering spring

mechanism.

To remove the freeplay, remove the mechanical stop (Item 1)

from the steering lever centering spring adjusting rod ~ .

NOTE: Freeplay will exist in the centering spring adjusting rod

if the adjusting nut is too loose, or in the centering
spring bushing if the adjusting nut is too tight.

Loosen the jam nut on the steering lever centering spring

adjusting rod 1m.

Turn the adjusting nut in or out to adjust the centering spring

mechanism so there is no freeplay [g.

Tighten the jam nut.

Adjust the steering lever if it is not straight up and down.

Loosen the jam nut (Item 1) on the steering lever linkage rod [Q].
Turn the rod in or out until the steering lever is straight up and
down and tighten the jam nut [Q].

After completing the steering lever adjustment, reinstall the bolt

that connects the steering linkage bar to the servo control spool
and tighten the nut (See figure ~ Page 3-31).

843 Loader
Revised April 96
-3 - 33- Service Manual
STEERING LINKAGE (SIN 31864-34221) (Cont'd)

Start the engine and increase engine speed to 2750 RPM.

Recheck the servo control spool neutral band center position

and the hydrostatic pump linkage adjustment.

NOTE: It may be necessary to alternate from the servo spool

adjustment to the hydrostatic pump linkage adjustment
to stop the wheel creep completely.

To make a final check of the wheel creep, pull the steering lever
all the way forward and let the lever snap back into neutral IAJ.

NOTE: The wheels should stop instantly with no wheel creep.

Repeat the lever snap back procedure 3 to 4 times in both

forward and reverse direction.

Stop the engine.

Repeat the complete adjustment procedure for the other side

of the loader.

Wheel RPM Adjustment (Left to Right)

When the steering linkage adjustment procedure is completed,

it is necessary to adjust the forward wheel RPM for the right
and left wheels.

Start the engine and increase the engine speed to 2750 RPM .

Take a wheel speed reading on both left and right sides rm.
If the two sides are different, adjustment is needed.

NOTE: There is no adjustment available for increasing wheel

RPM. A mechanical stop should be installed on the side
which has the faster of the two readings.

843 Loader
Revised April 96 -3-34- Service Manual
STEERING LINKAGE (SIN 31864-34221) (Cont'd)

Install the mechanical stop (Item 1) on the steering lever

centering spring mechanism (fast side) ~ .

With the engine running at 2750 RPM, push the steering lever
(lever on the fast side) as far forward as possible.

Turn the mechanical stop in until the forward RPM matches the
slower side lID.

Install the jam nut and t ighten [£] .

o
,"
....o
~
o
o
~

Install a mechanical stop on the steering lever centering

mechanism (slow side) IQI .

With the engine running at 2750 RPM, push the steering lever
(lever on the slow side) as far forward as possible.

Turn the mechanical stop in until it just makes contact with the
spring mechanism as shown IQI .

NOTE: DO NOT over tighten or the wheel RPM will be reduced .

Release the steering lever.

Install t he jam nut and t ighten.

843 Loader
Revised April 96 -3 - 35- Service Manual
HYDROSTATIC MOTOR

Removal and Installation

IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of all assemblies before beginning repairs.
Use plugs and caps to cover open ports. Dirt can quickly
damage the system.
1·2021·0284

Lift and block the loader (See Page 1- 2 for the correct
procedure).

Use a floor jack, remove the motor cover bolts, and lower the
motor cover ~.

Remove the case drain hose lID.

Use a crowsfoot wrench and remove the high pressure hoses

~.

Remove the bolts from the motor mounting flange lQJ.

Installation: Tighten the bolts to 65 - 70 ft.lbs. (88 . 95 Nm)

torque.

I
NOTE: When connecting the high pressure hoses, See Page
3-42 for the correct hose routing.

843 Loader
Added Sept. 90 -3-36- Service Manual
HYDROSTATIC MOTOR (Cont'd)

Turn the motor so there is clearance for the fittings, remove the
motor from the reduction gearcase ~ .

Disassembly and Assembly

NOTE: Clean the outside of the motor before disassembly.

Keep all the parts clean .

Put a mark across the sections of the motor for correct

assembly.

Remove the four bolts from the motor lru .

Assembly: Tighten the bolts to 65 - 70 ft.-Ibs. (88 - 95 Nm)
torque.

Lift the valve housing straight up. If done carefully, the springs
and balance plate w ill stay on the valve @ .

Remove the O-rings.

··
'"
'"
0"
iii"'

I
0
~

0
6 ·6692 ~
hl
0
0

'"
~

Remove the plug from the shuttle valve ~. ~

~

:;:

'""

·""
0
~

0-

'"'
~
"
0
0

n"
0

;;,
;;

843 Loader
Added Sept. 90 -3-37- Service Manual
 HYDROSTATIC MOTOR (Cont'd)

Remove the spring and sleeve rru .

Remove the shuttle valve spool lID .

Use a punch, through the housing and remove the poppet,

spring, O-ring and plug from the other side of the housing [g.

I
Assembly: Make sure all the parts are cleaned and check for
wear. Assemble as shown ~ .

"

D·1526

843 Loader
Added Sept. 90 -3-38- Service Manual
HYDROSTATIC MOTOR (Cont'd)

Remove the balance plate @ .

8·8731

Remove the inner seal from the balance plate 00.

Assembly: Put grease on the inner seal and install as shown 00.

8 -8733
Pin 8-3046

Remove the outer seal from the balance plate ~ .

Assembly: Put grease on the outer seal and install as shown ~.

o
Pin Inner Seal Pin 8-3046 o
o
~

Remove the valve [QJ.

8-8738

843 loader
Added Sept. 90 -3-39- Service Manual
HYDROSTATIC MOTOR (Cont'd)

I
NOTE: See Page 3-42 for timing the motor when installing
the valve, valve drive and geroler.

Remove the valve plate !A].

8-8737

Remove the valve drive [ID.

8-8729

Remove the geroler 1Ql.

8-8739

Remove the drive shaft [Q].

8-8736

843 Loader
Added Sept. 90 -3-40- Service Manual
HYDROSTATIC MOTOR (Cont'd)

Remove all the a-rings from the motor @.

NOTE: Always use new a-rings when assembling the

hydrostatic motor.

730

Inspection

Before the motor is assembled check the following items:

1. Check the geroler roller and rotor for wear and scratches
00·
2. Check the valve plate, valve and balance plate for
scratches.

3. Valve drive and main drive shaft.

4. Check the end plate surface for scratches.

NOTE: Put all the rollers back in their original position.

When installing the balance plate in the end housing, put your
finger through the hole and hold it in position until the housing
is in position ~.

o
N
o
o
~

843 Loader
Added Sept. 90 -3-41- Service Manual
 HYDROSTATIC MOTOR (Cont'd)
Rotate Valve Clockwise
Timing the Hydrostatic Motor 1/2 Tooth to Engage Spline

The timing of the motor controls the direction of rotation of the Anyone of 6 Ports
drive shaft of the motor. The timing parts are as follows: Open to Outside of Valve

1. Geroler (Item 1) ~.

2. Valve Drive (Item 2) @ .

3. Valve Plate (Item 3) @.

4. Valve (Item 4J @ .

Find the largest opening between the geroler star and the geroler
ring and mark the outside of the geroler ring at this point @ .

Align the two drain holes and the three pressure holes in the
geroler ring with the same holes in the mounting flange and
install the geroler assembly.

Install all new O-rings.

Install the valve drive @.

Align the drain hole in the valve plate with the drain hole in the
geroler. Install the valve plate with the O-ring toward the geroler. --C:'4'>r(!.I .. r Star
Make sure the slot opening of the valve plate is in alignment
with the largest opening of the geroler.
Pressure
Relief Hole (3)
Install the valve plate. C-2384

Install the valve on the valve plate. Make alignment with one
of the side openings with the mark on the geroler. Turn the valve
clockwise a small amount until the teeth on the valve drive
engage.

Continue with the rest of the assembly procedure.

High Pressure Hose Routing

Make sure to connect the high pressure hoses to the correct

ports of the hydrostatic pumps and motors rru.

Front Of
Loader

C-2970

843 Loader
Added Sept. 90 -3-42- Service Manual
HYDROSTATIC PUMPS

IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of all assemblies before beginning repairs.
Use plugs and caps to cover open ports. Dirt can quickly
damage the system.
1-2021-0284

Checking the High Pressure Relief/Replenishing valve

Lift and block the loader (See Page 1- 2 for the correct
procedure).

Raise the operator cab (See Page 1- 7 for the correct

procedure) .

If there is a loss of drive in one direction, to one side of the

loader, use this procedure to check the valves:

Remove the plug at the top and bottom ~ ~ .

Remove the high pressure relief valves from the top and bottom
and switch them around [ID [Q] .

Install the plugs and tighten.

Start the engine and check the drive.

I
lf the loss of drive goes to the other side, the relief/replenishing
valve which controls that side of the loader must be replaced.

o
~
c
o
~

843 Loader
Revised Feb. 94 -3-43- Service Manual
HYDROSTATIC PUMPS (Cont'd)

Checking Charge Pressure

The tools listed will be needed to do the following procedure:

MEL-1173 - Test Kit

MEL-1218 - Diagnostic Coupler

Open the rear door.

Connect a gauge at the diagnostic coupler, located at the

bottom of the hydrostatic filter ~.

Start the engine and run it at full RPM.

I
The correct pressure is as follows, with no hydraulic action:
SIN 12999 & Below: 120 - 140 PSI (827 - 965 kPa)
SIN 24001 & Above: 180 - 200 PSI (1241 - 1379 kPa)

NOTE: If the hydrostatic pumps need repairing, See Page

3-45 for the procedure.

Removal and Installation

Lift and block the loader (See Page 1- 2 for the correct
procedure).

Raise the operator cab (See Page 1- 7 for the correct

procedure).

Disconnect the steering linkage at the steering levers (both

sides) rID.

Disconnect the steering linkage at the pintle levers l£.

Installation: Tighten the bolts and nuts to 23 ft.lbs. (31 Nm)

torque. See Page 3-14 for neutral adjustment. Remove the
steering mechanism and pintle arms from the hydrostatic pumps
(See Page 3- 7 or 3-15 for the correct procedure). Installation:
See Page 3-6 or 3-14 for the neutral adjustment. Disconnect
the high pressure hoses at the hydrostatic pumps (both sides)
[Q].
NOTE: When connecting the high pressure hoses, See Page
3-42 for the correct hose routing.

843 Loader
Revised Feb. 94 -3-44- Service Manual
HYDROSTATIC PUMPS (Cont'd)

Disconnect all the hoses from the hydraulic pump.

Disconnect the hoses and wire from the charge pressure switch
fitting ~.

Remove the nuts from the front mounting bolts lID.

Remove the four bolts and nuts from the rear mounting flange
for the pumps @].

Slide the hydrostatic pumps forward and out of the u-joint on

the engine.

Lift the pumps from the loader.

Installation: Align the splines on the hydrostatic pump shaft and

the u-joint.

I
NOTE: If the rear mount for the hydrostatic pump is removed
See Page 3-52 for the correct installation
specifications.
ru
o

I
Disassembly and Assembly

IMPORTANT
Always keep hydraulic and hydrostatic parts clean.
Clean outside of an assemblies before beginning repairs.
Use plugs and caps to cover open ports. Dirt can quickly
damage the system.
'·2021-0284

Remove the two bolts from the center section [Q).

Installation: Tighten the bolts to 110-115 ft.-Ibs. (149·156 Nm)

torque.

843 Loader
Added Sept. 90 -3-45- Service Manual
 HYDROSTATIC PUMPS (Cont'd)

Pull the front and rear pumps apart @.

Remove the O-ring and coupler between the two pumps @ .

NOTE: The hydrostatic pump front and rear pump internal

parts are the same. Some of the external parts are
different and the copy will list the different procedures.

8·8874

Remove the plugs from the high pressure relief valves ~.

Remove the high pressure relief replenishing valves (both sides)

~.

B
"o
B
o
o Remove the bolts from the center section @.
"
S
Installation: Tighten the bolts to 35-40 ft.-Ibs. (47-54 NmJ
torque.

m
o
o
,
N

'"o

8-8845

843 Loader
Added Sept. 90 -3-46- Service Manual
HYDROSTATIC PUMPS (Cont'd)

Remove the section from the pump housing ~.

Remove the rotating group ~.

Put your hand under the rotating group and turn the pump
housing around so the rotating group will slide into your hand.

Rear Pump

Remove the snap ring from the drive shaft [g.

Remove the seal. ;:;

'Ii
00
0

'"
0
tD

I
0
0
::

0
N

0
~
8-8848 0
N

'"'
~

~
Front Pump ~

~
~

Remove the snap ring and spacer [QJ. '0

"
"
~
0
0-
0-
'<

'"
(!;

"
,."
0
0

"
0

~
~

843 loader
Added Sept. 90 -3-47- Service M;inual
HYDROSTATIC PUMPS (Cont'd)

Remove the drive shaft and bearing from the housing [!l .

Remove the snap ring from the pintle shaft cover lID.

Remove the pintle shaft cover [£).

Remove the O-ring ~ .

843 Loader
Added Sept. 90 -3-48- Service Manual
HYDROSTATIC PUMPS (CONT'D)

Remove the bearing from the pintle shaft IAJ.

Assembly: When installing the bearing, make sure the number
side of the bearing is toward the outside.

Remove the snap ring from the camplate shaft on the other side.
Remove the cover 00.

Remove the O-ring [£J.

Remove the bearing and race ~.

Assembly: When installing the race make sure the chamfer side
is toward the camplate.

843 loader
Added Sept. 90 -3-49- Service Manual
 HYDROSTATIC PUMPS (Cont'd)
A
Remove the camplate from the housing ~ .

8-8857

Inspection

NOTE: Keep all the parts for one pump separated from the
parts for the other pump.

Inspect the input drive shaft, bearings and races for wear and
damage to the shaft splines !ID. End play must not exceed
0.090" (2,29 mm).

The bearings in the center section and housing only have to be

removed if they are loose and show wear. Use a press to remove
and replace the bearings.

Inspect the flat surface of the sections. The finish must be

smooth and free of grooves. If the grooves can be felt on the 8·8859
finished surface with a fingernail, replace the section. Inspect
the camplate for wear. The finish must be smooth and free of
grooves. If grooves can be felt with a fingernail, replace the
camplate.

Inspect the rotating group for the following: Check each piston
in its bore. The piston must move freely.

Check the pins for wear or damage l£l. All the pins must be
the same length and must not be bent. Check the spherical
washer for sharp edges, wear or scratches l£l.

B·8860

Check the piston shoes for scratches. Check the end play of This Dimension Must be Maintained on All
each piston assembly rm. Measure the thickness of each shoe. Within 0.001" (0,0254 mm)
All shoes must be within 0.001" (0,025 mm) of each other rm
. Inspect the shoe plate for wear or cracks.

If there is any defect in the rotating group, the complete unit

must be replaced.

Clean all the parts in solvent and use air pressure to dry them.
N
DO NOT use cloth or paper because small pieces of material
o
can get into the system and cause damage.

DO NOT use sandpaper or a file to remove scratches.

1
Swivel Smoothly on Bell
End Play Must Not Exceed .003" (0,076 mm) A-1850
843 Loader
-3-50- Service Manual
HYDROSTATIC PUMPS (Cont'd)

Tow Valves

The tool listed will be needed to do the following procedure:

MEL-1197 - Towing Kit

The loader can be moved for a short distance at a slow speed

if it is unable to do so under its own power, use the following
procedure to install the tow valve kit:

Raise the operator cab {See Page 1- 7 for the correct

procedure}.

Remove the high pressure relief plug ~ .

Remove the high pressure relief valve rnJ.

Install the tow bar and tighten the plug [g.

Remove the other high p'ressure relief plug [Qj.

843 Loader
Added Sept. 90 -3-51- Service Manual
HYDROSTATIC PUMPS (Cont'd)

Remove the high pressure relief valve ~.

Install the tow bar and tighten the plug ~.

The loader can now be moved. Be sure to remove the tow bars
before operating the loader.

8-9322

Hydrostatic Pump Rear Mount (SIN 21574 & Above)

MEL·1395·1 - Main Frame
MEL·1395·2 - Shaft (843)
The tool has more than one application. Assembly parts needed MEL·1395·3 - Front Spacer (843)
for the 843 loader are listed in figure @l. MEL·13954 - Rear Spacer (843)
MEL·1395·9 - Shim (843)

1. Remove the engine from the loader (Page 7C -17).

2. Install the spacer (Item 3) @lin the right hand hole in the
belly pan as shown figure ~; Page 3-53. Install the nut
to hold the spacer in place.

3. Install the second spacer (Item 3) @lin the slotted hole in

the belly pan as shown in figure ~; Page 3-53. Push the
spacer fully to the left end of the hole.
MC-1140
4. Install the bolt through the spacer (Item 4) at the rear of
the tool main frame @l.

5. Install the shaft (Item 2) into the main frame @l.

6. Install the tool into the loader so the slot (Item 2) ~ fits
00
on the spacer in the belly pan and align the tool so the
spacer in the hole (Item 1) ~fits in the belly pan hole (Fig.
~, Page 3-53).

7. From under the loader, install the nuts on the spacer and
tighten.

TOP VIEW
OF. TOOL 8-12557
843 Loader
*Revised Feb. 94 -3-52- Service Manual
HYDROSTATIC PUMPS (Cont'dl

o FRONT o
8. Loosen the pump mounting bolts. Slide the tool shaft
forward and rotate until its aligned with the pump coupler. o 0 o 0

9. Tighten the pump mounting bolts. Pull the tool shaft from
the pump splines and check alignment by sliding the tool
shaft forward onto the pump shaft. Adjust pump height Install Spacer for Other Spacer in
with spacers (Item 11 as needed rID. Tool Slot Here Tool Fits Here

10. Remove the alignment tool. Engine

Mounting
REAR Plate

8-12564

HYDROSTATIC FLUID FILTER HOUSING

Removal and Installation

Engine Mounting

!
Plate

IMPORTANT 8-6938

Always keep hydraulic and hydrostatic parts clean.

Clean outside of all assemblies before beginning repairs.
Use p'lugs and caps to cover open ports. Dirt can quickly
damage the system.
1-2021-0284

Lift and block the loader (See Page 1-2 for the correct
procedure).

Open the rear door.

Disconnect the wire from the sending switch.

IDisconnect the tubelines from the filter housing ~.

IRemove the mounting bolts [Q].

Installation: Tighten the mounting bolts to 25 ft.-Ibs. (34 Nml

torque.

,Remove the differential pressure switch [Q].

Inspect all the parts for damage and replace as needed.

NOTE: 843 (SIN 20992 & Above) use a higher pressure rating
of the switch. Make sure to install the correct switch
if it is replaced (See Parts Microfichel.

843 Loader
* Revised Aug. 91 -3-53- Service Manual
 DRIVE SYSTEM

Page
Number
AXLES, SEALS AND BEARINGS
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4- 5
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-4

FINAL DRIVE CHAIN

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4-8

PARK ING BRAKE

Adjustment ................................ " 4-1
Block and Pucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 2
Removal and Installation..... . ... . ..... . ........ 4-1

REDUCTION GEARCASE DRIVE

Checking Reduction Gearcase . .......... . ....... . 4-11 SYSTEM
Disassembly and Assembly ... .. . .. ... .. . ...... . . 4-1 1
Reduction Gearcase Seal ....................... . 4-17
Removal and Installation . ......... . ............ . 4-10

843 loader
Service Manual
Page 189 - BOBf.!02:7201 B109J ~ 02/10/2009 17:56:15 - Printed by Ken Cook Co. ¥ eXprint.exe Iv2.24.3 fI/2 S /2 000}
4 DRIVE SYSTEM

PARKING BRAKE

Adjustment

When the brake is in good condition and adjusted correctly. it

will keep the loader from moving in the parked position.

Loosen the nut (Item 1) and turn the linkage rod to adjust the
brake pedal. There must be 3/4" (19 mm) free play under the
rear edge of the pedal ~.

NOTE: If the correct adjustment cannot be obtained by turning

the brake linkage rod. the brake lever must be adjusted.

Remove the front panel (See Page 3 - 3 or 3 - 9 for the correct

procedure) .

Loosen the bolt at the brake lever. Do not remove the bolt 00.
Using pry bar and hammer. hit the top of the bolt until the brake
lever is loose 00 .

Remove the bolt and lever. Turn the cam pin counterclockwise
until the brake pucks make contact with the brake discs.

Install the lever and bolt. Tighten the bolt to 65-70 ft.-Ibs. (88-95
Nm) torque.

Install the front panel.

1
Readjust the brake as outlined above.

~
o

o
~

,o
~
o
o
~

Removal and Installation

Remove the front panel (See Page 3 - 3 or 3 - 9 for the correct

procedure).

Remove the steering levers (See Page 3-4 or 3-12 for the
correct procedure).

Remove the cover and brake block @.

Installation : Align the brake discs so they are centered between

the brake pucks [Q].

843 Loader
Revised Julv RR -4-1- Service Manual
 PARKING BRAKE (Cont'd)

Remove the snap rings at the discs @.

Remove the brake discs lID.

Check the brake disc for damage. Replace the discs as needed.
DO NOT grind the discs.

Block and Pucks

Remove the brake lever [£].

~ Installation: TIghten the bolt to 65-70 ft.-Ibs. (88-95 Nm) torque.

m

~
x
~

B·5174

Remove the bolts which fasten the block to the cover @.

Installation: Put Loctite on the bolts and tighten to 65-70 ft.-

Ibs. (88-95 Nm) torque.

843 Loader
-4-2- Service Manual
PARKING BRAKE (Cont'd)

Remove the pucks form the block @ .

Check the pucks for wear or damage. The pucks can be turned
180 0 and the smooth side used again.

Check for a good fit between the pucks and block bore. They
must slide in and out freely.

Install a new O-Ring on the cam pin [[I.

Clean and dry the block and put a bead of R.T.V. sealant on the
brake block ©.

I
o
N

,o
N
o
o
~

Install the center cover on the brake block [QJ.

Install the bolts and tighten.

843 loader
-4-3- Service Manual
 AXLES, SEALS AND BEARINGS

Removal

NOTE: The removal and installation of the four axles use the
same procedure.

The tools listed will be needed to do the following procedure:

MEL-1242 - Port-a-Power
MEL-1053 - Axle Seal Tool
I MEL-1202C - Axle Bearing Race Service Set

Lift and block the loader (See Page 1- 2 for the correct
procedure).

Remove the wheel and tire assembly.

Raise the operator cab (See Page 1- 7 for the correct

procedure).

Remove the front panel (See Page 3-3 or 3-9 for the correct
procedure).

Remove the steering levers (See Page 3-4 or 3-12 for the
correct procedure).

NOTE: The following procedure will work for both the front
and rear axles, but for the rear axles the hydrostatic
pumps will have to be removed (See Page 3-25 for
the correct procedure).

Remove the chaincase covers and brake assembly (See Page

4-1).

Remove the drive chain(s) (See Page 4-8).

Put a wrench on the bolt at the sprocket; front @, rear 00.

Loosen the bolt (inside the chaincase) at the sprocket by turning
at the axle hub.
,
Installation: Put Loctite on the bolt and tighten to 475-525 ft.-
Ibs. (644-712 Nml torque.

Install the Port-a-Power ram jack between the two sprockets

~. Push the axle out until the ram jack is at the end of the
stroke. Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket.

Remove the sprocket from the chaincase. Install the bearing cup
puller tool into the axle tube 1m. Remove the bearing cup from
the axle tube.

8-3987

843 Loader
Revised Julv 88 -4-4- Service Manual
AXLES, SEALS AND BEARINGS (Cont'd)

Using a long punch, remove the inside bearing cup @.

Use a puller and remove the outer bearing from the axle lID.

Bearing

8·2813

Using a hammer and chisel, remove the wear sleeve (item 1)

from the axle ~ . Make sure not to damage the axle.

Clean and check all the parts for wear and damage. Replace
the parts as needed.
~
0
<g
~
~

g
!
'"
0
c:: 0

0
,
~

C-2528 ,
0
~
0
0
~

':;
Installation ~
~

:;;
Put Loctite on the inside of the wear sleeve ~. Install the wear
~

sleeve (item 1) on the axle ~. "

NOTE: When the bearing is installed, it will also position the ·

"
~

0-

'"'"
wear ring in its correct location.
·,.-
"
n
0
0
Lubricate the axle seal (Item 2) and install the seal on the axle n
with the open side toward the chaincase ~.
0

·
><
~

8-3986

843 Loader
_4_1;_ Service Manual
AXLES, SEALS AND BEARINGS (Cont'd)

Using a arbor, install the outer bearing on the axle @ .

Make sure the bearing seats correctly on the axle @ .

Press only on the inner race of the bearing. This will also position
the wear ring correctly.

Install the outer bearing cup using the correct size bushing driver
[[].

Install a long threaded bolt into the axle tube.

Install the correct size cup driver.

Install a washer and nut.

Inside the chaincase, install the new bearing cup, the bearing
cup driver tool, washer and nut [£].

Have a second person hold the wrench on the nut in the

chaincase [Q] .

Turn nut on the outside of the axle tube until the inner bearing
cup is on its seat.

NOTE: Pack the inner and outer axle bearing with grease
before installing the axle assembly.

Install the axle assembly into the axle tube.

843 Loader
-4-6- Service Manual
AXLES, SEALS ANO BEARINGS (Cont'd)

Put the sprocket into the chaincase.

NOTE: The long part of the sprocket hub goes

toward the inside for the front axle and the
outside for the rear axle.

Install the spring over the axle tube [A].

fH>4550
Install the inner halves of the installation tool behind the
out axle seal [A].

fH>4531

Install the outer halves of the tool on the inner halves [B].

Install the spring on the tool [B].

Push the axle inward, install the inner bearing and

sprocket on the axle.

Put the installation tool in contact with the axle tube.

Install the washer and bolt (inside the chaincase) and pull
the axle into position.
fH>4560

B--{)4559

Using a large hammer, hit the axle hub until it is in the

correct position [A].

Remove the spring from the tool. Remove the outer

halves of the tool [OJ. Remove the inner halves from the
axle [0].

Tighten the sprocket bolt to the correct torque. Check the

axle end play. It must be between 0.00 - 0.10" (0,254
mm).

If not, replace the washer, at the sprocket bolt to get the

correct end play.

fH>4567

843 Loader
-4-7- Service Manual
FINAL DRIVE CHAIN
Removal
MEL1269 - Chain Breaker
MEL1037 - Chain Link Press
MEL1049 - Chain Puller Tool

Lift and block the loader. (See Page 1-2 for the correct
procedure.)

Raise the operator cab (See Page 1-7 for the correct
procedure.)

Remove the front panel (See Page 3-3 or 3-9 for the
correct procedure.)

Remove the steering levers (See Page 3-4 or 3-12 for

the correct procedure.)

Remove the hydrostatic pump (See Page 3-25 for the

correct procedure.)

Remove the chaincase covers and brake assembly (See

Page 4-1.)

Remove the fluid from the chaincase using a transfer

pump.

NOTE: Check the chain for the connector link. If

there is no connector link, make separation
of the drive chain at any link.

Break the front chain using the chain breaker tool [A].

Remove the chain from the chaincase [8].

Remove the rear chain using the same procedure.

Installation
Push the axle out of the axle tube (See Page 4-4.)

Loosen the bolts at the reduction gearcase housing [C].

Put the drive chain(s) into the chaincase [0].

Put the drive chain over the reduction gearcase sprocket

and pull the ends out and above the chaincase.

843 Loader
Revised June 96 Service Manual
FINAL DRIVE CHAIN (Cent'd)

Put a flat bar under the chain across the chaincase ~.

Clamp the bar to the chaincase.

Install the connector link and plate [!J.

Install the chain link press If].

Tighten the chain link press to 180 ft.-Ibs. (244 Nm) torque to
press the connector plate into position [Q].

Remove the chain link press and flat bar.

Install the sprocket and axle (See Page 4- 6).

Center the reduction gearcase between the front and rear drive
chains. Tighten the bolts to 220-245 ft.-Ibs. (300-330 Nm)
torque.

843 loader
-4-9- Service Manual
 REDUCTION GEARCASE

Removal and Installation

Lift and block the loader (See Page 1- 2 for the correct
procedure).

Remove the hydrostatic motor (See Page 3 -17 for the correct
procedure).

Raise the operator cab (See Page 1- 7 for the correct

procedure).

Remove the front panel (See Page .3-3 or 3-9 for the correct
procedure).

Remove the steering levers (See Page 3-4 or 3-12 for the
correct procedure).

Remove the chaincase covers and brake assembly (See Page

4-1).

Remove the fluid from the chaincase using a transfer pump.

Remove the front chain (See Page 4-8).

Put a floor jack under the reduction gearcase ~.

Remove the bolts which fasten the gearcase to the chaincase

lID·

Installation: Tighten the bolts to 220-245 ft.-Ibs. (300-330 Nm)

torque.

Remove the bolt (Item 1) and washer (Item 2) ~. Drive the shaft
into the chaincase until it clears the bearing (Item 3) ~. Remove
the rear chain from the gearcase sprocket. Lower the gearcase
to the floor.

Installation: After complete assembling of the gearcase, install

a 1" (25,4 mm) longer bolt (Item 1), than normal bolt used, and
washer (Item 2) ~.

Drive the shaft inward until it clears the bearing (item 3) 1£] .
Make sure not to damage the bolt. Lift the gearcase into
position, angle the shaft which allows the installation of the rear
drive chain.

Pull the shaft back into position. Remove the longer bolt, put
the regular bolt back in position and tighten to 210-235 ft.-Ibs.
(285-305 Nm) torque.
~
~

'"oo Complete the installation of the reduction gearcase.

,"o
,
N
o

843 Loader
-4-10- Service Manual
 REDUCTION GEARCASE (Cont'd)

.. Checking Reduction Gearcase

Before disassembly of the gearcase do the following checks:

Install a dial indicator on the input shaft ~. The end play must
be between 0.00 - 0 .010" (0,0254 mm). If not the following
parts may need replacing: Bearing, bearing cups, gear or
gearcase housing.

Install the dial indicator on the output shaft 00. The end play
must be between 0.00 - 0.010" (0,0254 mm). If not, the
following parts may need replacing: Bearing, bearing cups, gear
or gearcase housing.

Remove the seal.

Install a feeler gauge between the teeth of the gears [g.

The back lash must be between 0.003-0.009" (0,076-0,228

mm). If not, the following parts may need replacing: Large gear
or the shaft.

Measure the bore diameter for the seal. Correct diameter is

3.750" ± 0.001" (95,25 mm ± 0,025 mm). Install a dial
indicator on the output shaft. Set the indicator so the stylUS
is against the pilot bore for the drive motor. Rotate the shaft
360 degrees. Maximum run -out should not exceed 0 .009"
(0,23 mm). If either check (Bore 1.0. or Run-Out) is not within
the specifications, replace the gearbox.
o
,
~

,o
~
o
o
'"
Disassembly and Assembly

The tool listed will be needed to do the fol iowing procedure:

MEL-1047 - Seal Installation Tool

Remove the bolts from the end plate ~.

Installation: lighten the bolts to 13-14 ft..tbs. (16-18 Nm) torque.

6·8705

843 Loader
Revised Feb. 94 -4-11- Service Manual
 REDUCTION GEARCASE (Cont 'd)

Remove the end plate @ .

8 ·8 70 4

Remove the dust cap [ID .

Installation: Put "Boretite" sealant on the edge of the dust cap

before installing it.

Remove the bolt from t he output shaft @.

Installation: Put Loctite on the bolt and tighten to 210-235 ft.-

Ibs. (285-305 Nm) torque.
"oo
N

'" N

'"~
~
N

N
>

Remove the bolt and washer [QJ .

~
o
o
N

o
N
o

843 Loader
-4-12- Service Manual
REDUCTION GEARCASE (Cont'd)

Remove the bolt at the disc hub @ .

Installation: Put Loctite on the bolt and tighten to 210-235 ft.-

Ibs. (285-305 Nm) torque.

Remove the bolt and washer lID .

Remove the disc hub and key I£J.

.
"
"'o
~
o
~

Put the gearcase housing in the press and remove the output
shaft ~.

843 Loader
-4-13- Service Manual
 REDUCTION GEARCASE (Cont'd)

Remove the bearing @.

---- - - I 8.8707

Remove the spacer lID.

-- -------------
Remove the output shaft [f].

Remove the large gear ~.

~
o
o
~

~
o

/ 8·8722

843 Loader
-4-14- Service Manual
REDUCTION GEARCASE (Cont'd)

Remove the bearing at the input shaft ~ .

Use a press and remove the input shaft ~.

I
B·8679

Remove the input shaft assembly from the housing ~ .

Use a punch and hammer and remove the bearing cups as

needed ~.

Installation: Use a press and bearing cup driver to install the

bearing cup.

843 Loader
-4-15- Service Manual
 REDUCTION GEARCASE (Cont'd)

Installation

Install a new Quad-ring. Install the back-up washer @.

Install the new seal using the seal installation tool 00.

~
o
C
N

'"
N

'"

~
o
o
N

o
N
o

843 loader
-4-16- Service Manual
REDUCTION GEARCASE (Cont'd)

Reduction Gearcase Seal

The tool listed will be needed to do the following procedure:

MEL-l047 - Seal Installation Tool

It is not necessary to remove the reduction gearcase to replace

the seal at the input shaft, use the following procedure.

Lift and block the loader (See Page 1- 2 for the correct
procedure).

Remove the hydrostatic motor (See Page 3 -17 for the correct
procedure).

Use a punch and hammer and bend the edge of the seal inward
~.

Use a screwdriver, pry the seal from the housing [!].

Remove the washer. Replace the Quad-ring ~.

;\'
~
~
0

"
~ g

{J( ~
~
I
I
~ \
6·8675
0
,
~

,
0
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~

Install the new seal using the seal installation tool [Q]. ":;:

.,""
.
=
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0
0
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~
(
\

843 loader
-4-17- Service Manual
 MAIN FRAME

Page
Number
BOB-TACH
Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . .. 5-13
Removal and Installation........................ 5-11
Tilt Cylinder Rod End Seal ..................... " 5-12

FUEL TANK (SIN 19999 & Below)

Removal and Installation........ .. ............... 5 -15

FUEL TANK (SIN 20001 & Above)

Fuel Tank Sender Switch. . . . . . . . . . . . . . . . . . . . . . .. 5-17
Removal and Installation........................ 5 -16

LIFT ARMS
Removal and Installation........................ 5- 9

OPERATOR CAB (SIN 19999 & Below)

Removal and Installation........................ 5-1

OPERATOR CAB (SIN 20001 & Above) MAIN

Removal and Installation........................ 5- 3 FRAME
OPERATOR CAB GAS CYLINDER
Removal and Installation........................ 5- 6

REAR DOOR
Door Latch Adjustment. . . . . . . . . . . . . . . . . . . . . . . .. 5- 7
Removal and Installation........................ 5-8

8',.
[I

843 loader
Service Manual
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 5 MAIN FRAME

OPERATOR CAB (SIN 19999 & Belowl

Removal and Installation

Lift and block the loader (See Page 1- 2 for the correct
procedure).

Disconnect the electrical harness IK].

96

Raise the operator cab.

Fasten a chain and chain hoist to the operator cab [[J.

C·2630

Remove the bolt and nut at the spring block. Remove the spring
block (both sides) © .

. Installation: Tighten the bolt and nut to 65-70 ft.-Ibs. {88-95

Nml torque.

8-4542

Remove the nuts at the pivot bolt for the operator cab (both
sides) [QJ.

Installation: Tighten the bolt and nut to 25-35 ft.-lbs. {34-47

Nml torque.

I , 8·4054

843 Loader
-5-1- Service Manual
OPERATOR CAB (SIN 19999 & Below) (Cont'd)

With the chain hoist tight.

Use a punch and hammer and remove the bolts (both sides) at
the pivot bracket [A].

Use a pry bar, pry the springs out of the operator cab 00 .
II I
Lift the operator cab with the chain hoist and remove it from
the loader.
1\ \ \ \ 8 ·4047

843 Loader
-5-2- Service Manual
OPERATOR CAB (SIN 20001 & Above)

Removal and Installation

Remove the stop blocks at the rear of the operator cab ~ .

IMPORTANT
After the stop blocks are removed and the operator cab
has a rear window, REMOVE THE REAR WINDOW to
prevent damage to the rear window.

Raise the operator cab (See Page 1- 7 for the correct

procedure).

Disconnect the electrical harness lID.

Remove the electrical harness clamp [£J.

,"
~

,"
""
'""
Install a bar through the operator cab balance point. Install a
chain and chain hoist [QJ.

843 Loader
-5-3- Service Manual
OPERATOR CAB (SIN 20001 & Above) (Cont'd)

Remove the clip at the upper pivot pin for the gas cylinder ~.

Remove the upper pivot pin for the gas cylinder (both sides) [ID.

Installation: Install the lower pivot pin first, use a screwdriver

to hold the gas cylinder and install the top pivot pin.

Remove the clip at the lower pivot pin 19.

Remove the lower pivot pin (both sides) [QJ.

843 Loader
-5-4- Service Manual
OPERATOR CAB {SIN 20001 & Above) {Cont'd)

Remove the gas cylinder (both sides) !A].

Remove the nuts from the pivot bolts lID.

Installation: Tighten the pivot bolts to 25-35 ft.-Ibs. (34-47 Nm)
torque.

/
/
/; ;1. 8·8553

Use a punch to remove the pivot bolt (both sides) [£J.

Lift the operator cab from the loader using the chain hoist.

..,
'"
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0
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~

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0
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11

843 loader
-5-5- Service Manual
OPERATOR CAB GAS CYLINDER

Removal and Installation

Remove t he stop blocks at t he rear of the operator cab ~ .

IMPORTANT
After the stop blocks are removed and the operator cab
has a rear window, REMOVE THE REAR WINDOW to
prevent damage to the rear window.

Raise the operator cab (See Page 1- 7 for the correct

procedure).

Remove the clip and the upper pivot pin at the gas cylinder lID.

8 ·8510
8 ·8 511

Remove the clip and lower pivot pin at the gas cylinder [9 .

Installation: Install the lower pivot pin first. use a screwdriver

to hold the gas cylinder down and install the top pivot pin.

8 ·8 516
8 ·8517

Remove the gas cylinder from the mounting bracket [QJ .

A WARNING
Gas cylinder holds the rod under high pressure. Never
open. To unfasten see directions in Service Manual to
avoid loader damage or personal injury.

843 loader
-5-6- Service Manual
REAR DOOR

Door Latch Adjustment

Loosen the set screw ~ .

8 · 577 2

Loosen the nut (Item 1) 00.

B I
Turn the bolt (Item 2) in or out 00, until the door contacts both

or!
the top and the bottom of the loader frame (Item 1) w ith the
lever in the latched position [£] .

NOTE: It takes approximately 50 Ibs. of force to push the lever

down when the latch is correctly adjusted.

8 ·7385

Lubricate the wear surface (Item 2) [£] .

NOTE: With the set screw up, the flanges at the bolt (Item 31
must be to the side so that the set screw aligns with
the flat surface at the end of the bolt [£].

Tighten the set screw @ .

Tighten the nut (Item 11 to 65-70 ft.-Ibs. (88-95 Nm) torque [[].

843 Loader
-5-7- Service Manual
 REAR DOOR (Cont'd)

Removal and Installation

Install a chain hoist on the rear door @.

Use a punch and remove both hinge pins [ID .

Lift the rear door from the loader frame.

13 1

~
M

~
o
o
N

o
N
o

843 Loader
-5-8- Service Manual
LIFT ARMS

Removal and Installation

Lift and block the loader (See Page 1- 2 for the correct
procedure).

Roll the Bob-Tach fully forwa rd.

Stop the engine. Activate the hydraulic controls to release the

hydraulic pressure.

Remove the Bob-Tach from the lift arms (See Page 5-11).

Fasten chains and a chain hoist to the lift arms ~.

Put a floor jack under the lift arms [[J .

Raise the lift arms, with the floor jack, until the pivot pin at the
rod end of the lift cylinders can be removed .

Remove the lock nut and bolt [9.

Installation: Tighten the bolt and nut to 18-20 ft.-Ibs. (24-27

Nm) torque.

Remove the pins at the rod end of the lift cylinders (both sides) '"'"
@.

Lower the lift arms. Remove the floor jack.

843 Loader
-5-9- Service Manual
LIFT ARMS (Cont'd)

Remove the lock nut and bolt at the pivot pins for the lift arms
(both sides) ~.

Installation: Tighten the bolt and nut to 18-20 ft.-Ibs. (24-27

Nml torque.

Tighten the chain hoist.

Use a punch and hammer and remove the pivot pins at the lift
arms (both sides) [ID.

Raise the lift arms, with chain hoist and remove them from the
loader frame.

843 loader
-5-10- Service Manual
BOB-TACH

Removal and Installation

nit the Bob-Tach fully forward until the front edge is on the floor
IA) .

Stop the engine. Activate the hydraulic controls to release the

hydraulic pressure.

6 ·2791

Remove the lock nut and bolt at the rod end of the tilt cylinder
lID·
Installation: Tighten the bolt and nut to 18-20 ft.-Ibs. (24-27
Nm) torque.

--======:::::=:===:=:....... 6 ·4398

Remove the pivot pin at the rod end of the tilt cylinder [£] .

15

I
§
c
c

Loosen the bolt at the Bob-Tach pivot pin IQ). DO NOT remove
the bolt.

Installation: Tighten the bolt at the pivot pin to 220-245 ft.-Ibs.

(298-332 Nm) torque.

c 6·4546

843 Loader
-5-11- Service Manual
 BOB-TACH (Cont'd)

Remove the grease fitting at the pivot pins IA].

NOTE: The grease fitting at the pivot pin must be removed,

because the grease can cause a lock and the pivot pin
can not be removed form the Bob-Tach frame.

Put a rag over the grease fitting hole.

6-4547

Hit the bolt to start the pivot pin into the Bob -Tach frame lID.
Remove the bolt and use a punch to push the pivot pin into the
Bob-Tach frame.

Repeat the above procedure for the other side.

Installation: Use a small diameter punch through the grease

fitting hole to push the pivot pin into the lift arms.

Remove the Bob-Tach from the lift arms.

Remove the Bob.:rach pivot pins [f].

Q
o
o
N

"'
N
Q

Tilt Cylinder Rod End Seal

After the Bob.:rach is installed on the lift arms, use this procedure
to install the rod. end seals.

Lift the Bob-Tach with a floor jack ~ .

o
o
N

o
N
o

843 loader
-5-12- Service Manual
BOB-TACH (Cont'd)

Install the new seals at the rod end ~ .

Put a piece of shim stock on each side of the seals [ID.

Lift the Bob-Tach with the floor jack and install the rod end into
the Bob-Tach frame [ID.

Remove the shim stock and finish installing the Bob-Tach

Disassembly and Assembly

Put the Bob-Tach on a work bench .

Remove the bolt at the Bob-Tach lever [9.

Installation: Tighten the bolt to 25-28 ft.-Ibs. (34-38 Nm) torque.

Using a punch and hammer, remove the Bob-Tach wedge and

spring assembly from the frame ~.

843 loader
-5-13- Service Manual
 BOB-TACH {Cont'd)

Put the wedge and lever assembly in the vise.

Remove the bolt at the lever ~.

Assemble: Tighten the bolt to 25-28 ft.-Ibs. (34-38 Nm) torque.

Remove the block from the wedge bolt OOJ.

*

I
Assemble: Turn the block down until there is 6.39" (162 mm)
from the center of the hole to the top of the wedge spring seat
00.

Remove the nut and the spring from the bolt ~.

8
§
Remove the plastic guides from the Bob-Tach frame IQJ.

Clean and inspect all the parts for wear and damage, replace
the parts as needed.

'"oo
,
N

o
N
o

843 loader
.
N
N

f
* Revised Feb. 87
-5-14- Service Manual
FUEL TANK (SIN 19999 & Below)

Removal and Installation

Raise the operator cab (See Page 1-2 for the correct
procedure).

Turn the fuel shut-off valve (Item 1) to the "OFF" position ~_

Use a transfer pump and remove all the fuel from the tank.

Disconnect the hoses {Item 2} from the fuel tank ~.

Disconnect the wires from the sending unit (Item 3) ~.

Remove the bolts (Item 4) at the holding strap (item 5) ~.

Remove the fuel tank from the loader.

0-1556

843 Loader
-5-15- Service Manual
FUEL TANK (SIN 20001 & Above)

Removal and Installation

Raise the operator cab (See Page 1- 7 for the correct

procedure).

Use a transfer pump and remove the fuel from the fuel tank.

Remove the harness clamp at the top plate of the fuel tank @.

Disconnect the fuel return hose at the tank rID.

-
8 -8486

Disconnect the wires at the fuel sender ~ .

Turn the fuel shut-off valve to the "OFF" position .

--- ~(~~
- - - I \\ \ \
8·8484

Disconnect the fuel hose at the shut-off valve ~.

8-8497

843 Loader
-5-16- Service Manual
FUEL TANK {SIN 20001 & Above} (Cont'd)

Remove the bolts from the holddown strap ~.

Remove the fuel tank from the loader.

Fuel Tank Sender Switch

Remove the top plate from the fuel tank rID.

Remove the screws from the sender switch ~.

·~

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w
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g'"

I
0
,'"
B·8811 ,w
0

0
0

::;'"
Remove the sender switch from the fuel tank ~. m
~

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~

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;;
0-

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~
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0
0
;<

"0

·"
~~

B·8810

843 Loader
-5-17 Service Manual
('

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 ELECTRICAL SYSTEM

Page
Number
ALTERNATOR
Alternator Belt Adjustment. . . . . . . . . . . . . . . . . . . . . .. 6-3
Checking Alternator Output . . .. .. . . .. .. .. .... ... , 6-4
Checking A lternator Regulator. . . . . . . . . . . . ...... .. 6-4
Checking Alternator Wiring Harnes ........ . ....... , 6-4
Disassemby and Assembly. . . . . . . . . . . . . . . . . . . . . .. 6-6
Removal and Installation... . . ... . . . . . . .. . .. .. . . . 6- 5

BATTERY
Checking the Battery. . . . . . . . . . . . . . . . . . . . . . . . . .. 6- 2
Removal and Installation. . ....... . .............. 6- 2

ELECTRICAL SYSTEM INFORMATION

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-1

MANDO ALTERNATOR
Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . .. 6-9
Removal and Installation.. .... .. .. . .... . .. . ..... 6- 8

STARTER
Checking the Starter . . .. .. .. . ... . . . ... .. .. . . . . . 6-12
Disassembly and Assembly .... ... .. . .. ... ... . .. . 6-14
Removal and Installation .. .. . ....... . .. . .... . .. . 6-12
Replacing the Brushes . .. .. .... . ... . . . .. .. ..... . 6-15 ELECTRICAL
SYSTEM
TROUBLESHOOTING
Chart . .. ....... . .. .. . . . . . . . . . . . . .......... . 6-1

843 loader
Service Manual
 A BUSINESS UNIT OF CLqRK EQUIPMENT COMPANY

f
~~
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 WIRING DIAGRAM (PIN 6722195)
BUCKET POSITION VALVE LOCKOUT (OPTIONAL)
Model 753, 7753, 843, 8438 & 853
(Printed April 1992)

MC·1450
.... 1

MC·1118
.,
'iI
'"
0

'"g

I
~
WIRE LEGEND PARTS LEGEND o ·
'"
,0
WIRE NO. COLOR CONNECTS TO • Switch Cover 0
0
~

12S·A Orange Loader Wiring Harness ::;

Fused & Switched Power • Switch ~
:;;
12S·B Orange Switch
• Solenoid
59E·A
59E·B
Orange
Orange
Switch
Solenoid • Terminal
.
~
"'"~'
0-

50·A Black Solenoid

50·B Black • Connector ,~
Ground
e
()
0
0

Buc;l,(et Position Valve ""

()
0

.,."., • Wiring Harness .x

"l

~
~
N
A

W
~

N
,"'
N
0
0
~
Page 231 - BOBM02720V' 02/10/200917:56:31 - Printed by Ken Cook Co. - eXprint,exe (v2.24.3 8/25/2008)
WIRING DIAGRAM (PIN 6570239)
843 (SIN 12999 & Below)
(Printed December 1985)

........
-e

,.'fa

0- (J):== 1--:::...·---i+W~§~~t~~
.... 0=--=
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Page 2)) - BOBM02720; ~"""- - - - 02/101200 9 11:56:31 H Pri nted by Ken Cook Co, - eXpr int,exe (v2,2 4 , ) 9/25/2008>

CAB HARNESS

WIRE LEGEND PARTS LEGEND

NOw's COLOR
1 Black
GAUGE
16
NO.'s COLOR
34 Dk. Blue 16
GAUGE o Harness Connectors CD Fuse • Ignition
2 Black 1.6 35 Black 16 8 Operator Cab Ground fa Ilnltlon Switch
3
4
Orange
Orange
16
12
36
37
Black
Black
16
16
e Fuel Sender e Glow Plug Indicator
(543 Only)
5 Orange/White 16 38 16 8 Alarm (Opt.)
6
7
White
Lt. Blue
16
16
39
40
Brown
Black
Brown
16
16
Back..Up
e Rear Lamp e Shut-Oown Module (Opt.)
8
9
Orange/Green
Yellow/Black
'6
.1 8
41
42
Yellow
Purple
16
16
e Tall Lamp
10 Yellow 18 43 White 1.6 o Left Flasher Lamp (Opt.)
• Tee splice
11
12
13
WhltelPurple
Purple
Lt. Blue/Black
18
18
16
44
45
46
Lt. Blue
Red
16
16
Orange (Not Used) 16
e Left Front Lamp
o Butt splice

14 Yenow 18 47 Grey (Not Used) 16 CD Wiper Motor (Opt.)

15
16
Purple
Orange
18
16
48
49
Brown (Not Used) 16
Black 16
CD Flasher (Opt.)
17 Orange 16 _ RIght Front Lamp
18 Whlte/Orange 16
19 Orange/Ok. Blue 16 48 Right Flasher Lamp (Opt.)
20
21
Orange
Black
18
16
e Hourmeter
22 Orange 18 e Ught Switch
23
24
Orange
Ok. Green/Yellow
18
16 e Fuse .. Accessory
25
26
Orange
Black
18
16 o Wiper Switch (Opt.)
27
28
Orange/Black
OrangelBlack
16
16
e Fuel G.auge
29 Orange/Ok. Blue 16 o Trans. Warning Light
30
31
Orange/Ok. Blue
White/OIl. Blue
16
16 e Enline Warn.lng Light
32
33
Pink
Brown
16
16 e Voltmeter
en
fa
z
It:
C
...
Z

-"
Z
Z
III
Page 235 - BOBM027201('·..··'·· - 02/10/200917:56:31 - Printed by Ken Cook Co . - exprint.exe (v2.24.3 8/25/2008)

ENGINE HARNESS

WIRE LEGEND PARTS, LEGEND

NO.'s COLOR GAUGE 0 Harness Connectors o Frame Ground
1
2
Black
Black
16
16 fa. . • Unfused " LIVe Accessories f) Diode
3 White/Orange ~: e Fuse and Live Accessories,
4
5
Orange
Whlte/Green 16 ee EngI.ne Connector
.,
6 White/Black
Orange/Green
16
16 ' .• Back·UpAlarm, Switch (Opt.)
8 YellowlBlack
~: 8 Trans. 011 Temperature
9
10
Yellow
Purple 16 e Trans. Charge Pressure
11
12
Lt. Blue/Black
Orange
16
12 e Brake Switch
13
14
White/Lt. Green 16
White 12 8'. Starter
15
16
Lt. Green
Orange
16
12
8 Engine Oil Pressure
17 Oranle 12 It Fuel Shut·Off Solenoid
18
19
Whlte/Oranee
WhltelGreen
16
16 8•'. Thermo-Start or Glow Plug
20 Lt. BluelOranle
cab.: CD Engine Coolant Temperature
21
22
23
Red
Black
Red
Cable
Cable
e Alternator

24 Red Cable 8 Batteries

2.5 Black Cable CD
. Pre-HeatRelay
e Start Relay
WIRING DIAGRAM (PIN 6566813)
843 (SIN 13001 Thru 19999)
(Printed December 1985)
Page 23 7 - BOBM02720) r ·"·"·' ~ - 02/ 10 / 2009 17: 56: 3 1 - Pr inted by Ke n Cock Co . - eXpri nt . e xe ( v2. 24.3 e/2S/200B)

CAB HARNESS

WIRE LEGEND PARTS LEGEND

NO.'s COLOR GAUGE NO.'s COLOR GAUGE 8 Harness Connectors e Voltmeter
lD
IF
Red
Red
12
16
41
42FL
Pink
Dk. Blue
16
16 8 Operator Cab Ground e Ignition Switch
lOA
lOB
Black
Black
12 42FR Dk. Blue 16
16
e Fuel Sender e Hourmeter
12
12A
Oranle
Orance
12
16
18
42R
46
46L
Dk. Blue/White
Brown
Brown
16
16
e Back-Up Alarm (Opt.)

12B Orance 16 46R Brown 16 8 Hear Lamp • Tee splice,

1.2C Oraole 16 49F Gray 16 Cit Tall Lamp o Butt splice
1.2F Orallie 18 49T .Gray 16
12L
12T
Orange
Orange
18
18
49V Gray
60W Black
16
16
e Lett flasher Lamp (Opt.)
19C Red/White 16 63 OranleiBlack 16 8 Lett Front Lamp
1.9F Red/White 16 66 Orange/Green 16
19H Red/White 18 f) Wiper (Opt.)
19L
195
Red/White
Red/White
16
16
CO Flasher (Opt.)
19W Red/White 16 4D Right Front Lamp
21R
23F
White
White/Black
16
16 e Right Flasher Lamp (Opt.)
26 Lt. Blue 16 G) Engine Temperature Gauge
28 Lt. Blue/Black 16
30 Black 16 e Fuel Gaule
30F
30G
30T
Black
Black
Black
16
16
16
e Light Switch
31P . YeI.•ow/Green 18 CD Wiper Switch (Opt.)
32PT
35H
Yellow
Yellow/Brown
18
18
e Trans. Wamlng Light
36 Purple 16 8 Engine Warning Light
36T PurplelWhit e' 18
40FL Black ' 16 fI) Fuse - Ignition
40FR Black 16 (II) Fuse - Accessory
40R Black 16
- -- 23F

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Page 239 - BOBM02720F' ~ - 02/10/200917:56:31 - Printed by Ken Cook Co. - eXprint.exe {v2.24.3 B/25/2008)

ENGINE HARNESS

WIRE LEGEND PARTS LEGEND

NO.'a COLOR GAUGE o Harness Connectors e Start Relay
o
1
Black
Red
Cable
Cable fit Unfused " Live Accessories o Frame Ground
lA Red 8 e Engine Connector CD Engine Ground
lB
lC
Red
Red
12
12 e Back-Up Alarm Switch (Opt.)
lD Red
lOA Black
12
12 e 'lrans. 011 Temperature Switch
12C White/Orange
14F Lt. Green
18
18
e bRS. Charge Pressure
Switch
14R Lt. Green/White 18
21R White 16 fa Starter
215 WhltelGreen
23F White/Black
12
16 e Engine Oil Pressure Switch
28 Lt. BluelBlack
28B Lt. Blue/Orange
16
I
e Fuel(Internal)
Shut-Off Solenoid
215 Lt. Blue/Yellow 16
31P Yellow/Lt. Green 16 CD Hydraulic Fluid Filter
Pressure Switch
32F Vel.ow/Dk. Blue 1.6
32" Yellow 16
32T VellowlBlack 16 4D Glow Plugs
3SH VellowlBrown
36T Purple/White
16
16
e Engine Coolant Temp. Sender
80B Black 18 CD Diode
68 Orange/Green 18
e Alternator
e Batteries
e Pre..Heat Relay
WIRING DIAGRAM (PIN 6570240)
843 (SIN 20001 Thru 23999)
(Printed July 1988)

I .

6570240 17·SSl
page 2U - BOBM027201r · • H 02 / 10/20091 7 :56:31 - Pri nted by Ken Cook Co. - cXprint . exe (\'2 .24 .3 B/2S/200S)

CAB HARNESS

WIRE LEGEND PARTS LEGEND

No.'5COLOR GAUGE NO.'5 COLOR GAUGE e Harness Connectors e Fuse· Accessory
lD
IF
Red
Red
12
16
40FL
40FR
Black
Slack
16
16 e Operator Cab Ground fa Voltmeter
lOA Slack
lOS Slack
12
12
40R
41
Slack
Pink
16
16
e Fuel Sender fa Ignition Switch
12 Orange
12A Orange
12S Orange
16
18
12
42FL
42FR
42R
Dk. Blue
Dk. Blue
Dk. Blue/White
1. CIte
16

16
Back-Up Alarm (Opt.)
Rear Lamp
tI) Hourmeter

12C Orange
12F Orange
16
18
46
46L
Brown
Brown
16
16
e Tail Lam.p • Tee splice
12L Orange 18 46R Brown 16 o Left Flasher Lamp (Opt.) o Butt splice
12T Orange.
19C Red/White
19F Red/White
18
16
16
49F
49T
49V
Gray
Gray
Gray
16
16
16
e Left Front Lamp

19M Red/White 1.8 60W Black 16 8 Wiper (Opt.)

19l Red/White
195 Red/White
16
16
66 Orange/Green 16 CD Wiper Switch (Opt.)
19W Red/White 16 4D Shut Down Module (Opt.)
21R White
21RM White
16
16 e Flasher (Opt.)
23F White/Slack
26 Lt. Slue
16
16
e Right Front Lamp <

28 Lt. SluelSlack 16 4D Right Flasher Lamp (Opt.)

30 Black
30F Black
30G Black
16
16
16
e Engine Temperature Gauge

30T Black 16 CD Fuel Gauge

31FP Yellow
31P Yellow/Green
16
18
e Light Switch
32FPT Yellow 18 CD Trans. Warning Light
32PT Yellow 18
3SH Yellow/Srown 18 eEnglne Warning Ught
36 Purple 16 CO Fuse· Ignition
36T Purple/White 18
 i
I

~ .
--'-1
' .
14F-_-~.
=-__
11

-a.
..
rr
. IL. ~O
-
--~
- · t~~ ~

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t

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Page 2013 - BOBM027201 C"-----· - 02/10/2009 11: S6: 31 - Printed by Ken Cook Co. - eXprint, exe (v2. 24.) 8/2S/200S>

-~".---- ~ .- • .•....... ~""'--~.-~- .,.' ~

ENGINE HARNESS

WIRE LEGEND PARTS LEGEND

NO.'s COLOR
o1 Black
GAUGE
Cable . .
e Harness Connectors
Red Cable W Back·Up Alarm Switch (Opt.)
lA Red 12 e Trans. Fluid Temp.. Switch
lB
lC
lD
Red
Red
Red
10
12
12
e Trans. Charge Pressure
Switch
lOA Black 12
12C WhIte/Orange 16 8 Starter
14F Lt. Creen. 16 e Injection Pump Shut.Off
14R Lt.. Creen/Whlte
21R White
215 Whlte/Creen
16
16
12 ...
e Hydrostatic Filter Switch
23F Whlte/Black 1 6 " Engine 011 Press. Switch
28 Lt. BluelBlack
28B Lt.. Blue/Orange
16
8
e Engine Coolant Temp. Sender
285 Lt. BluelYellow
31P Yellow/Lt. Green
16
16
G Engine Glow Plugs
32F Yellow/Dk. Blue 16 eD Diode
32P Yellow 16
32T Yellow/Black 16 8 Alternator
·35H Yellow/Brown
36T Purple/White
16
16
G Battery
60BBIack 16 4D Start Relay
66 Orange/Green 16
e Pre-Heat Relay
e Harness Connectors
WIRING DIAGRAM (PIN 6570913)
843 (SIN 24001 Thru 25999)
(Printed July 1988)

49T"-- -- - - - - -

0 ......0 r
461 {r-.
f
------:....I----:..-~

e-~n~rr-~~
e _. , ~ It::
'~t-•..1 . [[ ( !~-. --=-"':---1

e ,. ,-. r~
- ._._~· I·I~
---:.-.I

~. :~. ~~.~.!~!,!~•.:-.!l . W!l.2. . ~~..-;-~-=

,.:--,

a
,, ' ~~2IJ~': · .. "ll~
. - .:. . : .-.
o'~ .. :~ -l
,«*:
~e ~,----~~-

;:f-""li I
CI~-. ~~-:~i------~~~~~

J~~~ill
\

)IIB--:..-.J
-f/~.
"--:-~""'----,-",\,\,\ , ,/ /,/
,/

• ' "+
lOA

[I !'-----+--~
l
l

6570913 (NJ81
page 245 ~ BOBM02720J 0~ "-- ~ 02/ 1 0/2009 17:56:31 - Pr:inted by Ken Cook Co. - eXprint.exe (v2,24.3 8/25/2008)

CAB HARNESS

WIRE LEGEND PARTS LEGEND

NO.'s COLOR
lD Red
GAUGE
12
NO.'s COLOR
40Fl Black
GAUGE
16
o Harness Connectors fI) Fuse • Accessory

IF Red 16 40FR Black 16 faOperator Cab Ground fa) Voltmeter

lOA Black 12 40R Black 16 e Fuel Sender e Ignition Switch
lOB Black
1.2 Orange
1,2
16
41
42Fl
Piak
Dk. Blue
16
16 e Back-Up Ala.rm (Opt.) e Hourmeter
12A Orange
12B Orange
18
12
42FR
42R
Dk. Blue
Dk. Blue/White
16
16 eRear Lamp
12C Orange
12F Orange
16
18
46
46l
Brown
Brown
16
16
etaU Lamp • Tee splice
12l Orange 18 46R Brown 16 8Left Flasher Lamp (Opt.) o Butt splice
12T Orange
19C Red/White
19F Red/White
18
16
16
49F
49T
49V
Gray
Gray
Gray
16
16
16
eLett Front Lamp

19H Red/White 18 60W Black 16 eWlper (Opt.)

19l Red/White
195 Red/White
16
16
66 Orange/Green 16 CD
Wiper Switch (Opt.)
19W Red/Wh.l te 16 4D Shut Down Module (Opt.)
21R White 16
21RM White 16 _ Flasher (Opt.)
23F Whlte/Bla.c k
26 Lt. Blue
16
16
e Right Front Lamp
28 It.. Blue/Black 16 o Right Flasher Lamp (Opt.)
30 Black
30F Black
16
16 e Engine Temperature Gauge
30G Black
30T Black
16
16 e Fuel Gauge
31FP Yellow
31P Yellow/Green
16
18
e Light. Switch
32FPT Yenow 18 CD Trans. Warnln, Light
32PT Yellow
35H Yellow/Brown
18
18 e Engine Warning Light
36 Purple
36T Purple/White
16
18
e Fuse - Ignition
tn
gt.
Z
D:
C
Z
1&1

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Z

Z
1&1 w
~

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o
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Page 24'1 - BOBM02'120]!""'--" - 02/10/20091'1:56:31 - Printed b y Ken Cook Co . . e Xprint. exe (v2.2 4 .3 8/2 5/2 008)

., -.---- "-- - - - - - , - - - ---- - _.,--, " --

, - ----,,-- - --~ ,,~,,-,.

ENGINE HARNESS

WIRE LEGEND PARTS LEGEND

NO.'sCOLOR
o Black Cable
GAUGE e Harness Connectors
A
e start Relay

1 Red Cable W Unfused & Live Accessories CD Frame Ground

lA Red 8 o Engine Connector CD Engine Ground
18

lD
Red
le Red
Red
10
12
12
e
..
Back-Up Alarm Switch (Opt.)

lOA Black 12 . . Trans. Oil Temperature

12C Whit,elOrange 16 Switch
14F Lt. Green 16 6) Trans. Charge Pressure
14RLt. Green/White 16 Switch
21R White
21S White/Green
16
12 o Starter
23F White/Black
28 Lt.. BluelBlack
16
16 e Engine Oil Pressure Switch
28B Lt. BluelOrange
28S Lt. BluelYellow 16
8 e Fuel,Shut..Off Solenoid
(Internal)
31P Yellow/Lt. Green 16
32F Yellow/Dk. Blue 16
32PT Yellow 16
co Hydraulic Fluid Filter
Pressure Switch
32T Yellow/Black
35H Yellow/Brown
16
16
at Glow Plugs
36T Purple/White 16 e Engine Coolant Temp. Sender
60B Slack
66 OrangelGreen
16
16 e Diode
e Alternator
e Battery
CD Pre-Heat Relay
WIRING DIAGRAM (PIN 6570914)
843 (SIN 26001 Thru 28134)
(Printed July 1988,

.J
I
I
•
I
•
I

I{ I. I

l ( I
r
I
( I I .
l I

•
I

65'0914 (7·88)
Page 24 9 w BOBM02 7201("~--'" - 02/10/200911 : 56 : 32 w Printed by Ken Cook Co. - eXprint.exe (v2.24.3 9 /25/2 009)

CAB HARNESS·

WIRE LEGEND PARTS LEGEND

NO.'s COLOR GAUGE NO/s COLOR GAUGE o Harness Connectors It Fuse· Accessory
lD
IF
Red
Red
12
16
40FL
40FR
Black
Black ~: e Operator Cab Ground fa Voltmeter
lOA Black 12 40R Black 16
16
. . Fuel Sender
.,
fa) Ignition Switch
lOB Black
12 O,ang.
12A Orange
12
16
18
41
42FL
42FR
Pink
Dk. Blue
Dk. Blue
16
16
e ..
Back-Up Alarm (Opt.) o Hourmeter

12B Orang. 12 42R Dk. Blue/White 16 . , Rear Lamp

12C Orana. 16
18
46 Brown
!: e Tall Lamp • Tee splice
12F Oran••
t2L Oranae II
46L
46R
Brown
Brown 16 e Left Flasher lamp (Opt.) o Butt splice
12T Oranae
19C Red/White
18
16
49F
49T
4tV
Gray
Gray
Gray
16
16
16
e
..
Left Front Lamp
19F Red/Wlatte 16
19M RedfWhlte 18 60W Black 16 . . Wiper (Opt.)
19L Red/White 16
16
66 OrangeJGreen 16 e Wiper Switch (Opt.•)
19S RedlWhite
19W Red/White· 16 e Shut Down Module (Opt.)
21R White
21RM Whit.
16
16 e Flasher (Opt.)
23F WhltelBlack
2.6 Lt.. Blue
16
16
e Rleht Front Lamp
28
30
Lt.. Blue/Black
Black
16
16
at Rlaht Flasher Lamp (Opt.)
30F Black 16 CO Engine Temperature Gauge
30G Black
30T Black
16
16 e f'uel Gauge
31FP Yellow 16
18
e Licht Switch
31P Yellow/Green
32FPT Yellow
32PT Yellow
18
18
e Trans. Warning Light

35H Yellow/Brown 18 G) EngIne Warning Light

36 Purple
36T Purple/White
16
18
e Fuse • Ignition

.~ ~
, '1
 ,
i...
l

en
I
....Z
fI)

!32P-UJ·
/!\ 0:
32F
35H
~ 66 J J C ~
:&: i "o
\
III

J -"
Z

Z
1.11
Page 251 - BOBM02?20'r" "1 - 02/10/2009 17:56:32 - Printed by Ken Cook Co, - eXprint,exe {v2.24.3 8/25/2008}

ENGINE HARNESS

WIRE LEGEND PARTS LEGEND

NO.'. COLOR GAUGE 0 Harness Connectors CD Start Relay
o
1
Black
Red
Cable
Cable
..
. . UnftlSed a Live Accessories ·e Frame Ground
lA Red 8 e Engine Connector e Engine Ground
lB
lC
10
Red
Red
Red
10
12
12
e
..
Back-Up Alarm Swltchs (Opt.)

lOA Black 12 . , Trans. 011 Temperature

12C Whlte/Orange 16 Switch
14F Lt. Green
14R Lt.. GreenlWhite 16
16 8 Trans. Charge Pressure
Switch
21R White 16
21S Whlte/Green 12 8 starter
23' Whlte/Black
28 Lt. BlueJBlack.
16
16 e Engine Oil Pressure Switch
28B Lt. Blue/Orange
28S Lt.• BluelYellow 16
8 e Fu.. Shut-Off Solenoid
(lntemal)
31P Yellow/Lt. Green 16
32' Yellow/Ok. Blue 16 CD Hydraulic Fluid Filter
Pressure Switch
32PT Yellow 16
32T Yellow/Black
31H YellowlBrown
16
16
e Glow Plugs
36T Purple/White 16 e Engin.e Coolant Temp. Sender
60BA Black
60B Black
16
16 e Diode
66 OrangelGreen 16
e Alternator
e Battery
e Pre-Heat Relay

CAB HARNESS

WIRE LEGEND PARTS LEGEND

WIRING DIAGRAM (PIN 6570915)
843 (SIN 28135 & Above) & 8438
(Printed September 1990)

1
---1 II 1
t

E
• ~~~ ,
3tP-
3ZI'T-
te-
~t
t I
, I
•

llAM- a •• f I
D-ZISA-
*
l\ , I
• I
I t
3&
30

rI I
C
l 1 tOtt

.I rrw
IDS
t

II
JD
If

1111 :~ v G
cQ:GOW
tOW
I I I • I I I I
,
I • I I l • I I I
:=
ItiIt.

4e
~ . e
~:;::::~~~, ~
I I , I I I
I • • • • I II •I •I

IIIII~
~ !Iii i"I
ttilt.
IOF
few
, 11111' lOS

I J IllIII
tlRM
.....0 46L-
"
.!:
... ft. •
tm
12F
T I 128

~¥ . :~~
( ft I t
Z1tA

II l I Illille
40R +4OFR I
g
• I J Z8

W
en 0
----1"-.,.- -;"1'
.ZR II
r
":"'l---=-~
I
l : : :
31. ----..\
34T - - - - - - . . .

I ~:,---;--~:--.;-;---; Jill ,:-0-'-..~].oo

III 3m
II ~ it II M--~r'a

~..
z - - ' A..
-",'
·
II.l 1 L;;' __
' -'_L-_:~~~~::
I I I
I

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I
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6570915
Pa ge 253 _ BOBM027201" " "-.., - 02/10/2009 17 : 56:32 - Prilltecl by Ken Cook Co. - eXprint.exe (v2.2-4.3 B!2S!2000l

CAB HARNESS

WIRE LEGEND PARTS LEGEND

NO.'s COLOR GAUGE NO.'s COLOR GAUGE o Hamess Connectors G Fuel Gaule
lD
IF
Red
Red
12
16
36T
40R
Purple/White
Black
18
16 e Ground e Hourmeter
lOA Black 12 40FL Black 16 e Fuel Sender e Fuse (llnltlon)
lOB Black
10AB Black
14
12
40FR
41
Black
Pink
16
16 e Back..Up Alarm (Opt. 8438 fa Fuse (Accass.ory)
12A Orange
12B Orange
12C Orange
18
16
16
42FL Ok. Blue
42FR Ok. Blue
42R Ok. Blue/White
16
16
16
Only)
CIt Rear Light (Opt. 843B Only)
e Light Switch (Opt.
Only)
84~

12F
12L
Orange
Oranee
16
18
46
46L
Brown
Brown
16
16 8 Tall Light (Opt. 843B Only) e Ignition Switch
12T
12V
Orange
Orange
18
18
46R
41F
Brown
Gray
16
18
o Left Flasher Light (Opt.)
19C Red/White 16 41T Gray 18 fa Left Front Light (Opt. 843B
19F Red/White 1.6 49V Gray 18 Only)
19H Red/White 18 60W Black 16
IlL Red/White 16 66 Orange/Gree,n 16 CD Wiper Switch (Opt.)
195 Red/White 16
19W Red/White 16 CO Wiper (Opt.)
21R
21RM
White
White
16
16
e Shut Down Module (Opt.)
23F White/Black 16 CD Flasher (Opt.)
26
26A
Lt. Blue
Lt. Blue
16
16 e RIgbt Front Light (Opt. 8438
Only)
28 Lt. Blue/Black 16
30.
30G
Black
Black
16
16 e Right Flasher Light (Opt.)
30T Black 16 CD "&ans. Wamlng Light
31
31P
Yellow
Yellow/Green
18
18 o Engine Warning Light
32 Yellow
32PT YellOW
18
18 e Voltmeter
3SH
36
Yellow/Brown
Purple
18
16
CD Temperature Gauge
l
 . .
-..-._.- . ...,
1
1';
'CD
:s
: 0
; i:
J
-
...

..:s-
)
"CD

."E
t 0

i
.c
•
, .
.. ..
t - ,- -

o
N

l ,o
N
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o
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~

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.
• 31P
. ._.'...
.'. ¥1 ,
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!3ZP -!!1 . z:
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Page 255 - BOBM027201 r' ~ 02/10/2009 17: 56 : 32 ~ Printed by Ken Cook Co. - eXprint. exe (v2. 24.3 8/25/2009)

ENGINE HARNESS

WIRE LECEND PARTS LEGEND

NO.'sCOLOR CAUGE 8 Harness Connectors e Battery
o1 Black
Red
Cable a
Cable . . Unfused & Live Accessories CO Pre-Heat Relay
lA Red 8 e Eneine Connector e Start Relay
lB
lC
lD
Red
Red
Red
10
12
12
e
..
Bac.k-Up Alarm Switch (Opt.) CD Frame Ground
lOA Black 12 V Trans. Fluid Temp. Switch CD Engille Ground
12C White/Orange 16 fa Trans. Charge Pressure
14F Lt. Green 16 Switch
14R Lt. Green/White 16
21R White 16 8 starter
21S
23F
WhltelGreen
White/Black
12
16 e Engine Oil Pressure Switch
21
28B
Lt. BluelBlack
Lt. BluelOran,e
16
8
e Fa.el Shut-Off Solenoid
(Internal)
28S
31P
32F
Lt. BluelYellow
Yellow/Lt. Green
Yellow/Ok. Blue
16
16
16
co Hydraulic Filter Pressure
Switch
32PT Yellow 16
32T Yellow/Black 16 «8 Glow Plugs
35H
36T
YellowlBrown
Purple/White
16
16
8 Engine Coolant Temp. Sender
60BA Black 16 8DJ,ode
60B Black 16 4\
66 OrangelGreen 16 W Alternator
6 ELECTRICAL SYSTEM

ELECTRICAL SYSTEM INFORMATION

Description
A WARNING (

The loader has a 12 volt, negative ground electrical system. Instructions are necessary before operating or servicing
There are two main circuits. machine. Read Operator's Manual. Handbook and signs
(decals) on machine. Follow warnings and instructions
1. The charging circuit has an alternator (with built-in in the manuals when making repairs, adjustments or
regulator), a voltmeter and a battery. servicing. Check for correct function after adjustments,
repairs or service. Failure to follow instructions can
2. The starting circuit has a starter motor, solenoids and other cause injury or death.
components for starting the engine. W·2003-1285

The loader also has front and rear lights. Optional windshield
wiper, horn and back-up alarm .

The electrical system is protected by two fuses installed in the

instrument panel. Fuses protect the electrical system from an
overload.

TROUBLESHOOTING

The following troubleshooting chart is provided as an assistance

in locating and correcting problems which are most common.
Many of the recommended procedures must be done by
authorized Bobcat Service Personnel only.

PROBLEM CAUSE

Battery does not charge. 1, 2, 3, 4,5

Alternator will not charge. 1, 2, 5

Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

w
0
w

I
KEY TO CORRECT THE CAUSE
~
0
~
~

a
~

1. Alternator belt is loose or damaged. N

a
a
'"
2. Battery connections are dirty or loose. ~
~

'"'"
3. Battery is damaged. ~

4. The ground connection is not making a good contact. ."

"
5. The alternator is damaged. "
~
0
0.

6. The engine is locked. '"

'<

~
7. The starter is damaged. <)

~
8. The wiring or the solenoid is damaged. <)
?

9. Check the fuses.

(
\

843 Loader
Revised ADril 96 -6-1- Service Manual
 BATTERY

Checking the Battery

The tool listed will be needed to do the following procedure:

MEL-10004 - Battery Tester

To make a safe and complete check of the battery see the Clark
Battery Manual (PIN 6566047).

The Battery Manual has all the information and specifications

needed for checking and servicing the battery. Replace the
battery as needed.

A WARNING
Batteries contain acid which bums eyes or skin on
contact. Wear goggles and protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water
o
for several minutes and get medical attention.
W-2065-1285

DO NOT remove the vent caps from the battery while charging B-8481
the battery. The battery has vent caps which will decrease the
possibility of the battery being exploded by an external spark.

Removal and Installation

Disconnect the battery cables. Always remove the negative (-)

cable first to prevent sparks IAJ.

Remove the nuts and bolts from the holddown clamp and
remove the holddown clamp rID.

Ii Remove the battery from the loader ~.

§
,2"
.s
"3
~
'"

843 Loader
-6-2- Service Mal)ual
ALTERNATOR

Alternator Belt Adjustment

Open the rear door.

Remove the bolts from the belt shield.

Remove the belt shield from the engine ~.

Loosen the adjustment bolt 00.

Move the alternator to set the belt tension at 1/4" (6,5 mm)
deflection with 5 Ibs. pressure I£}.

Tighten the adjustment bolt 00.

Install the belt shield.

843 Loader
-6-3- Service Manual
ALTERNATOR (Cont'd)

Checking the Alternator Wire Harness

Turn the key switch to the "ON" position and make the checks
as follows ~.

Connect a voltmeter between ground and No. 1 terminal.

"BAT" Terminal--i~n,\HI}j
Connect a voltmeter between ground and No.2 terminal.

Connect a voltmeter between ground and "BAT" terminal.

If any of the tests show zero voltage, the wiring harness has
a defect. Repair the wiring harness as needed.

Checking Alternator Output

Lift and block the loader (See Page 1- 2 for the correct
procedure).

Disconnect the "BAT" terminal at the alternator 00.

Connect the "BAT" wire to one side of the ammeter. Con

the other side to the "BAT" terminal of the alternator [£] .

Disconnect the fuel shut-off wire at the injection pump. Turn

the engine, with the starter for 30 seconds to lower the charge
in the battery.

Connect the fuel shut-off wire.

Start the engine and run at full RPM.

The ammeter reading must be within 10% of rated amperage

(37 amps. @ 2JOO
:.p3:~~
RPM) [£]. ":'~'f~'
'fit"
8 ·7665

Checking Alternator Regulator

Use the same procedure as above for "Checking Alternator

Output" except for the following:

Put a small screwdriver in the test hole ~.

The alJlmeter reading must be within 10% of rated amperage

(37 amps. @ 2100 RPM).

If the reading is less than 10% of rated amperage, check the

diode trio, rectifier, stator or rotor.

843 Loader
-6-4- Service Manu~!.
ALTERNATOR (Cont'd)

Removal and Installation

Remove the belt shield at the engine.

Disconnect the negative (-) cable at the battery.

Disconnect the wire at the "BAT" terminal ~.

Disconnect the No.1 & 2 terminals [[J.

Remove the adjustment bolt [£J.

Remove the mounting bolt ~.

Remove the alternc:ltor from the engine.

843 Loader
-6-5- . Service Manual
 I '

10
1. Pulley
2. Bolts
3. Case Halves
4. Rotor
5. Nuts
6. Stator
7. Diode Trio t-«Hi-@-
8. Rectifier
9. .Capacitator QJ---@-
10. Brush Holder ----- - ---l
11. Regulator I

·--""'""""""'----e~
I
---aatt I
- - ~ - - ~+-;c:C)-~0
L--a$

~m--@)
-@~-@

ALTERNATDR (Cont'd)

Disassembly and Assembly

m
Disassemble the alternator as shown ~ .
a
0
,
N
~

,
N
Q

;i Connect an ohmmeter as follows to check the rotor lID .

oi
.::
~ Between one slip ring and the shaft. Check the other slip ring.
~
w
c
There must be maximum resistance.

.
"
Ii'
Between both slip rings. There must be 2.4 to 3.0 ohms.
resistance.
"
U
-"
0
0
U
c
:1
,.,
.Q Connect a battery powered test light as follows to check the
'0
stator ©. .
,~
,;:
Between the center wire and an outside wire. Light must come
...
~
"ON".
~
~

...
~

~
Between center wire and the other outside wire. Light ' must
0
0
N come "ON".
0
,
N
0
Between one of the wires and frame. Light must NOT come
0 f "ON".
0 ,

f
'"'"
0

'" 843 Loader

.
~

"
~
-6-6- Service Manual
 ALTERNATOR (Cont'd)

Connect a D.C. test light as follows to check the diode trio IAJ.

IMPORTANT
Do not use voltage which is more than circuit voltage
to check the diode trio or the rectifier on the alternator.
1·2026-0284

A·2382

Between a single connection and one of the three connections.

Connect the tester in the opposite direction . The light must
come "ON" in one direction, but not in the other direction.

Check each diode with the same procedure.

. Connect a test light as follows to check the rectifier lID.

Between one connection and insulated heat sink. Connect the
test light in opposite direction. The light must come "ON" in
one direction, but not in the other direction.

Between one connection and the grounded heat sink. Connect

test light in opposite direction. The light must come "ON" in
one direction, but not in the other direction.

Assembly: Reverse the order of disassembly.

;J
Also if regulator was removed, install new insulated washers 'Il
and spacers [9. ~
~

"'
0

"
~
§
0
0

0
,~

B·2128 ,0
~
0
0

'":;
When installing the brushes, put a piece of straight w ire through
'"
~

the housing to hold the brushes in the up position [Q]. :;

"0

Then install the rotor, when in position pull the wire out to seat "
the brushes.
·"
"-
!{

·"
,'"
0
~

"
0

.I
.~
·
~
X

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B-2097 ~

W
843 loader ,'"
-6 - 7- Service Manual N
,'"
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 MELROE ALTERNATOR

( Checking the Alternator Output

A WARNING
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

Lift and block the loader (Refer to Page 1- 2 for the correct
procedure). 8-9568

Disconnect the negative (-) cable from the battery.

Remove the belt shield.

Connect the orange lead (Item 1) from the alternator output

terminal to the negative (-) side of the ammeter. Connect the
positive (+) side of the ammeter to the output terminal on the
alternator (Item 2) ~ .

Disconnect the fuel shut-off w ire.

Connect the negative (-) cable to the battery.

Turn on the lights and crank the engine for 30 seconds to run
the battery down.

~
Connect the fuel shut-off w ire.
0
0
,
N

,"'
N Start the engine and run at 2600 R.P.M.
~

;;; The ammeter reading should be between 45 & 55 amps. @

N
8-9570
.': 2600 RPM .

·..
~
x

"" If the reading is low, disconnect the battery and connect a

jumper wire from the alternator output terminal (Item 1) to the
·
~

Ii
regulat or term inal (Item 2).

'50 Connect the battery cable, start the engine and check the
u
ammeter. If t he reading is within the rated amperage (45-55
·"
'"s amps. @ 2600 RPM) replace the diode trio lID.

~
£
~
~

"'
~
'"
0
0
,
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0

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0

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d
0 '
1'·
~ .\

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~ 843 Loader

·'"
N
Revised Mar. 86 -6 - 8- Service Manual
it
Checking the Alternator Regulator

Connect the positive (+) voltmeter lead to the positive (+)

battery terminal and connect the negative (-) voltmeter lead
to the negative (-) battery terminal ~.

A WARNING
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

8·3710
8·8068

A WARNING
When an engine is running in an enclosed area. fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary. vent the exhaust
outside. Exhaust fumes contain odorless. invisible gases
which can kill without warning.
W·2050·1285

Start and run the engine at 1500 - 2000 R.P.M. The voltmeter
should be between 13.9 - 14.7 volts ~.

If the ring is low, stop the engine and disconnect the battery.

Remove the sc;rews and pull the regulator cover away from the
alternator. Co~ct t~e jumper wire from the ~round stud (Item
1) to the brush"~erm,"al (Item 2) (the tan wire) lru.
x
Connect the battery and start the engine. Run at 1500 RPM.
DO NOT allow the meter to exceed 16 volts.

If the reading is 14.5 or above. replace the regulator.

If the reading is 14.5 or below, repair or replace the alternator.

843 Loader
Added Mar. 86 -6-8.1- Service Manual
 I MELROE ALTERNATOR (Cont'd)
Removal and Installation

Disconnect the negative cable from battery.

Disconnect the wire terminals from the back of the alternator

~.

Disconnect the battery terminal lru.

Remove the adjustment bolt and the mounting bracket bolt.

Remove the alternator.

A WARNING
AVOID INJURY
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-1285

8
§

843 Loader
Revised Mar. 86 -6-8.2- Service Manual
 1. Nut
2. Pulley
3. Fan
4. Bolt
5. Case Half (Front)
6. Bearing
7. Rotor
8. Slip Ring
9. Stator
10. Heat Sink (+)
11. Heat Sink (-)
12. Case Half (Rear)
13.
14.
Condenser Assy.
Brush Holder Kit ", --' --- -------
.... ~-

--- ------
,.,
15. Regulator Kit I
I
I
I
I
I
I
I
I
I
...

------ ------ --.)

-----_ .... -------

r----
I
",

I
I
I
I
14
I
I I ...
,
I ~. -,-.
L--- ,,

\u 0·1760

I MELROE ALTERNATOR (Cont'd)

Disassembly and Assembly

Disassemble the alternator as shown ~.

.
~

<g
Remove three (3) bolts (Item 4) holding halves together. '"
~
~

Pry halves apart. '"g

Use a soft jaw vise to hold rotor while removing pulley nut (Item
1).

Remove front case half (Item 5) from the rotor using a plastic
!
c
,'"
hammer or press .. 0
~

~
:.:;
Unsolder the stator wires from the rectifier to test the stator "'
~

and rectifier. Use a needle nose plier to aid in removal of the ~

wires.

.~
0-
.

'""
Use the following procedure with an ohmmeter to test the rotor: 0'"
"n
~
Touch both probes on the slip rings. There must be a 3 to 5 ohm b'
reading 00.
:?
';

\
Touch one probe to the shaft and one probe to a slip ring, then
to the other. There must be maximum resistance @.

843 Loader
Revised July 88 -6-9- Service Manual
I MELROE ALTERNATOR (Cont'd)

Use the following procedure with an ohmmeter to test the

stator:

Touch to (2) bare wires of the stator with the probes, take a
reading. Move one probe to the other wire. The readings should
be the same ~.

Test for ground by touching one probe on the metal surface of

the stator and the other probe on the bare wire. There must be
no needle movement lID.

Use the following procedure with a circuit tester to test the

rectifier: *
Touch the positive probe to the positive diode holder and the
negative probe to each diode terminal. There must be continuity
[£j.

Reverse the probes and check the other direction. There must
be no continuity lID. *

843 Loader
* Revised July 88 -6-10- Service Manual
MANDO ALTERNATOR (Cont'dl

Touch the negative probe to the negative diode holder and the
positive probe to each diode terminal. There must be continuity
~.

Reverse the probe and check the other direction. There must
be no continuity rID.

Check the brushes for wear. The maximum length of exposed

brushes should be .125" (3 mml.

Replace broken or rusted brush springs.

Reverse the order of disassembly.

Place the rotor in soft jaws when tightening the shaft nut.
TIghten to 50 ft.-Ibs. (70 Nm) torque ~.

1r
~
~

'"m
'"
0

'"
~
~
0
,~

8·9383 ,0
~
0
0
~

::;
~

'"
::;

~
,
n
0
C.

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"=
0

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g"

~
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843 loader
-6-11- Service Manual
STARTER
A Jumper Wire
Checking the Starter

The key switch must be in the "OFF" position.

The battery must be at full charge.

The cable connections must be clean and tight.

Connect a jumper wire between "S" terminal and "BAT"

terminal ~.

If the starter turns but does not turn the engine, the starter drive
has a defect. A·1992

Connect a jumper wire between the OM" terminal and the "BAT" Jumper Wire
terminal lID.

If the starter turns, the defect is in the solenoid.

If the starter does not turn, the starter is defective.

A·1991

Removal and Installation

Disconnect the negative (-) cable at the battery.

\
Disconnect the wire at the "BAT" terminal of the solenoid ~.

Disconnect the wires at the solenoid [Q].

843 loader
-6-12- Service Manual
STARTER (Cont'd)

Remove the bolts at the starter bracket @ .

Remove the starter mounting bolts lID.

Remove the starter from the engine [9.

843 loader
-6-13- Service Manual
 1. Bolt, solenoid
2. Solenoid
3. Spring, plunger
4. Pin, plunger/shift fork
5. Plunger
6. Shift Fork
7. Bolt, shift fork pivot
8. Bolt, end cap
9. End Cap
10. Shim Washer
11.
12.
13.
Armature
Thrust Washer
Drive Assembly
(j-8-~
@
8
14. Drive Stop Ring r- - - __ _
Thrust Collar
15.
- - - --- ---
I - - - - - ___ _

16. Bushing
17. Field Coils
J
J
-- -
J
18. Brush
" CD- - ,.-...F.=>a;:==s:

~
C-1802

STARTER (Cont'd)

Disassembly and Assembly

Disassemble the starter as shown @.

A WARNING
Wear safety glasses to prevent eye injury when any of
the following conditions exist: A-1995
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285

Cleaning and Inspection

Use a brush and air pressure to clean the drive, field coils,
armature and starter housing.

NOTE: Do not use solvent to clean the drive assembly. The

solvent will remove the lubricant and the drive will slip.

A-1994

843 Loader
Revised Mar. 86 -6-14- Service Manual
STARTER (Cont'd)

Check the following items:

Armature
To check the armature for grounds, place one probe from the
ammeter on the iron core and one probe on the commutator.
The test lamp should not light Page 6-14 @.

To check for open circuit, place the armature on a growler

as shown. Place a hacksaw blade on the armature. If the
hacksaw blade vibrates while the armature rotates, the
winding is short circuited and must be replaced Page 6 -14
00·
Also check:
Broken or burned insulation
Loose connections at commutator
Worn shaft or bearings
Rough commutator

Brush Holders
Brush springs
Broken insulation
Spring tension

Field Coils
To test for a continuity, disconnect the field widing ground
connections. Tough one probe to the filed connector and one
probe to the brush. The lamp should not light @.

To test for ground, touch one probe to the body and the other
probe to the field windings end of the brush. The lamp should
not light00.
Also check:
Broken or burned insulation
Brush connections
Brushes
15
Drive Gear
Worn teeth
Tooth engagement (Drive gear must engage ring gear by 1/2
I
'"oc
the depth of ring gear teeth)

Replacing the Brushes

I
Remove the brush screw and remove the brush. Replace the
brush wire by screws or by cutting the old wire. Solder the new
brush wire to the ends of the old wire, or screw the wire in place.

Assembly: Reverse the order of disassembly.

Put a small amount of grease on the splines of the armature

and the bushings.

843 Loader
Revised Mar. 86 -6-15- Service Manual
BE PARTS
a SERVICE
5
 ENGINE SERVICE

Section
Number

ENGINE SERV ICE (Perkins Engine) .................. . 7A-1

ENGINE SERVICE (200 Series Perkins Engine) ......... . 78-1

ENGINE SERVICE (Isuzu Engine) . ... .. . . '........... . 7C-1

ENGINE
SERVICE

Perkins

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200 Series ,o
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Perkins ~
o

Isuzu

843 loader
Added June 87 Service Manual
page 275 - BOBM02n01B1c.q.)",~~ 02/10/2009 17!56:18 - Printed by Ken Cook Co, - eXprint.exe (v2.24.3 8/2:~/200S)
 ENGINE SERVICE

Page
Number
CAMSHAFT AND TAPPETS
Inspection .................................. . 7A-45
Installation .......... . .. . ...... . .. . ... . ..... . 7A-45
Removal ......... . ............... . ......... . 7A-44
CAMSHAFT GEAR
Installation ....................... . ......... . 7A-41
Removal ..................... : ............. . 7A-41
COMBUSTION CHAMBER INSERTS
Removal and Installation .......... . ............ . 7A-27
CRANKSHAFT
Checking ................................... . 7A-35
Installation ..................... . ...... . .... . 7A-36
Removal ............................. . ..... . 7A-35
CRANKSHAFT GEAR
Removal ...................... . .. . ......... . 7A-42
CYLINDER HEAD
Cylinder Head Surface Alignment ....... .. ........ . 7A-22
Installing the Cylinder Head ..................... . 7A-23
Removing the Cylinder Head .................... . 7A-22
CYLINDER LINERS
Checking ......................... . ......... . 7A-32
Removal and Installation ....................... . 7A-32
ENGINE
Removal and Installation .............. . ........ . 7A-13
ENGINE BLOWER HOUSING
Removal and Installation ..................... . . . 7A-20
ENGINE COMPRESSION
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-3
ENGINE FLYWHEEL & U-JOINT
Flywheel Ring Gear. . . . . . . . . . . . . . . . . . . . . . . . . . .. 7A - 21
Removal and Installation... . . . . . . . . . . . . . . . . . . . .. 7 A - 21 '"
g

ENG INE MUFFLER

Removal and Installation.... . . . . . . . . . . . . . . . . . . ..
ENGINE TIMING TO INJECTION PUMP
(USING DIAL INDICATOR)
7A -19
ENGINE SERVICE
(PERKINS)
I
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A - 8
ENGINE TIMING TO INJECTION PUMP
USING TIMING TOOL)
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7A-9
FUEL FILTER
Removal and Installation... . . . . . . . . . . . . . . . . . . . .. 7A - 4
Water Trap.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7A-4
FUEL INJECTOR NOZZLE
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7A-12
Removal and Installation................. . . . . . .. 7A - 11
FUEL INJECTION PUMP
Removal and Installation.. . . . . . . . . . . . . . . . . . . . . .. 7A - 7
FUEL INJECTION PUMP DRIVE GEAR
Removal and Installation ...................... . . 7A-42
Continued on Next Page
843 loader
Revised June 87 Service Manual
 ENGINE SERVICE (Cont'd)
Page
Number
FUEL LIFT PUMP
Checking . .. . . . ... .. .. ... . .... . . ... . ... .. ... . 7A-5
Removal and Installation . .. .. . .. . . . . . .. . .. ..... . 7A-5
IDLER GEAR AND HUB
Installation . .... . . . .. . . .. . .... .. . . . . . . . . . .. . . 7A-39
Removal ......... . . . .... . . . ..... . .. .. . . .... . 7A-39
LUBRICATION SYSTEM
Description . .. . .. .. ........ . ............ ... . . 7A-46
MAIN BEARINGS
Crankshaft End Play . . ..... . .... . ..... . .. . . . . . . . 7A-34
Installation . . . . .... . . . .. . .. . . . . .... . . .. . . ... . 7A-34
Removal .. . .... .. ... . .... .. .. ... ... .. ... . .. . 7A-33
OIL COOLER
Removal and Install ation . .. .. . . . . . . .. .. .... .. . . . 7A-18
OIL PUMP
Checking . .. ... . . . . . . . .. ... .. . ... . . . . . .. . . . . . 7A-47
Disassembly and Assembly ... . .. . . . ... .. .. ... .. . 7A-47
Removal and Installation . . ... .... . .... .. . . . .. . . . 7A - 47
PISTON AND CONNECTING RODS
Disassembly . ... . . . . .. ... .. . .. .... . ... ... . .. . 7A-30
Inspection . . .. . . .. .. . . ... . . . . .. .. ... . .. . .. .. . 7A-30
Installation . .... .. .. ... ... . ... ... ... .. .. .. .. . 7A-31
Removal .. . ... . ..... . . . . .. .. . . . . ... ... .. . .. . 7A-29
REAR MAIN OIL SEAL
Removal and Installation . .... . ... . ... ... ....... . 7A-37
RADIATOR
Removal and Installation .. .. .. .. . ..... . .. .... . . . 7A-17
REMOVING A IR FROM THE FUEL SYSTEM
Procedure .. ...... . . ... .. .. .. . .... .... .. .. . . . 7A-6
ROCKER ARMS
Assembly . ... . . . . . . . . . . ..... . ... .... .. . . . .. . 7A-28
Disassembly ..... . .. . . . .... . ....... .. .. .. ... . 7A-28
TIMING CASE
Removal and Installation .. . .. ... . . .. . ... . . . . .. . . 7A-43
THERMOSTAT
Installation . . . ... . ..... .. ....... ... . . . .. ... . . 7A-51
Removal . .. .... .. ... . .... . . .. . ..... . ... . ... . 7A-51
Testing the Thermostat ... . .. . ..... .... . . .. . . .. . 7A - 51
TROUBLESHOOTING
Chart .... . . . . .. ... ... .. . ..... . ....... ... .. . 7A- l
VALVES
Checking Valve Springs . . ........ . ........ . . ... . 7A-26
Installing Valve Guides ... ....... . . .. . .. . . . . .. . . . 7A-25
Installing the Valves . .. . . ... .. . ... .. . . . . .. .. . .. . 7A-24
Reconditioning the Valve & Va lve Seats .. .. ... . . . .. . 7A-24
Removal of the Valves ....... . . .. .. . . . . . . .... .. . 7A-24
VALVE CLEARANCE
Adjustment . . ... .. . .. ..... .. ........ . ... . ... . 7A-2
WATER PUMP
Assembly .. . .. . .... . . ... . ..... . ......... . .. . 7A-50
Checking ... . ... . . .. . . ... .. ... . ..... . ...... . . 7A-50
Disassembly .... .. . . . . . . . .. ... . ...... .. . . . . . . 7A-49
Removal and Installation . ........ . .......... . .. . 7A-49
843 Loader
Service Manual
7A ENGINE SERVICE - PERKINS (4.154)
TROU BLESHOOTING

The following troubleshooting chart is provided as an assistance in locating and

correcting prob lems which are most common . Many of the recommended procedures
must be done by authorized Bobcat Service Personnel only.

PROBLEM CAUSE

Slow cranking speed. 1, 2, 3, 4

Engine will not start.
Difficult to start .
No power from engine.
Engine is mis-firing.
Too much fuel consumption.
Black exhaust.
Blue/white exhaust.
Low oil pressure.
Engine knocking.
Engine running rough .
Vibration .
High oil pressure.
Overheating.
Too much crankcase pressure.
Poor compression.
Start and stop.
2, 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 30, 31, 32
5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21 , 22, 23, 28, 30, 31, 32
8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 23, 24, 25, 26, 30, 31, 32
8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 24, 25, 27, 28, 29, 31
11, 13, 14, 18, 19, 20, 22, 23, 24, 26, 27, 28, 30, 31 , 32
11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32
4, 11, 18, 19, 20, 24, 26, 30, 32, 33, 53
4, 34, 35, 36, 37, 38, 40, 42, 55
9, 14, 16, 18, 19, 22, 25, 27, 28, 30, 32, 34, 43, 44, 56
7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 25, 27, 28, 29, 32, 43, 56
13, 14, 20, 24, 25, 28, 29, 32, 43, 45, 46
4, 36, 39
11, 13, 14, 16, 18, 19, 23, 24, 43, 47, 48, 49, 50, 54
25, 30, 32, 33, 43, 52
11, 19, 24, 27, 28, 30, 31, 32, 33, 44, 56
10, 11, 12

KEY TO CORRECT THE CAUSE

1. Battery capacity low. 29. Incorrect high pressure fuel pipes.

2. Bad electrical connections. 30. Worn cylinder bores.
3. Faulty starter motor. 31. Worn valves and seats.
4. Incorrect grade of oil. 32. Broken, worn or sticking piston rings.
5. Low cranking speed. 33. Worn valve stems or guides.
6. Fuel tank empty. 34. Worn or damaged bearings.
7. Faulty stop control operation. 35. Not enough oil in the oil pan.
8. Plugged fuel line. 36. Switch is defective.
9. Faulty fuel lift pump. 37. Oil pump worn.
10. Plugged fuel filter. 38. Pressure relief valve is sticking open.
11. Restriction in the air cleaner. 39. Pressure relief valve is sticking closed.
12. Air in fuel system. 40. Broken relief valve spring.
13. Faulty fuel injection pump. 41. Faulty suction pipe.
14. Faulty fuel injectors. 42. Plugged oil filter.
15. Incorrect use of ether start unit. 43. Piston seizure.
16. Faulty ether start unit. 44. Incorrect piston height.
17. Broken fuel injection pump drive. 45. Faulty engine mounting.
18. Incorrect fuel injection pump timing. 46. Incorrect alignment of flywheel.
19. Incorrect valve timing. 47. Faulty thermostat.
20. Poor compression. 48. Restriction in the water jacket.
21. Plugged fuel tank vent. 49. Loose alternator belt.
22. Incorrect type or grade of fuel. 50. Plugged radiator.
23. Exhaust pipe restriction. 51. Faulty water pump.
24. Cylinder head gasket leaking. 52. Plugged breather pipe.
25. Overheating. 53. Damaged valve stem oil deflectors.
26. Cold running. 54. Coolant level to low.
27. Incorrect tappet adjustment. 55. Plugged oil pump pipe strainer.
28. Sticking valves. 56. Broken valve spring.

843 Loader
-7A-1- Service Manual
VALVE CLEARANCE

Adjustment

Make the valve clearan ce adjustment with engine stopped and

cold.

Put the correct size feeler gauge between the rocker arm and
the valve stem and t urn the adjustment bol t until the clearance
is correct @ .

The correct clearance is 0.012" (0,30 mm) with the engine cold
fBl. B
Use the following sequence to set the val ves:

a. With the roc ker arm rocking on No. 4, set clearance at

No. 1 valves.

b. With the rocke r arm rocking on No.2, set clearance at

No. 3 valves.

c. With the rocker arm rocking on No. 1, set clearance at

No. 4 valves.

d. With the rocker arm rocking on No. 3, set the clearance 8·4123
at No. 2 valves.

843 Loader
-7A-2- Service Manual
ENGINE COMPRESSION

Checking

The tools listed will be needed to do the following procedure:

MEl-l0630 - Engine Compression Kit

The engine must be at operating temperature.

Remove the fuel injectors (See Page 7A-l11 ~ .

Install the correct compression adapter into the engine.

Connect the compress ion gauge lID.

The engine must be turning at about 300 RPM.

The compression must be between 300 - 500 PSI (2069 - 3448

kPa) with no more than 50 PSI (345 kPa) difference between
cylinders.

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843 loader
-7A-3- Service Manual
 FUEL FILTER

Removal and Installation

See the Service Schedule (Page 1- 1) for the correct sequence

when to replace the fuel filter.

Clean the area around the fuel filter.

Remove the bolt at the top of the fuel filter housing (Item 1) iKJ.
Remove the fuel filter element (Item 2) iKJ.
Lubricate the O-rings before installation.

Remove the air from the fuel system (See Page 7A-6).

Water Trap

The water trap is located between the fuel tank and the fuel
lift pump. See the Service Schedule (Page 1-1) for the correct
sequence when to service the water trap.

To clean the water trap:

Loosen the thumb screw (item 1) at the bottom of the filter

housing and drain the water from the filter [ID. Tighten the
thumb screw when all the water is removed.

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8"

843 Loader
-7A-4- Service Manual
FUEL LIFT PUMP

Checking

Install a gauge to the outlet side of the lift pump. Turn the engine
for 10 seconds.

STANDARD PRESSURE - 6 PSI (41 kPa)

MINIMUM PRESSURE ACCEPTED - 3.75 PSI (26 kPa)

Removal and Installation

Turn the fuel valve at the fuel tank to the "OFF" position.

Disconnect the inlet and outlet tubelines from the lift pump.

Remove the two nuts and washers that hold the lift pump to
the engine block.

Remove the lift pump from the engine block ~.

NOTE: Make sure to "Open" the fuel shut-off valve at the fuel
tank after installation is completed.

843 Loader
-7A-5- Service Manual
REMOVING AIR FROM FUEL SYSTEM

Procedure

Loosen the bolt (Item 1) at the top of the fue l fi lter ~.

Loosen the plug at the top (Item 1) and the side (Item 2) of the
fuel injection pump rID .

Operate the fue l lift pump lever pushing fuel and air through
the vent plugs ~ .

NOTE: If the lift pump will not pump fuel, rotate the engine
crankshaft a small amount.

When all the air is removed from the fuel system. close the vents
in the following order:

a. Final Fuel Filter (Item 1) ~ .

b. Injection Pump side plug (Item 2) [ID.

c. Injection Pump top plug (Item 1) [ID.

Loosen all the fittings at the fuel injectors high pressure lines
[Q) .

Move the throttle to half open position. Turn the engine with
the starter until fuel shows at the fitt ings. Tighten the fittings
to 15 ft.-Ibs. (20 Nm) torque.

843 Loader
-7A-6- Service Manual
FUEL INJECTION PUMP

The injection pump contains parts which have a very close

tolerance and its operation has a direct effect on the
performance of the engine.

IMPORTANT
If you do not have the correct equipment and trained
personnel, adjustment or maintenance must not be
done.
1-2028-0284

Removal and Installation

Disconnect the throttle control linkage (Item 1) at the pump @.

Disconnect the linkage (Item 2) from the electrical fuel shut-

off solenoid @.

IMPORTANT
Do not bend the tubelines when removing or installing
them on the injector pump or on the injectors.
1-2029-0284

.Disconnect the high pressure fuel lines at the fuel injection pump
and injectors. Remove all the high pressure tubelines.

Installation: Tighten the fittings to 15 ft.-Ibs. (20 Nm) torque.

Disconnect the low pressure lines at the fuel filter and injection
pump.
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Remove the cover at the timing cover lID .
Remove the three bolts at the gear for the injection pump.

Remove the nuts and washers from pump mounting flange.

Remove the injection pump.

Installation: Make sure the injection pump shaft is in correct

alignment with the dowel pin (Item 1) ~. A lign the timing marks
on the outside of the mounting flange, tighten the nuts [Q] .

843 Loader
-7A- 7- Service Manual
 ENGINE TIMING TO INJECTION PUMP
(USING DIAL INDICATOR)

Procedure

To see the timing mark on the inside of the injection pump, you
will have to break the manufacture's seal on the inspection
cover.

Remove the valve cover. Rotate the crankshaft until No. 1 piston
is at TDC, compression stroke (both rocker arms of No. 4
cylinder are moving).

Loosen the adjustment bolt of the No. 1 cylinder exhaust rocker

arm. Move the rocker arm to the side. Remove the push rod.
Remove the exhaust valve spring lAJ.

Put the head of the exhaust on top of the piston crown. Install
a dial indicator at the valve stem rID.

Rotate the crankshaft backward and forward a small amount

to find TOC and zero the dial indicator.

Turn the crankshaft in the opposite direction of normal rotation

until the dial indicator show the piston movement of 0.150" (3,8
mm) down.

NOTE: This is equal to 18° angle movement of the front pulley

BTDC and is the static timing point.

The"C" line on the rotor of the fuel injection pump must be in

alignment with the edge of the snap ring [g.

NOTE: DO NOT move the snap ring in the pump. It is put in

this position by the manufacturer.

N If the timing is not correct, do the following:

N
.::
a. Loosen the nuts at the mounting flange.

b. Turn the pump to align the timing marks [g.

c. Remove the old timing mark at the mounting flange and

make a new timing mark.

Repeat the above steps to make sure the timing is correct.

NOTE: Make sure to adjust the exhaust valve clearance before

installation of the valve cover.

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843 Loader
-7A-8- Service Manual
ENGINE TIMING TO INJECTION PUMP
(USING TIMING TOOL)

Procedure

The tool listed will be needed to do the following procedure:

MEL-l056 - liming Tool

Remove the valve cover. Turn the engine crankshaft until No.
1 cylinder is at TOC, compression stroke (both rocker arms are
moving at No.4 cylinder).

Align the TOC bolt with the mark in the front pulley ~.

Remove the fuel injection pump (See Page 7A-7).

Loosen the screw (Item 1) on the timing tool 00. Set the correct
angle at the gauge according to the Injection Pump Code in the
chart as listed.

ENGINE AND INJECTION PUMP TIMING MARKS

Injection Pump Eng. Checking Injection Pump Degrees

Code Angle Marking Angle BTDC

AJ46E 286-1/2 298 18

AJ47 286-1/2 298 18
LJ42 281 290 18 6·8069
LJ44E 281 290 18
LJ47 281 290 18
LJ51 281 290 18

Install the adapter into the gear [£]. Make sure the dowel pin
is in correct alignment. Install the three bolts and tighten.

Move the plate (with V-notch) over the mounting flange [QJ. Turn
the timing tool in opposite direction of engine rotation to remove
gear play.
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The engine flange timing mark must be in alignment with the o

V-notch of the timing tool plate. o

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NOTE: If the marks are 180 0 apart. the No. 1 cylinder is not
at TOC.

If the mark is not correct, remove the old timing mark. Make
a new timing mark on the mounting flange.

IMPORTANT
Make sure to turn the TOC bolt out of the front pulley
after the timing procedure is done.

843 Loader
-7A-9- Service Manual
CHECKING TIMING MARK ON INJECTION PUMP FLANGE

Procedure

Loosen the screw {Item 1} and install the shaft (Item 2) into the
t iming tool @.

Loosen the screw (Item 3) and turn the plate in the opposite
direction @.

Loosen the screw (Item 4) and set the gauge to the correct angle
according to Injection Pump Code as listed in the chart (See
Page 7A-9) .

Locate and mark the No. 1 port at the injection pump. Install
the timing tool on the injection pump.

Connect a test pump to the No. 1 port [ID.

Operate the test pump until the pressure is at 440 PSI (3033
kPa) maximum .

Turn the tool in t he normal rotation of the pump. When the pump
reaches the No.1 port there will be resistances or w ill not t urn.

- 8 · 7842

Move the plate over the mounting flange [£J .

NOTE: The mark on the mounting flange is put on at the
factory. The mark will almost always be correct. If it
is not, you must remove the old mark and make a new
mark.

843 Loader
-7A-10- Service Manual
FUEL INJECTOR NOZZLES

.A WARNING
Diesel fuel or hydraUlic fluid under pressure can
penetrate skin or eyes causing serious injury. Fluid leaks
under pressure may not be visible. Use a piece of
cardboard or wood to find leaks. Do not use bare hand.
Wear safety goggles. If fluid enters skin or eyes, get
immediate medical attention.
W·2074·1285

Some problems caused by faulty injector nozzles:

The engine is hard to start or will not start.

Rough engine operation and idle. The engine will not have full
power. The engine exhaust smoke is black, white or blue.

Removal and Installation

Remove the high pressure fuel lines (Item 1) ~.

IMPORTANT
Do not bend the tubelines when removing or installing
them on the injector pump or on the injectors .
•·2029·0284

Remove the fuel return line (Item 2J ~.

Remove the nuts from the mounting flange (Item 3) ~. o

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Installation: Tighten the nuts to 12 ft.lbs. (16 Nm) torque lID.

Remove the fuel injector nozzle from the cylinder head.

Installation: Always replace the copper washer (Item 1) with a

new copper washer when installing the fuel injector nozzle ~ .

843 Loader
-7A-11- Service Manual
FUEL INJECTOR NOZZLES (Cont'd)

Checking

IMPORTANT
Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing tools.
1-2027·0284

A-2513

The tools listed will be needed to do the following procedure:

MEL·1001S - Injector Nozzle Tester

MEL-10019 - Accessory Set

Connect the nozzle to a test pump, in a down position @.

Operate the test pump until the nozzle valve opens:

SETTING PRESSURE - 2205 PSI (15203 kPa)

WORKING PRESSURE - 1985 PSI (13687 kPa)

If the pressure is not correct, replace or clean the nozzle.

Check for inside leakage: A-2621

Operate the test pump to almost opening pressure. Record

pressure and check pressure decrease for six seconds. The
nozzle has a defect if the pressure deceases more than 740 PS I
(5163 kPa).

A WARNING
Do not test fuel injector nozzles unless you have correct
service and testing tools. Keep away from fuel coming
from the nozzles. Wear safety goggles. Fuel under
pressure can penetrate skin or eyes and cause serious
injury. If fuel enters skin or eyes, get immediate medical
attention.
W-2075·1285

Checking nozzle spray pattern 00:

Does not come out the side of nozzle.
Does not have drops coming from nozzle.
Does not have a solid stream coming from the nozzle.

Any of the above conditions show a defect or dirty injector

nozzle. Clean or replace any nozzle that does not operate
correctly.

843 Loader
-7A-12- Service Manual
ENGINE

Removal and Installation

Lift and block the loader (See Page 1- 2 for the correct
procedure ).

Raise the operator cab (See Page 1- 7 for the correct

procedure) .

Remove the batteries (See Page 6 - 2 for the correct procedure).

Disconnect all the wires at the two solenoids.

Disconnect the engine wire harness IA].

Disconnect the ground wire at the left side of the engine.

Remove the air cleaner hose at the intake manifold.

Remove the bolts and nuts at the air cleaner clamps rID .

8·4289

Remove the air cleaner assembly from the engine compartment

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a
~

Disconnect the throttle linkage at the throttle lever [QJ . 0"

:;;'"

'"
~.
"-
0'

"
'"
~

,.,"
0
0

n'"
0

0
x
~

8·4378

843 Loader
-7A-13- Service Manual
ENGINE (Cont'd)

Disconnect the throttle linkage at the injection pump ~.

Remove the bolt and nut at the cross lever lID.

Remove the throttle linkage assembly.

Remove the rear grill.

Remove the radiator cap.

Open the coolant drain on the engine block (above the starter)
@. Put a hose over the end of the coolant drain and drain into
a container.

Remove the both radiator hoses tru.

843 loader
-7A-14- Service Manual
ENGINE (Cont'd)
FueITank~~~~~~~
Turn the fuel shut-off valve to the "OFF" position at the fue l
tank ~ .

Disconnect the fuel line at the water trap filter.

Disconnect the fuel return hose at the fuel injector nozzles.

6·4304

Remove the exhaust pipe at the muffler [ID.

Remove the exhaust pipe at the exhaust manifold ~ .

;;
'Ii
~

'"
~

g
~
~
0
,
~

6·4314 ,
0
~
0
0

'"
:;
Remove the rear engine mounting bolts, washers and nuts (both ~
~

sides) ~. :;;
~

I
installation: Add liquid adhesive (LOCTITE) to the bolt threads
and tighten to 125 - 140 ft.-Ibs. {169 - 190 Nml torque.
.
~
"
"
0-
0'
"<

g
<"l

~
<"l
0

.
"
~

6·4319

843 Loader
-7A-15- Service Manual
 ENGINE (Cont'd)

Remove the front engine mount bolts, washers and nuts (both
sides) ~.

I
installation: Add liquid adhesive (LOCTITE) to the bolt threads
and tighten to 125-140 ft.-Ibs. (169-190 Nm) torque.

Lift the rear of the engine over the edge of the loader frame
with pry bars.

B·4316

Slide the engine out of the loader [!].

Installation: Move the engine into the loader until the universal
joint is in the blower housing. Have a second person reach
behind the blower housing (at the hydrostatic pump) and guide
the universal joint on the splines of the hydrostatic pump shaft,
while the engine is moved toward the front of the loader.

ro
o
o
,
N
~.
N

"m
~

o
o
N

o
,
N
o

o
0 '

~'
ill
g 843 Loader
-7A-16- Service Manual
Revised Feb. 94
RADIATOR

Removal and Installation

Remove the rear grill.

Remove the bolts at the cover on the blower housing. Remove

the cover from the blower housing @ .

Remove the radiator cap.

Open the coolant drain on the engine block (above the starter)
00. Put a hose over the end of the coolant drain and drain into
a container.

Remove the oil cooler (See Page 7A-18).

Disconnect the radiator hoses (both sides) [£] .

Remove the bolts at the bottom of the radiator.

Lift the radiator up and over the muffler shield ~.

Remove the radiator from the loader.

843 loader
-7A-17- Service Manual
OIL COOLER

Removal and Installation

Remove the engine from the loader (See Page 7A-13).

Disconnect the tubelines from the oil cooler (both sides) IKI.

8-4537

Remove the four bolts at the side brackets of the oil cooler lID.

8-4536

Drop the oil cooler down and pull it towards you to remove it
from the loader [£].

~ 8-4538

843 loader
-7A-18- Service Manual
ENGINE MUFFLER

Removal and Installation

Remove the rear grill.

Remove the bottom cover at the blower housing.

Disconnect the exhaust pipe at the muffler IA] .

Remove the bolts at the heat shield.

Remove the heat shield [ID.

Remove the bolts at the bottom of the muffler.

Remove the muffler from the loader @.

843 loader
-7A- 19- Service Manual
ENGINE BLOWER HOUSING

Removal and Installation

Remove the engine from the loader (See Page 7A-13l.

Remove the cover at the blower housing.

Remove the bolts along the top edge of the blower housing ~.

q
I Ii 8-4344

Remove the bolt at the bottom of the blower housing [@].

NOTE: If a rivet is used to hold the blower housing. use a punch

and hammer to remove the rivet.

Remove the blower housing from the loader 1£].

843 loader
-7A-20- Service Manual
ENGINE FLYWHEEL & U-JOINT

Removal and Installation

Remove the four bolts at the u-joint mounting flange IAJ.

Installation: Tighten the bolts to 25-28 ft.-Ibs. (34-38 Nm)
torque.

Remove the u-joint from the flywheel [!I.

Remove the bolts from the flywheel [g.

Installation: Tighten the bolts to 83-90 ft.-Ibs. (113-122 Nm)

torque.

Remove the washer 1m.

Remove the flywheel from the crankshaft flange.

Flywheel Ring Gear

The ring gear on the flywheel is an interference fit. Heat the

ring gear enough to expand it and hit it with a hammer, evenly,
to remove it.

Clean the outer surface of the flywheel to give a smooth fit.

Clean the new ring gear and heat it to a temperature of

450-500°F. (232-260 o C.I.

Fit the ring gear over the flywheel. Make sure the gear is on
its seat correctly.

843 Loader
-7A-21- Service Manual
CYLINDER HEAD

Removing the Cylinder Head

Clean all the debris from the engine and cylinder head. Maximum Grinding
Allowance
Remove the coolant from the engine and radiator. Remove the 0.012" (0,305 mm)
radiator hoses.
~bt-ri..t?ii~:~·:dt:i8 ~......~~ ~ 0ij
I --·..r·..···
Remove the fuel injectors and fuel tubelines (See Page 7A-l1). 0 .003" 0 .006" 0.006"
(0,08 mml (0,15 mm) (0,15 mml
Remove the fuel filter and bracket.

Remove the valve cover.

PI·2633
Remove the nuts from the support brackets of the rocker arms.

Remove the rocker arms. Remove the push rods.

Loosen and remove the cylinder head bolts.

NOTE: When removing the head, do not use a sharp tool

between the head and engine block. Always put the
cylinder head on a flat surface such as wood to prevent
damage to the machined surface.

Remove the head from the engine block.

See page 7A-24 for removing and reconditioning the valves.

Cylinder Head Surface Alignment

Check the surface of the head with a straight edge ~ .

A maximum of 0.012" (0,305 mm) can be removed from the

surface. After milling the head, install a fuel injector nozzle. The
nozzle must not extend more than 0.175" (4,4 mm) beyond the
surface. Replace the cylinder head if this dimension is over the
limit.

IMPORTANT
DO NOT add washers under injector nozzles to bring
them back into specifications.

843 loader
-7A-22- Service Manual
CYLINDER HEAD {Cont'd!

Installing the Cylinder Head

Install a new head gasket. Install it dry, no gasket cement is

needed.

When the new head gasket is installed, make sure it is

positioned correctly over the dowel pins and the markings
"TOP" and "FRONT" are located correctly ~ .

Put oil on the threads of the head bolts. Install the head bolts.

8·3207

Tighten the bolts in the correct sequence lID. Do this in a three

step procedure to 85 ft.-Ibs. (115 Nml torque.

Example: First tighten all bolts to 30 ft.-Ibs. (41 Nml torque, then
65 ft.-Ibs. {88 Nml torque and then the final torque.

To reduce the risk of early cylinder head gasket failure, after a

cylinder head has been fitted, the loader is to be operated under
a partially load for about a half an hour. Then re-torque the bolts
again. It is not a good practice to just run the engine without
a load to bring it to operating temperature.

Install the push rods. Install the rocker arms and support
brackets. All Bolts and Nuts
85 ft.-/bs. (115 Nm! torque
A-2646
Adjust the valve clearance (See Page 7A-21.

Install the valve cover.

Install the fuel injector nozzles and fuel tubelines.

Install the fuel filter and bracket.

o
Install radiator hoses. o

Add coolant to the engine and radiator.

843 loader
-7A-23- Service Manual
VALVES

Removal of the Valves

Mark the valves so they are put in the original position on

assembly ~.

Use a valve spring compressor and remove the valve spring locks
00·

Remove the valve spring and valve from the head ~.

Repeat this procedure for each valve.

Installing the Valves

Make sure the cylinder head is clean.

Put oil on the valve guides and valve stems.

Exhaust Spring Outer Spring Locks
J

~" T< >"·l

Put each valve in its correct location. Cup

\41 G15lI~
~t · ,
Assemble the valve springs and cups ~.
••A.

The intake valve is fitted with a rubber seal. VJ

Use a valve spring compressor and install the valve springs and
valve stem locks. ~. t'" Ifj},\~
\lli}'!.
{; Si~\11
r,s

Tap the valve stem with a hammer a small amount to seat the Intake Inner Seal Locks
valve stem lock. Valve Spring Spring
8·3355

Reconditioning the Valves and Valve Seats

Use the correct equipment to grind the valves and valve seats.

The angle of the intake and exhaust valves is 45°.

Check the valve head depth in the cylinder head after grinding
~. The correct specifications are as follows:

INTAKE - 0.029-0.045" (0,74-1,04 mm)

EXHAUST - 0.027-0.040" (0,69-1,02 mm)

843 Loader
-7A-24- Service Manual
VALVES (Cont'd)

Installing Valve Guides

Check the valve guides for wear with a dial indicator [AJ. If the
movement is more than the listed specification, replace the
guide:

INTAKE & EXHAUST - 0.024" (D,6 mm)

NOTE: Make sure to check the valve stem for wear before
replacing the valve guide [ID .
0.501/0.5018 in.

''',.~ -~;'" ,m!:';l ';.;,; 4.50314.521 in.

H14.381114.83 mml

IS!' ;~:;:"'I[U · 0.000251-000175.n.

m
U
'I
EXH. & IN. 0 .001510.0035 1n.
10.0410.09 mml

J L/o.04m l

~
l 0_63810.662.n.
116.2116.8 mml

0 .500/0 501 In
112.7112.73mml PI-2372

Remove the guide with a hydraulic press or hand operated tool

~.

Put oil in the bore and press in the new guide @.

NOTE: Once the guide is started into the bore, do not stop.

Press the guide into the head until 0.638 - 0.662" (16,2 - 16,8
mm) is above the cylinder head.

843 Loader
-7A-25- Service Manual
 VALVES (Cont'd)

Checking the Valve Springs 28 Ibs. ± '.5 Ibs.

1.74 in. (12,7 kg, ± 0,65 kg)
The valve springs for the intake and exhaust valves are the same. (44,19 mm) ~ ._'·l

Y1
Check the spring ends for damage and check the specifications
~.
~:;"':;<;11
_ _ J,
"

fc;·i.·1
....._ .. L...._c
'- --.J
1.49 in. VALVE SPRING INNER 401bs. ± 2.0 Ibs.
(37,84mm) (4k~~~~) (18, 1 kg ± 0,91 kg)

...L....i~-
~l ~.i.-,
L.:....--.J
VALVE SPRING OUTER
1 .59 in,
(40,38 mm) PI·2371

;:;
~
o
o
N
"-
o
N
o

843 Loader
-7A-26- Service Manual
COMBUSTION CHAMBER INSERTS

Removal and Installation

Remove the inserts, using a punch through the injector nozzle

bore and hit the punch with a hammer ~ .

Position the new insert by putting expansion washer in the

correct position !ID.

Make sure to check the height of the insert to the cylinder head
as shown 19 . 1.37211 .374 in.
(34.86/34,90 mm)

0.425/0.4281 "",,
110.79/10.87 """'I-f-~ '"
0

I
0.001 In.
(0.03 mm)

~' 0
N
~

PI-2376 0
N
0
0
~

::;
Use a hammer and punch to set the expansion washer in
position to hold the insert in the cylinder head ~.
.'"
~
~

"~.
0-
c-
o<

'"
0

"n
0
0

'"g
.
><
~

843 Loader
-7A-27- Service Manual
 ROCKER ARMS

Disassembly

Mark the rocker arms and support bracket for correct assembly.

Remove the snap rings (Item 11 form each end of the shaft (Item
21@.

Remove the rocker arm (Item 3). bracket (Item 4) and spring
(Item 5) !AI.

Inspect the rocker arm bushings for wear [!].

Replace the parts as needed.

I
8 .51 02/ 8.5412 in.
1216.16' 216.94 mml
0 .247/0 .25 in.
16,2716.35 mm)

PI·2595

Assembly
Align Oil Feed Holes
When installing a new bushing in the rocker arms, make sure
the oil holes are in alignment I£l.

Reverse the order of disassembly and make sure that each set
of rocker arm pair has the correct off-set.

Put oil on all the parts for protection .

..
x

A-2352

843 loader
-7A-28- Service Manual
PISTON AND CONNECTING RODS

Removal

Remove the cylinder head (See Page 7A-22l.

Remove the oil pan and oil pump (See Page 7A-47l.

Remove the ridge and carbon deposits at the top of the cylinder
bore with a ridge reamer.

Make sure the pistons have identification marks ~.

8·3248

Rotate the crankshaft until a pair of connecting rods are at

bottom dead center. Make sure the cab and rod have
identification marks lID.

Remove the nuts and remove the bearing cap (£].

NOTE: If the bearings are to be used again, they must be

identified so they are returned to their original location.

!
Using a hammer handle, push the piston and rod assembly out
of the block [Q).

After the pair has been removed, rotate the engine crankshaft
and remove the other pair of pistons.

....1 . . . . .
\ / '

8·3317

843 Loader
-7A-29- Service Manual
PISTON AND CONNECTING RODS (Cont'd)
A
Disassembly 0.002.'0.004 '"
I(I,06JO.10-m

Remove the rings from the pistons.

Remove the piston pin. O_OOUr.:l,0G4'" 10.01><0,10_

O.~:J;O,~ll",a.J.'2.l._

NOTE: If the piston pin does not come out easily, do not drive O.ot3JO.'»' I.., a.loGi2.»:..-I
it out. Warm the piston in oil to a temperature of O.OCl2,"Q_~ .... O,OOl2.-o.I)(I4''''{Q.OM1.'O~

~-' ,~;~:~';:~:',,;;;,
O.1"5-'Ol!)O~",l-C.":"'<l_

120 0 F. (50 0 C.l and push the pin out. '----'+--' Q,1&6.L'O.18J5;".(4.7.u.1.'1,_

LW-'''''~''''''''''''''''''''
o 18U.IO.1U$ ....
' •. )""'.7~-'

Inspection
PI-2393R
Clean all the parts in clean solvent.

Check the clearance of the new rings in the piston grooves ~.

Check the ring gap in the cylinder bore lID.

8-3334

Make sure the specifications are correct ~.

0.01410.019 in. ~~gg;g:~g3,;~~'

{0.aS/OA8 mml J1

~
V--1--:-~-"""-- 0.01110.016 in.
-= I (0.28/0.41 mml
______ .----i

PI-2394R

Check the piston and pin bushing ~.

Replace the bushings with a hydraulic press. Remove all metal

burrs from the piston bore before installing the new bushings. , .3785/1.380 in.
-0.000541" 0.00115 in.
(36.01135.05 nwnl (-0.011+ 0.04 mml
0.00074!0.0059 in.
Use the correct size reamer to fit the new bushing to the piston 1.375/1.37600. (0.018710.1280 mmI

~>."
~3"7413"75~":
134.,92/34,95 mml
pin.
1.2495Jl .250 tn,
f31.74f31.15 rnml

•. _,

1.2SOS{l.2S1S in.
t31.76/31,19 mml
1.047/1.05510.
(26.59/26.80 mrn)

PI-2396R

843 loader
-7A-30- Service Manual
PISTON AND CONNECTING RODS (Cont'd) 5 in.
(127 mm)
Check the connecting rod alignment ~.

Installation

Install the piston pin by putting the piston in clean oil at a

temperature of 120 0 F. (50 0 C.). ±O.01 in. ±O.01 in.
(±O,254 mmJ (±O,254 mm)
Make sure the identification marks are located correctly at the
rod and piston.

Install new snap ring on each side of the piston pin.

PI-2375

Install the piston rings using a expanding tool to prevent the

ring from breaking lID .

Put oil on the rings so they move freely in the piston grooves.

Position the ring gaps un-evenly around the piston.

NOTE: Before the pistons are installed, check the cylinder

bores.

Rotate the crankshaft until a pair of crank pins are at bottom

dead center.

Using a ring compression tool, compress the rings on the piston.

Make sure the "F" is to the front of the engine block and install
the piston into the block lID.

Put oil on the bearings. Install the bearing cap ~.

I
§
o
o

o
~

,o
N
o
o
~

Tighten the nuts on the connecting rod ~.

Rotate the crankshaft to put the other pair of crank pins at

bottom dead center_ Repeat the procedure and install the other
pair of pistons.

45 ft.-Ibs.
(61 NmJ
8-3325

843 loader
-7A-31- Service Manual
CYLINDER LINERS

Checking

The cylinder liners are made of cast alloy iron. They are an
interference fit in the engine block and are of the dry type.

Boring of these liners to a larger size is not possible. New liners

must be installed when the cylinder bores are worn over
specifications.

Check the cylinder bore with an inside micrometer. Check the

bores in three positions (top, center and bottom). The checks
must be made at parallel and right angles to the center line of
the bore, giving six dimensions for each bore. 8·3249
I
The standard bore of the cylinder liner is 3.501 - 3.502" (88,92
- 88,95 mml. When the bore dimension is 0.006" (0,15 mm)
over standard dimensions the liner must be replaced.

Removal and Installation

Remove all the parts from the engine. Press the cylinder liners
out through the top of the engine block.
Clean the bore and remove any metal burrs in the block.

Put lubricant on the outside of the liner. Push the liner into the
block.

Check the liner height in four positions for the correct height
[ru.

Follow the same procedure for the other cylinder liners.

Hone the cylinder bore to standard dimensions 00.

3.$'213."611<.
(100.Oil01 ftOIft)

:1.I"25/3.&135&.,
IS6,a4~.a41WN

G.OUrO.031 ....
IO,_6IO.71mrn1

I
3.501(3.'S(Il;in. I
lae.321se.9sm,"l
i
0.0001'0.004 in.
IO.Ooro.10IN'llJ

PI·2373

843 loader
-7A-32- Service Manual
MAIN BEARINGS
No. 2 Center
The crankshaft has five main bearings. The end play is controlled Rear Main
by a thrust washer on both sides of the center main bearing. No. 5

Each main bearing cap has an identification mark in relation to

the engine block ~.

The position of each cap can not be changed from the original
location.

Removal

Remove the oil pan. Remove the oil pump (See Page 7A-47l .

Remove the bolts from the main bearing caps.

Remove the main bearing cap and remove the bearing from the
cap half.

Remove the top half of the bearing by pushing on one side of

the bearing and rotating the crankshaft lID.

On the center main bearing, remove the cap and thrust washers
from each side of the cap [£j.

I
Remove the top half of the bearing and thrust washer by pushing
on one side of the bearing and rotating the crankshaft [QJ.

8·3289

843 Loader
-7A-33- Service Manual
 MAIN BEARINGS (Cont'dl

Installation

Check the crankshaft journals before installing the main bearings

o
('
(See Page 7A-351.

Lubricate the new bearings. Install them by putting the end

without the tab into the block and rotating the crankshaft until
the tab is on its seat.
o
Install the other bearing half in the main bearing cap. Lubricate
the bearing and install it on the engine block. 85 ft.-Ibs
(115 Nml
Install the bolts and tighten to position the cap, then loosen 8·3345
them.

Install the center main bearing and thrust washers.

Repeat the procedure until all the main bearings are installed.

Then tighten the bolts to the correct torque @.

Crankshaft End Play

The end play can be checked by either a feeler gauge [IDor a

dial indicator [£J.

The maximum end play is 0.014" (0,35 mm). The fitting of

oversize thrust washers can be used to correct the end play if
its over the specifications.

843 Loader
-7A-34- Service Manual
CRANKSHAFT

Removal

Remove the oil pan. Remove the oil pump (See Page 7A-471.

Remove the crankshaft pulley, timing case cover, timing gears

and timing case (See Page 7A-381.

Remove the flywheel (See Page 7A-211.

Remove the rear main seal (See Page 7A-371.

Remove the connecting rod caps (See Page 7A-30).

Remove the bolts and main bearing caps (See Page 7A-31.

Lift the crankshaft out of the engine block for inspection.

Checking

Using a micrometer, check the crankshaft for correct

dimensions ~.

1.391/1.421 in. 1.391/1.412 in.

135.4/36.1 mm) 135.4/36.1 mml

0.003/0.015 in.
IO.OS/0.3S
, mml
1'1
1
ji
..;;

STO
0.0896/0.0915 in.
12.2612.32 mm}

OVERSIZE
6". •
. - - - - - - - , 0.050/0.0S0 in.
<1.2712.03 mml

o.S75 in. f
122.22 mml ;
o
~

0.096610.0985 in.
"
c
(2.4512.50 mm) ' -_ _ _ _ _ _--:y o

2.211/2.212 in.
156.16/56.1 S mm} 1.2495/1.251 in.
1/8/9/64 in.
'-----'--+-'
0.5 in. (31.74/31.77 mml
0.0822 in.
3.9985/3.9995 in.
(101.56/101.59 mml
0.0822 in.
12.09mm}L
2.7515/2.753 in.
(69.S9/69.93 mml

2.7845/2.749 in.
169.81/69.82 mml

9/64 1 5132 in.

1.3725/1.3741 in. 13.5713.7 mm)
2.7845/2.749 in. 134.86/34.9 mml
169.81/69.82 mm)
PI·2370R

843 Loader
-7A-35- Service Manual
 CRANKSHAFT (Cont'd)

NOTE: You can grind the crankshaft to 0.010" (0,25 mm).

0.020" (0,51 mm) and 0.030" (0,76 mm) undersize.
See Page 8A-10 for the correct specifications.

Installation

Clean the crankshaft and check that all the oil passages are
clean and open.

Clean the engine block, lubricate and install the upper halves
of the main bearings.

NOTE: If you do not install new bearings, always return the

old bearings back to their original position.

Put the crankshaft, carefully in position.

Install the main bearing caps {See Page 7A-33}.

NOTE: Make sure the lower thrust washer is in its correct

location.

Check the crankshaft so that it rotates freely. Check the

crankshaft end play (See Page 7A-34).

Install the rear oil seal (See Page 7A-371.

Lubricate the connecting rod bearings. Install the bearings and

connecting rod caps (See Page 7A-30).

Install the oil pump.

Install the oil pan.

Install the timing case, timing gears, timing case cover and
crankshaft pulley (See Page 7A-38).

Install the flywheel (See Page 7A-211.

~
c
"N
"
N

"

843 Loader
-7A-36- Service Manual
REAR MAIN OIL SEAL

Removal and Installation

Put the housing (Item 1) in a vise and install the seal (Item 2)
into the groove @ .

Using a round bar and roll and press the seal into position. Cut
the seal ends off 0.010 - 0.020" (0,25 - 0,51 mm) above the
housing.

Repeat this procedure for the other half of the housing (Item
3)@ .

Remove all gasket material from the engine block.

Put gasket cement on the engine block and install the gasket
(Item 4) @ .

Lubricate the seal with grease.

Install the housing halves (Items 1 & 3) . Install the bolts (Item
5) and finger tighten only.

Install the bolts (Item 6) and tighten to 48 - 72 in.-Ibs. (5 - 8

Nm) torque [KJ.

Tighten the bolts (Item 4) to 12 ft.-Ibs. (16 Nm) torque and then
tighten the bolts (Item 6) to 12 ft.-Ibs. (16 Nm) torque @ .

843 Loader
-7A-37- Service Manual
TIMING CASE COVER

Removal and Installation

Remove the alternator and belt.

Remove the crankshaft pulley bolt and washer.

Remove the pulley from the crankshaft.

Remove the bolts and nuts from the cover.

Remove the cover from the engine.

Clean the timing case cover and timing case back plate.

Remove the front seal from the cover by pushing it out through
the front of the cover.
0.25 - 0.30"
Press the new seal in from the front until the seal is seated below (6,35 - 7,62 mm)
the front edge of the cover ~. Make sure it is seated at the
correct specification [!].

Put a new gasket on the cover. Install the cover, be carefull not
to damage the front seal.

Install the bolts and nuts and finger tighten only.

Install the crankshaft pulley to center the front seal on the pulley
hub.

Tighten the bolts and nuts. Remove the crankshaft pulley and 6-3194
tighten the bolts behind the pulley.

Install the crankshaft pulley with the mark on .the pulley in

alignment with the line on the front face of the crankshaft ~.

Install the bolt and washer and tighten IQ].

843 loader
-7A-38- Service Manual
IDLER GEAR AND HUB

Removal

Remove the timing case cover (See Page 7A - 38).

Remove the nuts at the idler gear plate.

Remove the retainer plate and gear ~.

Remove the idler gear hub rru.

The idler gear hub is an
interference fit, use a soft hammer to remove it.

Check the idler gear and hub ~.

0.001/0.0023 in.
Replace the parts as needed. (0,00/0.06 mml

0.000/0.002 in.
fO.001O,05 mml 2.322812.3240 in
(58.99/59.03 mm)

Installation

Make sure the oil passage is clean in the hub.

Turn the engine crankshaft until No. 1 piston is at TDC,

compression stroke.

Install the idler gear hub rru.

PI-2593

Install the idler gear. Make sure the timing marks are in alignment
with the crankshaft gear, camshaft gear, fuel injection pump
drive gear and idler gear iPJ.

843 Loader
-7A-39- Service Manual
 IDLER GEAR AND HUB (Coot'd)

Install the retainer plate. 40 - 50 ft.-Ibs.

~
19 - 21 ft.-Ibs.
(54 - 68 Nm) Torque (26 - 28 Nm) Torque
Tighten the nuts to the correct torque @.

21 ft.-Ibs.
(28 Nml Torque
8-3346

Check the clearance for end play at the idler gear lID.
The correct end play is 0.006 - 0.012" (0,15 - 0,30 mm).

196

Check the clearance at the gear teeth ~ for the correct

dimensions ~.

Replace any worn parts that do not meet specifications.

Install the timing case cover (See Page 7A-38l.

~
o
o
N
o

N
o

8-3188

843 Loader
-7A-40- Service Manual
CAMSHAFT GEAR

Removal

The tool listed will be needed to do the following procedure:

c
MEL-l054 - Puller

Remove the timing case cover (See Page 7A-38).

Remove the idler gear (See Page 7A-391.

Remove the bolt, tab washer and retainer washer.

Install the puller to remove the camshaft gear ~.

Remove the camshaft gear rru.

Installation

Put the gear over the end of the camshaft.

Install the retainer washer and tab washer.

Install the bolt and tighten to 40 - 50 ft.-Ibs. (54 - 68 Nml torque.

Install the idler gear (See Page 7A-391.

Install the timing case cover (See Page 7A-38).

843 Loader
-7A-41- Service Manual
FUEL INJECTION PUMP DRIVE GEAR

Removal and Installation

Remove the timing case cover (See Page 7A-381.

Remove the fuel injection pump (See Page 7A-7).

Remove the idler gear (See Page 7A-391.

Remove the three bolts ~.

Installation: Tighten the bolts to 19 - 21 ft.-Ibs. (26 - 28 Nml

torque.

Remove the gear from the hub.

8-3236

CRANKSHAFT GEAR

Removal

The crankshaft gear is an interference fit on the end of the

crankshaft. A key is installed between the gear and the
crankshaft.

Use a puller to remove the gear from the crankshaft.

843 Loader
-7A-42- Service Manual
TIMING CASE

Removal and Installation

Remove the timing case cover (See Page 7A-38).

Remove the idler gear (See Page 7A-39l.

Remove the camshaft gear (See Page 7A-41l.

Remove the fuel injection pump drive gear (See Page 7A-42l.

NOTE: The crankshaft gear does not have to be removed.

Remove the front bolts at the oil pan.

Remove the bolt and washers from the timing case.

Remove the timing case @.

Installation: Check that the bottom of the timing case is even C-2475R
with the face of the oil pan attaching surface lID.

843 Loader
-7A-43- Service Manual
CAMSHAFT AND TAPPETS

Removal

Remove the timing case cover (See Page 7A-38).

Remove the idler gear (See Page 7A-39).

Remove the camshaft gear (See Page 7A-41l.

Remove the valve cover.

Remove the rocker arm assembly and push rods.

Remove the fuel lift pump (See Page 7A-5).

Turn the engine over and remove the oil pan and oil pump (See
Page 7A-46).

Remove the thrust plate at the camshaft ~.

Remove the camshaft from the engine block lID.

B·3307

Remove the tappets from the engine block [g.

,I-
B·3294

843 loader
-7A-44- Service Manual
CAMSHAFT AND TAPPETS (Cont'd)

0.0024/0 .0047 in.

(0.06/0 , 12 mm)
0.0024/0.0047 in.
_ (0.06110. 12 mm)
= _J
~ "LJ£

' l
§f- ~T~~~~l'~~_

~
~
~
~ (29.27 mm)
2 .0437/2 .0448 in.
(51 .91/51.94 mm)
@
0.094/0.098 in.
(2.41/2.49 mm)
. =}
:T'
2.0339/2.035 in. ' 0.0012/0.0021 in.
(51.66/51 .69 mm) (0,031,0.18 mm)

D 0 .0024/0.0047 in.

<O'[2m~OO6/0'~
0 .0024/0.0047 in.

·0.0007/+0.0007 in. 1 .0 in.

(·0.021+0.02 mm) (25.4 mm)

0 .2374/0.240 in. 2 .045/2 .0252 in.

(6.03/6.10 mm) (51.41/51.44 mm)

,.,25/1 .126 in.

(28.57/28,6 mm)
-
a
2 .0142/2 .0154 in.
(51.15 /51.19 mml
--.l 0.28010.282 in.
(7. 11/7.16mm)

1 .12511. 1257 in.

(28, 58/28.59 mm)
PI-2397

Inspection

Check the camshaft and t he bearings [A].

Use the correct tools for removal and installation of the

camshaft bearings.

Installation

Lubricate the tappets before installation.

o
,
N

o
Lubricate the camshaft. Carefully install the camshaft to prevent N
o
damage to the bearings. o
~

After rocker arms are installed, make sure to set the valve
clearance (See Page 7A-2).

843 Loader
-7A-45- Service Manual
LUBRICATION SYSTEM

Description
5"1.A$.1tAJroiO or~ MlST'O V.t.LV[

The figure shows the engine oil lubrication system IA]. AM) Q..- ASSl.Ma:ts

The lubrication of the engine is done by a full flow oil filter to

the main oil gallery from which the oil is put through small holes
into the main bearing housings to each of the five main bearings.

Some of the oil is taken off at a hole at the No. 1 main bearing
to lubricate the idler gear and the timing gears. Holes in the
crankshaft distribute oil to the four connecting rod bearing
journals from which oil splash is thrown up to lubricate the
cylinder bores and the small ends of the connecting rods.

The four camshaft journals are lubricated directly by oil holes

from No. 1, 2, 4 & 5 crankshaft main bearings. The oil pressure
is reduced at the No. 1 journal of the camshaft and is used to
lubricate the rocker shaft. The oil pump has a pressure relief
valve which limits the oil pressure. The oil filter housing has a PI ·2369R
by-pass valve which prevents the engine from going without
lubrication if the filter element becomes plugged.

843 Loader
-7A-46- Service Manual
OIL PUMP

Removal and Installation

Remove the oil pan. Remove the bolts (Item 1) that fasten the
oil tube (Item 2) to the block ~.

Loosen the locknut (Item 3) at the bolt (Item 4) that holds the
oil pump in the block. Remove the oil pump.

Disassembly and Assembly

Remove the bolts (item 5) and tube (Item 2) ~.

Remove the bolts (item 6) and oil screen (Item 7) ~.

Remove the bolts (Item 1) and the end cover (Item 2) lID.
Remove the relief valve plunger and spring (Item 3) lID.
Remove the outer rotor (Item 4) lID.
Use a puller and remove the gear (Item 5) lID.
Remove the shaft and inner rotor (Item 6) lID.

Checking

Check the clearance between the outer rotor and housing [fJ.

'U
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~

'"
0

~
~
~
0

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0
0

0
,
~

8·4109 ,
0

'"
0
0

'"
~

Check the clearance between the inner rotor and outer rotor m
~

[Q). '"
0

'0

See Page 7A-48 for the specifications. "

0
~
0
0-
b"
"<

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0

8·4110

843 Loader
-7A-47- Service Manual
 OIL PUMP (Cont'd)

Check the relief valve and plunger @.

0.00210.00$ itI.

,o.o5i01·'~
O.UiIO.405 1ft,
fJ.QItO.29mmll_
<.) I I~
~I_ O.tn21n.
~ 120.82 mml
('~ 1,5625lft.
0.005210.010 1ft. 139.69 mm)
(O.131O.25mml

PI-2592

Installation: Check the end play of the shaft and inner rotor lID
and then install the outer rotor iCl.

~
~

""
N

"
N

"

843 Loader
-7A-48- Service Manual
WATER PUMP

Removal and Installation

Remove the coolant from the cooling system. Remove the belt
shield.

Loosen the alternator adjusting bolt and remove the alternator

belt.

Remove the four bolts from the pulley and remove the pulley.

Remove the bolts which fasten the water pump to the engine
block.

Remove the water pump 00 .

Installation: Clean the block surface. Put gasket cement on the
engine block and install a new gasket.

Disassembly

Remove the snap ring (Item 1) 00.

Press the complete assembly out of the impeller end of the
housing.

Remove the snap ring (Item 2) 00.

Press the two shaft bearings out through the front of the
housing.

Use a puller and remove the impeller from the shaft.

Remove the seal (Item 3) from the shaft lID .

N
m

'"g
~
'"oo

843 Loader
-7A-49- Service Manual
WATER PUMP (Cont'd)

Checking

Check the water pump as listed in the specifications IK].

Replace the seals and worn parts.

PI-2390

Assembly

Press the two bearings and spacer (between the bearings) on

the shaft.

Put grease on the spacer; about one-half to two-thirds of the

area between the bearings. Put grease inside the bearings.

Press the complete assembly in the front of the housing. Locate

it in the correct position by installing the snap ring (Item 21 lID·

Put a support under the shaft, impeller end of the shaft. Press
the hub on the shaft and install the snap ring (Item 1) lID.

Install the seal over the impeller end of the shaft (with carbon 8-3206
surface outl. Locate it in position in the flange area of the
housing. Install the ceramic counterface seal with ceramic face
toward the carbon seal (Item 3) lID.
c
Press the impeller on the shaft. Check the clearance to make
sure there is 0.015 - 0.030" (0,38 - 0,76 mm) between the
impeller and the housing ~.

843 Loader
-7A-50- Service Manual
THERMOSTAT

Removal

Remove the coolant from the cooling system.

Remove the hose from the housing of the thermostat.

Remove the bolts. housing and thermostat from the engine

block ~.

Testing the Thermostat

Put the thermostat in water and heat the water.

The thermostat valve must start to open at 179 - 183 0 F. (81

- 85° C.) and must be fully open to 0.315" (8 mm) at 185 - 200 0
F. (88 - 94 0 C.).

If the thermostat does not open in this range. replace the

thermostat.

Installation

Clean the surface of the engine block and housing.

Put gasket cement on the engine block and install a new gasket.

Install the thermostat and the housing on the block and tighten
the bolts.

Install the hose and tighten the clamp.

Add pre-mixed coolant of 50% ethylene glycol and 50% water

to the cooling system.

o
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N

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N
o

843 loader
-7A-51- Service Manual
 ENGINE SERVICE (200 Series)

Page
Number
CAMSHAFT AND TAPPETS
Inspection .................................. . 7B-47
Installation ................................. . 7B-47
Removal ............ . ...................... . 7B-46
CAMSHAFT GEAR
Installation ........... . ..................... . 7B-43
Removal ................................... . 7B-43
COMBUSTION CHAMBER INSERTS
Removal and Installation ....................... . 7B-28
CRANKSHAFT
Checking ................................... . 7B-36
Installation ................................. . 7B-37
Removal ............................... . ... . 7B-36
CRANKSHAFT GEAR
Removal ................................... . 7B-44
CYLINDER HEAD
Cylinder Head Surface Alignment ................. . 7B-23
Installing the Cylinder Head ..................... . 7B-24
Removing the Cylinder Head .................... . 7B-23
CYLINDER LINERS
Checking ................................... . 7B-33
Removal and Installation ....................... . 7B-33
ENGINE
Removal and Installation ....................... . 7B-14
ENGINE BLOWER HOUSING
Removal and Installation ....................... . 7B-21
ENGINE COMPRESSION
Checking ................................... . 7B-3
ENGINE FLYWHEEL & U-JOINT
Flywheel Ring Gear ........................... . 7B-22 ENGINE "
Removal and Installation ....................... . 7B-22 SERVICE
(200 Series)
ENGINE MUFFLER
Removal and Installation ....................... . 7B-20
FUEL FILTER (SIN 13315 & Below)
Removal and Installation................... . .... 7B-4
Water Trap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7B - 4
FUEL FILTER (SIN 13316 & Above)
Removal and Installation........................ 7B-4
Water Trap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7B-4
FUEL INJECTOR NOZZLE
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7B-12 '"'"
o'"
Removal and Installation........................ 7B -11
FUEL INJECTION PUMP
Maximum and Installation....................... 7B - 8
Removal and Installation................. . ...... 7B - 7
FUEL INJECTION PUMP DRIVE GEAR
Removal and Installation........................ 7B-44
GLOW PLUGS
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7B-13
IDLER GEAR AND HUB
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7B-42
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7B-41
Continued on Next Page
843 Loader
~~r\lil"~ M~nlt;ll
 ENGINE SERVICE (200 Series) (Cont'd)
Page
Number
LUBRICATION SYSTEM
Description . ..... .. ... .. ... .. . . .. .. . .. . .. ... . 78-48
MAIN BEARINGS
Crankshaft End Play .... . .. . . .. . .... ........... . 7B-35
Installation ... .... .... . .... ...... . . . . .. .. . .. . 78-35
Removal . . .. . ....... . ....... .. ............ . . 78-34
OIL COOLER
Removal and Installation ... ... . . .... .. .. ....... . 78-19
OIL FILTER ADAPTER HOUSING
Removal and Installation .. . .. . .. . ... ... . .. ..... . 7B-51
OIL PUMP
Disassembly and Assembly ...... . .... . ......... . 78-49
Inspection ... . ..... . ..... .. ........ . ... ... .. . 7B-50
Removal and Installation ....................... . 7B-49
PISTON AND CONNECTING RODS
Disassembly .... ... . .... ... .. . . .. .. .. . . . .... . 78-31
Inspection . ....... . .. . ....... . .......... . .. . . 78-31
Installation ... . . . .. . ..... . ... .. .. . ..... . . .. . . 7B-32
Removal .... . .... .. . . .. . ................... . 7B-30
REAR MAIN OIL SEAL
Removal and Installation . ...... .. .... ... ... . ... . 7B-38
RADIATOR
Removal and Installation . ....... . .......... . .. .·. 7B-17
REMOVING AIR FROM THE FUEL SYSTEM
(SIN 13315 & Below)
Procedure . ....... .... .. . ..... . . ..... ... . ... . 7B-5
REMOVING AIR FROM THE FUEL SYSTEM
(SIN 13316 & Above)
Procedure . ..... . ..... . .. .... .. . . . ... .. . . .. . . 78-6
ROCKER ARMS
Assembly .................................. . 7B-29
Disassembly . .. .. ... . ... . ....... . ... .. ..... . . 78-29
TIMING CASE
Removal and Installation . ....... . .... . .. . ..... . . 78-45
TIMING CASE COVER
Front Seal .... . ... . .. . ... . .. ... . . ..... .. .... . 78-40
Removal and Installation ....................... . 78-39
TIMING THE FUEL INJECTION PUMP
Procedure .................................. . 78-9
THERMOSTAT
Installation .. .. . ...... ....... . .. . ..... .... . . . 78-54
Removal .... . ..................... . ........ . 78-54
Testing the Thermostat . . . .. . . .... . ... . .... . ... . 7B-54
TROUBLESHOOTING
Chart . .............. . ...................... . 78-1
VALVES
Checking Valve Springs .... .................. .. . 78-27
C
N Installing Valve Guides ......................... . 78-26
'""' Installing the Valves ....... .. ............ . .... . . 7B-25
"
~ Reconditioning the Valve & Valve Seats ............ . 78-25
'"c Removal of the Valves .. ...... . . .. ...... .... . .. . 78-25
~
, VALVE CLEARANCE
N
C Adjustment .......................... . ...... . 7B-2
WATER PUMP
Assembly . ........ . ... .. ............. . .... . . 78-53
Checking ............ . ..... . ................ . 78-53
Disassembly ................................ . 78-52
Removal and Installation ....................... . 78-52
843 loader
Service Manual
7B ENGINE SERVICE - PERKINS (200 Series)
TROUBLESHOOTING
The following troubleshooting chart is provided as an assistance in locating and
correcting problems which are most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel only.

PROBLEM CAUSE

Slow cranking speed. 1,2, 3,4

Engine will not start.
Difficult to start.
No power from engine.
Engine is mis-firing.
Too much fuel consumption.
Black exhaust.
Blue/white exhaust.
Low oil pressure.
Engine knocking.
Engine running rough .
Vibration.
High oil pressure.
Overheating.
Too much crankcase pressure.
Poor compression.
Start and stop.
2, 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 30, 31, 32
5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 23, 28, 30, 31 , 32
8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 23, 24, 25, 26, 30, 31, 32
8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 24, 25, 27, 28, 29, 31
11, 13, 14, 18, 19, 20, 22, 23, 24, 26, 27, 28, 30, 31 , 32
11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32
4, 11, 18, 19, 20, 24, 26, 30, 32, 33, 53
4, 34, 35, 36, 37, 38, 40, 42, 55
9, 14, 16, 18, 19, 22, 25, 27, 28, 30, 32, 34, 43, 44, 56
7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 25, 27, 28, 29, 32, 43, 56
13, 14, 20, 24, 25, 28, 29, 32, 43, 45, 46
4, 36, 39
11, 13, 14, 16, 18, 19, 23, 24, 43, 47, 48, 49, 50, 54
25, 30, 32, 33, 4a 52
11, 19, 24, 27, 28, 30, 31, 32, 33, 44, 56
10, 11, 12

KEY TO CORRECT THE CAUSE

1 Battery capacity low. 29. Incorrect high pressure fuel pipes.

2. Bad electrical connections. 30. Worn cylinder bores.
3. Faulty starter motor. 31. Worn valves and seats.
4. Incorrect grade of oil. 32. Broken, worn or sticking piston rings.
5. Low cranking speed. 33. Worn valve stems or guides.
6. Fuel tank empty. 34. Worn or damaged bearings.
7. Faulty stop control operation. 35. Not enough oil in the oil pan.
8. Plugged fuel line. 36. Switch is defective.
9. Faulty fuel lift pump. 37. Oil pump worn.
10. Plugged fuel filter. 38. Pressure relief valve is sticking open.
11 Restriction in the air cleaner. 39. Pressure relief valve is sticking closed.
12. Air in fue l system . 40. Broken relief valve spring.
13. Faulty fue l injection pump. 41. Faulty suction pipe.
14. Faulty fuel injectors. 42. Plugged oil filter.
15. Incorrect use of ether start unit. 43. Piston seizure.
16. Faulty ether start unit. 44. Incorrect piston height.
17. Broken fuel injection pump drive. 45. Faulty engine mounting.
18. Incorrect fuel injection pump timing. 46. Incorrect alignment of flywheel.
19. Incorrect valve timing. 47. Faulty thermostat.
20. Poor compression. 48. Restriction in the water jacket.
21. Plugged fuel tank vent. 49. Loose alternator belt.
22. Incorrect type or grade of fuel. 50. Plugged radiator.
23. Exhaust pipe restriction. 51. Faulty water pump.
24. Cylinder head gasket leaking. 52. Plugged breather pipe.
25. Overheating. 53. Damaged valve stem oil deflectors.
26. Cold running . 54. Coolant level to low.
27. Incorrect tappet adjustment. 55. Plugged oil pump pipe strainer.
28. Sticking valves. 56. Broken valve spring.

(200 Series) 843 Loader

-7B-1 - Service Manual
 VALVE CLEARANCE

Adjustment

Make the valve clearance adjustment with engine stopped and

cold.

Put the correct size feeler gauge between the rocker arm and
the valve stem and turn the adjusting bolt until the clearance
is correct ~ .

The correct clearance is 0.012" (0,30 mm) with the engine cold
00· B
Use the following sequence to set the valves:

a. W ith the rocker arms rocking at No.4, set clearance

at No. 1 valves.

b. With the rocker arms rocking at No. 2, set clearance

at No. 3 valves.

c. With the roc ker arms rocking at No.1, set clearance

at No. 4 valves.

d. With the rocker arms rocking at No. 3, set clearance 9·4123

at No. 2 valves.

Q
o
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N

"'
N

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N

N
~

m
o
o
,
N

o
N
o

(200 Series) 843 Loader

-76-2- Service Manual
ENGINE COMPRESSION

Checking

The tool listed will be needed to do the following procedure:

MEL-10630 - Engine Compression Kit

The engine must be at operating temperature.

Remove the fuel injectors (See Page 7B - 11).

Insta ll the correct compression adapter into the engine.

Connect the compression gauge ~.

The engine must be turning at about 300 RPM.

The compression must be between 300 - 500 PSI (2069 - 3448

kPal, with no more than 50 PSI (345 kPa) difference between
cylinders.

,. .

(200 Series) 843 Loader

-7B-3- Service Manual
 FUEL FILTER (SIN 13315 & Below)

Removal and Installation

See the Service Schedule (Page 1-1) for the correct service
sequence when rep lacing the fuel filter.

Clean the area around the fuel filter. Remove the fuel filter ~
using a filter wrench.

Lubricate the seal before installation.

Remove the air from the fuel system (See Page 78 - 5).

Water Trap

The water trap is located between the fuel tank and the fuel
filte r. See the Service Schedule (Page 1-1) for the correct
service sequence when cleaning the water trap.

To clean the water trap: Loosen the thumb screw (Item 1) at

the bottom of the filter and drain the water from the filter lID.
Tighten the thumb screw when all the water is removed.

FUEL FILTER (SIN 13316 & Above)

Removal and Installation

Clean the area around the fuel filter. Close the shut-off valve
at the fuel tank. Remove the thumb screw (Item 1) to drain the
fuel from the filter ~.

Remove the bolt (Item 2) at the top of the filter, while holding
the nut below the filter bowl. Remove the filter element (Item
3) and bowl ~ .

Lubricate the seal before installing the fuel filter element.

Remove the air from the fuel system (See Page 78 - 6) .

Water Trap

Loosen the thumb screw (Item 1) and drain the bowl until the
water is removed ~ .

o
N

~
M

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o
o
N

o
N
o

(200 Series) 843 Loader

-78-4- Service Manual
REMOVING AIR FROM THE FUEL SYSTEM (SIN 13315 & Below)

Procedure

Loosen the vent plug (Item 1) ~ .

Operate the priming pump (Item 2) until the fuel, which flows
from the vent, shows no air bubbles.

Holding the priming pump down, t ighten the vent plug (Item
1) [AJ .

Loosen the tubeline connection (Item 1) at the fuel injection

pump [ID.

Operate the priming pump (Item 2) until the fuel which flows
from the tube line connection shows no air bubbles [ID .

Holding the priming pump down, tighten the tubeline

connection.

Loosen the fittings at the fuel injector high pressure lines.

Move the throttle to half open position. Turn the engine with
the starter until fuel shows at the fittings .

Tighten the fittings at the high pressure lines to 15 ft.-Ibs. (20

Nm) torque ~.

..
~

<.0

(200 Series) 843 Loader

Service Manual
REMOVING AIR FROM THE FUEL SYSTEM
(SIN 13316 & Above)

Procedure

Open the vent plug (Item 1) @.

Operate the hand pump (Item 2) until the fuel flows from the
vent plug with no air bubbles @.

Tighten the vent plug .

Operate the hand pump (item 2) until it feels solid ~.

Loosen the tubeline connection (Item 1) lID.

Operate the hand pump until the fuel flows from the tubeline
connection with no air bubbles.

Start the engine. When the eng ine runs smoothly, tighten the
tubeline connection lID .

(200 Series) 843 Loader

_7R_f>_ Service Manual
FUEL INJECTION PUMP

The injection pump contains parts which have very close

tolerances and its operation has a direct effect on the
performance of the engine.

IMPORTANT
If you do not have the correct equipment and trained
personnel, adjustment or maintenance must not be
done.
1·2028-0284

Removal and Installation

The tool listed will be needed to do the following procedure:

MEL-1200 - Puller

Disconnect the throttle control linkage (Item 1) from the injection

pump ~.

Disconnect the wire at the fuel shut-off solenoid [ID. ~B-5794

Disconnect the high pressure fuel lines at the injection pump.

IMPORTANT
Do not bend the tubelines when removing or installing g
them on the injector pump or on the injectors.
1-2029-0284

!
Remove the pump support bracket at the bottom of the pump 8-5790
[£J.

Remove the valve cover. Turn the engine crankshaft until both
valves at No. 4 cylinder are moving.

NOTE: Make sure the valves on No.4 cylinder are both open.
This will put the key for the injection pump at the top
so that the key will not fall into the timing case when
the pump is removed.

Remove the cover from the timing case cover ~.

(200 Series) 843 Loader

-7B-7- Service Manual
FUEL INJECTION PUMP (Cont'd)

Remove the gear nut and spring washer IKJ.

Installation: Tighten the nut to 50 ft.-Ibs. (69 Nm) torque.

Remove the nuts at the pump mounting flange.

With the injection pump supported, loosen the pump gear using
the special toolrru.

Remove the injection pump from the engine ~.

NOTE: Make sure that the key does not drop off the shaft and
into the timing gears.

Installation: Make sure the key enters the keyway of the gear.
Align the timing marks and tighten the nuts at the mounting
flange.

Maximum Speed Setting

The maximum speed screw (Item 1) is set by the manufacturer

!m. Any adjustment must be done by an experienced fuel
injection technician. The idle speed screw (Item 2) can be
adjusted to give the engine idle RPM of 500 - 600 RPM at
normal operating temperature !m.

(200 Series) 843 Loader

-78-8- Service Manual
TIMING THE FUEL INJECTION PUMP

Procedure

The tool listed will be needed to do the following procedure:

MEL-1201 - Timing Tool

Remove the valve cover_

Turn the engine crankshaft until No. 1 piston is at TOe on the

compression stroke. Both valves at No.4 cylinder are moving.

Loosen the adjustment bolt at the rocker arm intake valve ~ .

6 -580 5

Remove the snap ring at the end of the rocker arm shaft and
remove the rocker arm lID.

8-5806

Remove the valve spring 1£].

Put the valve head on the top of the piston crown_

11
'iI
0

"'to
0

I~
0
~

8-5798 0
~
0
0
~

Install a dial indicator on the top of the valve stem [Q]. ~

"''"
~
c
Turn the engine crankshaft backward and forward a small
~

amount to find TOe (maximum piston height) and zero the dial "
indicator. ~
0-

.!1
Remove the high pressure fuel lines from the injection pump. '"
0

"
n
8
"n
0

0
x
";

(200 Series) 843 Loader

-78-9- Service Manual
TIMING THE FUEL INJECTION PUMP (Cont'd)

Remove the plug and washer at the rear of the injection pump
~.

Install the t iming tool and dial indicator so the plunger of the
timing tool is against the pump plunger and dial indicator reads
approximately 0.08" (2,0 mm) ~.

Slowly turn the engine crankshaft counterclockwise until the

plunger of the timing tool reaches its maximum travel (minimum
plunger lift) and set the dial indicator to zero.

Turn the crankshaft clockwise until No. 1 piston is at TDC and

the dia l indicator at the intake valve reads zero.

Check the reading on the timing tool. If it reads 0.0386 -

0.0402" (0,98 - 1,02 mm) plunger lift, the injection pump timing
is correct.

If the timing is not correct, do the following procedure:

a. Disconnect the low pressure fuel line.

b. Loosen the flange nuts and support bracket bolt.

c. If the dial indicator reads more than 0.0402" (1,02 mm),

turn the pump counterclockwise (viewed from the rear)
until 0.0394" (1.0 mm) plunger movement is indicated.
Tighten the nuts and bolt.

d. If the dial indicator reads less than 0.0386 " (0,98 mml.
turn the pump clockwise (viewed from the rear) past
the 0.0394" (1,0 mm) and counterclockwise to
0 .0394" (1,0 mm). Tighten the nuts and bolt.

Turn the crankshaft a small amount in each direction and back

to TDC. Check the timing again.

(200 Series) 843 loader

-7B-1O- Service Manual
FUEL INJECTOR NOZZLES

A WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate the skin or eyes causing serious injury. Fluid
leaks under pressure may not be visible. Use a piece
of cardboard or wood to find leaks. Do not use bare
hand. Wear safety goggles. If fluid enters skin or eyes,
get immediate medical attention.

W·2074-1285

Problems caused by faulty injector nozzles:

The engine is hard to start or will not start.

Rough engine operation and idle.

The engine will not have full power.

The engine exhaust smoke is black, white or blue.

Removal and Installation

Remove the high pressure fuel lines (Item 1) ~ .

IMPORTANT 1?

Do not bend the tube lines when removing or installing

·
'"
~

them on the injector pump or on the injectors.

il
i
1·2029·0284

'"
0
0

Remove the fuel return line (Item 2) ~. 0

,
N

A·2668 ,
0
N
0
0
~

::;
Remove the nuts from the mounting flange lID. ~
~

:;'
,n
Installation: Tighten the nuts to 12 ft.-Ibs. (16 Nm) torque [9.
·
0-

S.
Remove the fuel injector nozzles from the cylinder head. "'"
d
0
,.-
d
Installation: Always replace the copper washer (Item 1) with a
new copper washer when installing the fuel injector nozzle [Q). ·,.
"
'0

A·2846

(200 Series) 843 Loader

-7B-11- Service Manual
 FUEL INJECTOR NOZZLES (Cont'd)

Checking

IMPORTANT
Do not disassemble or test the fuel injector nozzles
unless y6u have the correct service and testing tools.
'·2027·0284

A· 2513

The tools listed will be needed to do the following procedure:

MEL·10018 - Injector Nozzle Tester
MEL·10019 - Accessory Set

Connect the nozzle to a test pump in a down position ~ .

Operate the test pump until the nozzle valve opens:

NOZZLE PRESSURE - 1920 PSI (13238 kPa)

If the pressure is not correct, replace or clean the nozzle.

Check for inside leakage:

Operate the test pump to almost opening pressure. Record the

A·2621
pressure and check the pressure decrease for six seconds. The
nozzle has a defect if the pressure decrease is more than 740
PSI (5163 kPa).

A WARNING
Do not test fuel injector nozzles unless you have correct
service and testing tools. Keep away from fuel coming
from the nozzles. Wear safety goggles. Fuel under
pressure can penetrate skin or eyes causing serious
injury. If fuel enters skin or eyes, get immediate medical
attention.
o
w
W·2075·1285

Checking nozzle spray pattern lID:

Does not come out the side of nozzle.

Does not have drops coming from nozzle.

o
o
N

o Does not have a solid stream coming from the nozzle.

N
o
Any of the above conditions show a defect or dirty injector
nozzle.

Clean or replace any nozzle that does not operate correctly.

(200 Series) 843 Loader

-7B-12- Service Manual
 GLOW PLUGS

Checking

IMPORTANT
The bar that connects the four glow plugs together is
energized when the glow plugs are in use. Keep all
pipes. clips and other metal objects away from the bar.

Check the glow plug continuity, use the following procedure:

Remove the bar from the glow plugs.

Connect a 12V/6W test lamp to the positive (+) battery

terminal. Make sure the test lamp works.

Connect the test lamp to the top of each glow plug, if test lamp
is illuminated the glow plug is good .

... .~' If the test lamp does not illuminate, remove the glow plug ~IID.

Installation: Tighten the glow plug to 11 ft.-Ibs. (15 Nm) torque.

Check the electrical supply to the glow plugs, use the following
procedure:

Connect a 12V/6W test lamp at the glow plug farthest from the
supply connection. Connect the other end of the test lamp to
ground (-).

Turn the ignition switch to the "HEAT" position, the test lamp
must illuminate. If the test lamp does not illuminate, check the
switch and electrical connections.

o
w

,o
~
o
c
'"

(200 Series) 843 Loader

-78-13- Service Manual
ENGINE

Removal and Installation

Lift and block the loader (See Page 1- 2 for the correct
procedure) .

Raise the operator cab (See Page 1- 7 for the correct

procedure) .

Remove the batteries from the loader (See Page 6 - 2 for the
correct procedure).

Disconnect the engine wiring harness ~ .

Disconnect the wires at t he two solenoids [ID .

NOTE: Mark the wires for correct installation.

Disconnect the ground wire at the left side of the engine.

Disconnect the air cleaner hose at the intake manifold .

Disconnect the throttle linkage at the throttle lever 19 .

Disconnect the throttle linkage at the fuel injection pump ~ .

Remove the bolt and nut at the cross lever and remove the
throttle linkage assembly.

Remove the rear grill.

(200 S~ries) 843 Loader

-78-14- Service Manual
ENGINE (Cont'd)

Remove the radiator cap.

Open the coolant drain at the engine block (Item 1) ~. Put a

hose over the end of the coolant drain and drain into a container.

Turn the fuel shut-off valve to the "OFF" position at the fuel
tank.

Disconnect the fuel line at the fuel filter.

Disconnect the fuel return lines at the fuel injectors.

B-4256

Disconnect the radiator hoses at the engine and radiator I!JI£J.

B·5823
Remove the coolant pipe and radiator hose ~.

\\
0\
\

\\ 8 -5824

(200 Series) 843 Loader

-7B-15- Service Manual
 ENGINE (Cont'd)

Disconnect the exhaust pipe at the exhaust manifold .

Disconnect the exhaust pipe at the muffler @ .

Remove the rear engine mounting bolts, washers and nuts lID.

B·4319

Remove the front engine mounting bolts, washers and nuts ~ .

, Installation: Add liquid ahesive (LOCTITE) to the bolt threads

and tighten to 125 - 140 ft.-Ibs. (169 - 190 Nm) torque.

Lift the rear of the engine over the edge of the loader frame.

8·4316

Slide the engine out of the loader ~ .

Installation: Move the engine into the loader until the universal
joint is in the blower housing. Have a second person reach
behind the blower housing (at the hydrostatic pump) and guide
the universal joint unto the sp lines of the hydrostatic pump
shaft, while the engine is moved toward the front of the loader.

B· 5826

(200 Series) 843 Loader

Revised Feb. 94 -78-16- Service Manual
RADIATOR

Removal and Installation

Remove the rear grill ~.

Remove the radiator cap lID.

Open the coolant drain (Item 1) at the side of the engine block
and drain the coolant into a container ~.

·
0

"'
~

'"
'"g

I
c
"
8·4256 ,c
"
~
""
:;
Disconnect both radiator hoses at the radiator 1m. :;:
""
"'"
·
"
"-
"
"<

~
~
n
c

·
x
~

(200 Series) 843 Loader

-7B-17- Service Manual
 RADIATOR (Cont'd)

Remove the radiator holddown bracket at the right side of the

frame I!].

Remove the holddown bracket at the left side of the loader

frame 00.

Remove the bolts under the radiator.

Lift the radiator up and remove it from the loader [£] .

9·8672

o
N

'""'
~
~
o
o
,
N

o
,
N
o

o
c

'"o
'"
~
N
o
ili
g
(200 Seriesl 843 Loader
-7B-18- Service Manual
OIL COOLER

Removal and Installation

Remove the panels above the engine on the blower housing.

Remove the radiator (See Page 78-17).

Disconnect the tubeline at the right side of the oil cooler @.

Disconnect the tubeline at the left side of the oil cooler lID.

Remove the bolts at the right side bracket for the oil cooler [£J.

Remove the bolts at the left side bracket for the oil cooler [Q).

Remove the oil cooler from the mounting frame.

(200 Series) 843 Loader

-78-19- Service Manual
ENGINE MUFFLER

Removal and Installation

Remove the bolts from the plate which covers the muffler ~.

8-8740

Remove the four bolts inside the engine compartment lID.

Remove the shield from the muffler [g.

Loosen the clamp at the exhaust pipe.

Remove the bolts which fasten the muffler to the mounting

frame.

8-8764

Remove the muffler from the loader [Q].

(200 Series) 843 Loader

-7B-20- Service Manual
ENGINE BLOWER HOUSING

Removal and Installation

Remove the bolts along the top edge of the blower housing ~.

rlrrr====-==-S.4344
Use a punch and hammer and remove the rivet from the blower
housing lID.

Remove the blower housing from the loader ~ .

i5

~
"
o
o

Installation: After the blower housing is installed, install the rivet

in the bottom of the blower housing and hit it with a hammer
to spread the tabs I:ru.

8
g"

8·8760

(200 Series) 843 Loader

-7B-21- Service Manual
 ENGINE FLYWHEEL & U-JOINT

Removal and Installation

Remove the four bolts at the u-joint mount flange \Ai.

Installation: Tighten the bolts to 25 - 28 ft.-Ibs. (34 - 38 Nm)
torque.

Remove the u-joint from the flywheel lID.

Remove the bolts from the flywheel ~.

Installation: Tighten the bolts to 83 - 90 ft .-Ibs. (113 - 122 Nml

torque.

Remove the washer @.

Remove the flywheel from the crankshaft flange.

Flywheel Ring Gear

The ring gear on the flywheel is an interference fit. Heat the

ring gear enough to expand it and hit it with a hammer, evenly,
to remove it.
~
~

"o
o Clean the outer surface of the f lywhee l to give it a smooth f it.
~

o
Clean the new ring gear and heat it to a temperature of 450
"o - 500 0 F. (232 - 260 0 C.).

Fit the ring gear over the flywheel. Make sure the gear is on
its seat correctly.

(200 Series) 843 Loader

-78-22- Service Manual
CYLINDER HEAD

Removing the Cylinder Head

Clean all the debris from the engine and cylinder head.

Remove the coolant from the engine and radiator. Remove the :tt-dE.?:!l::'-dF'~ ~" ,,-~@j ~ CJ]ij
radiator hoses. t '-''1'-''
0 .004" 0,010" 0.010"
(0,1 mm) {0,25 mml (0.25 mm)
Remove the fuel injectors and fuel tubelines (See Page 78 -11).

Remove the valve cover. DO NOT GRIND CYLINDER HEAD

Remove the nuts from the support brackets for the rocker arms. PI·2597

Remove the rocker arms. Remove the push rods.

Loosen and remove the cylinder head bolts.

NOTE: When removing the head, do not use a sharp tool

between the head and engine block. Always put the
cylinder head on a flat surface, such as wood, to
prevent damage to the machined surface.

Remove the head from the engine block.

See Page 78-25 for removing and reconditioning the valves.

Cylinder Head Surface Alignment

Check the surface of the head with a straight edge. The

maximum limits for the cylinder head are shown in figure ~.

NOTE: DO NOT grind the cylinder head if it is over the

maximum limit. Replace with a new cylinder hea~.

I
o
,"
,o
o"
o
~

(200 Series) 843 Loader

-7B-23- Service Manual
CYLINDER HEAD (Cont'dl

Installing the Cylinder Head

Install a new head gasket. Install it dry, no gasket cement is

needed.

When the new head gasket is installed, make sure it is

positioned correctly over the dowel pins and the markings
"TOP" and "FRONT" are located correctly ~.

Put oil on the threads of the head bolts. Install the head bolts.

Tighten the bolts in the correct sequence [ru. Do this in a three

stop procedure to 85 ft.-Ibs. (115 Nml torque.

EXAMPLE: First tighten all the bolts to 30 ft.-Ibs. (41 Nml torque,
then 65 ft.-Ibs. (88 Nm) torque and the final torque.

To reduce the risk of early cylinder head gasket failure, after a

cylinder head has been fitted, the loader is to be operated under
a partial load for about a half an hour. Then re-torque the bolts
again. It is not a good practice to just run the engine without
a load to bring it to operating temperature.
All Bolts and Nuts
Install the push rods. Install the rocker arms and support A·2646
85 ft.-Ibs. (115 Nml Troque
brackets.

Adjust the valve clearance (See Page 7B-21.

Install the valve cover.

Install the fuel injectors and fuel tubelines.

Add coolant to the engine and radiator.

(200 Series) 843 Loader

-7B-24- Service Manual
VALVES

Removing the Valves

Mark the valves so they are put in the original position on

assembly ~.

8-1855

Use a valve spring compressor and remove the valve spring locks
00·
Remove the valve springs and valve f rom the cylinder head.

Repeat this procedure for each valve.

Installing the Valves

Make sure the cylinder head is c lean.

Put oil on the valve guides and valve stems.

Assemble the valve springs and cups [£] .

c Spring
Outer
The intake valve is f itted with a rubber seal. Spring Locks
Set

~ SP'ing~p ~
~
Exhaust Valve
Use a valve spring compressor and install the valve springs and
valve stem locks. t
Tap the valve stem with a hammer a small amount to seat the
valve stem locks.

t ~ ~4=
Intake Valve t
Outer
t
Inner
+
Seal
Spring
Cup
Spring Spring
8-3355

Reconditioning the Valves and Valve Seats

Use the correct equipment to grind the valves and valves seats.

The angle of the intake is 45° and exhaust valves is 30° [Q] .

INLET
(90° Included Angle)

8-4125

(200 Series) 843 Loader

-78-25- Service Manual
 VALVES (Cont'd)

Check the valve head depth in the cylinder head after grinding
~.

Correct specification are as follows:

INTAKE & EXHAUST: 0.053" (1,35 mm).

Installing the Valve Guides

Check the valve guides for wear with a dial indicator lID. If the
movement is more than the listed specifications, replace the
guide.

INTAKE & EXHAUST: 0.024" (O,6 mm)

NOTE: Make sure to check the valve stem for wear before
replacing the valve guide [g. Minimum Di.~ 7
INT.
0.3102 in .
(7 .88 mm)

~[0t
EXH .
0.3097 in.
{7.87~_

I
1 /
l-.--/

! l~0' 065 in.

J!::- :~I~¥:~ M .. ;m~~.".~

(0.14 mm)

ri (16.5 mml
__
I .
.314510.3155 on. P( 2372
(7.9918.01 mm) •

~ Remove the guide with a hydraulic press or hand operated tool

1> [Q] .

B·1887

(200 Series) 843 Loader

-7B-26- Service Manual
VALVES (Cont'd)

Put oil in the bore and press in the new guide @ .

NOTE: Once the guide has started into the bore, do not stop.

Press the guide into the head until 0.065" (16,5 mm) is above
the cylinder head.

Checking the Valve Springs

28 Ibs. ± 1.5 Ibs.
1.74 in. (12,7 kg: ± 0,65 kg)
The valve springs for the intake and exhaust valves are the same.
Check the spring ends for damage and check the specifications
lID· (4 "Y1 ~ ~!l
9mm

fc;.-L.-,
~_"I..'_":...-i
1.49 in. VALVE SPRING INNER
(37,84 mm)

1.81 in. 40 Ibs. ± 2.0 Ibs.

(45.97 mm) (18, 1 kg ± 0 ,91 kg)

...L.+-JL-

1.59 in.
(40,38 mm)
r;:l, ~ . .-i
VALVE SPRING OUTER
PI-2371

(200 Series) 843 Loader

-78-27- Service Manual
COMBUSTION CHAMBER INSERTS

Removal and Installation

Remove the inserts, using a punch through the injector nozzle

bore and hit the punch with a hammer ~.

Position the new insert by putting the expansion washer in the

correct position lru.

Make sure to check the height of the insert to the cylinder head
as shown I£j.

0.001 in.
(0.03 mm)

(' "

PI-2376

Use a hammer and punch to set the expansion washer in

position to hold the insert in the cylinder head rm.

(200 Series) 843 loader

-7B-28- Service Manual
ROCKER ARMS

Disassembly

Mark the rocker arms and support bracket for correct assembly.

Remove the snap rings (Item 1) from each end of the shaft (Item
2) [KJ .

Remove the rocker arm (Item 3), bracket (Item 4) and spring
(Item 51 [A] .

Inspect the rocker arm bushings for wear rID . *r---r------------------------------------------,

B
Replace the parts as needed. 0 .7188/0.7196 in.
(18.26/18 .28 mm) 0.0003/0.0019 in .

~
! (0.1010,05 mml

Assembly ' ~~ ,I -(-OJO.7199/0.7207 in

_ _ .. c·"-":>- -i {18.29/18,30 mm
\
When installing a new bushing in the rocker arms, make sure
the oil holes are in alignment [g.
I 0 .0006/0.0024 in.
8.5102/8.5412in.
1216.16/216.94 mm! 0 .247/0.25 in. ~
I ! (0,01/0,06 mm)
Reverse the order of disassembly and make sure that each set I (6 ,27/6,35 mml I,
. ' 0 .6234/0.6244 in.
of rocker arm pair has the correct off-set.
1\ 0 .62510.6258 in.[ ., • ti (15,83/15.86 mm)

Put oil on all the parts for protection. 1 Jj15,87/15.89 mm)

PI·2595

Align Oil Feed Holes

.
'0

'fl
~
c

1'5
'"
~
~
0
~

A·2352 ,0
~
0
0

'"
~
~

'"
~

"
""0_
~

~
g
~
fI
.
~

(200 Series) 843 loader

*Revised Feb. 94 -78-29- Service Manual
PISTON AND CONNECTING RODS

Removal

Remove the cylinder head (See Page 7B-23).

Remove the oil pan and oil pump (See Page 7B-49).

Remove the ridge and carbon deposits at the top of the cylinder
bore with a ridge reamer.

Make sure the pistons have identification marks ~.

8·3248

Rotate the crankshaft until a pair of connecting rods are at

bottom dead center. Make sure the cab and rod have
identification marks 00.

Remove the nuts and remove the bearing cap ~.

NOTE: If the bearings are to be used again, they must be

identified so they are returned to their original location.

Using a hammer handle, push the piston and rod assembly out
of the block @ .

After the pair has been removed, rotate the engine crankshaft
and remove the other pair of pistons.

(200 Series) 843 Loader

-7R-~O_ Service Manual
 *.---~----------------------------------------------,
PISTON AND CONNECTING RODS (Cont'd)

Disassembly
0.00210.004 in.
(0.0510.10 ~mZ
JJJl
.
0.093/0.938 In. (2.3612.3B mmJ
Remove the rings from the pistons. 0.0005410.00175 in.
0.09610.097 In. 12.4412.46 mm'
(0.0110.04 m.r.:m.:!)______-,

I··'~·"·
Remove the piston pin. !
009310938 In (2.3612..38 I'nml

NOTE: If the piston pin does not come out easily, do not drive
.2497611 .24996 in T =J
(31.74131.75 mm) L:::L m 0 096/0 097 It!
=" ••
(2.44/2 .38 mml

O.093fO 0938 In.. 12..36/2.38 mm)

it out. Warm the piston in oil to a temperature of 120°F. 0.002210.004 in. ~ 0.002210 004 In (0,05/0.10 mml
(50°C.) and push the pin out. (0.0510.10 mm) 1.2495/1.250 in. 01895/0.1905 'no 14.81/4.84 mm'

Inspection
[E (31.74131 .75 mm)
0.186510.1875 in.
(4.7414.76 mm)
. 0.186811'875 10. (4.7414.16 mm'
0 .00210.0036 in. 10.0510.10 mm)

0.189510.1905 in
14.8114.84 mm)
Clean all the parts in clean solvent. P(·2393
• Piston Diameter Measured at 90 0 of Piston Pin Bore

Check the clearance of the new rings in the piston grooves I!].

Check the ring gap in the cylinder bore lID.

~---='--=-~
Maximum Ring Gap
0.060' (1,5 mm) 6 ·3334

*r---~----------------------------------------------,
Make sure the specifications are correct [g.

0.011/0.D16 in.1+.---.;

(0.2810041 mm i~~~~~~~t
0.01410.019 in.
(0.35/0048 mm)
0.011/0.Q16 in.
(0.2810.41 mm)

o
~

PI·2394 o
N
o
o
~

*r---,---------------------~------------------------,
Check the piston and pin bushing [Q].

Replace the bushings with a hydraulic press. Remove all metal 1.37B511.280 in .
burrs from the piston bore before installing the new bushings. 138.01/35.05 mm) 0.00054/+0.00175 in.
0.0025/0.005 in. (0.011+0.04 mm)
0.00074/0.0059 in. ~
Use the correct size reamer to fit the new bushing to the piston
pin.
1.37511 .376 in. L
(0.06/0.13 mm)
(0.017/0.149 mm)

(34.92134.95 m T f r ) 1.2495/1.250 in.

tuJ-J:::=i=::::J._ 131 .74/31.75 mm)

,
I
I I .1.24976/1 .24996 in.
131.74/31.75 mml
1.047/1.055 in. 1.2505/1.2515 in.
(26.59/26.80 mm) (31.76/31.78 mm)

PI-2396

(200 Series) 843 loader

*Revised Feb. 94 -7B-31- Service Manual
PISTON AND CONNECTING RODS (Cont'd) 5 in.
1127 mm)
Check the connecting rod alignment ~.

Installation

Install the piston pin by putting the piston in clean oil at a

temperature of 120 0 F. (50 0 C.). ±O.01 in. ±O.01 in.
{±O,254 mml-t---J........-":'t:"---'---r{±O,254 mml
Make sure the identification marks are located correctly at the
rod and piston.

Install new snap ring on each side of the piston pin.

PI·2375

Install the piston rings using a expanding tool to prevent the

ring from breaking lID.

Put oil on the rings so they move freely in the piston grooves.

Position the ring gaps unevenly around the piston.

NOTE: Before the pistons are installed, check the cylinder bore.

Rotate the crankshaft until a pair of crank pins are at bottom

dead center.

Using a ring compression tool, compress the rings on the piston.

Make sure the "F" is to the front of the engine block and install
the piston into the block lID.

Put oil on the bearings. Install the bearing cap ~.

Tighten the nuts on the connecting rod ~.

Rotate the crankshaft to put the other pair of crank pins at

bottom dead center. Repeat the procedure to install the other
pair of pistons.

60 ftAbs.
(82 Nm) 8·3325

(200 Series) 843 loader

-7B-32- Service Manual
CYLINDER LINERS

Checking

The cylinder liners are made of cast alloy iron. They are an
interference fit in the engine block and are of the dry type.

Boring of these liners to a larger size is not possible. New liners

must be installed when the cylinder bores are worn over
specifications.

Check the cylinder bore with an inside micrometer. Check the

bores in three positions (top, center and bottom). The checks
must be made at parallel and right angles to the center line of
I'
the bore, giving six dimensions for each bore. 8-3249

The standard bore of the cylinder liner is 3.501 - 3.502" (88,92

- 88,95 mm). When the bore dimensions is 0.006" (0,15 mm)
over standard dimensions the liner must be replaced.

Removal and Installation

Remove all the parts from the engine. Press the cylinder liners
out through the top of the engine block.

Clean the bore and remove any metal burrs in the block.

Put lubricant on the outside of the liner. Push the liner into the
block.

Check the liner height in four position for the correct height IKJ.
Follow the same procedure for the other cylinder liners.

Hone the cylinder bore to standard dimensions rru.

* 3.972/3.976 in.
(100.0/101 mm! 0.01410.023 in.
i
_ , 1_ __ ._ _ . __T~r(0.35/0.57 mml
! I I ~'001/0'003 in.
0.14810.150 in. J LL- 3.81451 .8155 in. (0.0310.08 mml
(3.76/3.81 mm! I (96.89/96.91 '!1 m ) 1 ~ 0.15010.152 in.
t
,
3.990/3.995
(101.35'101.47 mm) i !
In.'''
(3 8 3 86
. 11. mm}

. r-I 3::-.8::-:1::::2-:::5/::::3-=.9""95=-=-in-.---I
(96.84/96.86 mm) 0.026/0.031 in.
(0.66/0.79 mml

=.;r"
!t I:
3.501/3.502 in.
(88.92/88.95 10m! i
bj'I.
il j
<L ...... -
0.000/0.004 in.
(0.00/0.10 mml

PI-2373

(200 Series) 843 Loader

"Revised Feb. 94 -78-33- Service Manual
 MAIN BEARINGS
Center
The crankshaft has five main bearings. The end play is controlled Main
by a thrust washer on both sides of the center main bearing.

Each main bearing cap has identification mark in relation to the

engine block ~.

The position of each cap can not be changed from the original
location.

Removal

Remove the oil pan. Remove the oil pump (See Page 7B-49).

Remove the bolts from the main bearing caps.

Remove the main bearing cap and remove the bearing from the
cap half.

Remove the top half of the bearing by pushing on one side of

the bearing and rotating the crankshaft lID.

On the center main bearing, remove the cap and thrust washers
from each side of the cap [£].

Remove the top half of the bearing and thrust washer by pushing
on one side of the bearing and rotating the crankshaft [Q].

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"

(200 Series) 843 loader

-78-34- Service Manual
MAIN BEARINGS (Cont'd}

Installation

Check the crankshaft journals before installing the main bearings

o
(See Page 7B-36). o

Lubricate the new bearings. Install them by putting the end

without the tab into the block and rotating the crankshaft until
the tab is on its seat.
o
Install the other bearing half in the main bearing cap. Lubricate
the bearing and install it on the engine block.
85 ft.-Ibs.
Install the bolts and tighten to position the cap, then loosen (115 Nml
8·3345
them.

Install the center main bearing and thrust washer.

Repeat the procedure until all the main bearings are installed.

Then tighten the bolts to the correct torque ~.

Crankshaft End Play

The end play can be checked by either a feeler gauge rIDor a

dial indicator ©.

The maximum end play is 0.014" (0,35 mm). The fitting of

oversize thrust washers can be used to correct the end play if
it is over specifications.

(200 Series) 843 Loader

-7B-35- Service Manual
 CRANKSHAFT

Removal

Remove the oil pan. Remove the oil pump {See Page 7B-49}.

Remove the crankshaft pulley, t iming case cover, timing gears

and timing case (See Page 7B - 39) .

Remove the flywheel (See Page 7B-22).

Remove the rear main seal (See Page 7B - 38).

Remove the connecting rod caps (See Page 7B-31).

Remove the bolts and main bearing caps (See Page 78 - 34).

Lift the crankshaft out of the engine block for inspection.

Checking

Using a micrometer, check the crankshaft for correct

dimensions [AJ .

*r---r---------------------------------------------------------------------------------------------~

1.39111.421 in. 1.391/1.412 In.

(35.4136.1 mm) (35.4136.1 mm)
1.426511.4385 in.
(36.49136.54 mm) 0 .00310.015 in.
(0.0810.38 mm)

i
.~
II

STO . - - - - - - -__ 0.05010.080 in.

~.~_--T (1.27/2.03 mm)

6.
0 .0896/0.0915 in.,...-_ _ _ _ _ __
(2.26/2.32 mm) •
- 0 . 8 7 5 in. !
(22.22 mm) .
OVERSIZE
0 .096610.0985 in.
12.4512.50 mm)
L------:-2.-=c21-11-2.-21-2-inV.
(56.1615G.18 mm) 1.249511 .251 in .
0.0025/0.0045 in . 118 1 9164 in. 0 .0822 in. 0.5 in. (31.74131.77 mm)
(0.OGIO.11 mm) (3.2/3.57 mm) 3 .98513.9995 in.
I (2.248512.2.49 in.
~57.10157.12 mm)
(2.09 mm) (12.7 mm)
(101.5G/101.59 mm)

Tir

9164 I 5132 in.

1.372/1 .374 in. 13.57/3.7 mm)
2.7845/2.749 in. (34.B6134.9 mm)
(69.B1169.B2 mm)

PI·2370R

(200 Series) 843 loader

* Revised Feb. 94 -7B-36- Service Manual
CRANKSHAFT (Cont'd)

NOTE: You can grind the crankshaft to 0.010" (0,25 mm),

0.020" (0,51 mm) and 0.030" (0,76 mm) undersize.
{See Page 8B-7 for the correct specifications}.

Installation

Clean the crankshaft and check that all the oil passages are
clean and open.

Clean the engine block, lubricate and install the upper halves
of the main bearings.

NOTE: If you do not install new bearings, always return the

old bearings back to their original position.

Put the crankshaft, carefully in position.

Install the main bearing caps (See Page 7B-341.

NOTE: Make sure the lower thrust washer is in its correct

location.

Check the crankshaft so that it rotates freely. Check the

crankshaft end play (See Page 7B-351.

Install the rear oil seal (See Page 7B-381.

Lubricate the connecting rod bearings. Install the bearings and

connecting rod caps (See Page 78-31).

Install the oil pump.

Install the oil pan.

Install the timing case, timing gears, timing case cover and
crankshaft pulley (See Page 78-39).

Install the flywheel (See Page 78-22).

(200 Series) 843 Loader

·78-37· Service Manual
REAR MAIN OIL SEAL

Removal and Installation

The crankshaft is fitted with a lip type rear oil seal and has a
mounting flange with an extended width to provide a seat for
the seal ~.

This seal is easily damaged and you must be careful not to

damage it. Any visual damage across the lip of the seal will
cause leakage.

When installing a new seal, check the crankshaft flange.lf it is

found to be grooved, the seal must be pressed further into the
housing 00. Lubricate both seal and the housing when installing
the seal.

If the three position have been used, the worn sealing area of
the crankshaft can be machined to not less than 3.993" (101,4
mm).

The rear main oil seal housing is located at the engine block
by two dowels, bolts and washers with a gasket between the
housing and the engine block.

(200 Series) 843 Loader

-7B-38- Service Manual
TIMING CASE COVER

Removal and Installation

Remove the alternator and belt.

Remove the crankshaft pulley bolt @.

Installation: Tighten the bolt to 180 ft.-Ibs. (245 Nm) torque 00.

B·3325

!9. .
'~
Remove the pulley from the crankshaft

Remove the bolts and nuts from the cover.

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Remove the timing case cover from the engine @. m

Clean the tim ing case cover and timing case back plate.
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Installation: Put a new gasket on the cover. Install the front
~
cover, be careful not to damage the seal.
~
Install the bolts and finger tighten only. Install the crankshaft "x-
0
0

pulley to center the front seat on the pulley hub. ii

Tighten the bolts and nuts. Remove the pulley to tighten the
."
~
bolts behind the pulley.

(200 Series) 843 Loader

-7S-39- Service Manual
 TIMING CASE COVER (Cont'd)

Front Seal

Remove the front seal from the cover by pushing it out through
the front.

Press the new seal in from the front until the seal is seated below
the front edge of the cover ~.

Make sure it is seated to the correct specifications ~.

0 .250/0.300 in.
(6,35/7 ,62 mm)

8·3194

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(200 Series) 843 loader

-78-40- Service Manual
IDLER GEAR AND HUB
A
Removal

Remove the timing case cover (See Page 7B-39).

Remove the nuts from the idler gear plate.

Remove the retainer plate from the gear lA] .

8-3205

Remove the idler gear lID.

8-3202

Remove the idler gear hub [£J .

The idler gear hub has an interference fit . Use a soft hammer
to remove it.

8-3238

Check the idler gear and hub as the specifications shown ~ .

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0.006/0.012 in.
(0.15/0.30 mm)
PI-2593

(200 Series) 843 Loader

-78-41- Service Manual
 IDLER GEAR AND HUB (Cont'd)

Installation

Make sure the oil passages are clean in the engine block and
hub.

Install the hub.

Turn the engine crankshaft until No. 1 piston is at TDC.

Install the idler gear. Make sure the timing marks are in correct
alignment ~.

Install the retainer plate.

Install the nuts and tighten to the correct torque lID.

6-3346

Check the end play for the idler gear 1£1. The correct end play
is 0.008 - 0.012" (0,20 - 0,030 mm).

Check the clearance at the teeth of the gears ©.

The correct specification is shown in figure 1m. 0.04 in.

---------,.

~'

0.04 in.
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6-3188
~
(200 Series) 843 Loader
-7B-42- Service Manual
CAMSHAFT GEAR

Removal

The tool listed will be needed to the following procedure:

c
MEL-1054 - Puller

Remove the timing case cover (See Page 76-39).

Remove the idler gear (See Page 76-41).

Remove the bolt and washer from the gear.

Install the puller to remove the camshaft gear @. 8·3200

Remove the camshaft gear [ID.

Installation

Put the gear over the end of the camshaft.

Install the washer and bolt.

Tighten the bolt to 40 - 50 ft.-Ibs. (54 - 68 Nm) torque.

Install the idler gear (See Page 76-41).

Install the timing case cover (See Page 76-39). 8-3199

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(200 Series) 843 Loader

-78-43- Service Manual
 FUEL INJECTION PUMP DRIVE GEAR

Removal and Installation

The tool listed will be needed to do the following procedure:

MEL-1200 - Puller

Remove the t iming case cover (See Page 76-39) .

Remove the idler gear (See Page 76-41).

Remove the bolt from the gear ~ .

Installation: Tighten the bolt to 50 ft.-Ibs. (69 Nm) torque.

Install the puller and remove the gear.

CRANKSHAFT GEAR

Removal

The crankshaft gear is an interference fit on the end of the

crankshaft. A key is installed between the gear and the
crankshaft.

Use a puller to remove the gear from the crankshaft.

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(200 Series) 843 Loader
-78-44- Service Manual
TIMING CASE

Removal and Installation

Remove the timing case cover (See Page 7B-39).

Remove the idler gear (See Page 7B-41).

Remove the camshaft gear (See Page 7B-43).

Remove the fuel injection pump drive gear (See Page 7B-44).

NOTE: The crankshaft gear does not have to be removed.

Remove the front bolts at the oil pan.

Remove the bolts and washers from the timing case.

Remove the timing case ~.

Installation: Check that the bottom of the timing case is even C-247SR
with the face of the oil pan attaching surface lID·

(200 Series) 843 Loader

-78-45- Service Manual
 CAMSHAFT AND TAPPETS

Removal

Remove the timing case cover (See Page 78 - 39).

Remove the idler gear (See Page 78-41).

Remove the camshaft gear (See Page 78-43).

Remove the valve cover.

Remove the rocker arm assembly and push rods.

Turn the engine over and remove the oil pan and oil pump (See
Page 78-49).

Remove the thrust plate at the camshaft @ .

Remove the camshaft from the engine lID .

Remove the tappets from the engine block [£J.

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(200 Series) 843 Loader

-78-46- Service Manual
CAMSHAFT AND TAPPETS (Cont'd)

l 0.0012/0.0071 in.
,....:..;;c.:.....c.:.;.;.;.;'--_ _ _ _ _(o_.o_3~/0.18 mml

D
2.045/2.0252 in.
(51.41/51.44 mml

2 .0142/2.0154 in.
(51.15/51.19 mm)

PI-2397

Inspection

Check the camshaft and the bearings as the specifications

shown ~.

Use the correct tools for removal and installation of the

camshaft bearings.

Installation

lubricate the tappets before installation. o

,'"
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Lubricate the camshaft. Carefully install the camshaft to prevent '"
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damage to the bearings. ~

'"'"
After rocker arms are installed. make sure to set the valve '"
N

clearance (See Page 78-2).

(200 Series) 843 Loader

.7R_47. Service Manual
 LUBRICATION SYSTEM

Description

The figure shows the engine oil lubrication system ~.

The lubrication of the engine is done by a full flow oil filter to

the main oil gallery from which the oil is put through small holes
into the main bearing housings to each of the five main bearings.

Some of the oil is taken off at a hole at the No.1-main bearing

to lubricate the idler gear and the timing gears. Holes in the
crankshaft distribute oil to the four connecting rod bearing
journals from which oil splash is thrown up to lubricate the
cylinder bores and the small ends of the connecting rods.

The four camshaft journals are lubricated directly by oil holes

from No.1, 2, 4 & 5 crankshaft main bearings. The oil pressure
is reduced at the No. 1 journal of the camshaft and is used to
lubricate the rocker shaft. The oil pump has a pressure relief
valve which limits the oil pressure. The oil filter housing has a PI-2369R
by-pass valve which prevents the engine from going without
lubrication if the filter element becomes plugged.

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(200 Series) 843 Loader
-7B-48- Service Manual
OIL PUMP

Removal and Installation

Remove the oil pan.

Remove the bolts which fasten the oil tube to the engine block
~.

Loosen the locknut at the bolt which holds the oil pump in the
block 00.

Remove the bolt and remove the oil pump.

~I 8·5814

Disassembly and Assembly

c
Remove the bolts (Item 1) and remove the tube (item 2) ~. 3
Remove the bolts (Item 3) and remove the tube (item 4) with
the screen ~.

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8·4105 o
a

Remove the relief valve plunger and spring ~.

8-5815

(200 Series) 843 Loader

-78-49- Service Manual
 OIL PUMP (Cont'd)

Remove the bolts (Item 1) and remove the end cover (Item 2)
@.

Remove the outer rotor (Item 3) from the housing @.

Use a puller and remove the gear (Item 4) from the shaft @.

Remove the shaft and inner rotor (Item 5) from the housing @.

Inspection

Check the clearance between the inner and outer rotor 00.
Check the clearance between the outer rotor and the housing
00·

8-4109 B-4110

The correct specifications are shown in figure (g.

L~~",
' ; ,('1-
1.6 in.
(40 mm) PI-2592
8
g
~" Check the end play [Q).

11 If any of the clearances are over specifications, the oil pump

.~ must be replaced as an assembly.
0.

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(200 Series) 843 Loader

-78-50- Service Manual
OIL FILTER ADAPTER HOUSING

Removal and Installation

Use a filter wrench and remove the oil filter (Item 1) ~.

Remove the hoses (Item 2) from the adapter housing ~ .

8 · 5776

Remove the bolt and the adapter housing lID.

Installation: Clean the surface of the adapter housing and install
a new D-ring before installation.

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8 -5816
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(200 Series) 843 Loader

"71:1 . 1;1. ~p.rvi"p' Manllal
 WATER PUMP

Removal and Installation

Remove the coolant from the cooling system. Remove the belt
shield.

Loosen the alternator adjustment bolt and remove the alternator

belt.

Remove the four bolts from the pulley and remove the pulley.

Remove the bolts which fasten the water pump to the engine
block.

Remove the water pump ~.

Installation: Clean the block surface. Put gasket cement on the

engine block and install a new gasket.

Disassembly

Remove the snap ring (Item 1) lID.

Press the complete assembly out of the impeller end of the
housing.

Remove the snap ring (Item 2) 00.

Press the two shaft bearings out through the front of the
housing.

Use a puller and remove the impeller from the shaft.

Remove the seal (Item 3) from the shaft lID.

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(200 Series) 843 Loader

-7B-52- Service Manua
WATER PUMP (Cont'd)

Checking

Check the water pump as listed in the specifications ~.

Replace the seals and worn parts.

Assembly I .
' .
·
I! .'
\
.·1"·'·'·"-
I
I

Press the two bearings and spacer (between the bearings) on

the shaft. PI · 2390

Put grease on the spacer, about one-half to two-thirds of the

area between the bearings. Put grease inside the bearings.

Press the complete assembly in the front of the housing. Locate

it in the correct position by installing the snap ring (Item 2) lID.

Put a support under the impeller end of the shaft. Press the hub
on the shaft and install the snap ring (Item 1) 00.

Install the seal over the impeller end of the shaft (with carbon
surface out). Locate it in position in the flange area of the
housing. Install the ceramic counterface seal with ceramic face
toward the carbon seal (Item 3) 00 .

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8 -3206 ~
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Press the impeller on the shaft. Check the clearance to make ~

sure there is 0.015 - 0.030" (0,38 - 0,76 mm) between the ~

impeller and the housing [£]. .,

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8-3285

(200 Series) 843 Loader

-78-53- Service Manual
 THERMOSTAT

Removal

Remove the coolant from the cooling system.

Remove the hose from the housing of the thermostat.

Remove the bolts, housing and thermostat from the engine

block @ .

Testing the Thermostat

Put the thermostat in water and heat the water. The thermostat
valve must start to open at 179 - 183 0 F. (81 - 85 0 C.) and must
be fully open to 0.315" (8 mm) at 185 - 200 0 F. (88 - 94 0 C,)"

If the thermostat does not open in this range, replace the

thermostat.

Installation

Clean the surface of the engine block and housing.

Put gasket cement on the engine block and install a new gasket.

Install the thermostat and the housing on the block and t ighten
the ·bolts.

Install the hose and tighten the clamp.

Add pre-mixed coolant of 50% ethylene glycol and 50% water

to the cooling system .

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(200 Series) 843 Loader

-7B-54- Service Manual
 ENGINE SERVICE

Page
Number

CAMSHAFT
Camshaft Bearings . .... . ... ......... . . ....... . 7C-57
Checking ..... . . . .. ........... ...... .. . ..... . 7C-56
Removal and Installation ...... . .. .. . . . . .. ...... . 7C - 56
Tappets ... .. . . ....... .... . ... . . ..... ...... . 7C-57
CAMSHAFT GEAR
Removal and Installation ... . . .. .. . . .. .. .. ... ... . 7C-54
CRANKSHAFT
Checking ..... . . .. . . . . . . . . .. ... .. . . . ...... .. . 7C-45
Crankshaft Gear .. ... . .. .. . . . ... . . . .... .. .. . . . 7C-47
Installation . ... . ... . ... . . .. .. . .. .. .. . . .. .. .. . 7C - 47
Removal . . . .. .. . .. . ....... . . ... . ....... .... . 7C - 45
CYLINDER HEAD
Cylinder Head Surface Alignment . ........ .. .. .... . 7C-30
Exhaust Manifold ... .. ........ .... . . . ......... . 7C-30
Removal and Installation . . ... . ... .. ... . . . . ..... . 7C-29
CYLINDER LINERS
Checking .. . .. . .. . . . . . ...... . ... . . .. ... .... . . 7C-41
Installation . . . . ... . .. .. . . .... . . . .. . . . . .. . ... . 7C-41
Removal ...... . .. . . . . . . .. . . ... . .. . . . . . . ... . . 7C-41
ENG INE
Removal and Install ation .... .. . .. ..... .. . .... . . . 7C-17
ENGINE BLOWER HOUS ING
Removal and Installation ........... .. . . ........ . 7C - 27
ENGINE COMPRESS ION
Checking . . ... . . ..... ..... . . .... .. . . . . ..... . . 7C - 3
ENGINE FLYWHEEL & U-JOINT
Flywheel Ring Gear . ...... . .... . .. . . ... . . ... . . . 7C - 26
Removal and Installation . . .. .. .. . .. . . .. . .... .. . . 7C-26
ENG INE MOUNTS
Removal and Installation . . . . ... . .. .. . .. . . .. ... . . 7C-28
ENGINE MUFFLER
Removal and Installation ........ ..... .. ... ..... . 7C-25
ENGINE OIL AND FILTER
Removal and Installation ....... .... . ... ... ..... . 7C- 15
ENGINE TIMING TO INJECTION PUMP
Procedure . . .. . ... . ... . .. . ... . . .. . . . .. . . ... . . 7C-9
FUEL FILTER
Fuel Filter Element .. . . . . . . . .. . . . . .. ... . ... . . .. . 7C-4
Water Trap . . .. ...... .... .... . . .. . .. . . . . . ... . 7C-4
FUEL INJECTOR NOZZLES
Checking . . ... ... ... ......... . .. . . . ... ...... . 7C-12
Removal and Installation ....... .. . . .. .... ...... . 7C-11 ENGINE SERVICE
FUEL INJECTION PUMP (ISUZU)
Removal and Installation ...... ... . ... .. . ... . ... . 7C-6
FUEL INJECTION PUMP IDLER GEAR
Bearing Installation . .. . . .... . .. . . . ... . . . ... . . . . 7C-53
Removal and Installation ... . .. ... .. . .. .. .. . . . . . . 7C-53
GLOW PLUGS
Removal and Insta llation . . . . . . . . . . . . . . . . . . . . . . .. 7C - 14
IDLER GEAR & HUB
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7C - 5 1
Removal and Installation......... ... ... .. ....... 7C - 5 1
843 Loader
Revised June 87 Service Manual
 THERMOSTAT

Removal

Remove the coolant from the cooling system.

Remove the hose from the housing of the thermostat.

Remove the bolts, housing and thermostat from the engine

block ~.

Testing the Thermostat

Put the thermostat in water and heat the water. The thermostat
valve must start to open at 179 - 183 0 F. (81 - 85 0 C.) and must
be fully open to 0.315" (8 mm) at 185 - 200 0 F. (88 - 94 0 C,)"

If the thermostat does not open in this range, replace the

thermostat.

Installation

Clean the surface of the engine block and housing.

Put gasket cement on the engine block and install a new gasket.

Install the thermostat and the housing on the block and tighten
the 'bolts.

Install the hose and tighten the clamp.

Add pre-mixed coolant of 50% ethylene glycol and 50% water

to the cooling system.

8
73
8

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(200 Series) 843 loader

-78-54- Service Manual
 ENGINE SERVICE

Page
Number
CAMSHAFT
Camshaft Bearings ........................... . 7C-57
Checking ................................... . 7C-56
Removal and Installation ....................... . 7C-56
Tappets ................................... . 7C-57
CAMSHAFT GEAR
Removal and Installation ....................... . 7C-54
CRANKSHAFT
Checking ................................... . 7C-45
Crankshaft Gear ............................. . 7C-47
Installation ................................. . 7C-47
Removal ................................... . 7C-45
CYLINDER HEAD
Cylinder Head Surface Alignment ................. . 7C-30
Exhaust Manifold ............................. . 7C-30
Removal and Installation ....................... . 7C-29
CYLINDER LINERS
Checking ................................... . 7C-41
Installation ................................. . 7C-41
Removal ................................... . 7C-41
ENGINE
Removal and Installation ... . ................... . 7C-17
ENGINE BLOWER HOUSING
Removal and Installation ....................... . 7C-27
ENGINE COMPRESSION
Checking ................................... . 7C-3
ENGINE FLYWHEEL & U-JOINT
Flywheel Ring Gear ........................... . 7C-26
Removal and Installation ....................... . 7C-26
ENGINE MOUNTS
Removal and Installation.... . . . . . . . . . . . . . . . . . . .. 7C - 28
ENGINE MUFFLER
Removal and Installation.. . . . . . . . . . . . . . . . . . . . . .. 7C - 25
ENGINE OIL AND FILTER
Removal and Installation........................ 7C -15
ENGINE TIMING TO INJECTION PUMP
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7C-9
FUEL FILTER
Fuel Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7C-4
Water Trap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7C-4
FUEL INJECTOR NOZZLES
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7C - 12
Removal and Installation.. . . . . . . . . . . . . . . . . . . . . .. 7C -11 ENGINE SERVICE
FUEL INJECTION PUMP (lSUZU)
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . .. 7C - 6
FUEL INJECTION PUMP IDLER GEAR
Bearing Installation............................ 7C - 53
Removal and Installation... . . . . . . . . . . . . . . . . . . . .. 7C - 53
GLOW PLUGS
Removal and Installation........................ 7C -14
IDLER GEAR & HUB
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7C - 51
Removal and Installation........................ 7C - 51
843 Loader
Revised June 87 Service Manual
 ENGINE SERVICE (Cont'd)
Page
Number
MAIN BEARINGS
Crankshaft End Play .......................... . 7C-44
Installation ................................. . 7C-43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-42
OIL COOLER
Removal and Installation ....................... . 7C-24
OIL PAN
Installation ................................. . 7C-59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-59
OIL PUMP
Checking ................. . ......... . ..... . . . 7C-60
Gear Replacement .............. . ............. . 7C-61
Oil Pump Relief Valve .................... . .... . 7C-62
Removal and Installation ........... . ......... . . . 7C-60
Rotor Replacement ........................... . 7C-62
PISTON & CONNECTING ROD
Assembly .................. . .. . ............ . 7C-39
Disassembly .......... . ......... . ..... . .. . .. . 7C-35
Inspection ...... . .. . ....................... . . 7C-36
Installation .... . .......................... .. . 7C-40
Removal ........... . .............. . ...... . . . 7C-35
RADIATOR
Removal and Installation ....................... . 7C-21
REMOVING AIR FROM THE FUEL SYSTEM
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C - 5
ROCKER ARMS
Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . .. 7C - 34
THERMOSTAT
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7C - 66
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . .. 7C - 66
TIMING CASE
Removal and Installation.. . . . . . . . . . . . . . . . . . . . . .. 7C - 55
TIMING CASE COVER
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . .. 7C - 49
TIMING CASE COVER SEAL
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . .. 7C 48
TROUBLESHOOTING
Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7C-l
VALVES
Removal and Installation ....................... . 7C-31
Reconditioning the Valves & Valve Seats ........... . 7C 31
Valve Guides ............................. .. . . 7C-32
Valve Seat Insert ............................. . 7C-32
Valve Springs ........................ : . ..... . 7C-33
VALVE CLEARANCE
Adjustment ................................. . 7C-2
WATER PUMP
Assembly .................................. . 7C-64
Disassembly ................................ . 7C-63
Removal and Installation ....... . ............... . 7C-63
WATER JACKET TUBE
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . .. 7C-67
843 Loader
Service Manual
7 ENGINE SERVICE

TROUBLESHOOTING

The following troubleshooting chart is provided as an assistane in locating and correcting problems which are most comm on .
Many of the recommended procedures must be done by authorized Bobcat Service Personnel only .

PROBLEM CAUSE
Slow cranking speed. 1, 2,3,4
Engine will not st art. 2,5, 6, 7,8,9, 1 1,12, 13, 14, 15, 16,17,19,27,28,29
Difficult to start . 5, 7,8,9,10.11 , 12,13, 15, 16,17.18.19. 20,25, 27 . 28, 29
')',No power from engine. 8. 9, 10,11,12, 13,15.1 6 . 17. 18. 20,21 , 22,23,27. 28,29
Engine is mis-firing. 8, 9. 11.12,13, 15, 16,1 7, 21 , 22, 24, 25.26,28
Too much fuel consumption . 10 ,1 2.13, 15,16, 17, 19,20. 21,23,24.25,27, 28. 29
Black exhaust. 10. 12,13,15,16, 17,19,20.21.23.24.25.27.28. 29
Blue/white exhaust. 4 , 10,15,16,17,21,23,27, 29,30,50
Low oil pressure. ~ 31, 32, 33, 3~ 35, 37, 39, 52
Engine kn ocking. 13, 15,16,19.22, 24,25.27, 29 , 31,40,41,53
Engine running rough . 7,8,9,10,11,12,13, 17.18, 22 ,24,25.26,29,40, 53
Vibration . "~.. '. ' 12. 13. 17,21 . 22. 25 . 26. 29 . 40 . 42 . 43
High oil pressure. 4 . 33,36
Overheating . 10, 12, 13, 15, 16, 20,21 . 40.44, 45,46,47, 51
Too much crankcase pressure . 22,27,29,30,40,49
Poor compression. 10, 16,21,24,25,27,28,29,30.41,53
Start and stop. 9, 10. 11

'L.
';"':1'::-...
,Iii-
KEY TO CORRECT THE CAUSE

1. Battery capacity low . 28.

2.
3.
Bad electrical connections.
Faulty starter motor.
29 .
30.
Worn valves and seats .
Broken, worn or sticking piston rings.
Worn valve stems or guides .
·'"
'"
0

""""
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the oil pan . g
6.
7.
Fuel tank empty.
Faulty stop control operation.
33.
34.
Switch is defective.
Oil pump worn . I
8. Plugged fuel line. 35. Pressure re lief va lve is sticking open . ~
9. Plugged fuel fi lter. 36. Pressure re lief valve is sticking closed .
0
10. Restriction in the air cleaner. 37, Broken re lief valve spri ng . ,~

11 . Air in fuel system . 38. Faulty suction pipe . ,0

~
0
12. Faulty fuel injection pump. 39. Plugged oil filter. 0

'"::;
13. Faulty fuel injectors. 40. Piston seizure .
~

14. Broken fuel injection pump drive. 41 . Incorrect piston height. ~

15. Incorrect fuel injection pump timing. 42. Faulty engine mounting . ~

16. Incorrect valve timing. 43. Incorrect alignment of flywheel. '"

g"
17 .
18.
19 .
Poor compression.
Plugged fuel tank vent .
Incorrect grade of fuel.
44.
45.
46.
Faulty thermostat.
Restriction in the water jacket.
Loose alternator belt.
·0-
0-
'<
g
20. Exhaust pipe restriction . 47 . Plugged radiator.
21 . Cylinder head gasket leaki ng . 48 . Faulty water pump . "
0
0

22 . Overheating . 49. Plugged breather pipe .

"
"
0

23 . Cold running . 50. Damaged valve stem oil deflectors.

24 ,
25 .
Incorrect tappet adjustment .
Sticking valves.
51 .
52.
Coolant level too low.
Plugged oil pump pipe strainer. I
·
"\
x

\
26. Incorrect high pressure f uel pipes. 53. Broken valve spring. g
27. Worn cylinder bores .
~
~

843 Loader ,""

~

-7C-l- Service Manual ,~

~
0
0

""
 VALVE CLEARANCE

( Adjustment
\ >
Make the valve clearance adjustment with engine stopped and
cold.

The correct clearance is 0.016" (0,41 mml with the engine cold
\ f!l.

Put the correct size feeler gauge between the rocker arm and
the valve stem. Turn the adjustment bolt until the clearance
is correct lID .

Use the following sequence to set the valve clearance:

Front Rear

Cylinder No. 1 2 3 4

Valve arrangement I E I E I E I E

Piston in No. 1 cylinder is at

TOC on compression stroke
0 0 0 0

Piston in No.4 cylinder is at 0 0

0 0
TOC on compression stroke

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t
843 Loader
* Revised Feb. 87 -7C-2- Service Manual
 ENGINE COMPRESSION

Checking

The tools listed will be needed to do the following procedure:

I MEL-10630-1
- Engine Compression Kit
MEL-1268 - Compression Gauge Test Adapter

The engine must be at operating temperature.

Remove the glow plugs (See Page 7C -14 for the correct
procedure) ~.

Install the correct compression adapter into the cylinder head.

Connect the compression gauge ~.

The engine must be turning at about 175 RPM.

The compression must be between 300 and 500 PSI (2069 -

3448 kPa) w ith no more than 50 PSI (345 kPa) difference
between cylinders.

The engine has an open crankcase ventilation system.

The ventilation hose comes from the valve cover tube (Item 1)
and passes down the side of the engine block ~.

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o"
o
~

843 Loader
Revised Feb. 94 -7C-3- Service Manual
 FUEL FILTER

Water Trap

See the Service Schedule (Page 1-1) for the service interval
to remove the water from the filter.

Push up on the spring loaded poppet at the bottom of the fuel

filter I!J, until all the water is removed from the filter.

Fuel Filter Element

See the Service Schedule (Page 1-1) for the service interval
to replace the element.

Clean the area around the filter element.

ILoosen the bolt (Item 1) 00.

Remove the water trap and filter element [g .

Put oil on the seal of the new filter element.

Install the filter element, water trap and tighten the nut.

Remove the air from the fuel system (See Page 7C-5) .

843 Loader
*Revised Feb. 94 -7C-4- Service Manual
REMOVING AIR FROM FUEL SYSTEM

Procedure

After replacing the fuel filter element or when the fuel tank has
run out of fuel, the air must be removed from the fuel system
to start the engine.

Loosen the plug at the top of the filter housing fA].

Operate the priming bulb until fuel flows from the plug with no
air bubbles showing [ID .

I Close the plug at the top of the filter housing .

Loosen the plug at the fuel injection pump (Item 1) [£J.

Operate the priming bulb until fuel flows from the plug with no
air bubbles showing [ID.
~
0
Tighten the plug at the fuel injection pump. -g
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0
~

0
~
B-11081 ~
0
0
~

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0.

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0
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0
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843 Loader
Revised Feb. 94 -7C-5- Service Manual
 FUEL INJECTION PUMP

The injection pump contains parts which have a very close

tolerance and its operation has a direct effect on the
performance of the engine.

IMPORTANT
If you do not have the correct equipment and trained
personnel, adjustment or maintenance must not be
done.
1·2028·0284

Removal and Installation

Disconnect the throttle linkage.

Disconnect the shut-off wire [A].

Remove the valve cover.

Rotate the engine until No. 1 piston is at TDC. Both valves at

No. 1 cylinder are not moving and have clearance [!].

*
The 4th mark on the front pulley is at TDC [g.

I Remove the oil fill pipe at the timing case cover.

Make alignment of the mark on the injection pump gear with *

the pointer in the window ~.

843 loader
* Revised Feb. 94 -7C-6- Service Manual
FUEL INJECTION PUMP (Cont'd)

IMPORTANT
Do not bend the tubelines when removing or installing
them on the injection pump or the injectors.
1-2029-0284

Disconnect the high pressure fuel lines at the injection pump

[AJ.

Disconnect the fuel lines at the injectors lID .

I
Installation: Tighten the fittings on the high pressure fuel lines
to 14-29 ft_-Ibs. (19-39 Nm) torque.

Remove the high pressure fuel lines from the engine ~.

.
."
0

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~

'"
0

I
0
~

,
0
~
0
0

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~
Remove the bolts at the rear of the injection pump and remove ~

the bracket [QJ. "

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"
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0-

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0
0

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0

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843 Loader
Revised July 88 -7C - 7- Service Manual
FUEL INJECTION PUMP (Cont'd)

Remove the bolts at the front of the timing case cover ~.

Installation: Tighten bolts & nuts to 10-17 ft.-\bs. (14-23 Nml

torque.

Remove the fuel injection pump lID.

Installation: After the injection pump is installed the air must
be removed from the fuel system (See Page 7C-5).

Also the injection pump timing must be set (See Page 7C-9).

843 loader
-7C-8- Service Manual
ENGINE TIMING TO INJECTION PUMP

Procedure

The tools listed will be needed to do the following procedure:

MEL-1201 - Timing Tool

Remove the valve cover.

Rotate the engine until No.1 piston is at TOC. Both valves at

No. 1 cylinder are not moving and have clearance ~.

The mark on the front pulley is at TOC lID.

Remove the plug at the rear of the injection pump !£J.

Install timing tool and dial indicator ~.

~
/ 8-8977

843 loader
-7C-9- Service Manual
 ENGINE TIMING TO INJECTION PUMP (Cont'd)

Rotate the engine counterclockwise so the front pulley mark

goes 30° to 40° before TOC ~.
(

Set the dial indicator to zero 00.

I
Rotate the engine back to 17° BTOC mark on the front pulley
~.

The dial indicator must read approximately 0.020" (0,50 mm)

00·

If not, loosen the bolts at the bracket l£Jand at the injection

pump flange ~.

I
Move the injection pump to obtain the 0.020-0.022"
(0,50-0,59 mm) reading at the dial indicator with the front
pulley marks at the 17° BTOC .
f,,, ___ _
fIr==-- ---:::,.
;~---

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>
---- ---=::::::

~ Repeat the procedure until the timing is correct.

~
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843 Loader
* Revised July 88 -7C-10- Service Manual
FUEL INJECTOR NOZZLES

.A WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes causing serious injury. Fluid leaks
under pressure may not be visible. Use a piece of
cardboard or wood to find leaks. Do not use your bare
hand. Wear safety goggles. If fluid enters skin or eyes,
get immediate medical attention.
W-2074-1285

Some problems caused by faulty injector nozzles:

The engine is hard to start or will not start.

Rough engine operation and idle.

The engine will not have full power.

The engine exhaust smoke is black, white or blue.

Removal and Installation

IMPORTANT
Do not bend the tubelines when removing or installing
them on the injection pump or the injectors.
1·2029·0284

Disconnect the high pressure fuel lines at the fuel injection

pump ~.

I
Installation: Tighten the fittings on the high pressure fuel lines
to 14-29 ft.-Ibs. (19-39 Nm) torque.

Disconnect the fuel lines at the fuel injectors lID.

Remove the high pressure fuel lines from the engine 1£].

Remove the low pressure hoses from the fuel injector nozzles
@.

843 Loader
Revised July 88 -7C-11- Service Manual
 FUEL INJECTOR NOZZLES (Cont'd)

Remove the nut at the fuel injector holddown clamp @ .

Installation: Tighten the nuts to 23-32 ft .-Ibs. (31-43 Nm)

torque .

Use a screwdriver and pry the injector from the cylinder head
[ffi .

Remove the injector nozzle from the head [g .

Checking

IMPORTANT
DO NOT disassemble or test the injector nozzle unless
you have the correct service and testing equipment.
1-2027-0284

The tools listed will be needed to do the following procedure:

DE M-l 064 - Injection Nozzle Tester

OEM-l065 - Accessory Set

Connect the nozzle to the test pump, in a down position @.

Operate the test pump until the nozzle valve opens:

~
o
o Injection Pressure: 2630 PSI (18134 kPa)
,
o
,
N
o

843 Loader
-7C-12- Service Manual
FUEL INJECTOR NOZZLES (Cont'd)

If the pressure is not correct, do the following:

Disassemble the injector nozzle and clean.

Replace the shim (Item 6) @.

Check the pressure again.

A WARNING
Do not disassemble or test fuel injector nozzles unless
you have correct service and testing tools. Keep away
from fuel coming from the nozzles. Wear safety
goggles. Fuel under pressure can penetrate skin or eyes.
If fuel enters skin or eyes, get immediate medical
attention. Failure to obey warnings can cause injury or
death.
W-2075-0284 1. Retaining Nut
2. Injection Nozzle
3. Spacer

I
Assembly: Tighten the retaining nut (Item 1) to 29-32 ft.-Ibs.
(39-43 Nml:, torque @.
4. Push Rod
5. Spring
6. Adjusting Shim
7. Nozzle Holder
8-8959

Checking nozzles spray pattern 00. INCORRECT

Does not come out the side of the nozzle. Does not have drops
coming from the nozzle. Does not have a solid stream coming
from nozzle.

Any of the above conditions show a defect or dirty injector

o
nozzle. Clean or replace any injector nozzle that does not o

operate correctly.

8-8895

843 Loader
Revised July 88 -7C-13- Service Manual
 GLOW PLUGS

Removal and Installation

Disconnect the negative (-) cable at the battery.

Remove the electrical bar holddown nuts at the glow plugs ~.

Remove the electrical connector bar lID.

Loosen the glow plug [9.

m
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,
N

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N

Remove the glow plug from the cylinder head IQ].

843 Loader
-7C-14- Service Manual
ENGINE OIL AND FILTER

Removal and Installation

See the Service Schedule (Page 1 -1) for the correct service
interval.

Check the oil level every day ~.

Add the correct oil as needed.

Use recommended engine oil [[J. RECOMMEND£D SA( VlSCOSITV NUMBER

(LUBRlCATlON 01t.S FOR ENGINE CRANKCASE!
co ·34 ·29

FO ~30 ·20 ~10

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT otL CHANGE

(GASOUNE: USE Al'l ClASSlflCATION SE 01 Sf!
(DtESEl: USE AP1 CLASSIFICATION CC Of' CO}
PI-2358

Run the engine until warm. Stop the engine.

Turn the plug at the oil filter housing out about 3 to 5 turns
to drain the oil in the filter element into the oil pan [£].

NOTE: This plug must be tightened after oil is removed from

the filter element. because if it is not. there will be no
engine oil pressure and engine damage will result.

A WARNING
Engines can have hot parts. Wear protective clothing
when removing oil filter to avoid burns.
W·210S·09S6

Remove the filter element ~.

Clean the filter housing surface. Put clean oil on the gasket of
the new filter. Install the filter element and hand tighten only.

843 Loader
-7C-15- Service Manual
 ENGINE Oil AND FilTER (Cont'd)

Remove the cap (Item 1) at the end of the hose ~ .

( Drain the oil into a container.

Install t he cap on the end of the hose and t ighten ~ .

8· 11 778

Remove the filler cap rru.

Fill to capacity ~ (See Specification, Section 8C - 2).

Start the engine and let it run for about 5 minutes. Check for
leaks at the filter.

g Stop the engine . Check the oil level.

~

;;; Add oil until the level is at the "FULL" mark on the dipstick.
Install the filter caprru.
'"
~ NOTE: Do Not overfill the crankcase .

c
u

8"

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843 Loader
* Revised July 88 -7C-16- Service Manual
ENGINE

Removal and Installation

Remove the battery (See Page 6-2 for the correct procedure) .

Lift the rear grill and remove the radiator cap ~.

Open the valve at the side of the engine block and drain the *
coolant !ru .

Disconnect the throttle linkage at the f uel injection pump.

Remove the four bolts at the exhaust manifold @.

~
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0

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0
0

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6·8708 ,
0

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0
0

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::;
Remove the exhaust pipe ~.
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843 Loader
* Revised July 88 -7C-17- Service Manual
 ENGINE (Cont'dl

Disconnect the radiator hose @ .

('

Disconnect the radiator hose [!].

Remove the holddown band for the coolant recovery tank ~.

Remove the coolant recovery tank [Q].

~i

r
g" 843 Loader
m
o -7C - 18- Service Manual
ENGINE (Cont'd)

Disconnect the wire harness connectors IA].

Disconnect the wires from the solenoid 00.

Disconnect the inlet and return fuel hoses lID.

8·8681

Disconnect the air cleaner hose at the intake manifold IQ].

-::::':::::==~::::~:::::::8-8754 o
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~

Disconnect the wire at the hydrostatic filter sending switch lQl.

8-8691

843 Loader
-7C-19- Service Manual
 ENGINE (Cont'd)

Remove the four engine mounting bolts and nuts ~ .

(

B·8668

Remove the panels over the oil cooler lID.

The lift hook at the rear of the engine is in a down position [g.

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Remove the lift hook and put it in the up position for removal
of the engine ~.

843 Loader
-7C-20- Service Manual
ENGINE (Cont'd)

Hook the chain hoist into the front lift hook ~.

Lift the engine just enough to make clearance at the rear edge
of the frame.

" ~~,'(' .,;7:":~.:~.",.

Slide the engirie od~f'the fra'~"{jn~'i(~he 2hain hOi:t' ~an be
hooked into the rear lift hooks 00.

Installation: Make sure to mak~ ,a lignment of the U-joint to the

spline on the hydrostatic pUlPP';shaft
~ 't-: •__ '_ "
wh~n installing the engine
.,.~~,

In the Feller Buncher. o~:,'>.,",, · ~ ~ "

.
,
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.;,--

843 Loader
-7C-21- Service Manual
 RADIATOR

Removal and Installation

Remove the rear grill @.

6·8336

Remove the radiator cap lID.

Open the valve at the side of the engine block and ,drain the
coolant [g. ' . *
Disconnect both radiator hoses at the radiator.

...:/~\

Remove the radiator holddown bracket at the right side of the

frame ~ .

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6·8763

843 Loader
.. Revised July 88 -7C-22- Service Manual
RADIATOR (Cont'd)

Remove the holddown bracket at the left side of the frame ~.

Remove the bolts under the radiator.

Lift the radiator up and remove it from the loader lID.

o
- ----- - B·8672

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843 Loader
-7C-23- Service Manual
 OIL COOLER

Removal and Installation

Remove the panels above the engine on the blower housing.

Remove the radiator (See Page 7C - 22).

Disconnect the tubeline at the right side of the oil cooler @.

Disconnect the tubeline at the left side of the oil cooler lID.

Remove the bolts at the right side oil cooler bracket ~.

ro
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ro

Remove the bolts at the left side oil cooler bracket lQ].

Remove the oil cooler from the mounting frame.

843 Loader
-7C-24- Service Manual
ENGINE MUFFLER
A~
Removal and Installation

Remove the bolts from the plate which covers the muffler IAJ.

B·8740

Remove the four bolts inside the engine compartment [!J.

Remove the shield from the muffler [£].

B·8764

Loosen the clamp at the exhaust pipe.

Remove the bolts which fasten the muffler to the mounting

frame.

Remove the muffler from the loader [Q].

843 Loader
-7C-25- Service Manual
 ENGINE FLYWHEEL & U-JOINT

Removal and Installation

Remove the four bolts at the u-joint mount flange ~.

Installation: Tighten the bolts to 25-28 ft.-Ibs. (34-38 Nm)

torque.

Remove the u-joint from the flywheel !ru.

Remove the bolts from the flywheel ~.

Installation: Tighten the bolts to 83-90 ft.-Ibs. (113-122 Nm)

torque.

Remove the washer [!!].

Remove the flywheel from the crankshaft flange.

Flywheel Ring Gear

The ring gear on the flywheel is an interference fit. Heat the

ring gear enough to expand it and hit it with a hammer, evenly,
to remove it.

Clean the outer surface of the flywheel to give a smooth fit.

~
o Clean the new ring gear and heat it to a temperature of
o
N

o
450-500 o F (232·260 o C).
~
N
o
Fit the ring gear over the flywheel. Make sure the gear is on
its seat correctly.

843 loader
-7C-2S· Service Manual
ENGINE BLOWER HOUSING

Removal and Installation

Use a punch and hammer and remove the rivet from the blower
housing [AJ .

Remove the bolts along the top edge of the blower housing.

Remove the blower housing from the loader lID.

After the blower housing is installed, install the rivet in the

bottom of the blower housing and hit it with a hammer @.

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8·8760 ,0

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843 Loader
-7C-27- Service Manual
 ENGINE MOUNTS

Removal and Installation

Lift the engine with a chain hoist.

Remove the flywheel (See Page 7C-26).

Remove the bolts around the crankshaft flange ~.

Installation: Tighten the bolts to 56-62 ft.-Ibs. (75-85 Nm)

torque.

8·8715

Remove the bolts around the engine block 00.

Installation: Tighten the bolts to 31-35 ft.-Ibs. (43-47 Nm)
torque.

Remove the bolts at the crankshaft pulley end of the engine I£J.
Installation: Tighten the bolts to 25-28 ft.-Ibs. (34-38 Nm)
torque.

o Lift the engine from the mounts.

o
N

"'m
N

843 Loader
-7C-28- Service Manual
 CYLINDER HEAD
A 3
Removal and Installation ~
I
The tools li sted w ill be needed t o do the fo llowing procedure : 1~ 1

MEL- 1267 - Cylinder Head Bolt Wren ch

Clean ali the debris from the cylinder head and engine.

Remove the coolant from the engine and radiato r. Remove the
radiator hoses .

Remove the fuel injectors and fuel tubelines (See Page 7C - 11

fo r the correct procedure l. 8·8186

Remove the valve cover nuts in the correct sequence ~.

Installation: Tighten the nuts to 6-13 ft .-Ibs. (8-17 Nm) torque

in the correct sequence ~ .

Remove the rocker arm assembly bolts in the correct sequence

00 ·
Installation: Tighte n the bolts in the correct sequence to 36 -43
ft.· lbs . (49·58 Nm) torque.

8·8188

Remove the cylinder head bolts in the correct sequence if] .

Installation: Lubricate the bolts and tighten them in two steps

as listed, in the correct numerical sequence [Q].

Step 1 Step 2 8·8189

' New Bolts 29 ft. ·lbs . (39 Nm) 59-67 ft.-Ibs.
(80-91 Nm)
Used Bolts 62 ft.-Ibs . (83 Nm) 72-80 ft.-Ibs.
(97-108 Nm)
D
NOTE: When removing the head, do not use a sharp tool
between the head and the engine block. Always put
the cylinder head on a flat surface, such as wood, to
prevent damage to the machined surface.

Remove the head from the engine .

See Page 7C-31 for removing and reconditioning the valves.

After the cylinder head is installed , adjust the valve clearance

(See Page 7C 2 for the correct procedure).
8·8189

843 Loader
Revised July 88 -7C-29- Service Manual
 CYLINDER HEAD (Cont'd)

Cylinder Head Surface Alignment

Check the surface of the head with the straight edge @.

Check the head at six different directions lID.

The standard distrotion is 0.002" (0,05 mm) and the maximum
lim it is 0.008" (0,20 mm) .

When the head distrotion exceeds the maximum limit , regrind

the head with a maximum limit of 0.012" {O,30 mm} .

B·8197

Exhaust Manifold

If the exhaust manifold has been removed, use the correct 4 8 5 1

torque sequence and t ighten the bolts to 10- 17 ft .-Ibs. (14-23
Nm) torque [£].

3 7 6 2
B-8187

o
o
,
N

o
N
o

843 Loader
-7C-30- Service Manual
VALVES

Removal and Installation

1. Spring Seat 9
The tools listed will be needed to do the following procedure : I
2. Springs ~-1
3. Valve I
MEL-1266 - Valve Stem Seal Installer 4. Oil Seal e
Mark the valves and parts so they are returned to their original
5. Spring Seat
~>2 I
position when assembling .
I I
Remove the valve spring locks ~, using a spring compressor
lID·
e- 4I

5-'P
Remove the valve springs, spring seats, oil seal and valve ~. I

Before reassembly, check the valves, valve seats and guides.

o
Installation: Make sure the head is clean .

Put oil on the valve guides and valve stems.

Put each valve in the correct location.

Install the valve springs, spring seats and oil seals ~.

I

t
NOTE: Install the valve springs with their closed pitched
(painted side) end toward the cylinder head .
a
Use a valve spring compressor and install the valve spring locks.

Tap the valve stem with a hammer a small amount to seat the 8 ·8192
valve stem locks.

Reconditioning the Valve and Valve Seats

Use the correct equipment to grind the valve and valve seats.

The angle of the intake and exhaust valves is 45 0 1£].

The valve head thickness is as listed 1£]:

Standard - 0 .071" (1,8 mm)

Limit - 0.059" (1,5 mm)

8·8202

843 Loader
-7C-31- Service Manual
 VALVES (Cont'dJ

Check the valve head depth in the cylinder head after grinding
the valves and seat. The correct specifications are as follows Contact
~: Width

Intake - Standard 0.029" {0,73 mm}

Limit 0.05" (1,28 mm)
Exhaust - Standard 0.028" {0,70 mmJ
Limit 0.047" (1,20 mm)

Check the valve seat contact width ~:

Intake - Standard 0.067" (1,70 mmJ

Limit 0.087" (2,20 mmJ 8·8199
Exhaust - Standard 0.079" (2,0 m)
Limit 0.098" (2,5 mm)
Welding
Bead
/'
Valve Seat Insert

To remove the valve seat insert, put a bead of weld around the
inner face of the insert and allow to cool a few minutes, then
pry them out 00. Insert
Press the new valve seat insert into the bore using a hydraulic
press.

After installation, grind the insert to the correct angle and check
the depth of the valve.

Valve Guides 0.40"

(10 mm)

-"~B=':0=at-- ~
The tools listed will be needed to do the following procedure:
m
c
o
,
N
MEL-1259 - Valve Guide Remover
""
N

Check the valve guides for wear with a dial indicator ~.

If the movement is more than the listed specifications, replace

the guide.

Intake - Standard 0.0015-0.0027" (0,039-0,068 mm)

Limit 0.008" (0,2 mmJ 8·8205

Exhaust - Standard 0.0025-0.0038" (0,064-0,96 mm)

Limit 0.010" (0,25 mmJ

+ + t
NOTE: Make sure to check the valve stem for wear before
replacing the valve guide ~.
--
t t t
Intake 0.3128-0.3134" Limit 0.310"
Standard [7,946-7,961 mm) (7,88 mm)

Exhaust 0.3119-0.3124"
Standard (7,921-7,936 mm)
8-8204

843 Loader
-7C-32- Service Manual
VALVES (Cont'dl

Remove the guide @.

Install the new guide lID.

The height of the valve guide top edge to the cylinder is 0.51"
(13 mml.

Valve Springs

Check the free length and inclination ~.

c r Inclination

Std. Limit

Inner 1.783" 1.748"

(45,3 mml (44,4 mm)
Free Length
Outer 1.957" 1.898"
(49,7 mm) (48,2 mml

Inner --- 0.118" Square

,..,
o
(3,0 mm)
Inclination 8·8208 ,o..,
o
Outer -- - 0.126"
o
'"
(3,2 mm)

Check the valve spring tension ~.

Set Length Std. Limit

Inner 1.46" 131bs. 11 Ibs.

(37 mm) (5,9 kg) (5,02 kg)

Outer 1.54" 461bs. 401bs .

(39,O mm) (2q,9 kg) (18,1 kg)

8·8209

843 Loader
-7C-33- Service Manual
 ROCKER ARMS

Disassembly and Assembly

Mark the rocker arms and support brackets for correct

assembly.

Remove the snap ring (Item 1) from each end of the shaft (Item
5)@ .

Remove the rocker arms (Items 2 & 4) and support brackets

(Item 3) @.

Assembly : The support bracket with the oil hole is toward the
front of the engine.

Inspect all the parts for wear or damage.

Standard - 0.7478-0 .7486" (18,98-19 mm)

Limit - 0.7427" (18,85 mm)

B·B214

Check the rocker arm ~.

Rocker arm diameter.

Standard - 0.7489-0.7497" (19,0 1-19,03 mm)

Limit - 0.7505" (19,05 mm)

Clearance between rocker arm and shaft .

Standard - 0.0003-0.002 " (0,01-0,05 mm)

Limit - 0.0078" (0,2 mm)

Replace the parts as needed .

B·8215

~ Push Rods

Check the push rods for run -out @ .

Limit - 0 .012" (0,3 mm)

M

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843 Loader
-7C-34- Service Manual
PISTON AND CONNECTING ROD

Removal

Remove the cylinder head (See Page 7C - 29 ). o ~ CR0 Cfu)

o 0 0 0 0 0 0 (jO 0 0 (jOCOJO
Remove the oil pan (See Page 7C-59).
0{1\o~OGOmo
O~O~O~O~O
Remove the ridge and carbon deposits at the top of the cylinder
bore with a ridge reamer.
OCOCDm 0
Make sure the pistons have identif ication marks I!]. 0 0 0 0 0 0 0 0 0 0 0 00

Rotate the crankshaft until a pair of connecting rods are at the

bottom dead center. Make sure the connecting rod caps and 8-3248
the rods have identification marks.

Remove the nuts and remove the bearing caps lID.

NOTE: If the bearings are to be used again, they must be
identified so they are returned to their original location.

A-2344

Using a hammer handle, push the piston and rod out of the block
[£).

After the pair has been removed, rotate the engine crankshaft
and remove the other pa ir of pistons.
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8-8909 ,
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Disassembly ~

:::
Remove the rings from the pistons ~.
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8-8194

843 Loader
-7C-35- Service Manual
 PISTON AND CONNECTING ROD (Cont'd)

Remove the piston pin snap ring @.

Drive out the piston pin using a brass rod 00.

B-8196

Inspection

Clean all the parts in clean solvent.

Check the clearance of the new rings in the piston grooves [£].
m
o
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N
Standard Limit
"m
N

1st 0.0035-0.0049" 0.006"

Compression (0,09-0,125 mm) (0,15 mm)
2nd 0.002-0.0033" 0.006"
Compression (0,05-0,085 mm) (0,15 mm)
Oil 0.001-0.003" 0.006"
(0,03-0,07 mm) (0,15 mm)

8
'a
8

£ Check the piston diameter @.

'.::O"~ Pistons are available in two sizes.

Piston Grade A 3.6608-3.6616"

(92,985-93,004 mm)
~
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Piston Grade C 3.6616-3.6624"
N

o (93,005-93,024 mm)
,
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B·8227

843 Loader
-7C-36- Service Manual
PISTON AND CONNECTING ROD (Cont'd)

Check the ring gap in the cylinder bore ~.

Standard Limit
Compression 0.008-.016" 0.059"
{O,2-0,4 mm} {1,5 mm}
Oil 0.004-0.012" 0.059"
(0,1-0,3 mm) (1,5 mm)

Check the piston pin diameter rnJ.

Standard -1.220" (31 mm)
Limit - 1.219" (30,97 mm)

Check the clearance between piston pin and piston pin bore [£] C
Clearance - 0.00008-0.0006"
(0,002-0,015 mm) if
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8 ·8231
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Check the connecting rod alignment [Q]. ~

:::
Standard - 0.002" (0,5 mm) or less ~

"~
Limit - 0.0079" (0,2 mm)
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8 ·8232

843 Loader
Revised April 96 -7C-37- Service Manual
 PISTON AND CONNECTING ROD (Cont'd)

Check the connecting rod small end bushing IE .

Standard - 1.2208-1.2211" (31,008-31,015 mm)

Check the clearance between the piston pin and connecting

rod rru.
Standard - 0.0003-0.00079" (0,008-0,02 mm)
Limit - 0.0002" (0,5 mm)

Replace the small end bushing if not within specifications using

a hydraulic press [£].

After installation of a new bushing, finish the bushing bore to

the correct specifications ~.

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843 Loader
"'
N
-7C-38- Service Manual
 PISTON AND CONNECTING ROD (Cont'd)

Assembly

Heat the piston to about 140°F (60°C) @.

I Assemble the piston and connecting rod [ID.

C·2936

* C
I
Install the piston to the connecting rod. The piston head front
mark (Item 1) and the connecting rod "ISUZU" casting mark
(Item 2) must be facing the same direction @ .
CD
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I Install the piston pin. Install the snap rings @.
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843 Loader
* Revised Julv 88 -7C-39- Service Manual
 PISTON AND CONNECTING ROD (Cont'd)
*
, Install the rings on the piston IAJ·
(
The face w ith the mark "NPR " or " TOP" must be turned up

1 for the 1st and 2nd compression rings.

B·8253

Installation

I
*
Using a ring compressor tool, compress the rings on the piston.
Make sure the "mark" is to the front of the engine and install
the piston in the block [!] .

I Put oil on the bearings. Install the bearing cap ~.

*

Tighten the nuts to 58-65 ft.-Ibs. (78-88 Nm) torque [Q].

*
Rotate the crankshaft to put the other pair of crank pins at
bottom dead center. Repeat the procedure and install the other
pair of pistons.

58 - 65 ft.-Ibs.
(78 - 88 Nm) 8-3325

843 Loader
* Revised July 88 -7C-40- Service Manual
CYLINDER LINERS

Checking

The tools listed will be needed to do the following procedure:

MEL-1180 - Puller Set

MEL-1261 - Cylinder Liner Remover Ankle

Check the cylinder bore with an inside micrometer. The checks

must be made at parrallel and right angles to the center line of
the bore ~.

Measuring point is done approximately 0.75" (20 mm) below

the top of the cylinder bore.

Standard - 3.6622-3.6638" (93,021-93,060 mm)

Limit - 3.6653" (93,100 mm)

Removal

Remove all the parts from the engine.

Using a cylinder liner tool, remove the cylinder liner from the
engine block [i] .

There is only one size liner available.

Installation

The tools listed will be needed to do the follow ing procedure:

MEL-1262 - Cylinder Liner Installer

Clean the bore and remove any metal burrs.

Clean the grease from the cylinder liner and dry it.

Use dry ice to cool the cylinder liner, so it will install easier and
smoothly into the engine block.

Using the correct tool, install the cylinder liner [g .

First apply a load of 11031bs. (500 kg) using a hydraulic press.

NOTE: Do Not use a hammer to install the cylinder liners.

Then, apply a final load of 5513 Ibs. (2500 kg) . Push the liner
in until 0- 0.0039" (0 - 0,1 mm) of the liner is above the block
face [Q].

I NOTE: Liners are chrome plated and must not be honed after
installation.

Measure the inside diameter of the liner and select the correct
size piston for the liner.

Minimum Diameter
Piston Grade A 3.6622-3.6630"
(93,021-93,040 mm)
Piston Grade C 3.6630-3.6638"
(93,041-93,060 mm)
843 loader
Revised Jan. 94 -7C-41 - Service Manual
 MAIN BEARINGS

The crankshaft has f ive main bearings. The end play is

controlled by a thrust washer on both sides of the center main
bearing.

Each main bearing cap has identification mark in relation to the

engine block [!].

The position of each cap can not be changed from the original
location.

Removal

Remove the oil pan (See Page 7C-59).

Remove the oil pump (See Page 7C-60).

Remove the bolts from the main bearing caps.

Remove th main bearing cap and remove the bearing from the
cap half.

Remove the top half of the bearing by pushing on one side of

the bearing half and rotating the crankshaft I!J.

On the center main bearing, remove the cap .

Remove the top half of the bearing and thrust washers by

pushing on one side of the bearing and rotating the crankshaft.

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N

843 Loader
-7C-42- Service M;mual
MAIN BEARING (Cont'd)
A
Check the bearing spread as listed @.

Limit - 2.93" (74,5 mm)

Check to see if the bearing has enough tension, so that finger

pressure is needed to fit the bearing into the cap Ii].

8-8242

Installation With Oil Hole Fit Correctly

and Groove
Check the crankshaft journals before installing the main (Upper Side)
bearings (See Page 7C-45).

Make sure to position the bearing halves in their correct

locations [g.

Lubricate the new bearings. Install them by putting the end

without the tab into the block and rotating the crankshaft until
the tab is on its seat.

Install the other bearing half in the bearing cap. Lubricate the :....-No Oil Groove
bearing and install the cap on the engine block. and Hole
(Lower Side) 8-8254
Lubricate the bolts, install them finger tight only.

Install the center main bearing and thrust washers [Q].

The thrust washer must be installed so that their oil grooves

are turned to the rotating face of the crankshaft.

Repeat the procedure until all the main bearings and caps are
installed.

843 Loader
-7C-43- Service Manual
 MAIN BEARING (Cont'd)

Tighten the crankshah bearing cap bolts in the correct sequence

lKJ ·
Torque - 116-130 ft.-Ibs . (157-176 Nm) .

8 ·8257

Crankshaft End Play

The end play can be checked by either a feeler gauge liJor dial
indicator ~ .

Std. Limit
End Play 0 .004" (0, 1 mm) 0 .012" (0,3 mm)

The f itting of oversize thrust washer can be used to correct the

end play if it is over t he specifications.

~
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!~
843 Loader
-7C-44- Service Manual
CRANKSHAFT The portion to be tested
shall be held horizontally so
Removal as not to let the test
solution flow.
Remove the oil pan (See Page 7C-591. No testing solution near
the oil hole.
Remove the oil pump (See Page 7C - 60).
The sliding surface of -~--~.
\
f\
"
Remove the crankshaft pulley, timing case cover and timing pin or journal / /

~
gears (See Page 7C-49).

Remove the flywheel. Approximately

0.393" (10 mm)
Remove the connecting rod cap (See Page 7C-351.
8 ·8243
Remove the main bearing cap (See Page 7C -42).

Lift the crankshaft out of the engine block.

Checking Tuffriding (Soft Nitriding) Coating

Clean the crankshaft thoroughly using an organic solvent. Make

sure there is no oil or grease in the area to be tested.

Using a glass rod, put a drop of cupric ammonium chloride

5/1 0% solution at the test location @.

If no change takes place after an interval of 30-40 seconds,

the crankshaft can be re -used if within specifications.

Replace the crankshaft, if within the 30-40 seconds, the original

color of the solution (light blue in color) becomes transparent
where the test solution was dropped and will dis-color to a
copper color.

Immediatley after the test is completed, wipe off the area with
a cloth and thoroughly rinse with water.

I
NOTE: Since the crankshaft is tuffride coated it cannot be
re-ground.
g

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Checking
B
Check the crankshaft connecting rod journals lID.
Standard - 2.0833-2.0839" (52,915-52,930 mm)
limit - 2 .0829" (52,906 mm)

8·8244

843 Loader
Revised July 88 -7C-45- Service Manual
CRANKSHAFT (Cont'd)

Check the crankshaft main bearing journals ~.

Standard - 2.7526-2.7532" (69,917-69,932 mm)

Limit - 2.7524" (69,910)

8-8246

Check the clearance between connecting rod bearing and

crankshaft journal 00.

Install the bearing and cap and tighten nuts to 58-65 ft.-Ibs.
(79-88 Nm) torque. Put oil on the bearing and measure.

Nominal Diameter - 2.09" (53 mm)

Clearance between journal and bearing:

Standard - 0.0011-0.0026" (0,029-0,066 mm)

Limit - 0.004" (0,10 mm)

Check the clearance between main bearings and crankshaft

journals [g.

Install the main bearing and caps and tighten the bolts to
116-130 ft.-Ibs. (157-176 Nml torque . Put oil on the main
bearings and measure:

Nominal Diameter - 2.76" (70 mm)

Clearance between the journal and bearing:

Standard - 0.0014-0.0031" (0,035-0,080 mm)

Limit - 0.0043" (0,11 mm)

Check the crankshaft run-out [Q).

Standard - 0.0019 (0,05 mm) or less

Limit - 0.003" (0,08 mml

8 -8248

843 Loader
-7C-46- Service Manual
CRANKSHAFT {Cont'd}

Crankshaft Gear

The tools listed will be needed to do the following procedure:

MEL-1263 - Crankshaft Gear Installer

MEL-1264 - Crankshaft Rear Oil Seal

Removal and Installation

Use a puller to remove the gear @.

Use the correct size driver tool to install the gear lID.

Installation

Clean the crankshaft and check that all the oil passages are
clean and open .

Clean the engine block, lubricate and install the upper halves
of the main bearings.

Put the crankshaft carefully in position.

Install the main bearing caps and bolts {See Page 7C-42} .

Check the crankshaft so that it rotates freely. Check the end

play {See Page 7C-441.

Install a new rear oil seal @. Using the correct size driver tool.

Lubricate the connecting rod bearings. Install the bearings and

rod caps {See Page 7C-35J.

Install the oil pump {See Page 7C-60}.

Install the oil pan (See Page 7C - 59).

Install the timing gears, timing case cover and new front seal
{See Page 7C-49J.

Install the flywheel (See Page 7C-26J.

843 Loader
-7C-47- Service Manual
 TIMING CASE COVER SEAL

Removal and Installation

The tools listed will be needed to do the following procedure:

MEL-1265 - Crankshaft Front Oil Seal Installer

Remove the alternator and belt (See Page 6-8 for the correct
procedure} .

Remove the bolt at the crankshaft pulley ~.

Installation: Tighten the bolt to 123-152 ft .-Ibs. (167-206 Nm}

torque. B·8945

Install a standard puller and remove the crankshaft pulley 00.

Use a screwdriver and pry the front seal out of the timing case
cover ~.

B·8946

Use the seal installation tool and install the new seal ~.

~
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o
N

N
o

843 Loader
-7C-48- Service Manual
TIMING CASE COVER

Removal and Installation

Remove the alternator and belt (See Page 6-6 for the correct
procedure).

Remove the bolt at the crankshaft pulley ~.

Installation: Tighten the bolt to 123-152 ft.-Ibs. (167-206 Nm)

torque.

8·8945

Use a puller to remove the crankshaft pulley 00.

Remove the bolts which fasten the noise dampening shield to

the timing case cover 1£].

Remove the noise dampening shield [QJ.

843 Loader
-7C-49- Service Manual
 TIMING CASE COVER (Cont'd)

Remove the bolts from the timing case cover @.

Installation: Tighten the bolts to 10 ft.-Ibs. (14 Nm) torque .

Use a Allen wrench to remove the allen head bolt from the cover
lID·
Installation: Tighten the bolt to 11-17 ft.-Ibs. (1 5-23 Nm)
torque.

Remove the timing case cover ~.

8·8974

Installation: Put the O-ring gasket in the groove and hold it in

position using Form-A-Gasket so it will not fall out when
installing the cover @.

~
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,
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843 Loader
-7C - 50- Service Manual
IDLER GEAR AND HUB

Removal and Installation

Remove the timing case cover (See Page 7C -49).

Remove the bolts at the tube for gear lubrication ~.

Remove the tube lID .

Remove the bolts at the idler gear 1£].

Installation: Tighten the bolts to 10 - 12 ft.-Ibs. (14 - 16 Nm)

torque.

Remove the idler gear and hub @.

Checking

Check the idler gear hub:

Standard - 1.7695-1.7707" (44,945-44,975 mm)

limit - 1.7656" (44,845 mm)

Check the clearance between the idler gear and hub:

Limit - 0.0079" (0,2 mm)

Check the end play at the gear and hub:

Standard - 0 .003" (0,07 mm)

limit - 0.008" (0,2 mm)

843 Loader
-7C-Sl- Service Manual
 IDLER GEAR AND HUB (Cont'd)

Installation: Install the idler gear on the hub.

Make sure the timing marks are in alignment with the

crankshaft, camshaft and fuel injection pump idler gears @.

Check the backlash between the gears, the correct backlash

is 0.003" (0,178 mm).

o
o
N
o

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o

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M '

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o
'" 843 Loader
-7C-52- Service Manual
FUEL INJECTION PUMP IDLER GEAR

Removal and Installation

Remove the t iming case cover (See Page 7C-49).

Remove the idler gear (See Page 7C - 51 ).

Remove the bolt at the fuel injection pump idler gear @.

Installation : Tighten the bolt to 72-87 ft. -Ibs. (98-118 Nm)

torque.

Remove the idler gear and bearing lID.

If the bearing needs rep lacement, remove the snap ring at the
bearing ~ .

Use a press to remove and install the new bearing.

Bearing Installation

When installing t he new bearing, make sure the projection and

height is correct [QJ .
Projection
Projection - 0 .016-0 .024" (0,4-0,6 mm)
Height - 0.933-0.945" (23,7-24 mm)

Height
f
8 ·8896

843 Loader
-7C-53- Service Manual
 CAMSHAFT GEAR

Removal and Installation

Remove the timing case cover (See Page 7C - 49) .

Remove the idler gear (See Page 7C - 51 ).

Remove the bolt at the camshaft gear ~ .

Installation: Tighten the bolt to 72-87 ft.-Ibs. {98-118 Nml

torque.

Install t he puller and remove the gear lID .

Remove the bolts at the retainer plate ©.

Installation: Tighten the bolts to 11 - 17 ft .-Ibs. (15 - 23 Nml
torque.

/1
6 ·6960
8
'"o
8
~ Remove the retainer plate ~.

Installation : Check the camshaft end play.

Standard - 0.002-0.0045" (0,05-0,114 mml

Limit - 0.0079 (0,2 mml

o
o
N
o

N
o

o
o

~
iEo
"' 843 Loader
-7C-54- Service Manual
TIMING CASE

Removal and Installation

Remove the timing case cover (See Page 7C-49).

Remove the idler gear (See Page 7C - 51 ).

Remove the fuel injection pump (See Page 7C-6).

Remove the fuel injection pump idler gear (See Page 7C -53).

Remove the camshaft gear (See Page 7C - 54) .

Remove the water pump (See Page 7C-63).

Remove the oil pan (See Page 7C - 59).

Remove the bolts at the timing case ~.

Installation: Tighten the bolts to 11-17 ft.-Ibs. (15-23 Nm)

torque.

Remove the timing case 00.

Installation: After the timing case cover is installed with the

new gasket, cut the excess gasket at the engine block [£].

843 Loader
-7C-55- Service Manual
 CAMSHAFT

Removal and Installation

Remove t he rocker arm cover, rocker arm assembly and the

push rods (See Page 7C-29J.

Remove the timing case cover (See Page 7C-491.

Remove the camshaft gear (See Page 7C-54J.

Remove the oil pan and oil pump (See Pages 7C - 59 &
7C-60) .

Remove the camshaft from the engine. 8 ·8217

Checking

Check the camshaft journals @ .

B
Standard - 1.9662-1.9675" (49,945-49,975 mm) )
Limit - 1.9528" (49,60 mm ) 0
I
Check the bearing inside diameter lID . )
~
0
Standard - 1.9685- 1.9697" (50,0-50,03 mm)

Clearance between camshaft journal and bearing.

8 ·8218
Standard - 0 .002" (0,05 mm)
Limit - 0 .0047" (0,12 mm)

Check camshaft run -out @ .

Limit - 0.0039" (0, 1 mm)

Check cam lobe height !ru .

Standard - 1.654" (42,02 mm)
Limit - 1.640" (41,65 mm)

~
o
o
N

N
o

843 Loader
-7C - 56- Service Manual
CAMSHAFT (Cont'd)

Camshaft Bearings

The tools listed will be needed to do the following procedure:

MEL-1260 - Camshaft Bearing Remover/Installer

Use the correct tool to remove the bearings rAJ.

When installing the new bearings, make sure to align the oil
hole in the bearing with the hole in the engine block (Item 1)
00 ·

Tappets

Remove the tappets from the engine block. Mark the cylinder
number on each tappet after removal ~.

o
,
8·8190 o
~
o
o
~

Inspect the tappets for wear, damage or abnormal conditions

~.

Pitted Crack Normal Contact

Irregular Contact

8·8210

843 loader
-7C-57- Service Manual
 CAMSHAFT (Cont'dl

Check the diameter of the tappets ~.

(
Standard - 0.51091-0.51142" (12,977-12,990 mml
Limit - 0.50984" (12,950 mml

8·8211

Clearance between tappet and engine block bore as listed lID.

Standard - 0.0012" (0,03 mml
Limit - 0.0039" (0,09 mml

Installation
Lubricate the tappets before installation.

Lubricate the camshaft bearings and journals. Install the

camshaft, carefully not to damage the bearings.

Install the camshaft gear (See Page 7C - 541.

Check the camshaft end play using a feeler gauge ~.

Standard - 0.0002-0.0045" (0,05-0,114 mml

Limit - 0.0079" (0,2 mml

After the rocker arm assembly is installed, make sure to set

the valve clearance (See Page 7C-21.

~
o
o
,"o
,
N
o

0\
0 ,

!
~
g
843 Loader
-7C-58- Service Manual
OIL PAN

Removal

Remove the oil drain plug and remove the oil.

Remove the fastening bolts and nuts from the oil pan ~ .

Installation: Tighten the bolts and nuts to 13.7-18.6 f t .-Ibs .

!19-26 Nm) torque.

Installation

Clean the surface on the oil pan and engine block.

Put Three Bond (TB-1207B) at the front and rear main bearing
caps (Item 1) lID, [g.

Put liquid gasket on the oil pan surface area of the eng ine block .

8-8911

I
Install the oil pan. Install and tighten the bolts in the sequence
shown [ Q ] . -

8-12200

843 Loader
Revised December 87 -7C-59- Service Manual
 OIL PUMP

Removal and Installation

Remove the oil pan (See Page 7C - 59).

Remove the bolts at the oil pump tru .

Installation: Tighten the bolts to 10- 17 ft.-Ibs. (14-23 Nm)
torque .

Remove the oil pump assembly from the engil)e block lID .

Checking

Disassemble the oil pump as illustrated ~.

1. Oil Pipe
2. Strainer
3. Pump Cover
4. Vane

N
N
>

~
~

;:;
'"oo
,o
N

,
N
C

8-8420

843 Loader
-7C-60- Service Manual
OIL PUMP (Cont'd)

Check the clearance between vane and body!!].

Standard - 0.0008-0 .0028" (0,02-0,07 mm)

Limit - 0.0059" (0,15 mm)

Check t he clearance between the rotor and vane [ID .

Standard - 0.0055" (0,14 mm) or less

Check the clearance between the vane and pump body [ID .

Standard - 0.0079-0.0105" (0,2-0,27 mm)

Check clearance between rotor shaft and pump body .

Standard - 0 .0016" (0,04 mm)

Limit - 0.0079" (0,2 mm)

Gear Replacement

File off one end of the roll pin at the gear. Use a punch and
hammer and remove the pin ~.

.
11
"'
'"
'"en
0

~
~
0
,
~

,
0
~

'"
0
~

::;
NOTE: It maybe necessary to drill a hole in one side of the "'
~

gear for service as it does not have a hole on both sides

~.
.
~

"
~
0-
Installation: Install the gear and new pin. Peen the end of the 0-

pin after installation. "g

n
8
"b'
.><
'g
,
\

~
8-8425 ~

843 Loader ,'"

~

-7C-61 - Service Manual '"

~
0

~
 OIL PUMP (Cont'd)

Rotor Replacement

Remove the pin at the rotor using a punch and hammer @.

Installation: When installing the new pin in the rotor, make sure
to check the end of the pin that it does not project from the
end of the rotor @.

After the oil pump is assembled, put oil into the pump and turn
the shaft to prime the pump.

8·8426
8·8427

Oil Pump Relief Valve

Remove the relief valve from the oil filter housing IID.
Check the relief valve and clean. Replace as needed.

8
g

843 Loader
-7C-62- Service Manual
WATER PUMP

Removal and Installation

Remove the alternator belt.

Remove the water pump pulley @.

Remove the water pump bolts [!].

Installation: Tighten the bolts to 11-18 ft.-Ibs. (15-24 Nml

torque.

Remove the water pump from the engine block ~.

o
~

,o
~
o
o
'"

Disassembly

Remove the hub for the pulley using a press IQ].

8-8429

843 Loader
 WATER PUMP (Cont'd)

Disassemble the water pump IA].

8-8428

Check the bearing for abnormal noise, binding or wear ~ .

Replace the parts as needed.

Assembly

Apply a thin coat of liquid gasket cement to the outer surface

of the seal unit before assembly ~.

N
.::

8-8432

Press the bearing assembly into position by aligning the set

screw hole in the bearing with that in the pump body @.

8-8431

843 Loader
-7C-64- Service Manual
WATER PUMP (Cont'd)

After installation, check that the rear face of the impeller has
the correct height rAJ·

Height - 0.98" (25 mm)

8·8433

Check the distance between the pulley hub and pump body ~.

Distance - 3.13 ± 0.01" (79,5 ± 0,3 mm).

8 -8434

843 loader
-7C-65- Service Manual
 THERMOSTAT

Removal and Installation

Remove the bolts from the thermostat housing ~.

Installation: Tighten the bolts to 10-17 ft.-Ibs. (14-23 Nm)

torque.

Remove the thermostat.

Inspection

Check the thermostat opening temperature [ID.

Standard - 176- 183°F (80-84°C)

Check the thermostat valve lift:

Standard - Approximately 0.3" (8 mm) @ 203°F (95°C)

6·8435

If the thermostat housing assembly is removed, tighten the

bolts to 10-17 ft.-Ibs. (14-23 Nm) torque (Item 1) @.

'"oo
N
"-
~
N

'"
"

, ~~r

6-8419

~
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"-

N
o

843 Loader
-7e-56- Service Manual
WATER JACKET TUBE

Removal and Installation

Remove the timing case cover {See Page 7C-491.

Remove the idler gear and hub (See Page 7C-51).

Remove the fuel injection pump (See Page 7C-6).

Remove the fuel injection pump idler gear (See Page 7C - 53).

Remove the camshaft gear (See Page 7C-54J.

Remove the timing case (See Page 7C-55).

Remove the water pump (See Page 7C -63).

Grip the eds.e of the water jacket tube with a vise grip. Use
a screwdriver to pry the jacket from the engine block ~.

Remove the water jacket tube from the engine block 00·

843 Loader
-7C-67- Service Manual
 TECHNICAL DATA

Section
Number

TECHNICAL DATA (Perkins Engine) . . . . . . . . . . . . . . . . . . 8A-1

TECHNICAL DATA (200 Series Perkins Engine). . . . . . . . . 88-1

TECHNICAL DATA (lsuzu Engine). . . . . . . . . . . . . . . . . . . 8C-1

GENERAL SPECiFiCATIONS. . . .. .... . . .. ... .. .. .. . 8-1

TECHNICAL
DATA

o
,
~

SPECIFICATIONS ,o
~

(Perkins) o
o
'"

SPECIFICATIONS
((200 Series Perkins)

SPECIFICATIONS
(lsuzu)

GENERAL
SPECIFICATIONS

843 Loader
Service Manual
Page 457 - BOBH027201BI001 - 02/10/2009 17:56:25 - Printed by Ken Cook Co, - e>:print. e xe (v2.24.3 8/2 5 /2008)
"'" ---.
 GENERAL SPECIFICATIONS

Page
Number

DEC IMAL & MILLIMETER EQUIVALENTS

Chart .. ... .. ...... . ... . ........... . ....... . 8-13

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS

Specifications .... .. ....................... .. . 8-12

STANDARD TORQUE SPECIFICATIONS FOR BOLTS

Chart .... . ........... .. .......... . . . .. .. . . . 8-14

TORQUE SPECIFICATIONS
Brake, Axle & Chaincase Group .. .. . . .. .. . .. .... . . 8-3
Engine Group (Perkins) ................ . ........ . 8-6
Engine Group (Perkins) ..... .. . ... ...... .. .... . . . 8-7
Engine Group (200 Series Perkins) ...... .. . ... . . .. . 8-8
Engine Group (200 Series Perkins) . . . .... . ...... . . . 8-8
Engine Group (Isuzu) .. .. . ...... . ..... ... ...... . 8-10
Engine Group (Isuzu) . . . . . .. . . .. .. . .. .. . .... .. . . 8-11
Hydraulic/Hydrostatic Group . . .. . . .. . ... ..... . . . . 8-5
Operator Guard, lift Arm & Main Frame Group ....... . 8-4
Seat Bar, Fuel Tank & Panel Group . . .. .. .. ... .. .. . 8-1
Steering Levers, linkage & Pedal Group . . ... . . . .... . 8-2

U.S . TO METRIC CONVERSION

Chart .. .. . . .... .. . .. .. ... . . . . .. . . . .. .. .... . 8-13

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,
o

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'"

GENERAL
SPECIF ICA TIONS
843 Loader
Revised June 87 Service Manual
TORQUE SPECIFICATIONS

Seat Bar. Fuel Tank & Panel Group

Ref. Torque

1. 16-20 ft.-Ibs.
(21-27 Nm)

2. 40-45 ft.-Ibs.
(54-61 Nm)

3. 9-11 ft .-Ibs.
(12-15 Nm)

4. 25-28 ft.-Ibs.
(34-37 Nm)

5.* 7 -8 ft.-Ibs.
(9-10 Nm)

~/
(1fl
I
I

I
l ______ _ __ ..,

I
I
@
/ i .t_ _ _____ _ -.

----- 1
I
I
I
I
I
I
I
I
I
I
q
0 ·1596
0 ·1548
* Put Lock.:rite on the Treads 0·1696

843 Loader
-8-1- Service Manual
 TORQUE SPECIFICATIONS (Cont'd)

Steering Levers, Linkage & Pedal Group

•
Ref. Torque

1. 25-28 ft.-Ibs.
(34-38 Nm)

2. 11-13 ft.-Ibs.
(15-18 Nm)

18-20 ft.-Ibs.
(24-27 Nm)

8
'8
u
§
'"

~
N

'"oo
,o
N

N
o

E·1525
k :r'te on the Treads
*Putloc-I E·1617

843 Loader
-8-2- Service Manual
TORQUE SPECIFICATIONS (Cont'd)

Brake. Axle & Chaincase Group

Ref. Torque
rt'
~,*r-r - _-----~ I

1. 65-70 ft.-Ibs. ~ 0 I:r ------- ___ _

~,

(88-95 Nm) $=====4/ :

I
I r
I
2.* 65-70 ft.-Ibs. : ~J'
I

(88-95 Nm) Il,. ... _J' -

3.* 475-525 ft.-Ibs.

(645-710 Nm)

4. 16-20 ft.-Ibs.
(21-27 Nm)

5. 220-234 ft.-Ibs.
(300-330 Nm)

----to<=:>
cp
0 ·1 553
C·2528
* Put Lock:nte on the Treads 0 -1524

843 Loader
-8-3- Service Manual
 TORQUE SPECIFICATIONS (Cont'd)

Operator Guard, Lift Arm & Main Frame

Group

Ref. Torque

1. 65-70 ft.-Ibs.
(88-95 Nm)

2. 20-40 ft.-Ibs.
(27-55 Nm)
Required to push the
handle into lock
position

3. 55-70 ft.-Ibs.
(75-95 Nm)

4~ 15-17 ft.-Ibs.
(21-23 Nml

5. 15-20 ft.-Ibs.
(21-27 Nm)

6. 25-28 ft.-Ibs.
(34-38 Nm)

7. 220-245 ft.-Ibs.
(300-330 Nm)

8. 18-20 ft.-Ibs.
(24-27 Nm)

9. 105-115 ft.-Ibs.
(142-156 Nm)

~11'
ch
,.
~

m
o
o
N
o

N
o

o
o
m' .
o
N
<-
N E·1 618
o
ffi 0·1522
g
843 Loader
-8-4- Service Manual
TORQUE SPECIFICATIONS (Cont'd)

Hydrau ,.IeIHydrostatic Group

r--r:
~
."..t,..

o
,
~

,o
~
o
o
'"

E-1726
E-1806
E- 1725

843 Loader
* Revised July 88 -8-5- Service Manual
TORQUE SPECIFICATIONS (Cont'd)

Engine Group {Perkins}

Ref. Torque

1. 125-140 ft .-Ibs.
(169-190 Nm)

2. 25-28 ft.-Ibs.
(34-38 Nm)

3. * 40-45 ft.-Ibs.
(51-54 Nm)

4. 75-80 ft.-Ibs.
(102- 108 Nm)

5. 16-20 ft.-Ibs.
(21-27 Nm) . ~~.:~ _w ___ ___ ~

6. 65-70 ft.-Ibs . A/ t
(88-95 Nm) g:;,\"@!>'~' f
7. 15-17 ft.-Ibs.
(21-23 Nm) ;--~'0cb
L V
!:·-·-------l'0
- -~ :,
; :
~ :

* Put lock-Tite on the Treads E-1252

843 Loader
Revised June 87 -8-6- Service Manual
TORQUE SPECIFICATIONS (Cont'd)

Engine Group (Perkins)

Ref. Torque

1. 15-17 ft .-Ibs.
(21-23 Nm)

2. 25-28 ft.-Ibs.
(34-38 Nm)

3. 16-20 ft .-Ibs .
(21-27 Nm)

4. 75-80 ft.-Ibs.
(102-108 Nm)

5 ... 25-28 ft.-Ibs. ,

(34-38 Nm) ,
,
,
,,
6 ... 23-25 ft.-Ibs.
/ / .• ••• • . • •. . ...!
(31 -34 Nm)
,...~.,

* Put Lock-Tite on the Treads E·1339

.
x"

843 Loader
Revised June 87 -8-7- Service Manual
 TORQUE SPECIFICATIONS (Cont'd)

Engine Group (200 Series Perkins)

,/1"'"" ___ ___ _

Ref. Torque I
I

,//
1. 125- 140 ft. -Ibs. /
/
,~
(169-190 Nm) / fl/ ~,,
I
/ /
/

(J)· -g-.-'~i,. //~7

2. 25-28 ft .-Ibs. / //// ,
/
(34-38 Nm) ,,
(

'.
(' .

3 .* 40-45 ft .-Jbs . . -""

(51-54 Nm)

4. 75-80 ft.-Ibs.
(102-108 Nm) *
5. 16-20 ft. -I bs.
(21-27 Nm)

6. 65-70 ft.-Ibs .
(88-95 Nm)

7. 15-17 ft. -Ibs.

(21-23 Nm)

----- --------_J
* Put lock-Tite on the Treads
E· 1626

843 loader
Revised June 87 -8 - 8- Service Manual
TORQUE SPECIFICATIONS (Cont'd)

Engine Group (200 Series Perkins)

Ref. Torque

I
1. 15-17 ft.-Ibs .
(21 -23 Nm)

2. 25-28 ft .-Ibs.
(34-38 Nm)

3. 16-20 ft.-Ibs.
(21-27 Nm)

4. 75-80 ft .-Ibs.
(102-108 Nm)

5. * 25-28 ft .-Ibs.
(34-38 Nml

6.* 23-25 ft.-Ibs.

(31-34Nm)

....,....1,'/,'/

* Put Lock-Tite on the Treads E-1627

843 Loader
Revised June 87 -8-9- Service Manual
TORQUE SPECIFICATIONS (Cont'd)

Engine Group (Isuzu)

Ref. Torque

1. 125-140 ft.-Ibs.
(169-190 Nm)

2. 25-28 ft.-Ibs.
(34-38 Nm)

3.* 40-45 ft.-Ibs.

(51-54 Nm)

4. 75-80 ft.-Ibs.
(102-108 Nm)

5. 16-20 ft.-Ibs.
(21-27 Nm)

6. 65-70 ft.-Ibs.
(88-95 Nml

7. 15-17 ft.-Ibs .
(21-23 Nm)

* Put Lock-Tite on the Treads E· 1686

843 Loader
Revised June 87 -8-10- Service Manual
TORQUE SPECIFICATIONS (Cont'd)

Engine Group (Isuzu)

Ref. Torque

1. 15- 17 ft .-Ibs.
(21-23 Nm)

2. 25-28 ft.-Ibs.
(34-38 Nm)

3. 16-20 ft. -Ibs .

(21-27 Nm)

4. 75-80 ft.-Ibs .
(102-108 Nm)
-,
I
I
5.* 25-28 ft. -Ibs. I
I
(34-38 Nm) I
I
I
I
I
I
I
I
I
I
I
I

--" ! I
I
I
I
J

//

.........
f
// '"
~

"-g
~
~
0

T
------_1 "'
g

* Put Lock-Tite on the Treads

E-1701
I
,
0
~

,0
~
0
0
~

~
~

~
~

'"
~

"'"
"
~
0
"-

.
rr
"
'"
n"
0
~
S'

843 Loader
Revised June 87 -8-11- Service Manual
 HYDRAULlC/HYDROSTATIC FLUID SPECIFICATIONS
NOTES _________________

/
( Specifications

Use Melroe hydraulic/hydrostatic transmission fluid (PIN 6563328) . If this fluid is not
available, use 10W-30 or lOW·40 SAE Motor Oil (5W-30 for OOF [-18°C] and Below).

DO NOT use automatic transmission fluids in the loader or permanent damage to the
transmission will result.

Avoid contact with leaking hydraulic fluid

which under pressure can be forced
through the skin. Never check for leaks
in a hydraulic system with your bare
hands . Use a piece of wood or
cardboard. If your skin is penetrated by
a fluid under pressure, consult a qualified
medical service.

Where temperatures below zero are common, the loader must be kept in a warm
building. Extra warm -up time must be used each time the loader is started during cold
temperature conditions. Cold fluid will not flow easily and it makes action of the
hydraulic function slower. Loss of fluid flow to the hydrostatic transmission pump
(ind icated by " TRANS" light "ON") will cause transmission damage in less then 60
seconds time.

m
o
o
N Stop the engine if the "TRANS" light
o
, comes "ON" and stays "ON". The light
N
o indicates the loss of fluid flow to the
hydrostatic pumps which will cause
transmission damage in less than 60
seconds time.

843 Loader
Added June 87 -8-12- Service Manual
 DECIMAL AND MILLIMETER EQUIVALENTS
NOTES
FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 0 .015625- 0.397 33/64 0 .515625-13.097

1/32 0.03125 - 0.794 17 /32 0.53125 -13.494
3/64 0 .046875 - 1.191 35/64 0.546875 - 13.891
1116 0.0625 1.588 9/16 0.5625 - 14.288
5/64 0 .078125- 1.984 37/64 0.578125- 14 .684
3/32 0 .09375 - 2.381 19/32 0 .59375 -15.081
7/64 0 .109375 - 2.778 39/64 0.609375 - 15.478
1/8 0.1250 3 .175 5/8 0 .6250 -15.875
9/64 0.140625- 3.572 41164 0.640625- 16.272
5/32 0.15625 - 3.969 21/32 0.65625 - 16.669
11/64 0.171875- 4.366 43/64 0.671875-17.066
3/16 0 .1875 4 .762 11/ 16 0 .6875 -17.462
13/64 0.203125- 5. 159 45/64 0 .703125-17.859
7/32 0.21875 - 5 .556 23/32 0.71875 -18 .256
15/64 0 .234375- 5.953 47/64 0.734375- 18 .653
1/4 0.2500 6.350 3/4 0.7500 -19 .050
17/64 0.265625 - 6.747 49/64 0.765625- 19.447
9/32 0.28125 - 7.144 25/32 0.78125 -19.844
19/64 0 .296875- 7 .541 51/64 0.796875-20.241
5/16 0 .3125 7.938 13/16 0.8125 -20.638
21/64 0 .328125- 8.334 53/64 0 .828125-21 .034
11/32 0 .34375 - 8.731 27/32 0.84375 -21.431
23/64 0.359375 - 9.128 55/64 0.859375-21.828
3/8 0.3750 - 9.525 7/8 0.8750 -22.225
25/64 0 .390625 - 9 .922 57/64 0 .890625-22 .622
13/32 0 .40625 -10.319 29/32 0 .90625 -23 .0 19
27/64 0 .421875-10.716 59/64 0 .921875-23.416
7/16 0.4375 - 11.112 15/16 0.9375 -23.812
29/64 0.453125-11.509 61/64 0.953125-24.209
15/32 0.46875 - 11.906 31/32 0.96875 - 24.606
31/64 0.484375 - 12.303 63/64 0.984375-25.003
1/2 0.5000 - 12.700 1 1.000 -25.400
1 mm = 0 .03937" 0 .00'" = 0.0254 mm

U.S. TO METRIC CONVERSION

-,
0
TO CONVERT INTO MULTIPLY BY ~
LINEAR Miles Kilometers 1.609 ...
~

MEASUREMENT Yards Meters 0.9144

Feet Meters 0.3048 '"
0

'"
Feet
Inches
Centimeters
Meters
30.48
0 .0254
~
Inches Centimeters 2 .54
'"
0
0

Inches Millimeters 25.4

0

AREA Square Miles Square Kilometers 2.59 ,

~

Square Feet Square Meters 0 .0929 ,

0

'"
0
Square Inches Square Centimeters 6.452 0

Acre Hectare 0.4047 :;'"

~
~

VOLUME Cubic Yards Cubic Meters 0 .7646 ~

~

Cubic Feet Cubic Meters 0 .02832

Cubic Inches Cubic Centimeters 16.39 ,"'"
WEIGHT Tons (Short)
Pounds
Metric Tons
Kilograms
0 .9078
0.4536
·"
~

.,.
'"
PRESSURE
Ounces (Avdp .)
Pounds/Sq. In.
Grams
Kilopascal
28.3495
6 .895
·,.,
'"
0
,...
0

WORK Foot-pounds Newton-Metre 1.356 ,.,

0

LIQUID VOLUME Quarts

Gallons
Liters
liters
0.9463
3.785 ·
x
;:;
LIQUID FLOW Gallons/Minute Liters/Minute 3 .785
TEMPERATURE Fahrenheit Celsius 1. Subtract 32 0
2. Multiply by 5/9

843 Loader
Added June 87 -8-13- Service Manual
 STANDARD TORQUE SPECIFICATIONS FOR BOLTS
NOTES ________________

The following table shows standard torque specifications for bolts with zinc phosphate
coating. Bolts purchased from Clark that have zinc phosphate coating are specified by the
letter "H" following the part number.

THREAD
SIZE SAE GRADE 5 SAE GRADES

INCH. .250 SO-90 110-120

LBS. (9-10) (13-14)
(Nm)
.3125 1SO-2OO 215-240
(21-23) (24-27)
.375 25-28 35-40
(34-38) (48-54)
.4375 40-45 60-65
(54-61) (82-88)
.500 65-70 90-100
(88-95) (125-135)
.5625 90-100 125-140
(125-135) (170-190)
.625 125-140 175-190
(170-190) (240-2601
FOOT .750 220-245 300-330
LBS. (300-3301 (410-450)
(Nm)
.875 330-360 475-525
(450-490) (645-710)
1.000 475-525 725-800
(645-710) (985-1085)
1.125 650-720 1050-1175
(880-975) (1425-1600)
1.250 900-1000 1475-1625
(1200-1360) (2000-2200)
1.375 1200-1350 2000-2200
(1630-1830) (2720-29801
1.500 1500-1650 2600-2850
(2040-2240) (3530-3870)
1.625 2000-2800 3450-3800
(2720-2980) (4680-5150)
1.750 2500-2750 4300-4800
(3390-3730) (5830-6500)
1.875 3150-3500 5500-6100
(4270-4750) (7450-8300)
2.000 3800-4200 6500-7200
(5150-5700) (8800-9800)

843 Loader
Added June 87 -8-14- Service Manual
 TECHNICAL DATA

Page
Number

ENGINE SPECIFICATIONS
Cooling System & Water Pump Dimensions ....... . . . BA-B
Crankshaft & Main Bearing Dimensions ............ . BA-5
Cylinder Block & Liner Dimensions ................ . BA-5
Cylinder Head Dimensions ...................... . BA-3
De-Rating for Altitude ......................... . BA-9
Engine Torque ............................... . BA-9
Fuel System Specifications ..................... . BA-B
Grinding Specifications for Crankshaft ............. . BA-10
Oil Pump Dimensions .......................... . BA-7
Piston & Connecting Rod Dimensions .............. . BA-4
Timing Case, Camshaft & Drive Dimensions ......... . BA-6

LOADER SPECIFICATIONS
Capacities .................................. . BA-2
Drive System ............................... . BA-2
Electrical ................................... . BA-2
Engine ..................................... . BA-l
Loader Hydraulics ............................ . BA-2
Specifications ............................... . BA-l
Tire ....................................... . BA-2

SPECIFICATIONS
(Perkins)

843 Loader
Revised June 87 Service Manual
 8A LOADER SPECIFICATIONS

Where applicable, specifications

Ir-- (1584)
conform to SAE standards.
Specifications are subject to 62.4--j
change without notice. .,/ !
/:"",::::::
99 0
t
155.2
I
, /.,-,-.~' -:/:' :.- :'-:': >fo/,:,~-: -\~ -' ' ':' '\L.____~(3941)
./ . ,- ..-
(: ...... ~ ...-::
/<,/ 37
0
••••. , •• \

,/ ../..:? ;:-::;';---¥-----,.
"---1 -----;-'-~
8004
(2042)

131.4
t - - - - - - - ( 3 3 3 8 ) ---~

PI-2585
Dimensions are given for a loader equipped with standard tires and dirt bucket.
Dimensions may vary with other bucket types. All dimensions are shown in inches.
Respective metric dimensions are given in millimeters enclosed by parentheses.

NOTES _______________
SPECIFICATIONS

Weights
Operating Weight ., ...... , ... , . . . . . . . . . . . . . . . .. 6500 Ibs. (2951 kg)
Rated Operating Capacity ......................... 17001bs. (772 kg)
Tipping Load (SAE) ................ . ............ 3400 Ibs. (1544 kg)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.0 to 6.3 MPH {10,1 km/hr.l g
Controls
Vehicle . . . . . . .. Direction and speed controlled by two hand-operated levers.
Loader Function .. . . . .. Lift, tilt functions controlled by separate foot pedals.
Auxiliary function controlled by the right steering lever.
Engine . . . . . . . . . . . . . . . . . . . .. Hand lever throttle; key type starter switch
i
Main Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Hydrostatic
Brakes. . . . . . . . . . . . . . . . . . . . . . . . .. Mechanical disc, foot-operated pedal.

ENGINE

Make .................. . ............................... Perkins

Model ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.154
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Diesel
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 54 HP (40,3 kWI
Maximum Governed RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2600 RPM
Torque ............................. 113 ft.-Ibs. (153 Nm) @ 1800 RPM
Number of Cylinders ........................................... 4
Bore/Stroke ................................. 3.50 (88,9)/4.00 (101,6)
Displacement '" . . . . . . . . . . . . . . . . . . . . . . . . . . .. 153.9 cu. in. (2522 cm 3 )
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Liquid
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Open PCV System
Air Cleaner .................. Dry replaceable paper element, dual element
ILow Idle ......................................•....... 1150 RPM
High Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2725-2775 RPM

843 Loader
Revised Feb. 94 -8A-1- Service Manual
 LOADER SPECIFICATIONS (Cont'd)
NOTES _________________
LOADER HYDRAULICS

Pump .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Gear type

Pump Capacity .................... 15.4 GPM (58,3 Llmin.) @ 2720 RPM
System Relief Pressure ... 2325-2500 PSI (16030-17238 kPa) @ Aux. Couplers
Hydraulic Fluid Filter. . . . . . . . .. Replaceable cartridge 10 micron paper element
& 40 micron metal filter
Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Doubleacting
Bore Diameter:
Lift Cylinder (2) .................................... 2.25 (57,2)
Tilt Cylinder (2) . . .......... . ...... . ............. . .. 3.25 (82,6)
Rod Diameter:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.50 (38,1)
Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.50 (38,1)
Stroke:
Lift Cylinder (2) ... . .............................. 33.50 (850,9)
Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. 17.95 (455,9)
Control Valve . . . . . . . . . . . . .. 3-spool, open center type W/float detent on lift,
detent on auxiliary and self leveling on tilt.
Fluid Lines .............. . ......... SAE standard tubes, hoses & fittings

Hydraulic Function Time:

Raise Lift Arms to Maximum Height . . . . . . . . . . . . . . . . . . . . .. 4.8 Seconds
Lower Lift Arms from Maximum Height. . . . . . . . . . . . . . . . . . .. 3.8 Seconds
Move Bucket to Dump Position . . . . . . . . . . . . . . . . . . . . . . . . .. 2.2 Seconds
Move Bucket to Retracted Position ....................... 2.1 Seconds

ELECTRICAL

Alternator ..................... Belt driven, 37 amps. @ 2750 RPM open

Battery ........ Two (2) batteries, in parallel @ 12 volt, 370 cold crank amps.
@ OOF (-17,8°C) 106 min. reserve capacity
Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 volt gear drive

DRIVE SYSTEM

Transmission ............... Hydrostatic infinitely variable fully reversing (2)

Final Drive. . . . . . . . . . . . .. Gear reduction with #100 roller chain, operating in
N sealed chain case with oil lubrication.
N
2: Total Engine to Wheel Reduction:
Gear Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.54:1
Chain Reduction ......................................... 31.11:1
Fluid Type. . . . .. Clark Bobcat Fluid (PIN 6563328 [5 gal. Package]). If the fluid
is not available, use 10W-30 or 10W-40 Class SE Motor Oil.

CAPACITIES

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22 qts. (21 L)

Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22 gals. (83 Ll
Engine Lubrication W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9.5 qts. (9 Ll
Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 gals. {34 Ll
Hydraulic/Hydrostatic Reservoir. . . . . . . . . . . . . . . . . . . . . . .. 15.5 qts. (14,7 L)

TIRES

rl Standard ...................... 8.25 x 15, 6 Ply Rating, Nylon W/Bar Lug

o
o
rl Pressure ............................•.... 45-50 PSI (310-345 kPal

I
@
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .• 12 x 16.5, 6 Ply Rating
Pressure ................................. 45-50 PSI {310-345 kPal

" 843 loader

-8A-2- Service Manual
ENGINE SPECIFICATIONS
NOTES _________________
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parenthesis.

Cylinder Head Dimensions

Cylinder Head:
Overall Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.248/3.252 (82,5/82,6)
Grinding Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. DO NOT GRIND
Valve Seat Angle ............ . ............................. 45 0
Bore for Valve Guide ........................ 0.500/0.501 (12,7/12,73)
Bore for Combustion Chamber Insert. . . . . . . . . .. 1.375/1.3766 34,92/34,96)
Depth of Bore for Inserts . . . . . . . . . . . . . . . . . .. 0.424/0.4281 (10,80/10,87)

Combustion Chamber Inserts:

Outside Diameter. . . . . . . . . . . . . . . . . . . . . . . . .. 1.3724/1.374 (34,86/34,9)
Clearance Fit in Bore . . . . . . . . . . . . . . . . . . . . .. 0.00110.0042 (0,025/0,106)
Insert Thickness .................. . . . . . .. 0.425210.426 (10,80110,82)
Height of Insert in Relation to Cylinder Head Face ..... 0.0029 (0,07) Below

Valve Guide, Inlet & Exhaust:

Outside Diameter ........................ 0.501/0.50175 (12,73/12,74)
Interference Fit in Bore ............... 0.00025/0.00175 (0,0063/0,0444)
Overall Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.13 (54,10)
Guide Height Above Cylinder Head. . . . . . . . . . . .. 0.638/0.662 (16,20/16,81)
Valve Guide Bore Diameter ................... 0.3145/0.3155 (7,9918,01)

Valves, Inlet:
Valve Stem Diameter. . . . . . . . . . . . . . . . . . . . . . . .. 0.312/0.313 (7,92/7,95)
Clearance Fit of Stem in Guide ............. 0.0015/0.0035 (0,038/0,089)
Valve Head Diameter . . . . . . . . . . . . . . . . . . . . . . .. 1.59/1.598 (40,41/40,59)
Valve Face Angle .......................................... 45 0
Valve Depth into Cylinder Head ....... 0.027/0.040 (0,69/1,02) (Production)
0.060 (1,52) (Service)
Overall Length .............. . ........... 4.503/4.521 (114,38/114,83)
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . . . . .. Synthetic Rubber Deflector

Valves, Exhaust:
Valve Stem Diameter. . . . . . . . . . . . . . . . . . . . . . . .. 0.312/0.313 (7,9217,95)
Clearance Fit of Stem in Guide ............. 0.0015/0.0035 (0,03810,089)
Valve Head Diameter. . . . . . . . . . . . . . . . . . . . . .. 1.3937/1.4016 (35,4135,6)
Valve Face Angle .......................................... 45 0
Valve Depth into Cylinder Head ....... 0.027/0.040 (0,69/1,02) (Production)
0.060 (1,52) (Service)
Overall Length .......................... 4,503/4.521 (114,38/114,83)
Valve Stem Seal ................. . . . . . . . . . . . . . . . . . . . . . . . .. None

Valve Springs, Inner:

Fitted Length ......... . . . ..... . . . . . . . . . . . . . . . . . . . . .. 1.49 (37,85)
Load at Fitted Length ............ 281bs. ± 1.4 Ibs. (12,7 kg ± 0,635 kg)
Free Length ........................................ 1.74 (44,20)

Valve Springs, Outer:

Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.59 (40,39)
Load at Fitted Length. . . . . . . . . . . .. 40 Ibs. ± 2.0 lbs. (18,1 kg ± 0,908 kg)
Free Length ........................................ 1.81 (45,97)

Rocker Arms:
Bore Diameter .......................... 0.718810.7196 (18,26118,28)
Outside Diameter of Bushing ............... 0.7199/0.7207 (18,29/18,30)
Interference Fit of Bushing ................ 0.0003/0.0019 (0,008/0,048)
Inside Diameter of Bushing (Fitting) 0.62510.6528 (15,88/15,90)

843 Loader
-8A-3- Service Manual
ENGINE SPECIFICATIONS (Cont'd)
NOTES ________________
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parenthesis.
Cylinder Head Dimensions (Cont'd)

Rocker Arm Shaft:

Outside. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.6234/0.6244 (15,83/15,86)
Clearance Fit of Rocker Arm . . . . . . . . . . . . . . . .. 0.0006/0.0024 (0,0110,06)
Lubrication .. '.' . . . . . . . . . . . . . . . . . . . . . . . .. No. 1 Bracket Through Shaft

Push Rods:
Overall Length. . . . . . . . . . . . . . . . . . . . . . . .. 8.5102/8.5412 (216,16/216,94)
Outside Diameter ............................ 0.246/0.25 (6,27/6,35)

Piston and Connecting Rod Dimensions

Piston:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Flat Top
Piston Height to Cylinder Block Face . . . . . . . . . . .. 0.00010.004 (0,0010,102)
Piston Pin Bore Diameter ................... 1.2495/1.250 (31,74/31,75)
Transition Fit of Pin in Bore . . . . .. 0.00024 in clearance/0.00046 interference
(0,006/0,012)
Ring Groove Width (Top, 2nd & 3rd) . . . . . . . . . . . .. 0.09610.097 (2,4412,46)
Ring Groove Width (4th & 5th) . . . . . . . . . . . . . . .. 0.1895/0.1906 (4,8114,84)

Pistons Rings:
Compression (Top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Chrome Plated
Compression (2nd & 3rd) . . . . . . . . . . . . . . . . . . . . . . . . .. Internally Stepped
Scraper (4th) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Chrome Plated, Slotted
Scraper (5th) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Slotted
Ring Width (Top, 2nd & 3rd) . . . . . . . . . . . . . . . . .. 0.093/0.0938 (2,36/2,38)
Ring Clearance in Groove .................. 0.0022/0.004 (0,05610,102)
Ring Width (4th) .......................... 0.1868/0.1875 (4,74/4,76)
Ring Clearance in Groove . . . . . . . . . . . . . . . . . .. 0.00210.0038 (0,05/0,097)
Ring Width (5th) ............ . ............. 0.1865/0.1875 (4,74/4,76)
Ring Clearance in Groove ........... . ........ 0.00210.004 (0,05/0,102)
Ring Gap (Top) ............................. 0.014/0.019 (0,36/0,48)
Ring Gap (2nd & 3rd) ..................... . ... 0.01110.016 (0,28/0,41)
Ring Gap (4th) ....... . ..................... 0.014/0.019 (0,3610,48)
Ring Gap (5th) ....................... . ...... 0.01110.016 (0,28/0,41)

NOTE: The ring gaps which are given are measured in a 3.501 (88,93) diameter bore.
If the gaps are measured in a larger bore, you must add 0.003 (0,08) for every
0.001 (0,025) above 3.501 (88,93).

Piston Pins:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Fully Floating
Outside Diameter ...................... 1.24976/1.24996 (31,74/31,75)
Clearance in Rod End ............ . ..... 0.00054/0.00175 (0,01410,044)

Connecting Rods:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. "H" Section
Big End Bore ................. . . . . . . . . .. 2.39512.3955 (60,83/60,85)
Small End Bore .. . . . . . . . . . . . . . . . . . . . . . . . .. 1.37511.376 (34,93/34,95)
Big End Width ............................ 1.361/1.363 (34,57/34,62)
Length from Center Line of Big End to
Center Line of Small End ............... 6.8115/6.8135 (173,01/173,06)
Rod End Play ............................ 0.0095/0.0131 (0,2410,33)
Big End Bolt Size ..................................... 7/16 (11,11)
Thread of Bolt ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. U.N.F.
Type of Nut ........................................ Self-Locking

Small End Bushing:

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Steel Backed, Bronze Lined
Length of Bushing ......................... 1.047/1.055 (26,59/26,80)
Outside Diameter. . . . . . . . . . . . . . . . . . . . . . . .. 1.3785/1.380 (35,01/35,05)
Interference Fit of Bushing in Rod . . . . . . . . . . .. 0.0025/0.005 (0,064/0,127)
Inside Diameter (Bushing in Position After Reaming) 1.2505/1.2515 (31,76131,79)
843 Loader
-8A-4- Service Manual
ENGINE SPECIFICATIONS (Cont'd)
NOTES _________________
All dimensions are given in inches. Re spective metric dimensions are given in millimeters enclosed by
parenthesis.
Piston and Connecting Rod Dimensions (Cont'd)

Connecting Rod Bearings:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel Backed, Aluminum Tin Lined
Width . . ................... . .. . .. . .. . . . 1.1 208 /1.1280 (28,47 /28,65)
Outside Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.3955 (60,85)
Inside Diameter ..... . . . . . . . . . . . . . . . . . . . . 2.2504/2.2515 (57,16/ 57,19)
Bearing Running Clearance . . . . . . . . . . . . . . . .. 0 .0014/0.003 (O,036 /0,076 )

Cylinder Block and liners Dimensions

Cylinder Block:
Total Height of Cylinder Block ... . . ...... ..... 11.177/11.181 (283,9/284,O)
Bore Diameter for Cylinder Liner . ... . .. . . .. . 3 .8125/3.8135 (96 ,84/96,86)
Liner Flange Depth in Block ... . .. . .. .. . .. .... . . 0.15010 .152 (3,81 /3,86)
Cylinder Block Recess Bore. . . . . . . . . . . . . . . .. 3.990/3.995 (101,35 /101.47)
Main Bearing Bore . . . . . . . . . . . . . . . . . . . . . . . .. 2.916 /2.917 (74,07f74,09)
No.1 Bore for Camshaft. . . . . . . . . . . . . . . . . . . 2.0472 /2.0484 (52,O/52,03 )
No.2 Bore for Camshaft . ...... .... . . ..... 2.0374/2.0386 (51,75/51,78)
No. 3 Bore for Camshaft . . . . . . . . . . . . . . . . . . . 2.0275/2.0287 (51,5151.53)
No.4 Bore for Camshaft . . . . . . . . . . . . . . . . . .. 2.0177 /2.0189 (51 ,25 /5 1,28)
Tappet Bore Diameter .... .. ...... .. ..... 0 .5625 /0 .56375 (14,29 /14,32)
Crankshaft Thrust Washer Recess in
Block Diameter. . . . . . . . . . . . . . . . . . . . . . . . . .. 3.756/3.764 (95,4/95,6)

Cylinder Liners:
Type . ...... . ... . ............ ... .. . .. . . ...... Dry Interference Fit
Outside Diameter ..... ... .. . .... . . .. . .... 3.8145 /3.8155 (96 ,89 /96,91)
Interference Fit of Liner into Cylinder Block Bore .. 0 .001 10.003 (0,025 /0,076)
Liner Finish Bore . . . . . . . . . . . . . . . . . . . . . . . . .. 3.501 13.502 (88,93 /88,95)
Liner Flange Thickness . . . . . . . . . . . . . . . . . . . . . . .. 0.148/0.150 (3,76/3,81)
Depth of Flange BELOW Top Face of
Cylinder Block. . . . . . . . . . . . . . . . . . . . . . . . . .. 0.00010.004 (0,00/0,102)
Liner Flange Diameter . . . . . . . . . . . . . . . . . . .. 3.97213.976 (100,88/100,99)
Height of Liner Collar ABOVE Flange . . . . . . . . . . . .. 0.028/0 .033 (0,71/0,84)
Height of Collar ABOVE Top Face of Cylinder Block .. 0 .026/0.031 (0,66/0,79)
Clearance Fit of Liner Flange in Block Recess ... . 0 .014/0.023 (0,356/0,584)

Crankshaft and Main Bearings Dimensions

Crankshaft:
Main Journal Diameter ............ .... .. .. 2.7485/2.749 (69,81/69,82)
Main Journal Width, No. 1 . . . . . . . . . . . . . . . . . . . . 1.391 /1.421 (35 ,3/36,09)
Main Journal Width, No.2, 4 & 5 . . . ...... .. ... 1.433511.4415 (36,4/36,6)
Main Journal Width, No.3 . . . . . . . . . . . . . . . . . 1.4365/1.4385 (36,49/36,54)
Main Journal Fillet Radius ... .. . . ....... ..... . . 9/64 - 5/32 (3,57/3,97)
Crankshaft Pin Diameter. . . . . . . . . . . . . . . . . . .. 2.2485/2.248 (57 ,11/57,12)
Crankshaft Pin Width ...... . .... . . . ... .. .. . 1.3725/1.3741 (34,86/34,9)
Cran kshaft Pin Fil let Radius .... . ... . ... . .. .. ...... 1/8 - 9 /64 (3 ,2 /3,57)
Surface Finish, All Journals .. . . . ....... 15 micro. max. (0,4 microns max.)
Cran kshaft Journa ls & Pins Grind ing . . . . . . . . . . . . . . . 0 .010, 0 .020 & 0 .030
Undersizes ...... ... . ... .. .. . .. . . . . ... . .. .... (0,25, 0,51 & 0,76)
Oil Seal Heliz Diameter . .. ...... . ... . ...... .. 2.211/2.212 (56 ,16/56,18)
Oil Seal Heliz Width ....... . .... . . . . .. ... .... 0.050/0.080 (1,27/2,03)
Oil Seal Heliz Depth ... . .... .. .. .... .. . .... , 0.004/0.008 (0,101 /0,203)
Crankshaft Flange Diameter .. .. . . . . . . . . . . 3.9985/3.9995 (101,56/101,59) .
x
~
Crankshaft Flange Width .... .. .... . ... . .. ... ...... . . . ... , 0.5 (12,7)
Crankshaft End Play ...... .... .. . . .. .... .. .. 0.001/0.015 (0 ,025 /0,38)

843 loader
-SA- 5- Service Manual
 ENGINE SPECIFICATIONS (Cont'd)
NOTES _________________
All dimensions are given in inches. Respective metric dimensions are given in millimeters encfosed by
parenthesis.
Crankshaft and Main Bearings Dimensions (Cont'd)

Type . ... . ... . .. .. .. . . .. . . . ... ... . Steel Backed, Aluminum Ti n Lined

Shell Width for ali Journals . . . . . . . . . . . . . . . . . . . . . 1.122/1.130 (28 ,5/28,?)
Outside Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.917 (74,09)
Inside Diameter . ......... . . ... ... .. . . ..... 2.75/2.753 (69,89 /69,93)
Bearing Running Clearance . ... ....... . .... . 0 .0025/0 .0045 (O,064/0,114)

Crankshaft Thrust Washer:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel Backed, Aluminum Tin Lined
Position on the Crankshaft . . . ..... . . . . ... . . . . . . .. Center Main Bearing
Thrust Washer Thickness (STD) .... ... . . .. . . . 0.0896 /0.0915 (2,28/2,32)
Thrust Washer Thickness (O/S) ..... . ...... . .. 0 .0966/0.0985 (2A5/2 ,50)
Thrust Washer Diameter . . . . . . . . . . . . . . . . . . . .. 3.744/3.756 (95,09/95A)

Timing Case, Camshaft and Drive Dimensions

Camshaft:
Journal Length, No.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.18 (29,97)
Journal Diameter, No. 1 . ..... .. . . . . . . .. ... 2.0437 /2.0448 (51,91 / 51,94)
Journal Clearance Fit, No.1 . .. .... . . .. .... " 0.0024/0 .0047 {0 ,06/0,119}
Journal Length, No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.0 (25A)
Journal Diameter, No. 2 . . . . . . . . . . . . . . . . . . .. 2.0339/2 .035 (51 ,66/51.69)
Journal Clearance Fit , No.2. . . . . . . . . . . . . . . .. 0 .0024/0 .0047 (O,06 /0,119)
Journal Length, No. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.0 (25,4)
Journal Diameter, No. 3 . ... . .. .. .. . . . ... . , 2.0241/2 .0252 (51,41/51,44)
Journal Clearance Fit, No. 3 . . . . . . . . . . . . . . . .. 0.0024/0.0047 (O,06/0,119)
Journal Length, No.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 (25,4)
Journal Diameter, No. 4. . . . . . . . . . . . . . . . . . .. 2.0142/2.0154 (51,16/51,19)
Journal Clearance Fit, No. 4 . ..... .. .... . ... . 0 .0024/0.0047 (O,06/0,119)
Cam Lift . . ..... ... . ..... . ... .. . . . . . ... . . . . 0 .28010.282 (7,11/7,16)
Lift Pump Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.095/0.098 (2,41 /2,49)
Camshaft Flange for Gear . . . ..... . . .. .... .. 1.1251/1.1257 (28,58/28,59 )
Camshaft Flanage Width for Thrust Washer . . . . . . 0.2374/0.2401 (6,03/6 ,09)
Lubrication for Rocker Arms ... .. ... ... . ...... . . . ...... No. 1 Journal

Camshaft Thrust Plate:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Oil-Impregnated
Inside Diameter of Bore . .... . ....... .... . ... . . . . . . . ..... 1.4 (35,6)
Thrust Plate Thickness. . . . . . . . . . . . . . . . . . . . . . 0 .233 /0.2362 {5,92/6,00}
Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . .. 0.0012/0.0071 (O,625/0,18)

Camshaft Gear:
Inside Diameter of Gear. . . . . . . . . . . . . . . . . . . . . 1.125111.126 (28,58 /28,60)
Gear Fit on Camshaft Flange . . . . . . . . . 0.0007 interference/O.0009 clearance
(0,018/0 ,023)

Fuel Injection Pump Gear:

Inside Diameter of Gear for Fuel Injection
Pump Flange . . . .... .. .... ... . ..... . .... 1.75011.751 (44,45/44,48)

Idler Gear and Hub:

Idler Gear Bore Diameter . . . . . . . . . . . . . . . . .. 1.8898/1.8908 (48,00/48,02)
Idler Gear Bushing Outside Diameter. . . . . . . . . . 1.8915/1.8924 (48 ,04/48,07)
Interference Fit of Bushing . .. .... .. .. . .. . . 0 .0007/0.0027 (0,017/0,068)
Idler Gear Bushing Bore . ..... .. . .. .. . . . .. . 1.7327/1.7337 (44,01/44,04)
Outside Diameter of Hub ... . . .... . . . ...... 1.730311.7313 (43,95/43,98)

r
o
o
Clearance Fit of Bushing in Gear on the Hub . . . 0.0014/0.0034 (0,035/0,086)
Idler Gear Width ....... . . .. .... . ...... . . . 1.1320/1.1340 (28,75/28,80)
Hub W idth .. . . . . ...... . . . ..... .... . .. . . .. 1.14011 .144 (28,96/29,06)
~
"' 843 Loa~
-8A-6- Service ManWij£
. ' w.-
ENGINE SPECIFICATIONS {Cont'd}
NOTES _________________
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parenthesis.
Timing Case, Camshaft and Drive Dimensions (Cont'd)

Idler Gear & Hub Cont'd):

Idler Gear End Play . . . . . . . . . . . . . . . . . . . . . . . . .. 0.006/0.012 (0,25/0,30)
Cylinder Block Idler Hub Bore. . . . . . . . . . . . . . . .. 1.732/1.733 (43,99/44,02)
Idler Gear Hub Flange Diameter for the Block ..... 1.73111.732 (43,97/43,99)
Size & Clearance Fit of Flange in
Cylinder Block Bore. . . . . . . . . . . . . . . . . . . . . . .. 0.00010.002 (0,0010,05)
Timing Case Idler Hub Bore ........ . ... . .. 2.3228/2.3240 (58,99/59,03)
Diameter of Flange for Timing Case .......... 2.3217/2.3229 (58,97/59,00)
Transition Fit of Flange in Timing Case Bore. .. 0.0001/0.0023 (0,0025/0,058)

Crankshaft Gear:
Inside Diameter of Gear ................... 1.249611.2505 (31,74/31,76)
Crankshaft Flange for Gear Diameter. . . . . . . . . .. 1.249411.250 (31, 73/31, 75)
Transition Fit for Gear on Shaft .. . . . .. 0.0004 interference/0.0011 clearance
(0,01/0,03)

Timing Gear Backlash:

All Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.004 (0,102) Minimum

Oil Pump Dimensions

Oil Pump Pressure 30 - 60 PSI (207 - 414 kPa)

Oil Pump:
Type ....................... . .................... . ...... Rotor
Number of Lobes - Inner Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Four
Number of Lobes - Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Five
Method of Drive ....................... Spiral Gear from the Camshaft
Bore in Cylinder Block. . . . . . . . . . . . . . . . . . . . .. 1.375/1.376 (34,93/34,95)
Oil Pump Body Outside Diameter. . . . . . . . . . . .. 1.374/1.3746 (34,90/34,91)
Clearance Fit of Pump in Bore. . . . . . . . . . . . . . . .. 0.0004/0.002 (0,0110,05)

Oil Pump Clearance:

Inner Rotor to Outer Rotor. . . . . . . . . . . . . . . . . . . .. 0.002/0.006 (0,05/0,15)
Outer Rotor to Pump Body. . . . . . . . . . . . . . . . . . . .. 0.005/0.010 (0,13/0,25)
Rotor End Play ............................. 0.001/0.005 (0,025/0,13)
Body Bore for Drive Shaft ................... 0.62510.626 (15,87/15,90)
Outside Diameter of Shaft .................. 0.62310.6235 (15,82/15,84) o
~

Running Clearance of Shaft in Bore. . . . . . . . . . . .. 0.001510.003 (0,04/0,08) a

~
o
a
~

Oil Pump Drive Gear:

Inside Diameter of Gear Bore . . . . . . . . . . . . . .. 0.4965/0.4968 (12,61/12,62)
Outside Diameter of Drive Shaft. . . . . . . . . . . .. 0.4983/0.4988 (12,66/12,67)
Interference Fit of Gear on Shaft. . . . . . . . . . . . .. 0.001310.0021 (0,0310,05)
Drive Gear Backlash .................. . .... 0.0155/0.0019 (0,3910,48)

Oil Pump Relief Valve:

Type ...................................... Spring-Loaded Plunger
Pressure Setting. . . . . . . . . . . . . . . . . . . . . . . . . .. 36/44 PSI (2481303 kPa) "g
Relief Valve Bore . . . . . . . . . . . . . . . . . . . . . . .. 0.5605/0.5621 (14,24/14,28) g"
Outside Diameter of Plunger . . . . . . . . . . . . . . .. 0.5585/0.5595 (14,18/14,21)
Clearance of Plunger in Bore. . . . . . . . . . . . . . . .. 0.00110.0036 (0,025/0,09)
Length of Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.78125 (19,84)
Outside Diameter of Spring. . . . . . . . . . . . . . . . . . .. 0.398/0.405 (10,1/10,29)
Spring, Free Length ................................ 1.5625 (39,69)
Spring, Solid Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.812 (20,62)

843 Loader
-8A-7- Service Manual
 ENGINE SPECIFICATIONS (Cont'd)
NOTES _________________
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
( parenthesis.
Cooling System and Water Pump Dimensions

Water Pump:
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Centrifugal
Outside Diameter of Shaft for Pulley Hub. . . . .. 0.7873/0.7876 (19,99/20,01)
Inside Diameter of Pulley Hub Bore .......... 0.7849/0.7857 (19,94119,96)
Interference Fit of Pulley Hub on the Shaft ..... 0.0016/0.0027 (0,0410,068)
Inside Diameter of Water Pump Pulley Assembly ... 1.613/1 ..616 (40,97/41,05)
Outside Diameter of Hub for Pulley Assembly ... .. 1.611/1.613 (40,92/40,97)
Clearance Fit of Pulley to Hub .... ... . ...... . . .. 0 .00010.005 (0,0010,13)
Impeller Bore . ...... . .... .. ... . ....... . .. 0.497/0.4975 (12,62 /12,64)
Outside Diameter of Shaft for Impeller. . . . . . . . . . 0.498/0.499 (12,65/12,67)
Interference Fit of Impeller on Shaft. . . . . . . . . .. 0.0005/0.002 (0,01310,051)
Impeller to Body Running Clearance ............. 0.015/0.030 (0,38/0,76)
Water Pump Seal, Type . .. . ... .......... Synthetic Rubber-Carbon Faced
Counter Face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Rotating Ceramic

Thermostat:
Opening Temperature ........ . ..... . . ..... 175 - 181°F (79.5 - 83.5°C)
Fully Open at .. . . .. ...... ....... ..... .. ... ..... .. 208°F (97.5°C)
Travel at Fully Open ... .. ........ ....... . . . . . . . . . . . . . 0.562 (14,27)

Fuel System Specifications

Fuel Lift Pump:

Method of Drive Eccentric on Camshaft
Delivery Pressure 5 - 8 PSI (34 - 55 kPa)

Fuel Filter:
Element Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Paper
Valve Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Ball Check Valve
~
o
o
,
N

Fuel Injection Pump:

'"
N

'" Manufacture ......... . . ....... ............ ... . .. ... . .... C.A.V.

Type .................. .. ... . .................. . ....... D.P.A.
N

N Pump Rotation .. . . . . . . . . . . . . . . . . . . . . . . . .. Clockwise (from drive end)

~
Timing Letter, Mechanically Governed ........................... "C"
No. 1 Cylinder Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. "W"

Static TIming:
Mechanically Governed ................................ 18° B.T.D.C.
0.125 (3,18) Piston Displacement

Fuel Injectors:
Manufacture .......... .. ..... .. ............. ..... ... . ... C.A.V.
l~ectorBody .......... .. .. ..... ................ . . BKB35SD5247
Injector Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. BDN4SD6346
Working Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1980 PSI (13,652 kPa)
Setting Pressure ............................. 2200 PSI (15,169 kPa)
m
o
Identification Code Letter .. .. ....... . ...... .. . ... . . .... . ..... . CJ
o
N

o
N
o Starting Aid:·
Manufacture ............................... .. ........... C.A.V.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Thermostart Type 357
Voltage ..................................... . . .. ..... . 12 Volt
Maximum Current. . . . . . . . . . . . . . . . . . . . . . . . . .. 12.9 amps. @ 11.5 volts

843 Loader
-SA-S- Service Manual
ENGINE SPECIFICATIONS (Cont'd)
NOTES _________________
De-Rating for Altitude

The following is given as a general guide, which may be used on a percentage basis,
where specific figures for an engine rating which are not available.

Maximum Fuel Delivery De-Rating

Altitude Measured at 800 RPM Pump Speed

2,000
°- 2,000 ft.
- 4,000 ft.
(600 Meters) .................. No Charge
(1200 Meters). . . . . . . . . . . . . . . . . 6%
4,000 - 6,000 ft. (1800 Meters). . . . . . . . . . . . . . . .. 12%
6,000 - 8,000 ft. (2400 Meters). . . . . . . . . . . . . . . .. 18%
8,000 - 10,000 ft. (3000 Meters). . . . . . . . . . . . . . . .. 24%
10,000 - 12,000 ft. (3600 Meters) . . . . . . . . . . . . . . . .. 30%

Any necessary adjustments for the fuel injection pump must be done by Trained
Service Personnel.

Engine Torque

The following figures will apply with the bolts and/or nuts having a light coat of oil
before assembly.
g

Rear Main Seal Mounting Bolts .............

Ft.-Lbs.

4-6
Nm

5-8 7A-37
Page
I
U-Joint Mounting Bolts ................... 25-28 34-38 7A-21
Engine Mounting Bolt & Nuts .............. 125-140 169-190 7A-15,
7A-16
Cylinder Head Bolts (Also Rocker Arm Brackets) 85 115 7A-23
Main Bearing Bolts ...................... 85 115 7A-34
Connecting Rod Nuts* ................... 45 61 7A-31
Flywheel Bolts ......................... 83-90 113-122 7A-21
Crankshaft Pulley Retaining Bolt ............ 123 167 7A-38
Camshaft Gear Bolt ..................... 40-50 54-68 7A-41
Idler Gear Hub to Cylinder Block Nuts ........ 21 28 7A-40
Fuel Injector Nuts ....................... 12 16 7A-11
Fuel Pump Drive Gear Bolt ................ 19-21 26-28 7A-40,
7A-42
High Pressure Fuel Line Fittings ............ 15 20 7A-6,
7A-7

* Once the Connecting Rod Nuts are removed, they must be replaced.
843 Loader
Revised July 88 -8A-9- Service Manual
 ENGINE SPECIFICATIONS (Cont'd)

All dimensions are given in inches. Respective metric dimensions are given in ml'llimeters enclosed by parenthesis.

Grinding Specifications for Crankshaft

F c o c c

PI·2598

0.010 (0,25) 0.020 (0,51) 0.030 (0,76)

Undersize Undersize Undersize

A 2.7395/2 .739 2.7285 /2.729 2.7185/1.719

(69,56/69 ,57) (69,30/69,32) (69,04/69,06)

B 2.2385/2.239 2.2285/2.229 2.2185/2.219

(56 ,86 /56,87) (56,60/56,62) (56,35 /56,36)

C 1.4459 (36,73) Maximum

D 1.4416/1. 4445 1.4466/1.4495 1.4516/1.4545

(36,62 /36,69) (36,74/36,82) (36,87/36,94)

E 1.3806 (35,07) Maximum

F 1.4045 (35,67) Maximum

R1 0.146/0.157 (3,7113,99) All Journals

R2 0.1 26/0.142 (3,20/3,61) All Crankpins

Surface finish of crankpins, journals and fillet radii 8 micro inches (0,2 microns) C.L.A.
Magnetic Crack Detection D.C. Flow - 2.5 Amps. A.C. Current - 1300 Amps.
Limits of taper and out-of-round for pins and journals:
Taper 0.00025 (0,006) Out-of-Round 0.00025 (0,006)

Maximum Run-out with the crankshaft mounted on the end main journals.
m
o
o
,
N
Independent Readings:
o
, Crankshaft Pulley Rear Oil Seal Flywheel Flange
'"o Diameter T.I.R. Diameter T.I.R. Diameter T.I.R.
0.002 (0,05) 0 .002 (0,05) 0 .002 (0,05)

Journals T.I.R. - Run -out must not be opposed .

Number 1 Number 2 Number 3 Number 4 Number 5
Mounting 0.003 (0,08) 0.006 (0,15) 0.003 (0,08) Mounting

843 Loader
-SA-10- Service Manual
 TECHNICAL DATA (200 Series Perkins)

Page
Number

ENGINE SPECIFICATIONS
Cooling System & Water Pump Dimensions . . ....... . 8B-5
Crankshaft & Main Bearing Dimensions .. .. . ... . . .. . 8B-4
Cylinder Block & Liner Dimensions .. ... . . .. ... .. . . . 8B-4
Cylinder Head Dimensions .. ... . .. . .... ... . . . . . . . 88-3
De-Rating for Altitude . .. ..... . . .... ...... .. ... . 88 - 6
Engine Torque . .... . .. . .. .. . .. . . . .... . . . . . . .. . 88 - 6
Fuel System Specifications . .... ... . . . .. . . ... ... . 88-6
Grind ing Specifications for Crankshaft . . ... . .. .. ... . 88-7
Oil Pump Dimensions . . .. . . . . . ... . .. . . . . . ... . . . . 88-5
Piston & Connecting Rod Dimensions .. .. ... . . .. .. . . 88-3
Timing Case, Camshaft & Drive Dimensions .. .. .. ... . 88 - 5

LOADER SPECIFICATIONS
Capacities . .. . . . .. .. . . . .... . . . . . .. . ... . . ... . . 88-2
Drive System . .. .. . . . . . . . . . . .. . ........ .. . . . . 88-2
Electrical .. . . ...... . .. . ..... .. ........ . . .... . 88 - 2
Engine .. . .... .... . . ...... . . . . . .. . . . .. . ... .. . 88-1
Loader Hydraulics . .... . ...... . . . . .. ... . .. . ... . 88-2
Specifications .. .. . . . . . . .. .. . . . . . . . . . .. ... . . . . 88-1
Tire .. . . . ... .. ... . .. . .. . . . ... .. . .. ......... . 88-2

is

i
o
,
N

,o
N
o
o
~

SPECIFICATIONS
(200 Series Perkins)

843 loader
Revised June 87 Service Manual
88 LOADER SPECIFICATIONS

Where applicable, specifications

Ir- {15841 ---lI

conform to SAE standards.
Specifications are subject 62.4
change without notice.
/~ f
./ : 99 0 155.2

.. //[,·::::;><f.L:~ ~ ":'.\-·:':'" }L.:___1_19-.-~:941)

/<. .~?"
./
-:-;:l;----=:4L-----
(3037)
-r.

94 5
I
{2399}1
1
80.4
(2042)
c=:; 63.3

1~~~8I
~{1311l 60.8
{15431

131.4
t-------(3338} - - - - I

PI ·2585
Dimensions are given for a loader equipped with standard tires and dirt bucket.
Dimensions may vary with other bucket types. All dimensions are shown in inches.
Respective metric dimensions are given in millimeters enclosed by parentheses.

SPECIFICATIONS
Weights
Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6500 Ibs. (2951 kg)
Rated Operating Capacity . . . . .... . .... . . . . . . . . . . .. 1700 Ibs. (772 kg) NOTES
.
~

~
Tipping Load (SAE Rating) . . . . . . . . . . . . . . . . . . . . . . . . 3420 Ibs. (1551 kg) ~
~

Travel Speed .................... Infinately Variable 6.3 MPH (10,1 km/hr.)

Controls "
0

'"
Vehicle . . . . . . .. Direction and speed controlled by two hand-operated levers.
Loader Function . . . . . .. Lift, tilt functions controlled by separate foot pedals.
~
Front auxiliary function controlled by the right steering lever.
Rear auxiliary function controlled by left steering lever.
~
0
Engine . . . . . . . . . . .. Hand lever throttle; key type starter switch & shutdown N
"-
Main Drive . ........ . . ... ... ........ ..... .. . ... .... . , Hydrostatic ,
0
N
0
Brakes. . . . . . . . . . . . . . . . . . . . . . . . .. Mechanical disc, foot-cperated pedal. 0

'"
::;
~

ENGINE "
N

"
Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Perkins (200 Series)
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.154
Fuel .. . .. ...... .. , . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Horsepower ... , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 54 HP (40,3 kW)
.
,"'"
0

0-

~
Maximum Governed RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2600 RPM "
0
0

Torque . . ........ . . . . . . . . . . . . . . . . . .. 113 ft.-Ibs. (153 Nm) @ 1800 RPM "8

;<
Number of Cylinders . . ..... .... ... . ......... ...... .. . . ......... 4
Bore/Stroke ..................... .. ........ . . 3.50 (88,9)/4.00 (101,6) "0
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 153.9 cu. in. (2522 cm 3 )
Cooling System ... . .. . . .. . . .... , . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open PCV System
Air Cleaner .......... . ..... '. . Dry rep laceable paper element, dual element
ILow Idle ............................•................. 1150 RPM
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2720 RPM
843 Loader
1200 Series)
Service Manual
LOADER SPECIFICATIONS (Cont'd)
NOTES ________________
LOADER HYDRAULICS

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Gear type

Pump Capacity (SIN 15000 & Below) ..... 16 GPM (61,3 Llmin.l @ 2700 RPM
(SIN 14999 & Below) .... 15.5 GPM (58,7 Llmin.) @ 2750 RPM
System Relief Pressure. . .. 2325-2500 PSI {16031-17238 kPa} @ Aux. Couplers
Hydraulic Fluid Filter . . . . .. Replaceable #3 micron paper element in charge line
Replaceable #10 micron paper element in return line
Hydraulic Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Doubleacting
Bore Diameter:
Lift Cylinder (2) ............................... . .... 2.25 (57,2)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.25 (82,6)
Rod Diameter:
Lift Cylinder {2} . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.50 (38,1)
Tilt Cylinder (1) ..... . .. . ... . ............. . . . . . ...... 1.50 (38,1)
Stroke:
Lift Cylinder (2) .................................. 33.50 (850,S)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17.S5 (455,S)
Control Valve ......... 4-spool, open center series type W/float detent on lift,
detent on auxiliary and self leveling on tilt.
Fluid Lines ........................ SAE standard tubes, hoses & fittings

Hydraulic Function Time:

Raise Lift Arms to Maximum Height . . . . . . . . . . . . . . . . . . . . .. 4.3 Seconds
Lower Lift Arms from Maximum Height. . . . . . . . . . . . . . . . . . .. 2.9 Seconds
Move Bucket to Dump Position. . . . . . . . . . . . . . . . . . . . . . . . .. 2.3 Seconds
Move Bucket to Retracted Position . . . . . . . . . . . . . . . . . . . . . .. 2.0 Seconds

ELECTRICAL

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Belt driven, 37 amps. open

Battery ........ Two (2) batteries, in parallel @ 12 volt, 370 cold crank amps.
@ OOF (-17,8°C) 106 min. reserve capacity
Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 volt gear drive

DRIVE SYSTEM

Transmission. . . . . . . . . . .. Two hydrostatic piston pumps driving fully reversing

hydrostatic motors. Seperate gear type charge pump
Final Drive. . . . . . . . .. Gear reduction with #100 HS roller chain & sprockets in
sealed chaincase with oil lubrication.
Total Engine to Wheel Reduction .............................. , 3S.4:1
Fluid Type. . . . .. Clark Bobcat Fluid {PIN 6563328 [5 gal. Package]}. If the fluid
is not available, use 10W-30 or 10W-40 Class SE Motor Oil.

CAPACITIES

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22 qts. (21 L)

Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22 gals. (83 L)
Engine Lubrication W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7.5 qts. (7 L)
Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36 qts. (34 L)
HydrauliclHydrostatic Reservoir (Steel) . . . . . . . . . . . . . . . . . .. 15.5 qts. (14,7 L)
(Nylon) . . . . . . . . . . . . . . . . . .. 18 qts. (17,02 L)

TIRES

Standard ................. 8.25 x 15, 6 Ply Rating, Nylon W/Chevron Tread

Pressure .. . .......... . . . . . . . . . . . . . . . . . . .. 45-50 PSI (310-345 kPa)
Flotation ........................ . ........... 12 x 16.5, 6 Ply Rating
Pressure ................... . ............. 45-50 PSI (310-345 kPa)

(200 Series) 843 Loader

-88-2· Service Manual
ENGINE SPECIFICATIONS NOTES _________________

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parenthesis.

Cylinder Head Dimensions

Cylinder Head:
Grinding Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. DO NOT GRINO
Valve Seat Angle (Intake) . . . . . . . . . . . . . . . . . . .. 45 0 (90 0 Included Angle)
(Exhaust) . . . . . . . . . . . . . . . . .. 30° (120 0 Included Angle)
Valve Seat Width ................................. 0.079 (2,0 mm)

Combustion Chamber Inserts:

Height of Insert in Relation to Cylinder Head Face ..... 0.001 (O,025) Above
0.0029 (O,073) Below

Valve Guide, Inlet & Exhaust:

Guide Height Above Cylinder Head . . . . . . . . . . . . . . . . . . . . . .. 0.065 (1,65)
Valve Guide Bore Diameter. . . . . . . . . . . . . . . . . .. 0.3145/0.3155 (7,99/8,01)

Valves, Inlet:
Maximum Worn Valve Stem Diameter . . . . . . . . . . . . . . . . . . .. 0.3102 (7,88)
Maximum Worn Clearance of Valve Stem in Guide. . . . . . . . . . .. 0.005 (O,13)
Minimum Valve Head Thickness ........... . . . . . . . . . . . . .. 0.053 (1,35)
Valve Face Angle .......................................... 45 °
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . . . . .. Synthetic Rubber Deflector
Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.012 (O,30)

Valves, Exhaust:
Minimum Worn Valve Stem Diameter . . . . . . . . . . . . . . . . . . .. 0.3097 (7,87)
Maximum Worn Clearance of Valve Stem in Guide. . . . . . . . . .. 0.0055 (0,14)
Minimum Valve Head Thickness ................... . . . . .. 0.053 (1,35)
Valve Face Angle .............. . ............. . ............. 30 0
Valve Stem Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Not Used
Valve Clearance (Cold) . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .012 (O,30)

Valve Springs, Inner:

Fitted Length ........ . ........ . . . . . . . . . . . . . . . . . . . . .. 1.49 (37,85)
Load at Fitted Length ............. 28 Ibs. ± 1.5 Ibs. (12,7 kg ± 0,68 kg)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.74 (44,20)

Valve Springs, Outer:

Fitted Length ................. . . . . . . . . . . . . . . . . . . . . .. 1.59 (40,39)
Load at Fitted Length ............. 40 Ibs. ± 2.0 Ibs. (18,2 kg ± 0,91 kg)
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.181 (10,0)

Rocker Arms:
Clearance Fit of Rocker Arm Bushing on Shaft. .. 0.0006/0.0024 (0,015/0,06)
Maximum Worn Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.003 {D,08}
Inside Diameter of Bushing (Fitting) 0.625/0.6528 (15,88/15,90)

Rocker Arm Shaft:

Outside Diameter of Shaft ......... . ....... 0.6234/0.6244 (15,83/15,86)

Pistons and Connecting Rod Dimensions

Pistons:
Type . . . . . . . . . . . . . . .. Flat Topped, Controlled Expansion, Offset Piston Pin
Piston Diameter (Measured at 90° to piston pin
and 0.7 (18) above bottom of piston) ......... 3.499/3.500 (88,87/88,90)
Maximum Ring Clearance in Groove (New Ring Fitted) ........ 0.008 (0,20)

(200 Series) 843 Loader

-8B-3- Service Manual
 ENGINE SPECIFICATIONS (Cont'd)
NOTES ________________
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parenthesis.

Piston and Connecting Rod Dimensions (Cont'd)

Pistons Rings :
Compression (Top) . . . ...... . ......... .... .... .. . .. .. Chrome Inlay
Compression (2nd) . . . . . . . . . . . . . . . . . . .. Internally stepped chrome faced
Scraper (3rd) .. . . . . . . . . ..... . ... .... . . Coil Spring Loaded, Oil Control
Maximum Clearance in Groove ...... ... .... .. ..... .. : .. 0.0 12 (0,30)

I *Ring Gap (New Rings) .. . . .. . .. .. ..... . 0.014- 0 .022 (0,356 - 0,559)

(Maximum) ....... . . .. ..... ... .... . ..... .. . 0.060 (1,52)
* The ring gap is measured in a clean un-worn part of the cylinder bore.

Piston Pins:
Type ...... .. . .. ............. . .... : . . . . . . . . . . . . . . . Fully Floating
Clearance Fit in Small End Bushing . . .... . .... 0 .0006/0.0016 (0 ,015/0,04)
Maximum Worn Clearance .. .... ... . . . .•.•.. . ....... .. , 0.002 (0,05)

Connecting Rods:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. "H" Section
Maximum Side Play at Big End . ....... . ........... .. . . .. 0.016 (0,41)
Small End Bushing .... ... . . . . . . . . . . . . . . . . . Steel Backed, Bronze Lined

Connecting Rod Bearings:

Type . .... .... .... ..... .. . . .. .. . . . Steel Backed, Aluminum Tin Lined
Rod Bearing Running Clearance .... .. ........ , 0.0014/0.003 (0,035/0,08)
Maximum Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,102)

Cylinder Block and Liner Dimensions

Cylinder Block:
Bore Diameter of Cylinder Liner. . . . . . . . . . . .. 3.8125/3.8135 (96,84/96,86)
Main Bearing Bore . . . . . . ... . . .. ..... ... .... 2.916/2.917 (74,97/74,09)
No. 1 Bore for Camshaft. . . . . . . . . . . . . . . . . . . 2.047212.0484 (52,0/52,03)
No. 2 Bore for Camshaft .. . .......... . . . .. 2.0374/2.0386 (51,75/51,78)
No.3 Bore for Camshaft . . . . . . . . . . . . . . . . . .. 2.0275/2.0287 (51,5/51,53)
No. 4 Bore for Camshaft . ... .... ... .. . . .. . . 2.0177/2.0189 (51,25/51,28)
Cylinder Block Surface Distortion
Limit - Longitudinal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0 .010 (0,25)
- Transverse . . ... . ..... . ... . .... . . . .... .. . . . 0.004 (0,102)

Cylinder Liners:
Type ....... . ... . ... .. .. .. . .. .............. .. .. Dry Interence Fit
Cylinder Liner Finished Bore .. . . ... ... ..... . . 3.501/3.502 (88,93/88,95)
Maximum Worn Bore Diameter . . .. . . . . . . . . . . . . . . . . . . . .. 3.509 (89,13)
Depth of Flange BELOW Top Face of Cylinder Block . 0.000/0.004 (0,00/0,102)
8 Height of Collar ABOVE Top Face of Cylinder Block . . 0 .026/0.031 (0,66/0,79)
§
Crankshaft and Main Bearings Dimensions

Crankshaft:
Main Journal Diameter ... .... ..... ... .... 2.7485/2.7491 (69,81169,83)
Minimum Journal Diameter ... .. .. ....... . . . . . .. . ..... 2.7466 (69,76)
Crankshaft Rod Journal Diameter .. . .. .. . ... . 2.2485/2.2491 (57,11/57,13)
Minimum Rod Journal Diameter . . . . . . . . . . . . . . . . . . . . . .. 2.2466 (57,06)
~
o
o Main Journal & Rod Journal Diameter Out-of-Round Premitted. 0.0005 (0,013)
,'"o Crankshaft End Play . .... . . ......... . . .. . . . 0.003/0.015 (0,080/0,038)
,
o'"
Maximum End Play ... . . . .... . . . . . .... . .. . . . ... . . . .. . . 0 .016 (0,41)

Main Bearing:
Type . ... . ... .. . . . . . . . . . . . . . . . . . .. Steel Backed, Aluminum Tin Lined
Main Bearing Running Clearance ..... . . .. ..... 0.0025/0.0045 (0,0610,11)
Maximum Clearance . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 (0,13)

(200 Series) 843 Loader

Revised Sept. 86 -88-4- Service Manual
ENGINE SPECIFICATIONS (Cont'd)
NOTES _________________
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parenthesis .
Crankshaft and Main Bearings Dimensions (Cont'd)

Crankshaft Thrust Washer:

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Steel Backed, Aluminum Tin
Position in Cylinder Block . . . . . . . . . . . . . . . . . . . . . . .. Center Main Beari ng
Thrust Washer Oversize .. .. . .. .... .. ....... . ... .. ... . . 0.007 (0,18)

Timing Case, Camshaft and Drive Dimensions

Camshaft:
Journal Diameter, No.1 ... . ... . . ... ...... . 2.0437/2.0448 (5 1, 91151,94)
M inimum Journal Diameter, No. 1. . . . . . . . . . . . . . . . . . . . . . 2.0434 (51,90)
Journal Diameter, No.2 .. ... ....... .. .. . .. . 2.0339/2.035 (51.66151,69)
Minimum Journal Diameter, No. 2. . . . . . . . . . . . . . . . . . . . . . 2.0336 (51,65)
Journal Diameter, No.3 .. .. .. .. ... .... . ... 2.024112.0252 (51,41/51,44)
Minimum Journal Diameter, No. 3 . . . . . . . . . . . . . . . . . . . . .. 2.0237 (51,40)
Journal Diameter, No.4 .. . ... ...... ... ... " 2.0142/2.0154 (51,16151,19)
Minimum Journal Diameter, NO.4 . . . . . . . . . . . . . . . . . . . . . .. 2.0139 (51,15)
Maximum Journal Running Clearance .. . .. .. ... .... . ....... 0.006 (0,15)
Maximum Camshaft Runout . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0 .003 (0,08)
M inimum Cam Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.6727 (42,49)
Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . .. 0.0012/0.0071 (0,0310,18)
Maximum End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25)

Idler Gear and Hub:

Clearance Fit of Gear Bushing on Hub .. . . ...... . 0.0014/0.0034 (0,04/0,09)
Idler Gear End Play. . . . . . . . . . . . . . . . . . . . . . . . . 0 .008/0.012 (0,02010,30)
Maximum End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 .015 (0,38)

Timing Gears:
All Gears Backlash . ... . . . ... ... ....... . .... .. . 0.004 (0,102) m inimum

Oil Pump Dimensions

Oil Pump Pressure . .... . . . ..... . . . ....... .. .. . 30-60 PSI (207-414 kPa)

Oil Pump:
Type ... .. . . . ...... . . ... . ... ... .. .. .. . . . .. ... . .. . . . ... . . Rotor g
Number of Lobes-Inner Rotor .. . ....... . .. . . . ... ... .. . . .. . . . . . Four
Number of Lobes-Outer Rotor ... . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . Five
Method of Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spiral Gear on Camshaft
Clearance of Inner to Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . 0 .012 10,30)
Clearance of Outer Rotor to Pump Housing. . . . . . . . . . . . . . . .. 0 .012 (0,30)
Rotor End Play .. . . . ...... .... . . . . .. .. . . ... . .... . . . .. 0 .006 (0,15)
I
Oil Pump Relief Va lve:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring-Loaded Plunger
~pring, Free Length ... . ... . . .... .. .. . . . .. . ... . ... . . ... " 1.6 (40,1)

Cooling System and Water Pump Dimensions

Water Pump:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal
Water Pump Seal, Type . . .. . ...... .... .. Synthetic Rubber-Carbon Faced
Counter Face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotating Ceramic

Thermostat:
Type ....... .. .. .. ... .. . .. . . .....• . . ... .... Wax By-Pass Blanking
Opening Temperature .. .. . . . ... .. ... .. ... " 166°/173°F (74.5°178.5°C)
Fully Open Temperature . . . ....... . . . . . . . . . . . . . . . . . . . . 194°F (90 0 C)
M inimum Travel at Full Open . . ... .. .. . ... . .. . . . . ... . . .. ... 0.3 (7,6)

(200 Series) 843 Loader

-88-5- Service Manual
 ENGINE SPECIFICATIONS (Cont'd)
NOTES ________________
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parenthesis.

Fuel System Specifications

Fuel Filter
Type. . . . . . . . . . .. Spin on canister element. Printing pump in filter housing.

Fuel Injection Pump

Manufacturer ........................ . ............... Diesel Kiki
Type ............. . . . .................................... VE
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Clockwise (from drive end)
Plunger Diameter ............ . ........................ 0.394 (10)
Cam Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.09 (2,3)
Static Timing ........................... 0.039 (1,0) cam lift at TDC

Fuel Injectors
Type .................................................. Pintle
Operating Pressure. . . . . . . . . . . . . . . . . . . . . . . . . .. 1990 PSI (13721 kPa)

Starting Aid-Glow Plugs

Type ............................................... Sheathed
Voltage and Current ........................... 10.5 volt - 6.5 amps.

De-Rating for Altitude

The following is given as a general guide, which may be used on a percentage basis,
where specific figures for an engine rating are not available.

Maximum Fuel Delivery De-Rating

Altitude Measured at 800 RPM Pump Speed

o- 2,000 ft. (600 Meters) .................. No Charge

2,000 - 4,000 ft. (1200 Meters). . . . . . . . . . . . . . . . . 6%
4,000 - 6,000 ft. (1800 Meters)............... . . 12%
6,000 - 8,000 ft. (2400 Meters). . . . . . . . . . . . . . . .. 18%
8,000 - 10,000 ft. (3000 Meters). . . . . . . . . . . . . . . .. 24%
10,000 - 12,000 ft. (3600 Meters). . . . . . . . . . . . . . . .. 30%

Any necessary adjustments for the fuel injection pump must be done by Trained
Service Personnel.

Engine Torques

The following figures will apply with the bolts and/or nuts having a light coat of oil
before assembly.

Ft.-Lbs. Nm Page

Engine Mounting 80lts & Nuts ............ . 125-140 169-190 7B-16

U-Joint Mounting 80lts .................. . 25-28 34"38 7B-22
Cylinder Head Bolts (Also Rocker Arm Brackets) 85 115 ; 7B-24
Main Bearing Bolts ..................... . 85 115 i 78-35
Connecting Rod Nuts* .................. . 60 82 78-32
Flywheel 80lts ........................ . 83-90 113-122 7B-22
Crankshaft Pulley Retaining Bolt ........... . 180 244 7B-39
Camshaft Gear Bolt .................. . . . 40-50 54-68 7B-43,
7B-42
Idler Gear Hub to Cylinder Block Nuts ....... . 21 28 7B-42
~
o
o
Fuel Injection Pump Drive Gear Nut ........ . 50 58 7B-8,
,
N
7B-42,
o
N
o
7B-44
Fuel Injector Nuts ...................... . 12 16 7B-ll
High Pressure Tubeline Fittings ............ . 15 20 78-5
Glow Plugs .......................... . 11 15 7B-13
* Once the Connecting Rod Nuts are removed, they must be replaced.
(200 Series) 843 Loader
Revised July 88 -88-6- Service Manual
ENGINE SPECIFICATIONS (Cont'd)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parenthesis.

Grinding Specifications for Crankshaft

F C o c C

A A

Rl

PI ·2598

0.010 (0,25) 0.020 (0,51) 0.030 (O,76)

Undersize Undersize Undersize

A 2.7385/2.739 2.7285/2.729 2.7185/1.719

(69,56 /69,57) (69,30/69,32) (69,05/69,06)

B 2.2385/2.239 2.2285/2.229 2.2185/2.219

(56,86/56,87) (56,60/56,62) (56,35/56,36)

C 1.4459 (36,73) Maximum

D 1.441611.4445 1.4466/1.4495 1.4516/1.4545

(36,62/36,69) (36,74/36,82) (36,87/36,94)

E 1.3806 (35,07) Maximum

F 1.4045 (35,67) Maximum

Rl 0.146/0.157 (3,71/3,99) All Journals

R2 0 .126/0.142 (3,20/3,61) All Crankpins

Surface f inish of crankpins, journals and fillet radii 8 micro inches (0,2 microns) C.L.A.
Magnetic Crack Detection D.C. Flow - 2.5 Amps. A.C. Current - 1300 Amps.
Limits of taper and out-of-round for pins and journals:
Taper 0.00025 (0,006) Out-of-Round 0_00025 (0,006)

Maximum Run-out with the crankshaft mounted on the end main journals.
b'
o
Independent Readings: ,.-

Crankshaft Pulley Rear Oil Seal Flywheel Flange b'

Diameter T.LR. Diameter T. LR. Diameter T.LR .
0.002 (0,05) 0.002 (0,05) 0.002 (0,05)

Journals T.LR. - Run-out must not be opposed.

Number 1 Number 2 Number 3 Number 4 Number 5
Mounting 0.003 (0,08) 0.006 (0,15) 0.003 (0,08) Mounting

(200 Series) 843 loader

-88-7- Service Manual
 TECHNICAL DATA (lsuzu)

Page
Number

ENGINE SPECIFICATIONS
Camshaft .. . .. . .... . ......... .. ..... ... . .. . . 8C-4
Connecting Rod & Bearing . .... .... .... .. . ..... . . 8C-4
Crankshaft .. .......... .. ..... .. .. . .. . . .. . . . . 8C-5
Cylinder Head ... . ... .. ..... .... . . . .. . . . ... .. . 8C-3
Cylinder Liners . . ... .. ..... .. .. : ... . . ..... . . . . 8C-4
Engine Torque . .... . .. . . .... . . . . . ........ . ... . 8C-6
Idler Gear . . ... . .. .. ... . ....... . .. . ...... ... . 8C - 5
Oil Pump . . .. .......... . . ... . .... .. .. . .... . . . 8C-5
Piston, Pin & Rings .. . .................. .. ... . . 8C-4
Rocker Arm . . .. . .. .... . . . . . . ...... .. . ..... . . . 8C-3
Tappets .......... . ....... . .......... . ... .. . 8C-4
Valve Spring . .. ...... . . ....... . .... ... . .. .. . . 8C-3
Valve, Valve Guide & Seat Insert .............. . . . . 8C-3

LOADER SPECIFICATIONS
Capacities . .. ..... . ...... ..... ... . .... . . .. . . . 8C-2
Drive System .. .. . ... . .. ... . .. . .. .. ... . ..... . 8C-2
Electrical . . . .. .. . . .... ..... . .. . .. . ...... .. . . . 8C-2
Engine . ...... . ... . ... .. ...... . ...... .. ..... . 8C-1
Loader Hydraulics .... .... .. . .. . . . . . . ......... . 8C-2
Specificatlo(ls ... . ...... . ... . ... . ...... . ..... . 8C-l
T ire . . ... ... ... . .. . . . . . .. . .. ............ ... . 8C-2

SPECIFICATIONS
(Isuzu)

843 loader
Revised June 87 Service Manual
18C LOADER SPECIFICATIONS
f
155.2
Ir- (158
62.4-'1
4) I
Where applicable. specifications (3941)
conform to SAE standards. 76 .7
Specifications are subject to i - - -- - (1948}
change without notice.

80.4
(2042)

32.8
(833)

f.<-_ _ _ __ _ 13 1.4 ---ool

(3 3 38)
PI·2585
Dimensions are given for a loader equipped with standard tires and dirt bucket.
Dimensions may vary with other bucket types. All dimensions are shown in inches.
Respective metric dimensions are given in millimeters enclosed by parentheses.

This loader was designed without counterweights or ballasts. Changes of structure

or weight distribution of the loader can cause changes in control and steering response
and can cause failure of the loader parts.

OPERATION AND PERFORMANCE NOTES _ _______________

Weights
Operating Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6480 Ibs. (2939 kg)
Rated Operating Capacity. . . . . . . . . . . . . . . . . . . . . . . . . 1700 Ibs. (772 kg)
Bucket Capacity (SAE) (60" Dirt) . . . . . . . . . . . . . . . . .. 12.5 cu.-ft. (0,35 m 3 )
Travel Speed ... . ..... .. . . .... ... Infinitely variable 0-6.3 MPH (10 km/hr.)
Controls '"o
Vehicle . . ... .. ....... .. . . Direction & speed controlled by two hand levers.
Loader Function ...... . . Lift & tilt function controlled by separate foot pedals.
Auxiliary function controlled by the right steering lever.
Engine .. ... ....... . ..... . . Hand lever throttle & key type starter switch.
Main Drive . . . .... . . . . . .. . ..... .. . . .... .... ..... ..... . Hydrostatic
I
Parking Brake .... .. ..... . .. . . . . .. .. . .. . Mechanical disc. foot operated.

ENGINE
Make . .. . . . .. . .. .... .... ....... . .... .. . . ... . . . . . .. .. ...... Isuzu
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4JB1-PK01
Fuel .. ... .... ... . .. . . . .. .... .. ... . . .. . . ..... .. .... ..... . . Diesel
Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . 54 HP (40.3 kW) @ 2600 RPM
Torque . . . .. . . . . .. .. . . . ..•... 120 ft.-Ibs. (163 Nm) Maximum @ 1600 RPM
Maximum Governed RPM . .. . ....... .. ..... . . .. ..... .. .. .. . 2600 RPM
Number of Cylinders .. .. ... .. . . ... .. . ... .. . . .... .. .... ...... .. Four
Bore/Stroke . ....... ... .... .. ...... . ...... ... ... 3.66 (93)/4.016 (102)
Displacement . .. .. ... .. . .... . . . . . . . .. ...... ... ... ... 169 CID (2,8 L)
Cooling System ...... ..... . .... . . .. . .. . ..... .. . . .. . . .. ...... Liquid
Lubrication . ........ ... . ... . .... .... . . . ... .. . Pressure System W/Filter
Crankcase Ventilation ........ . . . .... ... ...... .. ..... ... ... .... Open
Air Cleaner ..... ..... . ... . .. .. Dry replaceable cartridge (W/Safety Element)
I Low Idle ... .. . . ... .. . .. .. .. . ... ... .. .... .. . . . ... ... .. . . 1150 RPM
High Idle .. ........ .. .... .. .. ... . . ... ... . . ...... . . . 2725-2750 RPM

843 Loader
Revised Feb. 94 -8C-1- Service Manual
LOADER HYDRAULICS
NOTES _________________
Hydraulic Pump (Rear)
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Engine driven, gear type
Capacity. . .. 16.2 GPM (61,3 lImin.) @ 2700 RPM @ 1050 PSI (7239 kPa)
Charge Pump (Front)
Type ............................... '.' .... Engine driven, gear type
Capacity .... 10.8 GPM (40,9 lImin.) @ 2700 RPM @ 1050 PSI (7239 kPa)
System Relief Valve Setting ............ 2250-2400 PSI (15513-16548 kPa)
Hydraulic Fluid Filters. . . . . . . . . . . . . .. Replaceable 3 element paper filter and
replaceable 10 micron paper filter

HydrauliC Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Doubleacting

Bore Diameter
Lift Cylinder (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.25 (57,2)
Tilt Cylinder (1) .................................... 3.25 t82,6}
Rod Diameter
Lift Cylinder (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.50 (38,1)
Tilt Cylinder (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.50 (38,1)
Stroke
Lift Cylinder (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33.50 (850,9)
Tilt Cylinder (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17.95 (455,9)
Control Valve .............. 4-spool, open center, series-type W/float detent
on lift, detent on auxiliary and self-leveling on tilt
Bucket Positioning Valve ............. Provides self leveling of bucket when
lift arms are raised

Hydraulic Function Time:

Raise Lift Arms to Maximum Height. . . . . . . . . . . . . . . . . . . . .. 4.0 Seconds
Lower Lift Arms from Maximum Height. . . . . . . . . . . . . . . . . .. 3.0 Seconds
Move Bucket to Dump Position. . . . . . . . . . . . . . . . . . . . . . . .. 2.2 Seconds
Move Bucket to Retracted Position. . . . . . . . . . . . . . . . . . . . . .. 1.9 Seconds

ELECTRICAL

Alternator ................... , Belt driven, 55 amps. @ 2600 RPM (Open)

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 volt, 700 cold crank amps.
@ OaF (-18°C) 170 min. reserve capacity
Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 volt, gear drive

DRIVE SYSTEM

Transmission. . . . . . . . . . . . .. Hydrostatic, infinitely variable, fully reversing (2)

Traction relief - 3500 PSI (24132 kPa) in forward only
Final Drive ......... Gear reduction and #100 roller chains operating in sealed
chaincase W /oil lubrication
Fluid Type .......... Bobcat Fluid (P/N 6563328) (5 gal. package). If the fluid
is not available use 10W-30 or 10W-40 Class SF Motor Oil

CAPACITIES

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22 qts. (21 L)

Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22 gals. (83 L)
Engine Lubrication W/Filter .............................. 7.5 qts. (7 L)
Chaincase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36 qts. (34 L)
Hydraulic/Hydrostatic Reservoir. . . . . . . . . . . . . . . . . . . . . .. 1 5.5 qts. (14,7 L)
Hydraulic/Hydrostatic System (incl. reservoir) ............... 33 qts. (31 L)

TIRES

Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8.25 x 15, 6 ply rating

Pressure ................................. 45-50 PSI (310-345 kPa)
Flotation ...... '. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 x 16.5, 6 ply rating
Pressure ................................. 45-50 PSI (310-345 kPa)

843 Loader
-8C-2- Service Manual
ENGINE SPECIFICATIONS
NOTES _________________
All dimensions are given in inches . Respective metric dimensions are given in millimeters enclosed by
parenthesis.

Cylinder Head

Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.002 (0,05)

Limit 0 .008 (0,20)
Re-Grind . .. . .... . . . . . . . . . .. . . . .. . ... . .. . ... . . . Limit 0.012 (0,30)
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees

Valve, Valve Guide & Seat Insert

Valve Seat W idth

Intake ... .. . . . . .. . ... . . .. . . ... . ... . ..... . . . . " Std . 0 .067 (1,7)
Limit 0.087 (2,2)
Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std . 0 .029 (2,0)
Limit 0.079 {2,0}
Valve Head Depth
Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Std . 0 .029 {0,73}
Limit 0.05 {1,28}
Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Std. 0 .028 {O,70}
Limit 0.047 (1,2)
Valve Seat Angle ... . ... . . . .. ...... . . . .. . ... . . . .. . . . .. 45 degrees
Valve Head Thickness .. .. . . ... .. . ........ . . .... . . . . Std. 0.07 (1,8)
Limit 0 .059 {1,5}
Valve Stem Diameter
Intake ........ .... . . . .. . . . . . . .. Std. 0.3128-0.3134 (7,946-7,961)
Limit 0.310 (7,88)
Exhaust ......... . ... . . .. ... . . .. Std. 0.3119-0,3124 (7,921-7,936)
Limit 0.310 (7,88)
Valve & Valve Guide Clearance
Intake . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.0015-0 .0027 (0,039-0,068)
Limit 0 .008 (0,2)
Exhaust .. . . .... . ... . .. . . . . . .. . . Std . 0.0025-0.0038 (0,064-0,096)
Limit 0.0 10 (0,25)
Valve Guide Height . . .. . . .. .. ... . .. .. . .. .. . . .... . .. .. .. . 0.5 1 (13)

o
o
Valve Springs
"iii

!
Free Length
Inner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 1.783 (45,3)
Limit 1.748 (44,4)
Outer . .. . . . .. . . . .. . .. . . . .. ... . .. . . .... . . . . .. Std. 1.957 (49,7)
Limit 1.898 (48,2)
Inclination
Inner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lim it 0.118 (3,0)
Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limit 0.126 {3,2}
Tension
Inner - Set Length. . . . . . . . . . . . . . . . . . .. 1.46 (37) Std. 13 Ibs. (5,9 kg)
Limit 11 Ibs. (5,02 kg)
Outer-Set Length. . . . . . . . . . . . . . . . .. 1.54 (39) Std . 46 Ibs. (20,9 kg)
Limit 40 Ibs. (18,1 kg)

Rocker Arm

Shaft Diameter . . .. . . . . . . . . . . . .... . . Std. 0 .7478-0.7486 (18,98-19,0)

Limit 0.7427 (18,85)
Rocker Arm I.D .. .... . . . . .. . . . . . .. .. Std . 0 .7489-0.7497 (19,01 - 19;(3)
Limit 0.7505 (19,05)
Clearance between Rocker Arm & Shaft. ... Std. 0.0003-0 .0020 (0,01-0,05)
Limit 0 .0078 (0,2)
Push Rod Run-Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Limit 0.012 (0,3)

843 loader
-8C-3- Service Manual
 ENGINE SPECIFICATIONS (Cont'd)
NOTES _________________
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parenthesis.

Tappets

Diameter ... .. . .. .. ... .. ... ........ Std. 0.511 -0.5114 (12,98- 12,99)
Limit 0.510 (12,95)
Clearance .... ......... . . .... .... . . .. .. . ... .. . Std. 0 .0012 (0,03)
Limit 0.0039 (0,10)

Piston, Pin & Rings

Piston 0.0 .
Piston Grade A . . . . . . . . . . . . . . . . . . . . 3 .6608-3 .6616 (92,985-93,004)
Piston Grade C . . . . . . . . . . . . . . . . . . .. 3.6616-3.6624 (93,005-93,024)
Clearance in Bore . . . . . . . . . . . . . . . . . . . .. Std. 0.001-0.0018 (0,025-0,04)
Clearance Between Ring & Piston Groove
1st. Compression .. . ............... Std. 0 .0035-0.0049 (0,09-0,125)
Limit 0.006 (0,15)
2nd Compression ...... ... .... ... ... Std. 0.002-0.0033 (0,05-0,085)
Limit 0.006 (0,15)
Oil ... .. ... . .. .. . .......... ... ..... Std . 0.001 -0 .003 (0,03-0,07)
Limit 0.006 (0,15)
Piston Ring Gap
Compression . . . . . . . . . . . . . . . . . . . . . . . .. Std. 0.008-0.0016 (0,2-0,4)
limit 0 .059 (1,5)
Oil ..... ........... .... .... . ... . .. .. . Std. 0.004-0.012 (0,1 -0,3)
Limit 0.0059 (1,5)
Piston Pin 0.0 .. ... ... ... . ...... " ..... .. ..... .... Std. 1.220 (31)
Limit 1.219 (30,97)
Interference Fit Clearance ........ .. ..... 0 .00008-0.0006 (0,002-0,015)

Connecting Rod & Bearing

Connecting Rod Misalignment. . . . . . . . . . . . . . . . . . Std. 0 .002 (0,05 or less

Limit 0.0079 (0,2)
~
o
o Small End Bushing I.D .............. Std. 1.2208-1.2211 (31,008-31,015)
N

"'
N
Clearance Between Piston Pin &
~
Small End Bushing. . . . . . . . . . . . . . .. Std. 0.0003-0.00079 (0,008-0.20)
M

N
limit 0.0002 (0,05)
N
> Clearance Between Crankshaft Journal &
Bearing ... .... . .... ... . . . ...... . , Std . 0.001-0.0026 (0,029-0,066)
limit 0.004 (0,10)

Cylinder Liners

Cylinder liner 1.0 .................. Std. 3 .6622-3.6638 (93,021-93,06)

limit 3.6653 (93,10)
Interference Fit in Block . . . . . . . . . . . . . .. 0.00004-0.00075 (0,001-0,019)
Projection above Block. . . . . . . . . . . . . . . . . . . . . . . . 0.0-0 .0039 (0,0-0,01)
Cylinder liner Bore 1.0.
Piston Grade A. . . . . . . . . . . . . . .. Min. Dia. 3 .6622-3.6630 (93,021-93,04)
Piston Grade C . . . . . . . . . . . .. Min. Dia. 3.6630-3.6638 (93,041 -93,060)

Camshaft
_____________ :'·"t:-
~
o
o
N
~
o Gear Backlash ............ ...... ....... Std. 0.004-0.007 (0,10-0,17)
"
N Limit 0.012 0,3)
o
End Play. . . . . . . . . . . . . . . . . . . . . . . . .. Std. 0.0002-0.0045 (0,05-0,114)
Limit 0.0079 (0,2)
Journal Diameter .... . ... . . ..... .. Std. 1.9663-1 .9675 (49,945-49,975)
Limit 1.9528 (49,60)
Camshaft Bearing I.D .... . ....... . .... Std . 1.9685-1.9697 (50,0-50,03)

843 Loader
-8C-4- Service Manual
ENGINE SPECIFICATIONS (Cont'd)
NOTES _________________
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parenthesis.

Camshaft {Cont'd}

Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Std. 0.0020 (0,05)

Limit 0.0047 (0,12)
Camshaft Run-Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Limit 0.0039 (0,1)
Cam Lobe Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Std. 1.654 (42,02)
Limit 1.640 (41,65)
NOTE: Crankshaft is Tuffride coated and cannot be re-ground.

Crankshaft

End Play ............................... . .... . ... Std. 0.004 (0,1)

Limit 0.012 (0,31)
Connecting Rod Journal 0.0... . ...... Std. 2.0833-2.0839 (52,915·52,930)
Limit 2.0829 (52,906)
Main Bearing Journal 0.0......... . .. Std. 2.7526-2.7532 (69,917-69,932)
Limit 2.7524 (69,910)
Clearance Between Journal & Main Bearing Std. 0.0014-0.0041 (0,035-0,080)
Limit 0.0043 (0,11)
I Crankshaft Run-Out. . . . . . . . . . . . . . . . . . . . . . . .. Std. 0.002 (0,05) or less
Limit 0.003 (0,08)

Idler Gear

End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0,07)

(0,2)
Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . .. Std. 0.004-0.007 (0,10-0,017)
Limit 0.012 (0,3)
Idler Gear Hub 0.0.. . . . . . . . . . . . . . .. Std. 1.7695-1.7707 (44,945-44,975)
Limit 1.7656 (44,845)
Clearance Between Hub & Gear. . . . . . . . .. Std. 0.0009-0.003 (0,025-0,085)
Limit 0.0079 (0,2)
Bearing Replacement
Projection ................................ , 0.016-0.024 (OA-O,6)
Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.933-0.945 (23,7-24,0)

Oil Pump

End Play Between Vane & Body. . . . . . . . . .. Std. 0.0008-0.0028 (0,02-0,07)

Limit 0.0059 (0,15)
Clearance Between Rotor & Vane. . . . . . . . . . . . .. Std. 0.0055 (0,14) or less
Clearance Between Vane & Body. . . . . . . . . .. Std. 0.0079-0.0105 (0,2-0,27)
Clearance Between Rotor Shaft & Body. . . . . . . . . . . . . .. Std. 0.0016 (0,04)
Limit 0.0079 (0,2)
Oil Pump Pressure. . . . . . . . . . . . . .. 57-71 PSI (393-lJ,90 kPa) @ 1400 RPM
21 PSI (145 kPa) @ Idle RPM

Fuel System

Pump Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Bosch VE

Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Bosch Multi-hole (4 orifices)
Injector Pressure (Opening) . . . . . . . . . . . . . . . . . . . . .. 2630 PSI (18134 kPa)
Supply Pump Pressure
Idle RPM ..................................... 37 PSI (255 kPa)
High Idle RPM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 71 PSI (490 kPa)
Injection Pump Timing. . . . . . . . . . . . . . . . . . . . . • . . . • . . . . . . .. 17 0 BTeiG

843 Loader
Revised Feb. 94 -8C-5- Service Manual
 ENGINE SPECIFICATIONS (Cont'dl
NOTES-
(
i Engine Torque

Ft.-Lbs. Nm Page

Valve Cover Nuts ... . .. ... . . ..... . . . 6-13 8-18 7C-29

Rocker Arm Bracket Bolts .. . .. .. . .. . .. 36-43 49-58 7C-29
Rocker Arm Adjustment Nut ... ....... . 12-14 16-19
Cylinder Head Bolts . . . . . ..... . ..... . New 57-67 77-91 7C-29
Used 72-80 98·108 7C-29
Exhaust Manifold Bolts . . .... . .. . . . . .. 10-17 14-23 7C-30
Intake Manifold Bolts .. .. .. . .. . . .. .. . 10-17 14-23
Intake Manifold Pipe Bolts .. . . ... ... . .. 20-35 27-47
Thermostat Housing Bolts . .. . .. . ..... . 10-17 14-23 7C-66
Water Jacket Tube (Outside) .. . .. .. ... 10- 17 14-23
Exhaust Pipe to Exhaust Manifold . .. ... . 20-35 27-47
Main Bearing Cap Bolts . . . . .. .. ... .. . . 116-130 157-176 7C-44,
7C-46
Oil Pan Nuts & Bolts ....... . . . ... . . .. 14-19 19·26 7C-39
Oil Filter Housing Bolts .. . .... . .... . . . 10-17 14-23
Water Pump Bolts .. .... ... . . . ... . . . . 11-18 15-24 7C-63
Oil Pump Mounting Bolts . ...... . ..... 10-17 14-23 7C-60
Camshaft Gear Bolt .... . .... . . . . . .. . 72-87 98-118 7C-54
Camshaft Retainer Plate Bolts . .. . . . ... . 11-17 15-23 7C - 54
Flywheel Bolts . . . ..... ... . ......... *83-90 113-122 7C-26
Connecting Rod Bolts .. .. . .. .. . . . ... . 58-65 79-88 7C-40
Crankshaft Pulley Bolt .... . ... . .... . . . 123-152 167-206 7C-48,
7C-49
Fuel Injector Holddown Nut .. . . .. . .... . 23-32 31-43 7C-12
High Pressure Tubeline Fittings . . . . ..... 14-29 19-39 7C-7,
7C-l1
Injection Pump Mounting Bolts & Nuts . . . 10- 17 14-23 7C-8
Injection Pump Gear Bolt ... ... .. . .. .. 43-51 58-69
Timing Case Cover Bolts . ... ......... . 11 -17 15-23 7C-50
U-Joint Mounting Bolts . ... ... . .. . . . .. 25-28 34-38 7C-26
Engine Rear Mounting Bracket Bolts (Large) 56-62 75-85 7C-28
Enginne Rear Mounting Bracket Bolts (Small) 31-35 43-47 7C-28
Engine Front Mounting Bracket Bolts . . ... 25-28 34-38 7C-28
Idler Gear Bolts .. ... ............ .. . . 10-12 14-16 7C-51
Injection Pump Idler Gear Bolt .. .. ... . .. 72-87 98-118 7C-53
Timing Case Bolts .. . .. . ... . .... . . .. . 11 -17 15-23 7C-55
Oil Pump Bolts (Hollowl . ..... . .. ... . . 9-12 12-16

*Lubricate Thread with Oil

~
o
o
N

o
N
o

o
o

!
"
g

.
o
'"
~
-8C-S-
843 loader
Service Manual
M'ELROECOMPA.NI'
__ W'___ 843-1
Revision Number

12 March 1986
Date
SERVICE MANUAL
REVISION
, ROUTE TO
AFFECTING: ATTENTION
Product ____~B_O_B_C~A_~__
LO_A
__D_E_R_________________________ PARTS MANAGER o
[B'
SERVICE MANAGER
Model 843 SALES MANAGER o
o
M anua I N o. __ 6566091 (12-85) __________________________
~~~~~~~~

The attached sheets are a revision to the 843 Service Manual (PIN 6566091). The revision includes information on checking the
Melroe alternator and checking the Delco starter.

Remove the following pages from the Service Manual and replace them with the revised pages as follows.

TAKE OUT PUT IN

6-7, 6-8 6-7, 6-8 (Revised Mar. 86)

6-8.1 {Added Mar. 86}. 6-8.2 {Revised Mar. 86}
6-13, 6-14,6-15 6 -13, 6 -14, 6 -15 {Revised Mar. 86}

A BUSINESS UNIT OF CLqRK EQUIPMENT COMPANY Printed in U.S.A .

Page 505 - BOBM027201B1001 - 02/10/2009 17:56:27 ~ Printed by Ken Cook Co. - eXprint.exe Iv2.24.3 9/25/2009)
MELROECOMPANT
__ fM___
• "bobcat
843 - 2
Revision Number

14 April 1986
Date
SERVICE MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION
Product ____~BO~B~CA~J~L~O~A_D_E_R_______________________ PARTS MANAGER D
SERVICE MANAGER D
Model 843 SALES MANAGER D
D
Manual No. __~6~5~66~O~9~1~{1~2~-8~5~)_______________________

Remove the following page from the Service Manual (P/N 6566091) and replace it
with the revised page.

TAKE OUT PUT IN

4-3,4-4 4-3, 4-4 (Revised April 86)

Hydraulic/Hydrostatic Chart #6570242 Hydraulic/Hydrostatic Chart #6570242

Dated Jan. 86 (Revised April 86)

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A BUSINESS UNIT OF Cl'lRK EQUIPMENT COMPANY

(
__m ___
IIIELROECOMPANT
Jt.C bobcat 843-3
Revision Number

25 September 1986
Date
SERVICE MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION
Product ______
B_O_B_C_A_T__
LO_A
__D_E_R_______________________ PARTS MANAGER o
Qr
SERVICE MANAGER
Model 843 SALES MANAGER o
o
M anua I N o. __ 6566091 (12-85)
~~~~~ __ _________________________
~~

The attached sections 7C and 8C include information dealing with the Isuzu engine. Add the sections to the Service Manual.

The following pages are revision to the 843 Service Manual.

Take out the following pages and put in the revised or added pages:

TAKE OUT PUT IN

88-3,88-4 88-3, 88-4 (Revised Sept. 86)

Technical Data Sheet Technical Data Sheet (Revised Sept. 86)

A BUSINESS UNIT OF ClRRK EQUIPMENT COIIPANY

Page 509 - BOBM027201Bl0Q). - 02/10/2009 17:56:2'7 Printed by Ken Cook Co. - eXprint,exe (v2.24.3 8/25/2008)
MELROECOMPANT
__ m ..__ ~
., bobcat 843-4
Revision Number

20 February 1987
Date
SERVICE MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION
Product ______B_O_B_C_A_T_L_O_A
__D_ER________________________ PARTS MANAGER
SERVICE MANAGER
t}
Model 843 SALES MANAGER o
M anua I No. __________ ____ _________________________
6566091 (12-85)
~ ~
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Remove the following pages from the 843 Service Manual (PIN 6566091) and put in the revised pages.

TAKE OUT PUT IN

1-1,1-2 1 - 1, 1 - 2 (Revised Feb. 87)

1-5,1-6 1-5, 1-6 {Revised Feb. 87}

2-37,2-38 2-37 (Revised Feb. 87), 2-38

5-13,5-14 5-13,5-14 (Revised Feb. 87)

7C-1,7C-2 7C-1, 7C-2 (Revised Feb. 87)

TECHNICAL DATA TAB PAGE TECHNICAL DATA TAB PAGE (Revised Feb. 87)

8C-1,8C-2 8C-l (Revised Feb. 871. 8C-2

8C-5,8C-6 8C-5 (Revised Feb. 87), 8C-6 (Revised Feb. 87)

A BUSINESS UNIT OF ClIIRK EQUIPMENT COMPANY

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Revision Number

12 June 1987
Date
SERVICE MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION
Product ______B_O_B_C_A_T__L_O_A_D_E_R_________________________ PARTS MANAGER D
SERVICE MANAGER [B"
Model 843 SALES MANAGER D
6566091 (12-85)
D
Manual No.

Remove the following pages from the 843 Service Manual (P/N 6566091) and put in the revised or added pages.

TAKE OUT PUT IN

2-35, 2-36 2-35 (Revised June 87). 2-36

HYDROSTATIC SYSTEM , Tab Page HYDROSTATIC SYSTEM. Tab Page (Revised June 87)
HYDRAULIC/HYDROSTATIC FLOW CHART
(S /N 26000 & Above)

3-16a (Added June 871. 3-16b (Added June 87)

AT THE BEGINNING OF THE ENGINE SERVICE SECTION.

Tab Page (Added June 87)

ENGINE SERVICE (7Al. Tab Page ENGINE SERVICE (7Al. Tab Page (Revised June 87)

ENGINE SERVICE (7Cl. Tab Page

7C-5.7C-6
ENGINE SERVICE (7C)' Tab Page (Revised June 87)
7C - 5 (Revised June 871. 7C - 6 (Revised June 87)
I
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7C-9.7C-10 7C - 9 (Revised June 871. 7C - 10 (Revised June 87)
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TECHNICAL DATA (8Al. Tab Page TECHNICAL DATA (8A). Tab Page (Revised June 87)

TECHNICAL DATA (8B), Tab Page (Revised Feb . 87) TECHNICAL DATA (8B), Tab Page (Revised June 87)

TECHNICAL DATA (8Cl. Tab Page TECHNICAL DATA (8CI. Tab Page (Revised June 87)

GENERAL SPECIFICATIONS. Tab Page GENERAL SPECIFICATIONS. Tab Page (Revised June 87)

8-5,8-6 8-5.8-6 (Revised June 87)

8-7,8-8 8-7 (Revised June 871. 8-8 (Revised June 87)
8-9,8-10 8-9 (Revised June 87). 8-10 (Revised June 87)
8-11 (Added June 87). 8-12 (Added June 87)
8-13 (Added June 87), 8-14 (Added June 87)

A BUSINESS UNIT OF CLqRK EQUIPMENT COMPANY

IIIELROECOMPANY
843-6
Revision Number

9 December 1987
Date
SERVICE MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION
Product ____~B~O~B~C~A~T__
LO~A~D~E_R___________________ PARTS MANAGER o
[tr
SERVICE MANAGER
Model 843

6_56_6_0_9_1~(_12_-_8_5~}_______________________
Manual No. ___
SALES MANAGER
B
Remove and replace pages as follows to update your 843 Service Manual.

TAKE OUT PUT IN

7C-29,7C-30 7C - 29 (Revised Dec . 87), 7C - 30

7C-59, 7C-60 7C - 59 (Revised Dec. 87l, 7C - 60

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A BUSINESS UNIT OF CIIIRK EQUIPMENT COMPANY

~ELROECOMPANT
-~i·. __
A BUSINESS UNIT OF ClARK EQUIPMENT COMPANY
~
'- bobcat 843 - 7
Revision Number

21 July 1988
Date
SERVICE MANUAL
REVISION
ROUTE TO
AFFECTING:
ATTENTION
Product ______
B_O_B_C_A_T_L_O
_A__
D_E_R_______________________ PARTS MANAGER D
SERVICE MANAGER [B"
Model 843 SALES MANAGER D
D
M anua I N o. __________ ____ _________________________
6566091 (12-85) ~ ~

Remove the following pages from the 843 Service Manual (P/N 6566091 ) and put in the revised or added pages .

TAKE OUT PUT IN

New MAINTENANCE SAFETY PAGE

FOREWORD & CONTENTS PAGE New FOREWORD PAGE (Revised July 88)'
New CONTENTS PAGE (Revised July 88)

i, ii
iii, iv i (Revised July 88)' ii (Revised July 88)

SECTION ONE
1-7, 1-8 1- 7, 1-8 (Revised June 88)
1-9 1 - 9 (Revised July 88)

SECTION TWO
HYDRAULIC/HYDROSTATIC SYSTEM OPERATION
Chart #6570552 (Printed June 87)
HYDRAULIC/HYDROSTATIC SYSTEM OPERATION
Chart #6570552 (Printed July 88)
HYDRAULIC/HYDROSTATIC HIGH HORSE POWER
FLOW CHART & ELECTRICAL DIAGRAM
Chart #6570916 (Printed July 88)

SECTION THREE
HYDROSTATIC SYSTEM TAB PAGE (Revised June 87) HYDROSTATIC SYSTEM TAB PAGE (Revised July 88)
3-16c thru 3-16j (Added July 88)

SECTION FOUR
4-1,4-2 4- 1 (Revised July 88)' 4-2
4-3, 4-4 (Revised Apr. 86) 4-3, 4-4 (Revised July 88)

SECTION SIX
WIRING DIAGRAM (P/N 6570240) WIRING DIAGRAM (PIN 6570240)
843 (S/N 20001 & Above) (Printed Dec. 85) 843 (SIN 20001 thru 23999) (Printed July 88)
WIRING DIAGRAM (P/N 6570913)
843 (S/N 24000 thru 25999) (Printed J uly 88)
WIRING DIAGRAM (PIN 6570914)
843 (SIN 26000 thru 28134) (Printed July 88)
WIRING DIAGRAM (PIN 6570915)
843 (S/N 28135 & Above) (Printed July 88)
6-9,6-10 6-9 (Revised July 88), 6-10 (Revised July 88)
 TAKE OUT PUT IN

SECTION SEVEN
7C-7, 7C-8 7C - 7 (Revised July 88), 7C-8
7C-9 (Revised June 87)' 7C - 10 (Revised June 87) 7C - 9 (Revised July 88), 7C -1 0 (Revised July 88)
7C -11 , 7C - 1 2 7C -11 (Revised July 88), 7C -12
7C-13,7C-14 7C-13 (Revised July 88), 7C-14
7C-15, 7C-16 7C - 1 5, 7C - 16 (Revised July 88)
7C-17,7C-18 7C -17 (Revised July 88), 7C -18
7C-21,7C-22 7C-21, 7C-22 (Revised July 88)
7C-29 (Revised Dec. 87), 7C-30 7C - 29 (Revised July 88)' 7C-30
7C-39,7C-40 7C-39 (Revised July 88)' 7C-40 (Revised July 88)
7C-45,7C-46 7C-45 (Revised July 88), 7C-46 .

SECTION EIGHT
8A-9,8A-1O SA-9 (Revised July 88)' 8A-1O
88-5, 88-6 88-5, S8-6 (Revised July 88)
8C -1 (Revised Feb. 87), 8C - 2 8C - l (Revised July 88), 8C-2
8C-5 (Revised Feb. 87), 8C-6 (Revised Feb. 87) SC-5 (Revised July 88)' 8C-6 (Revised July 88)

8-5, C-6 (Revised June 87) 8-5 (Revised July 88), S-6 (Revised July 88)

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JIIELROECOJIIFANT
• • bobcat
843-8
Revision Number

22 November 1988
Date
SERVICE MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION

~
Product ____~B~O~B~C~A~T~LO~A~D~E~R_______________________ PARTS MANAGER
SERVICE MANAGER
Model 843 SALES MANAGER D
D
Manua I No. __ 6566091 (12-85) _________________________
~~~~~~~~

Remove the following pages from the 843 Service Manual (P/N 6566091) and put in the revised or added pages.

TAKE OUT PUT IN

HYDRAULIC FLOW CHART #6566716 (Printed July 1983) HYDRAULIC/HYDROSTATIC FLOW CHART #6566716
HYDROSTATIC FLOW CHART #6566717 (Printed July 1983) (Printed November 1988)

HYDRAULIC FLOW CHART #6566747 (Printed July 1983) HYDRAULIC/HYDROSTATIC FLOW CHART #6566748
HYDROSTATIC FLOW CHART #6566748 (Printed July 1983) (Printed November 1988)

A BUSINESS UNIT OF CUIRII EQUIPMENT COMPANY Printed in U.S.A.

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Revision Number

8 May 1989
Date
SERVICE MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION
Product ___B=-O-=-=-BC-=.;Jj>.~:r.:......::LO-=-A~D-=.E,--"R_ _ _ _ _ _ _ _ _ __ PARTS MANAGER
SERVICE MANAGER
@,
Model 843 SALES MANAGER D
D
M anua I No. __ 6566091 (12-85) _________________________
~~~~~~~

Remove the following pages, Hydraulic/Hydrostatic Flow Charts and Wiring Diagram from the 843 Service Manual (P/N 6566091)
and put in the revised or added pages, Hydraulic/Hydrostatic Flow Charts and Wiring Diagram.

TAKE OUT PUT IN

Hydraulic/Hydrostatic Flow Chart and Wiring Diagram Hydraulic/Hydrostatic Flow Chart and Wiring Diagram
843 High Horse Power Hydraulics (Optional) 843 High Horse Power Hydraulics (Optional)
Chart #6570916 (Printed July 1988) Chart #6570916 (Printed May 1989)

Hydraulic/Hydrostatic Flow Chart Hydraulic/Hydrostatic Flow Chart

843 (S/N 26000 & Above) 843 (S/N 26000 Thru 19925)
Chart #6570552 (Printed July 1988) Chart #6570552 (Printed May 1989)

Hydraulic/Hydrostatic Flow Chart

843 (Starting With SIN 29926)
Chart #6720178 (Printed May 1989)

Hydrostatic System - Tab Page (Revised July 88) Hydrostatic System - Tab Page (Revised May 1989)
o
3-16a thru 3-16j (Added June 87) 3-16a thru 3-16j (Revised May 1989) ,
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3-16k thru 3-16m (Added May 1989) ,o

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Wiring Diagram (6570915)

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Wiring Diagram (P/N 6570915)
843 (S/N 28135 & Above) (Printed July 1988) 843 (SIN 28135 & Above) (Printed May 1989)
JIIELROEcOMPANT
• .. bobcat 843-10
Revision Number

18 September 1990
Date
SERVICE MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION
Product _ _---:..B....:;O....:;B...,;:C_A....::T_l-'O'-A_D_E_R_ _ _ _ _ _ _ _ _ _ __ PARTS MANAGER D
SERVICE MANAGER []?"
Model 843 SALES MANAGER D
6566091 (12-85)
D
Manual No.

Remove and put in the following pages, Wiring Diagram Chart and Hydraulic/Hydrostatic Flow Chart as follows:

TAKE OUT PUT IN

COVER NEW COVER

i, ii i (Revised Sept. 90)' ii

Sheet 2 of 2 843 High Horsepower Hydraulic Sheet 2 of 2 843 High Horsepower Hydraulic
(Chart #6570916) Printed May 89 (Chart #6570916) Printed Sept. 90)
Hydraulic/Hydrostatic Flow Chart 843B Chart #6720555
<Printed September 90)

2-31,2-32 2-31 (Revised Sept. 90), 2-32

2-33,2-34 2-33 (Revised Sept. 90), 2-34
2-35,2-36 2-35 (Revised Sept. 90), 2-36 (Revised Sept. 90)
2-37,2-38 2-37 (Revised Sept. 90), 2-38 (Revised Sept. 90)
2-39,2-40 2-39 (Revised Sept. 90)' 2-40
2-43,2-44 2-43 (Revised Sept. 90), 2-44

HYDROSTATIC SYSTEM TAB PAGE (Revised May 89) HYDROSTATIC SYSTEM TAB PAGE (Revised Sept. 90)

3-1 Thru 3-34 3-1 Thru 3-53

WIRING DIAGRAM <P/N 6570915) WIRING DIAGRAM (P/N 6570915)

843 (S/N 28135 & Above) 843B (S/N 28135 & Above)
(Printed May 1989) & 843B (Printed September 1990)

A BUSINESS UNIT OF CUIlIK EQUIPMENT COMPANY Printed in U.S.A.

 •
IIIELROECOMPANY
__ fM'::== .. bobcat
843-11
Revision Number

17 September 1991
Date
SERVICE MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION
Product ____~B~O~B~C~A~~~L~O~A~D~E~R~______________________ PARTS MANAGER o
SERVICE MANAGER ffi"
Model 843 SALES MANAGER o
o
M anua I No. __________ __ _________________________
6566091 (12-85)
~ ~

Remove and replace pages as follows to update your 843 Service Manual.

TAKE OUT PUT IN

HYDRAULIC/HYDROSTATIC FLOW CHART
and WIRING DIAGRAM
For Model
843H (S/N 50450 & Above)
Chart #6720945 (Printed September 1991)

3-51 (Added Sept. 90)' 3-52 (Added Sept. 90) 3-51 (Added Sept. 90), 3-52 (Revised Sept. 91)
3-53 (Revised Sept. 90) 3-53 (Revised Sept. 91)

4-7,4-8 4- 7, 4-8 (Revised Sept. 91)

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SERVICE MANUAL
• • bobcat
843-12
Revision Number

24 September 1992
Date

REVISION
ROUTE TO
AFFECTING: ATTENTION
Product _ _--=B-=O-=B-=C:.:-.A:.:.:r.,..:.L::.;;O:.:.A..:.;D:..:E=:R..:..-_ _ _ _ _ _ _ _ _ __ PARTS MANAGER D
SERVICE MANAGER [B'
Model 843 SALES MANAGER D
D
M anua I No. __ 6566091 (12-85)
~~~~~=....:.~~ _________________________

Remove and replace pages as follows to update your 843 Service Manual.

TAKE OUT PUT IN

FOREWORD (Revised July 88) FOREWORD (Revised Sept. 92)

HYDRAULIC/HYDROSTATIC FLOW CHART HYDRAULIC/HYDROSTATIC FLOW CHART

For Model For Model
843B 843B
Chart #6720555 (Printed September 1990) Chart #6720555 (Printed September 1992)

HYDRAULIC/HYDROSTATIC SYSTEM OPERATION HYDRAULIC/HYDROSTATIC SYSTEM OPERATION

Chart #6720555 (Printed September 1990) Chart #6720555 {Printed September 1992}

HYDRAULIC/HYDROSTATIC FLOW CHART

AND WIRING DIAGRAM
For Model
843H (With Pilot Operated Main Relief)
Chart #6722305 (Printed September 1992)

HYDRAULIC/HYDROSTATIC SYSTEM OPERATION

Chart #6722305 (Printed September 1992)

SECTION 6 WIRING DIAGRAM (P/N 6722195)

BUCKET POSITION VALVE LOCKOUT (OPTIONAl)
Model 753, 7753, 843, 843B & 853
(Printed April 1992

A BUSINESS UNIT OF CI!IRII EQUIPMENT COMPANY

---.-
IIIELROECOMPANY
u . .. bobcat
843-13
Revision Number

22 February 1994
Date
SERVICE MANUAL
REVISION
ROUTE TO
AFFECTING: ATTENTION
Product _-=B-=O-=B-=C.:;..P..::.;:..:r......:L::..:O:..:.A..:..:D::....:E::..;R..:..-_ _ _ _ _ _ _ _ _ _ _ __ PARTS MANAGER o
SERVICE MANAGER Q?'
Model 843 SALES MANAGER o
M anua I No. __ 6566091 (12-85)___________________________
~~~~~=......:~

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 843 Service Manual PIN 6566091 (12-85).
Take out the pages shown and put in the revised pages as follows:

TAKE OUT PUT IN

3-43 (Added Sept. 90)' 3-44 (Added Sept. 90) 3-43 (Revised Feb. 94)' 3-44 (Revised Feb. 94)
3-51 (Added Sept. 90)' 3-52 (Added Sept. 90) 3-51 (Added Sept. 90), 3-52 (Revised Feb. 94)
4-11,4-12 4-11 (Revised Feb. 94), 4-12
7A-15, 7A-16 7A-15 (Revised Feb. 94), 7A-16 (Revised Feb. 94)
78-15, 78-16 78-15,78-16 (Revised Feb. 94)
78-29, 78-30 78-29 (Revised Feb. 94), 78-30
78-31, 78-32 78-31 (Revised Feb. 94), 78-32
78-33, 78-34 78-33 (Revised Feb. 94), 78-34
78-35, 78-36 78-35, 78-36 (Revised Feb. 94)
7C-3,7C-4 7C-3 (Revised Feb. 94)' 7C-4 (Revised Feb. 94)
7C-5 (Revised June 87), 7C-6 (Revised June 87) 7C-5 (Revised Feb. 94), 7C-6 (Revised Feb. 94)
7C-41, 7C-42 7C-41 (Revised Feb. 94), 7C-42
BA-1, BA-2 BA-1 (Revised Feb. 94). BA-2
B8-1,88-2 BA-1 (Revised Feb. 94), B8-2
8C-l,8C-2 8C-1 (Revised Feb. 94), BC-2
8C-5 (Revised July 88), 8C-6 (Revised July B8) 8C-5 (Revised Feb. 94), (8C-6 (Revised Feb. 94)

A BUSINESS UNIT OF CIRRlI EQUIPMENT COMPANY Printed in U.S.A.

MELROE
INGERSOLL-RAND ~
• bobcat®
843-14
Revision Number

30 April 1996
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
Product BOBCAT LOADER
PARTS MANAGER 0
SERVICE MANAGER IXI
Model 843 SALES MANAGER 0
Manual No. 6566091 (12-85)

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 843 Service Manual PIN 6566091 (12-85).
Take out the pages shown and put in the revised pages as follows:

TAKEOUT PUT IN
3-29,3-30 3-29, 3-30 (Revised April 96)
3-31,3-32 3-31 (Revised April 96), 3-32 (Revised April 96)
3-33,3-34 3-33 (Revised April 96), 3-34 (Revised April 96)
3-35,3-36 3-35 (Revised April 96), 3-36
4-9,4-10 4-9, 4-10 (Revised April 96)
6-1,6-2 6-1 (Revised April 96), 6-2
7C-37,7C-38 7C-37 (Revised April 86), 7C-38

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843-15
INGERSOLL-RAND .bobcat® Revision Number
17 June 1996
SERVICE MANUAL Date

REVISION
AFFECTING:
Product BOBCAT LOADER
PARTS MANAGER 0
SERVICE MANAGER [XJ
Model 843 SALES MANAGER 0
Manual No. 6566091 (12-85)

Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 843 Service Manual PIN 6566091 (12-85).

Take out the pages shown and put in the revised and added pages as follows:

TAKEOUT PUT IN
4-7,4-8 (Revised Aug. 91) 4-7,4-8 (Revised June 96)

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843-16
INGERSOLL-RAND .bobcat® Revision Number

1 August 1997
SERVICE MANUAL Date

REVISION
AFFECTING:
Product BOBCAT LOADER
PARTS MANAGER D
SERVICE MANAGER [X]
Model 843 SALES MANAGER D
Manual No. 6566091 (12-85)

Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 843 Service Manual PIN 6566091 (12- 85).

Take out the pages shown and put in the revised and added pages as follows:
TAKEOUT PUT IN

Maintenance Safety Page Maintenance Safety Page dated 8-96

CONTENTS, FOREWORD & i, ii CONTENTS, FOREWORD & i, ii (Revised Aug. 97)

iii thru viii (Added Aug. 97)