Bobcat 843 Service Manual

Bobcat 843 Serial Numbers 502012999 & Below
Perkins 2.5 Liter Four Cylinder Diesel
Bobcat 843 Serial Numbers 5026 13001 to 23999

Perkins 2.5 L TK200 Series Four Cylinder Diesel
Bobat 843 Serial Numbers 24001 and up

Isuzu 2.8 Liter Diesel
Service
Manual
Bobcat 843 Serial Numbers up to 12999 – Perkins 2.5 Liter Four Cylinder Diesel
Bobcat 843 Serial Numbers 13001 to 23999 – Perkins 2.5 L TK200 Series Four Cylinder Diesel
Bobat 843 Serial Numbers 24001 and up – Isuzu 2.8 Liter Diesel
Notes:
Worldwide Parts Source LLC

Phone: 269 673 2313
email: PartsAndGaskets@gmail.com
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731a B-12365 B-7469

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
B-11799 B-15231 B-15280

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-6590 B-6580 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW01-0805
CONTENTS
PREVENTIVE
MAINTENANCE
FOREWORD ...................................................... ii
SAFETY INSTRUCTIONS ........................................... v
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
SPECIFICATIONS
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 ROPS/FOPS 9. Enclosure door latches must
(Including sidescreens) is in good open and close freely.
condition and is not modifie
d.
2. Check that ROPS mounting 10. Bob-Tach wedges and

hardware is tightened and is Melroe linkages must function correct!
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 indicator lamps (Optional on some
d, clean and lubricated. models).
5. Machine signs must be legible 13. Check hydraulic fluid level,

and in the correct location. .iM·iiltii:t?Miif
' .... _,_,••,-�"'�"'''"'"·••'·'"'"''I engine oil level and fuel supply.
• :·;:.·:�·-:::::".. .... ,• ··- -··· I
··--····-····
. ..... ............ ... .. ....... .
, ,,
.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.
()
/1,,,
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 ) )

"
)))n> ))))))» >J)>J))JJJ½
all functions. ) )))l)))))))>) ))JJ

) ) &
�
22. Check for any field

modification not completed.
23. Check for correct function of

the Bobcat Interlock Control System
(BICS™) 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 returned to service.
843 Loader
Added Aug. 97 iv Service Manual
SAFETY INSTRUCTIONS
AWARNING
Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual,
Handbook and signs (decals) on machine. Follow warnings and Instructions In the manuals when making
repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure
to follow Instructions can cause Injury or death. w-2003-0797
The following publications provide information on the safe use and maintenance of the loader and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
• The Operation & Maintenance. Manual delivered with the loader gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance manuals can be rdeed from your Bobcat loader dealer.
• The loader has a plastic Operator's Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The handbook is available from your dealer in an English edition or one of the following languages: French,
German, Italian, Dutch & spanish.
• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop-type service and
repair work.
• The Skid-Steer Loader Operator training Course is available through your local Bobcat dealer. This course in intended
to provide rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish
version.
• The Bobcat Skid-Steer Loader Safety Video is available from your Bobcat Dealer.
AWARNING IMPORTANT
Warnings on the machine and In the This notice identifies procedures
manuals are for your safety. Failure to which must be followed to avoid
obey warnings can cause Injury or damage to the machine.
death. w-2044-12as 1-2019-0284
I
\
843 Loader
Added Aug. 97 V Service Manual
FIRE PREVENTION
The loader has several components that are at high temperature under normal operating conditions. The primary source of
high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a
source of arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase
the fire hazard. The loader must be cleaned as often as necessary to avoid this accumulation. Flammable debris in the engine
compartment is a fire hazard when the loader is parked with a hot engine.
The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the
muffler and the exhaust gases are .still hot.
• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.
• The engine compart11_1ent 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
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for
cleaning parts. Use commercial nonflammable solvents.
• 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 welding
painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.
• Stop the engine and let it cool before adding fuel. No smoking!
• Use the procedure in the Operation & Maintenance 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 fire extinguisher is available from your Bobcat dealer. The fire extinguisher can be installed in the location shown [A].
$106-0398
843 Loader
Added Aug. 97 vi Service Manual
SERIAL NUMBER LOCATIONS
A
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:
T
xxxxx
Production Sequence (Series) B Perkins 2.5 Liter
(
Perkins 2.5L TK200
Model/Engine Version
ENGINE SERIAL NUMBER

Perkins (2.5 Liter Diesel)
The engine serial number is on the left side of the engine
block, above the fuel injection pump [B].
Perkins TK200 (2.5 Liter Diesel)
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 D _ == �DELIVERYE
R POT
R
is delivered. An explanation of the form must be given to = ------

--- =--
the owner. Make sure it is filled out completely [D]. =- -- --
=--
1 I
843 Loader
Added Aug. 97 vii Service Manual
BOBCAT LOADER IDENTIFICATION
OPERATOR
ltffl��-.---SEAT
REAR LIGHT (Opt.)
UPRIGHT
--._.
-
REAR GRILL�== .'b,.,,...r.e:.w�
�._.
2 5�1/c1-
--==--===
c::::s� �
LIFT CYLINDER
/��Ir_,,
REAR DOOR
B---07377
B---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 A RM 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 I nspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 5
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Seat Bar System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 5
REMOTE START SWI TCH

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
SERVI CE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TRAN SPORTING THE LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
USING AND EXTRA BATTERY (JUMP STA RT)

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
843 Loader
Service Manual
SERVICE SCHEDULE
The service schedule is a guide for correct maintenance of the Bobcat loader that must be done regularly. Always 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 will 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 Check the oil level and add oil as needed.
Engine Air Cleaner Empty the dust cup. Replace the outer filter element only when
the red ring shows in the indicator window. Check for leaks
and damaged components.
Engine Cooling System Clean debris from shrouds and grills. Check coolant level in
the recovery tank and add as needed.
Tires Check for damaged tires and correct air pressure.
Seat Belt and Seat Bar Check the condition of seat belt. Check the seat bar for correct
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.:rach Add grease to the fittings until extra grease shows.
Pivot Areas
Engine Fuel Filter Remove water from filter.
Operator Cab Check the fastening bolts, washers and nuts. Check the
*
condition of the cab.
Wheel Nuts Check for loose wheel nuts. Tighten to correct torque if loose.
Engine Oil and Filter Replace the oil and the engine oil filter.
Battery Check the water level. Check battery cables for corrosion.
Check that the battery cables are tight. Check covers.
Hydraulic Fluid, Tubelines Check the fluid level and add as needed. Check for damage
and Hoses and leaks and replace as needed.
Alternator Drive Belt Check the tension and adjust as needed.
Chaincase Check the fluid level and add as needed.
Controls and Brakes Check operation and adjust as needed.
Spark Arrestor Muffler Remove the plug and clean the spark chamber.
Seat Bar Grease pivot as needed.
Steering Shaft Pivots Grease two (21 fittings. Add oil to steering shaft.
Hydraulic and Hydrostatic Replace filter elements.
Filters
U-Joint Grease three (31 fittings with correct grease.
Engine Fuel Filter • Replace the filter element.
Hydraulic/Hydrostatic Replace breather cap.
Reservoir Breather Cap
Chaincase Replace the fluid.
Hydraulic Fluid Reservoir Replace the hydraulic fluid.
* Check wheel nut torque every 8 hours for the first 24 hours of operation.
• Also replace hydrostatic filter element when the transmission warning light stays on for five (51 minutes after the hydrostatic
fluid is at operating temperature.
843 Loader
-1-1- Service Manual
PREVENTIVE MAINTENANCE
A
I
I
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
B-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 jackstands [ID.
Put floor jack under the front of the loader.
Lift the front of the loader and put jackstands under the axle
tubes 19.
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 � -
Lower the lift arms and bucket to the transport vehicle.
Stop the engine. Engage the parking brake.
Fasten chains to the uprights as shown �.
C-2563
Fasten chains to the front as shown lg.
843 Loader
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 I!]. 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.
B-6581
843 Loader
OPERATOR CAB
ROPS
The loader has an operator cab (ROPS and FOPS) as standard
equipment. The ROPS and FOPS protect the operator from roll
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
Sit in the seat and fasten the seat belt snugly.
Pull the seat bar all the way down and start the engine.
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.
843 Loader
OPERATOR CAB (Cont'd}
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

B-7387
Clean the debris or dirt from moving parts �.
Inspect the linkage bolts and nuts . The correct torque is 25-28
ft.-lbs. (34-38 Nm).
Use general purpose grease to lubricate the seat bar pivot points
at each side of the cab �.
I
If 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
843 Loader
Revised Feb. 87 -1-6- Service Manual
OPERATOR CAB (Cont'd)
A ROPS
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
Fender
1-4).
Bolt
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 �.
C-2599
If the lift arms are down, stand on the safety tread [ID.
If the lift arms are up, stand beside the loader lg .
Slowly raise the cab until it is all the way up [IDor lg .

B-7465
Lowering the Operator Cab
Stand on the safety tread A or beside the loader lgand slowly C

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.
B-7463
843 Loader
USING AN EXTRA BATTERY (JUMP START)
Procedure
If it is necessary to use an extra battery to start the engine.

A WARNING
BE CAREFUL! There must be one person in the operator's seat
and one person to connect and disconnect the battery cables. Batteries contain acid which burns eyes and skin on
The extra battery must be the same voltage as the loader contact. Wear goggles and protective clothing and
battery. rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water
1. Turn the key switch to the "OFF" position. for several minutes and get medical attention.
W-2065-1285
Connect the first jumper cable to the positive(+I terminal
of the extra battery(Item 1) and to the positive(+I terminal Keep arcs, sparks, flames and lighted tobacco away
of the battery (Item 21 IA! - from batteries. When "jumping" from an extra battery
make final connection (negative) at engine frame.
NOTE: Never connect the negative (- I cable to the negative
(- I terminal of the battery. Do not jump start or charge a frozen battery. Warm
battery to 60 ° F (16 ° C) before connecting to a charger.
3. Connect the second jumper cable to the negative (-I Unplug charger before connecting or disconnecting
terminal of the extra battery (Item 31 and to the engine cables at battery.
(Item 41 IA!. Battery gas can explode and cause serious injury.
W-2066-1285
4. Keep the jumper cables away from moving parts.
5. Start the engine.
6. Immediately remove the negative(-) cable(Item 41 from

the engine IA! .
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
or when welding on the loader (Remove both cables
from the battery).
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 � .
This remote start switch is required when the serviceman is

adjusting the steering linkage or check the hydraulic/hydrostatic
system.
A
B-9842
WARNING
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
843 Loader
HYDRAULIC SYSTEM
Page
Number
BUCKET POSITION VALV E (S/N 15001 & Above)
Disassembly and Assembly ...................... 2-49
Removal and Installation........................ 2-49 HYDRAULIC
SYSTEM
HYDRAULIC CONTROL PEDALS (S/N 14999 & Below) I
Adjustment .................................. 2-60

Removal and Installation........................ 2-60
HYDRAULIC CONTROL PEDALS (S/N 15001 & Above)

Adjustment .................................. 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
Tilt Section.................................. 2-23
Valve Spool Bolt .............................. 2-28
HYDRAULIC CONTROL VALV E (MELROE)

Centering Mechanism.......................... 2-38
Checking the Main Relief Valve................... 2-30
Detent Assembly .............................. 2-35
Disassembly and Assembly...................... 2-33
HYDRAULIC CYLINDER REPAIR

Assembly ................................... 2-15
Disassembly ................................. 2-13
HYDRAULIC FLUID FILTER HOUSING (S/N 15001 & Above)

By-Pass Valve................................ 2-57
HYDRAULIC/HYDROSTATIC RESERVOIR (S/N 21514 & Below)

HYDRAULIC PUMP (DOUBLE STAGE)

Checking the Output of the Hydraulic Pump.......... 2-43
Inspection ................................... 2-48
HYDRAULIC PUMP (SINGLE STAGE)

Checking the Output of the Hydraulic Pump.......... 2-39
Inspection ................................... 2-42
Continued on Next Page
843 Loader
Service Manual
HYDRAULIC SYSTEM (Cont'd)
Page
Number
HYDRAULIC SYSTEM INFORMATION
Flare Connections............................. 2-2
Straight T hread 0-Ring Fitting.................... 2-2
Tubelines and Hoses........................... 2-2
LIFT CYLINDERS
Checking the L ift Cylinder(s)..................... 2-3
PEDAL LOCK LINKAGE

Adjustment .................................. 2-62
PORT BLOCK (S/N 14999 & Below)

40 Micron Filter (Bronze)........................ 2-51
Neutral By-Pass Valve.......................... 2-52
PORT BLOCK (S/N 15001 & Above)

Charge By-Pass............................... 2-56
Cold Oil By-Pass.............................. 2-56
TILT CYLINDER
Checking the T ilt Cylinder....................... 2-5
Removal and Installation........................ 2- 5
Rod End Seal................................. 2-6
TILT CYLINDER (CESSNA)

Assembly ................................... 2-9
Disassembly ................................. 2-7
T ROUBLESHOOTING
Chart .. .................................... 2-1
843 Loader
Service Manual
M* bobcat
HYDRAULIC/ HYDROSTATIC FLOW CHART RED - - - - - - - High Pressure
For Model BLUE - - - - - - Low Pressure
843 (S/N 11001 Thru 12999) CJ
GREEN - - - - - Case Drain & Reservoir
ORANGE - - - - Charge Pressure
Chart #6566716 (Printed November 1988)
0
+
'
NOTE
Chart shows oil flow in Forward Drive
Position and with Hydraulic Cylinders
Partially Extended. For Hydraulic/
Hydrostatic System Operation, refer to
Sheet 2 of this publication.
I.
E-1502
E-1503
6566716 (11-88) (Sheet 1 of 2) Printed in U.S.A.
HYDRAULIC/ HYDROSTATIC SYSTEM OPERATION
To Be Used With
HYDRAULIC / HYDROSTATIC FLOW Ct,JART
For Model
843 (S/N 11001 Thru 12999)
Chart# 6566716 {Printed November 1988)
===�=-===-===== CHART LEGEND ===========

8 FLUID RESERVOIR, G) FILTER BY-PASS, .. 3 0 PSI (207 kPa)
Cap.:. . .. . . .... 6.0 Gals. (22, 7 L) � OIL COOLER
Working Cap.: ....... 3 .5-4.0 Gal. fJ PRESSURE SWITCH, .... 2.5-3 .5 PSI
(1 3,2-15,1 L) (17, 3 -24, 1 kPa)
f) HYDROSTATIC MOTOR, .. 15 cu. in. fl) BY-PASS VALVE, .. ... 180-200 PSI
(246 cm 3) (1241-1 3 79 kPa)
E) HYDROSTATIC PUMP G) ACCUMULATOR, Nitrogen Precharge
8 HIGH PRESSURE RELIEF REPLENISHING 120 PSI (827 kPa) (Starting at
VALVES, ... 3500 PSI (241 32 kPa) S/N 119 36)
8 HYDRAULIC PUMP, .... . 15.4 GPM
(58, 3 Lmin.) at 2720 RPM
f) TEMPERATURE SWITCH, ... 210 ° F.
(99 ° C)
0 PORT BLOCK
8 RELIEF VALVE, ......... 4 3-57 PSI
(296-393 kPa)
f) FILTER ............... 40 Micron
G) TILT CYLINDER (Cushioned)
G LIFT CYLINDERS
8 ORIFICE, .... 0.099" (2,51 mm) Dia.
SN 119 35 l Below
ORIFICE, .... 0.1 3 8" ( 3 ,51 mm) Dia.
Starting With SN 119 36
C9 HYDRAULIC CONTROL VALVE,
Self-Level
4D MAIN RELIEF, . . . . . . 2 325-2500 PSI
(160 30-172 3 7 kPa) (Measured at Quick
Couplers)
G, RESTRICTOR (In Float and Lower Position
Only)
0 PORT RELIEF (Lift Section)
3500PSI (241 32 kPa)
4D AUXILIARY QUICK COUPLERS
CB) FILTER, . . . . . . . . . . . . .. . 10 Micron
6566716 (11-88) (Sheet 2 Of 2) Printed in U.S.A.

OIL FLOW EXPLANATION
The fluid flows from the reservoir O to the inlet of the port block 8 . Reservoir fluid is
joined by the hydrostatic motor 8 case drain and the return fluid from the oil cooler e
This combined flow. supplies fluid to the hydraulic pump C, .
The hydraulic pump C, (a "gear" type) forces the fluid to the hydraulic control valve G) .
When all three spools are in neutral position, the fluid goes through the control valve G) and
either to the reservoirO or to the port block 8 . The hydraulic control valve G) is a three
section, parallel open center, closed port valve with a main relief valve 4D built into the
inlet section of the control valve G) .
When one of the spools is activated, the fluid flow is directed to either the base end or
the rod end of the cylinder(s) G) 4D . Return fluid from the other end of the
cylinder(s) G) 4D goes back to the hydraulic control valve G) and goes to the 40 micron
filter E) in the port block G . The "tee" fitting at the outlet of the. control valve G) allows
fluid to return to either the by-pass valve e and to the fluid reservoir O through a diffuser
or to the 40 micron filter E) in the port block 8 during normal operation. *The "tee" fitting
also connects to an accumulator 9 which will provide a temporary charge pressure flow
when the lift and tilt cylinders are being extended. Two sections on the control valve G) can
be used at the same time if the main relief valve e is not open.
*The accumulator 9 is standard beginning with serial number 11936.
The by-pass valve e) will open during cold weather or if there is excessive fluid pressure.
The normal fluid flow through the 40 micron filter E) , goes by the temperature switch 8
and against the neutral charge by-pass valve C, . The normal flow is through the "tee"
fitting between the temperature switch e and the charge by-pass valve e to the front
O . The fluid flow is called "charge pressure" and supplies
and the rear hydrostatic pumps
the hydrostatic pumps O and the hydrostatic motors 8 with charge fluid. The charge
fluid is used by the pump and motor, but as the charge pressure increases, the charge
by-pass valve e will open to prevent excessive pressure built up.
The neutral charge fluid flows into each hydrostatic pump O and hydrostatic motor 8 to
cool, lubricate and replenish the fluid supply which is lost through case drain. Hydrostatic
pumps O case drain flows into the inlet side of the hydraulic pump e through internal
porting.
There are two hydrostatic pumps O and two hydrostatic motors 8 . One pump and one
motor work together as a pair to drive on one side of the loader. The other pump and motor
work as a pair to drive the opposite side of the loader.
When the hydrostatic pumps O , swashplate are angled in either direction, the hydrostatic
pumps 9 force fluid, under high pressure, to the hydrostatic motors f) . The _hydrostatic
e to be
J ,.. - __ _._..
motors • turn and push the low pressure fluid back to the hydrostatic pumps
used again. The hydrostatic motors f) also contain a shuttle valve to allow some of the
fluid from the "drive loop" to go to the oil cooler 9 for cooling. The hydrostatic
pumps E) center section contains four high pressure relief /replenishing va_lves 8 . Two
for each side, one for forward travel and one for reverse travel. The high pressure
replenishing valves 8 have a dual function. In neutral the valve cartridges 8 are pushed
off their seats to allow fluid flow from the charge loop to the cool, lubricate and replenish
the pumps and the motors. When the swashplates are angled, the fluid is at a higher
pressure than the charge fluid, this pressure difference causes the high pressure replenishing
valves 8 to be forced against the seats. The high pressure replenishing valves 8 also
act as a high pressure relief valve for the hydrostatic pumps e t in case of excessive
pressure being generated by the hydrostatic pumps E) . The high pressure replenishing
valves G will open allowing the "drive pressure" to relieve into the charge loop to be
used again.
Excess charge pressure fluid which is relieved over the charge by-pass valve E) is routed
to the "tee" and joins the hydrostatic motor f) case drain fluid and flows to the oil
cooler 9 . The "tee" fitting has a pressure switch f) that senses a drop in pressure of
the fluid which goes to the oil cooler 9 . Fluid from the oil cooler 9 flows through the
filter O which has a built in by-pass valve G) . The fluid then flows into the inlet of the
port block and back to the hydraulic pump e
HYDRAULIC/ HYDROSTATIC FLOW CHART RED - - - - - - - High Pressure
For Model BLUE - - - - - - Low Pressure
l(
843 (S/N 13001 Thru 14999) GREEN - - - - -
ORANGE - - - -
Case Drain & Reservoir
Charge Pressure
(With Accumulator and Charge Line Filter)
• bobcat Chart #65667 48 (Printed November 1988)
0
i
NOTE
t
G
E-1456
E-1475

�bobcat
To Be Used With
HYDRAULIC/ HYDROSTATIC FLOW Cf·l'ART
For Model
843 (S/N 13001 Thru 14999)
(With Accumulator and Charge Line Filter)
Chart# 6566748 (Printed November 1988)
==c-========= CHART LEGEND========--====--

0 FLUID RESERVOIR,
e
f) OIL COOLER
Cap.:. ... . . .... 6.0 Gals. (22, 7 L) ORIFICE RESTRICTOR, ... . . 0.275"
Working Cap.:. ...... 3.5-4.0 Gal. (6.99 mm) Dia.
(13,2-15,1 L) I) PRESSURE SWITCH, .... 2.5-3.5 PSI
f) HYDROSTATIC MOTOR, .. 15 cu. in. (17, 3 -24, 1 kPa)
(246 cm 3) e, BY-PASS VALVE, ..... 180-200 PSI
E) HYDROSTATIC PUMP (1241-1379 kPa)
0 HIGH PRESSURE RELIEF REPLENISHING
VALVES, .. . 3 500 PSI (24132 kPa)
9 HYDRAULIC PUMP, ..... 15.4 GPM
(58,3 Lmin.) at 2720 RPM
0 TEMPERATURE SWITCH, 225-23 2° F.
(108-130° C)
8 PORT BLOCK
f) RELIEF VALVE, .. ....... 43-57 PSI
(296- 3 93 kPa)
f) FILTER . .. . . ... ... .. .. . . .. . . # 3
G) DIFFERENTIAL PRESSURE SWITCH,
19 PSI (131 kPa)
G TILT CYLINDER (Cushioned)
8 LIFT CYLINDERS
G) FILTER BY-PASS, .. 25 PSI (172 kPa)
4D MAIN RELIEF, . .... . 2125-2225 PSI
(146 51-15341 kPa)
f) ORIFICE..... 0.099" (2,51 mm) Dia .
G, RESTRICTOR (In Float and Lower Position
Only)
Q PORT RELIEF (Lift Section)
3 500 PSI (24132 kPa)
G) HYDRAULIC CONTROL VALVE,

Self Level
G) AUXILIARY QUICK COUPLERS
El) ACCUMULATOR
6566748 ( l 1-88) (Sheet 2 Of 21 Printed in U.S.A.

==:::-::-;::=====-- OIL FLOW EXPLANATION
The fluid flows from the reservoir Oto the inlet of the port block G . Reservoir fluid is
joined by the hydrostatic motor e case drain and the return fluid from the oil cooler 6)
This combined flow supplies fluid to the hydraulic pump C, .
The hydraulic pump e (a "gear" type) forces the fluid to the hydraulic control valve G
When all three spools are in neutral position, the fluid goes through the control valve G and
either to the reservoir O or to the port block G . The hydraulic control valve G is a three
section, parallel open center, closed port valve with a main relief valve CD built into the
inlet section.
When one of the spools is activated, the fluid flow is directed to either the base end or
the rod end of the cylinder(s) e 48 . Return fluid from the other end of the
cylinder(s) e 48 goes back to the hydraulic control valve G and through the 3 micron
filter E) and back to the port block G . The "tee" fitting at the outlet of the control
valve G allows fluid to return to either the by-pass valve O and to the fluid
reservoir 8 through a diffuser or through the #3 filter E) and to the port block G during
normal operation. *The "tee" fitting also connects to an accumulator f! which will provide
a temporary charge pressure flow when the lift and tilt cylinders are both being extended.
Two sections on the control valve G can be used at the same time if the main relief
valve CD is not open.
The by-pass valve O will open during cold weather or if there is excessive fluid pressure.
The flow of fluid is through the #3 filter E) , into the port block G , past the temperature
switch 8 and against the neutral charge by-pass valve C) . The normal flow is through
the "tee" fitting between the temperature switch e and the charge by-pass valve e to
the front and the rear hydrostatic pumps E) . This fluid flow is called "charge pressure"
and supplies the hydrostatic pumps e and the hydrostatic motors e with charge fluid.
The charge fluid is used by the pump and motor, but as the charge pressure increases,
the charge by-pass valve e will open to prevent excessive pressure build up.
The neutral charge fluid flows into each hydrostatic pump E) and hydrostatic motor f) to
cool, lubricate and replenish the fluid supply which is lost through case drain. Case drain
from the hydrostatic pumps e flows into the inlet side of the hydraulic pump e through
internal porting.
There are two hydrostatic pumps E) and two hydrostatic motors f) . One pump and one
motor work together as a pair to drive one side of the loader. The other pump and motor
When the swashplates, of the hydrostatic pumps E) , are angled in either direction, the
hydrostatic pumps E) force fluid, under high pressure, to the hydrostatic motors f) . The
hydrostatic motors 8 turn and push the low pressure fluid back to the, Q_y_d!g�tatic
pumps E) to be used again. The hydrostatic motors f). also contain a shuttle valve to allow
f.D for cooling. The hydrostatic
'\
some of the fluid from the drive loop to go to the oil cooler
pumps E) center section contains four high pressure relief/replenishing valves O . There
are two for each side; one for forward travel and one for reverse travel. The.high pressure
replenishing valves O have a dual function. In neutral the valve cartridges O are pushed
off their seats to allow fluid flow from the charge loop to the cool, lubricate and replenish
the pumps and the motors. When the swashplates are angled, the fluid is at a higher
pressure than the charge fluid, this pressure difference causes the high pressure replenishing
valves G to be forced against the seats. The high pressure replenishing valves G also
act as a high pressure relief valve for the hydrostatic pumps O , in case of excessive
pressure being generated by the hydrostatic pumps O . The high pressure replenishing
valves O will open allowing the "drive pressure" to relieve into the charge loop to be
used again.
Excess charge pressure fluid which is relieved over the charge by-pass valve G is routed
to the "tee" block and joins the hydrostatic motor 9 case drain fluid and flows to the
oil cooler @. e that senses a drop in pressure
The "tee" fitting has a pressure switch
of the fluid which goes to the oil cooler f.D . Fluid from the oil cooler f.D flows into the
inlet of the port block • and back to the hydraulic pump e .
�
�
HYDRAULIC/ HYDROSTATIC FLOW CHART
For Model
843 (S/N 15001 Thru 25999)
-
c:::::::J
RED - - - - - - -
BLUE - - - - - -
GREEN - - - - -
High Pressure
Low Pressure
• bobcat
-
Chart #6570242 (Printed April 1986) ORANGE - - - - Charge Pressure
c:::::::J LT. ORANGE - Hydraulic Pump Charge
8
JI
E-1508
6570242 (1-86) Revised (4-86) Printed in U.S.A.

(Sheet 1 of 2)
� ...._.......at
.. UUU\.
To Be Used With
HYDRAULIC/ HYDROSTATIC FLOW CHART
For Model
843 (S/N 15001 Thru 25999)
Chart # 6570242 (Printed April 1986)
========== CHART LEGEND==========

0 fJ
e
RESERVOIR. Cap.: .. ... 3.5-4. 0 Gals. PRESSURE RELIEF VALVE
(13,2-15,1 L) UN-LOADING SPOOL
8 TEMPER ATURE SWITCH,. 225-232 ° F 9 FILTER, Hydraulic . . . . . . . #10 Micron
(108-111 ° C) f! BY-PASS VALVE. . . 72 PSI (496 kPa)
E) COLD OIL BY-PASS VALVE,. . 297 PSI f!OIL COOLER
(2048 kPa)
9 FILTER, Hydrostatic . . . . . #3 Element
0 PORT BLOCK
e,DIAGNOSTIC COUPLER
C, CHARGE BY-PASS VALV E,. . . 110 PSI
i) PRESSURE SWITCH, Differential
(758 kPa)
S/N 15001-20991 - 19 PSI (131 kPa)
C, ORIFICE. . . Motor Case Drain 0.217" Starting W/ S/N 20992 - 40 PSI (276 kPa)
(5,51 mm) Dia. $ BY-PASS VALVE,
8 HYDROSTATIC MOTOR S/N 15001-20991 - 25 PSI (172 kPa)
C, PRESSURE SWITCH (Dual Function), Starting W/ S/N 20992 - 50 PSI (345 kPa)
Hourmeter Starts @ 19-23 PSI (132-158 G DEFUSER
kPa) Warning Light Turns off@ 17-21 PSI @) SCREEN . . . . . . . . . . . . . . 100 Mesh
(118-144 kPa)
e
6) BREATHER CAP ... __ .. _ _ 5 Micron
f) HYDRAULIC PUMP. Gear Type HYDROSTATIC PUMPS
a. Charge Pump, 11.5 GPM (43,5 L/min.)
@ 2700 RPM @ 1050 PSI (7239 kPa) G, HIGH PRESSURE RELIEF VALVES
b. Hydraulic Pump, 16.1 GPM (60,9 Umin.) 3500 PSI (24133 kPa)
@ 2700 RPM @ 1050 PSI (7239 kPa)
E) HYDRAULIC AUXILIARY LINES
• LIF T CYLINDERS
'9 TILT CYLINDERS
G) LOAD CHECK VALV ES (Four)
Q> ANTI-CAVITATION CHECK VALVE
G) ORIFICE
0 MAIN RELIEF VALVE,. 2250-2400 PSI
(15514-16548 kPa)
CD PORT RELIEF VALVE ... ... 3500 PSI
(24132 kPa)
CB, HYDRAULIC CONTROL VALV E
G) BUCKET POSITION VALVE
� FLOW-CONTROL SPOOL
9 CHECK VALVE
6570242 (1-86) Revised 14-86) (Sheet 2 Of 21 Printed in U.S.A.
The fluid reservoir O is filled by removing the breather cap G and filling fluid through the
100 mesh screen e.
Hydraulic fluid flows from the reservoir O and enters the inlet port of the tandem (2
sections) gear pump 8.
The larger section Ob of the tandem pump supplies pressure to the inlet of the hydraulic
control valve G) . The pump pressure is controlled by the main relief valve O . The control
valve 8 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 either to the hydraulic
e or to the bucket position valve G) .
G)
filter
The lift section and tilt section of the control valve G) work together to position the bucket
as the lift arms of the loader are being raised. When the lift arms are being raised, the
hydraulic pump flow is directed to the base end of the lift cylinders •. The fluid from
h
E)
the rod end of the lift cylinders • returns into the bucket position valve G) and is directed
to the center of the flow-control spool e . The flow-control spool e has an orifice at each
end. Fifty nine percent (59%) of the fluid flow is directed to the base end of the tilt
cylinder 8 . Forty one percent (41% ) of the fluid is directed through the opposite end of
the flow-control spool e and to the return port of the control valve • lift section.
The fifty nine percent (59%) of the fluid flow from the flow-control spool e is against
the Un-loading spool e and a check valve f) . An increase in fluid pressure causes the
check valve f) to open which allows the flow of the fluid to the base end of the tilt
cylinder 8 . The fluid from the rod end of the tilt cylinder 8 is contained by the un-loading
spoof e until the tilt cylinder base end • pressure is high enough to open the Un-loading
spool e and allow the rod end fluid to return into the control valve . The pressure relief
G)
valve � is to relief fluid from the base end of the tilt cylinder C8 if the bucket is fully rolled
out and lift cylinders • are still extending.
The fluid flows from the charge pump

a
either to the oil cooler e or to the cooler by
e will open when the fluid temperature is low or if there is excessive fluid
E)
pass valve
pressure. The fluid flows through the oil cooler e , then through the hydrostatic filter and f1,
into the four-way cross fitting. The fluid flows past the pressure switch E) to the charge
by-pass valve C, . The pressure switch E) has a dual function, it starts the hourmeter and
turns the warning light off.
Normal flow of fluid is through the four-way cross fitting to the front and rear hydrostatic
pumps G) . This fluid flow is called "charge pressure" and supplies the hydrostatic
pumps G) and the hydrostatic motors 8 with charge fluid. The charge fluid is used by the
pump and motor, but as the charge pressure increases, the ch<:1rge by-pass valve e will
open to prevent excessive pressure build up.
The charge fluid flows into each pump G, and motor O to cool, lubricate· and replenish
the fluid supply which is lost through case drain. Case drain from the pumps G, flows into
the inlet side of the hydraulic pump O through internal porting.
There are two hydrostatic pumps G
and two hydrostatic motors O
. One pump and one
The the swash plates of the hydrostatic pumps G, are angled in either direction, the
pumps G, force fluid, under pressure, to the motorsO . The motors 8 turn and push the
low pressure fluid back to the pumps G to be used again. The motors 8 contain a shuttle
valve which allows some fluid from the "drive loop" to go to the port block O and back
to the reservoir O . The hydrostatic pumps G, contain four high pressure relief/replenishing
valves f) . There are two valves f) for drive on each side of the loader: one for forward
travel and one for reverse travel. The high pressure relief/replenishing valve f) have a dual
function. In neutral the valve cartridges f) 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. This pressure difference forces one of the high pressure replenishing valves (one per
pump) f) against the seat. The high pressure replenishing valves f) also act as a high
pressure relief valve for the hydrostatic pumps G . The high pressure replenishing
valves e will open allowing the "drive pressure" to relieve into the charge loop to be used
again if excessive pressure is generated by the pumps G.
Excess charge pressure fluid which is relieved over the charge by-pass valve C, goes through
the port block G and joins the hydrostatic motors O case drain fluid and flows to the
reservoir O through the defusser 9 . Fluid from the cold oil by-pass valve 9 flows into
the port block O and back to the reservoir O .
Both the hydraulic filter e and the hydrostatic filter G have a by-pass valves. The hydraulic
filter 9 has a 72 PSI (496 kPa) by-pass valve$ . The hydrostatic filter fa has a 25 PSI
(172 kPa) (S/N 15001-20991) or 50 PSI (345 kPa) (Starting at SIN 20992) by-pass
valve G and also contains a pressure differential switch fJ) which indicates the condition
of the filter.
The diagnostic coupler e provides a quick access for checking the charge pressure.
HYDRAULIC / HYDROSTATIC FLOW CHART RED - - - - - - - High Pressure
� For Model
BLUE - - - - - - Low Pressure
�
"'? 843 (S/N 26001 Thru 29925)
..� bol)c Chart #6570552 (Printed May 1989) GREEN - - - - - Case Drain & Reservoir
ffl ORANGE - - - -
[::=J LT. ORANGE -
Charge Pressure
Bucket Position Fluid Flow
-t--
0
- - 1---,..---1
NOTE
6570552 (5-89) (Sheet 1 of 2) Printed in U.S.A. MC-1027

.bobcat
HYDRAULIC / HYDROSTATIC SYSTEM OPERATION
To Be Used With
HYDRAULIC / HYDROSTATIC FLOW CHA_RT
For Model
843 (SIN 26001 Thru 29925)
Chart #6570552 (Printed May 1989)
========== CHART LEGEND==========
8 RESERVOIR, Cap.: . . . . . 3.5- 4.0 Gals. fl) PRESSURE RELIEF VALVE

(13,2-15,1 L) @) UN-LOADING SPOOL
f) TEMPERATURE SWITCH, . 225- 232 ° F fJ FILTER, Hydraulic. . . . . . . #10 Micron
(108-111 °C) fJ) BY-PASS VALVE . . . 72 PSI (496 kPa)
f) COL D FLUID BY-PASS VALVE, 297 PSI 9 OIL COOLER
8
(2048 kPa)
9 FILTER,· Hydrostatic. . . . . #3 Element
PORT BLOCK
fJ DIAGNOSTIC COUPLER
C, CH ARGE BY-PASS VALVE, ... 110 PSI fl PRESSURE SWITCH, Differential
(758 kPa)
S/N 15001-20991 - 19 PSI (131 kPa)
8 ORIFICE. . . Motor Case Drain 0.217" Starting W/ S/N 20992 - 40 PSI (276 kPa)
(5,51 mm) Dia.
� BY-PASS VALVE,
8 HYDROSTATIC MOTOR S/N 15001-20991 - 25 PSI (172 kPa)
8 PRESSURE SWITCH (Dual Function), Starting W/ S/N 209 92 - 50 PSI (345 kPa)
Hourmeter Starts@ 19-23 PSI (131-159 8 DIFFUSER
kPa) Warning Light Turns off@ 17-21 PSI
f> SCREEN. . . . . . . . . . . . . . 100 Mesh
(117-145 kPa)
8
8 e
BREATHER CAP . . . . . . . . . 5 Micron
HYDRAULIC PUMP, Gear Type
HYDROSTATIC PUMPS
a. Charge Pump, 11.5 GPM (43,5 Umin.)
@ 2700 RPM @ 1050 PSI (7240 kPa) 9 HIGH PRESSURE RELIEF VALVES
b. Hydraulic Pump, 16.1 GPM (60,9 Umin .) 3500 PSI (24133 kPa)
@ 2700 RPM @ 1050 PSI (7240 kPa) G STEERING SERVO VALVE (2)
f) HYDRAULIC AUXILIARY LINES
4D LIFT CYLINDERS
8 TILT CYLINDER
G) LOAD CHECK VALVES (Four)
• ANTI-CAVITATION CHECK VALVE
8 ORIFICE
0 MAIN RELIEF VALVE,. 2250-2400 PSI
(15514-16548 kPa)
8 PORT RELIEF VALVE. . . . . . 3500 PSI
(24133 kPa)
48 HYDR AULIC CONTROL VALVE
0 BUCKET POSITION VALVE
fl FLOW-CONTROL SPOOL
0 CHECK VALVE

Hydraulic fluid flows from the reservoir O and enters the inlet port of the tandem (2
sections) gear pump O. The larger section O b
of the tandem pump supplies pressure
to the inlet of the hydraulic control valve 8 . The pump pressure is controlled by the main
relief valve 8. The control valve 8 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 e.
The lift section and tilt section of the control valve 8 work together to position the bucket
as the lift arms of the loader are being raised. When the lift arms are being raised, the
b
hydraulic pump O flow is directed to the base end of the lift cylinders G.
The fluid from
the rod end of the lift cylinders G returns into the bucket position valve � and is directed
to the center of the flow-control spool� . The flow-control spool � has an orifice at
each end. Forty one percent (41 %) of the fluid flow is directed through the opposite end
of the flow-control spool � and to the return port of the control valve 8 lift section.
Fifty nine percent (59%) of the fluid flow from the flow-control spool� is against the
un-loading spool e and a check valve f) . 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 e
The fluid from the rod end of the tilt cylinder G) is contained by the Un-loading spool e until
the tilt cylinder e base end pressure is high enough to open the Un-loading spool @) and
allow the rod end fluid to return to the control valve 8 . The pressure relief valve � is
to relieve fluid from the base end of the tilt cylinder 49 if the bucket is fully rolled out and
the lift cylinders G are still being extended.
The fluid from the charge pump section 9a flows to either the oil cooler 9 or to the
cooler by-pass valve 9. The cooler by-pass valve E) will open when the fluid temperature
is low (cold) or if there is excessive fluid pressure. The fluid flows through the oil cooler 9
then through the hydrostatic filter G and into the four-way cross fitting. The fluid flows
past the pressure switch 8 to the charge by-pass valve 9 . The pressure switch 8 has
a dual function, it starts the hourmeter and turns the warning light off.
pumps G , and also supplies fluid to actuate the steering servo controls G . This fluid
flow is called charge pressure fluid. The charge fluid flows into each pump G, and
motor 8 to cool, lubricate and replenish the fluid supply which is lost through case drain.
Case drain from the pumps G flows into the inlet side of the hydraulic pump O through
internal porting. The return fluid from the steering servos G flows to the port block O
There are two hydrostatic pumps G and two hydrostatic motors 8 . One pump and one
The swash plates of the hydrostatic pumps 9 are angled by the steering servo ,v.alves...G) in
either direction, the pumps 9 force fluid, under ··pressure, to the motors Q. The
motors • turn and push the low pressure fluid back to the pumps e to be used again.
The motors O contain a shuttle valve which allows some fluid from the drive loop to go
to the port block O and back to the reservoir O . The hydrostatic pumps 9 contain four
high pressure relief/replenishing valves G . There are two valves G for drive on each side
of the loader: one for forward travel and one for reverse travel. The high pressure
relief/replenishing valves G have a dual function. The valve cartridges G 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 swash plates are angled), the fluid
has a higher pressure than charge fluid. This pressure difference forces the high pressure
replenishing valves G onto the seat. The high pressure replenishing valve G 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.
Excess charge pressure fluid which is relieved over the charge by-pass valve 9 goes
through the port block O and joins the hydrostatic motors 8 case drain and flows to the
reservoir • through the diffuser ED . Fluid from the cold oil by-pass valve e flows into
the port block O and back to the reservoir O under conditions of cold fluid or excess flow.
fJ, has a by-pass valves to protect the system if the filter element
The hydraulic filter
becomes plugged. The hydrostatic filter f1, has a by-pass valve and a pressure differential
switch� which indicates the condition of the filter element.
The diagnostic coupler 9 provides a quick access for checking the charge pressure in
the system.
HYDRAULIC / HYDROSTATIC FLOW CHART RED - - - - - - - High Pressure
� For Model BLUE - - - - - - Low Pressure
� 843 (S/N 29926 & Above) GREEN - - - - - Case Drain & Reservoir
• bobcat Chart #6720178 (Printed May 1989) ORANGE - - - -
CJ LT. ORANGE -
Charge Pressure
Bucket Position Fluid Flow
t
e
MC-1252
6720178 (5-89) (Sheet 1 of 21 Printed in U.S.A.

� bobcat
To Be Used With
HYDRAULIC / HYDROSTATIC FLOW CHART
For Model
843 (S/N 29926 & Above)
Chart #6720178 (Printed May 1989)
========== CHART LEGEND ==========
8 RESERVOIR. Cap.: ..... 3.5-4.0 Gals. fB UN-LOADING SPOOL

(13,2-15,1 U 9 FILTER. Hydraulic .. . . . . . #10 Micron
8 TEMPER ATURE SWITCH,. 225-232 ° F 9 BY-PASS VALVE... 72 PSI (496 kPa)
(108-111 ° C) f) OIL COOLER
E) COLD FLUID BY-PASS VALVE, 297 PSI fl FILTER, Hydrostatic. . . . . #3 Element
8 PORT BLOCK
(2048 kPa)
9 DIAGNOSTIC COUPLER
fJ) P RESSURE SWITCH, Differential
8 CHARGE BY-PAS S VALVE, ... 110 PSI 40 PSI (276 kPa)
8 ORIFICE... Motor Case Drain 0.217"

(758 kPa)
e> BY-PASS VALVE ... 50 PSI (345 kPa)
@ DIFFUSER
(5,51 mm) Dia.
8 HYDROSTATIC MOTOR
9 SCREEN . . . . . . . . . . . . . . 100 Mesh
E) PRESSURE SWITCH (Dual Function},
f> BREATHER CAP. . . . . . . . . 5 Micron
Hourmeter Starts@ 19-23 PSI (131-159 G HYDROSTATIC PUMPS
kPa) Warning Light Turns off@ 17-21 PSI • HIGH PRESSURE RELIEF VALVES
(117-145 kPa) 3500 PSI (24133 kPa)
8 HYDR AULIC PUMP. Gear Typ e G STEERING SERVO VALVE (2)
a. Charge Pump, 11.5 GPM (43,5 L/min.)
@ 2700 RPM @ 1050 PSI (7240 kPa)
b. Hydraulic Pump, 16.1 GPM (60,9 L/min.)
@ 2700 RPM @ 1050 PSI (7240 kPal
f) HYDR AULIC AUXILIARY LINES
• LIFT CYLINDER S
8 TILT CYLINDER
8 LOAD CHECK VALVES ( Four)
ft ANTI-CAVITATION CHECK VALVE
8 ORIFICE
C, MAIN RELIEF VALVE,. 2250-2400 PSI
(15514-16548 kPa)
8 PORT RELIEF VALVE. . . . . . 3500 PSI
(24133 kPa)
G) HYDR AULIC CONTROL VALVE
G) BUCKET POSITION VALVE
fJ FLOW-CONTROL SPOOL
f) FLOW ADJUSTMENT VALVE

Hydraulic fluid flows from the reservoir O and e�ters the i_nlet port of the tandem (2
sections) gear pump O. The larger section f) b
of the tandem pump supplies pressure
to the inlet of the hydraulic control valve G) . The pump pressure is controlled by the main
relief valve G) . The control valve G) is a four-section, open center, closep ·port, series type
valve. When all four spools are in neutral position, the fluid goes through the control
valve • and to the hydraulic filter e.
The lift section and tilt section of the control valve G) work together to position the bucket
as the lift arms, of the loader, are being raised. When the lift arms are being raised, the
b
hydraulic pump O fluid flow is directed to the base end of the lift cylinders G, . The fluid
from the rod end of the lift cylinders • returns to the bucket position valve G) and is
directed to the center of the flow-control spool 9. The flow-control spool 9 and
adjustable metering orificefJ split this flow. Fifty-nine percent (59%) of the fluid flow is
directed over the metering orifice fJ to level the bucket. Forty-one percent (41%) of the
fluid is directed through the orifice in the flow-control spool 9 and on to the return port
of the control valve (lift section) G).
Fifty nine percent (59%) of the fluid flow from the flow-control spool 9 and metering
orifice • is against the un-loading spool e . The Un-loading spool moves to allow extension
of the tilt cylinder e as the lift cylinders • raise the lift arms.
The fluid from the charge pump section 9a flows to either the oil cooler 9 or to the
cooler by-pass valve 9 . The cooler by-pass valve f) will open when the fluid temperature
is low (cold) or if there is excessive fluid pressure. The fluid flows through the oil cooler 9 ,
then through the hydrostatic filter 9 �nd into the four-way cross fitting. The fluid flows
past the pressure switch 8 to the charge by-pass valve 8 . The pressure switch 8 has
a dual function, it starts the hourmeter and turns the warning light off.
pumps 9 , and also supplies fluid to actuate the steering servo controls e . This fluid
flow is called charge pressure fluid. The charge fluid flows into each pump 9 and
motor O to cool, lubricate and replenish the fluid supply which is lost through case drain.
Case drain from the pumps 8 flows into the inlet side of the hydraulic pump 8 through
internal porting. The return fluid from the steering servos e flows to the port block 8 .
There are two hydrostatic pumps 9 and two hydrostatic motors O . One pump and one
The swash plates of the hydrostatic pumps 9 are angled by the steering servo valves G in
either direction, the pumps 9 force fluid, under pressure, to the motors 8 . The motors
8 turn and push the low pressure fluid back to the pumps 9 to be used again. The motors
0 contain a shuttle valve which allows some fluid from the drive loop to go to--the port
block 8 and back to the reservoir O . The hydrostatfc pumps fD contain four high pressure
relief/replenishing valves e . There are two valves e for drive on each side of the loader:
one for forward travel and one for reverse travel. The high pressure relief/replenishing
valves 9 have a dual function. The valve cartridges G 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 swash plates are angled), the fluid has a higher pressure
than charge fluid. This pressure difference forces the high pressure replenishing
valves 9 onto the seat. The high pressure replenishing valve e, will open allowing the
drive pressure to relieve into the charge loop to be used again if excessive pressure is
generated by the pumps fD .
Excess charge pressure fluid which is relieved over the charge by-pass valve 8 goes through
the port block 8 and joins the hydrostatic motors O case drain and flows to the
reservoir O through the diffuser 9 . Fluid from the cold oil by-pass valve 8 flows into
the port block 8 and back to the reservoir O under conditions of cold fluid or excess flow.
e has a by-pass valve fJ to protect the system if the filter element

The hydraulic filter
becomes plugged. The hydrostatic filter e has a by-pass valve e and a pressure differential
switch e which indicates the condition of the filter element.
The diagnostic coupler G provides a quick access for checking the charge pressure in the
system.
HYDRAULIC / HYDROSTAT IC FLOW CHART RED - - - - - - - High Pressure
AND WIRING DIAGRAM BLUE - - - - - - Low Pressure
For Model GREEN - - - - - Case Drain & Reservoir
843 HIGH HORSEPOWER HYDRAULICS c::J ORANGE - - - - Charge Pressure
� c=J LT. ORANGE - Bucket Position Fluid Flow
� (OPTIONAL)
• bobcat Chart #6570916 (Printed May 1989)
NOTE
Chart shows fluid flow in Forward Drive
Partially Extended.
* THE LATER PRODUCTION LOADER WITH HIGH

HORSEPOWER HYDRAULICS (OPTION) MAY BE
DIFFERENT THAN THE EARLY PRODUCTION
LOADERS, AS LISTED BELOW:
G) Orifice, could be in either location shown on the
chart, but not in both.
e, External
d
relief valve was replaced by internal relief
valve e in the end cap of the hydraulic pump.
Case drain hose was added from the hydrostatic
pump G) to the hydraulic reservoir 8 and the
internal port between the hydraulic pump and
hydrostatic pumps was removed on later production
loaders.
0
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C � � � : : �--=====
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---sov-�J
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MC1Z59
6570916 (5-89) (Sheet 1 of 2) Printed in U.S.A. MC-1124

� bobcat
HYDRAULIC/ HYDROSTATIC SYSTEM OPERATIONS
To Be Used With
HYDRAULIC / HYDROSTAT IC FLOW CHART AND WIRING DIAGRAM
For Model
843 HIGH HORSEPOWER HYDRAULICS (OPTIONAL)
Chart #6570916 (Printed September 1990)
==========CHART LEGEND==========
0 RESERVOIR , Capacity: .. 3.5-4.0 Gals. G) *ORIFICE, ....0.024" (0,61 mm) Dia.
(13,2-15,1 L) 9 PORT RELIEF VALVE, ......3500 PSI
f) TEMPERATURE SWITCH,. 225-232° F (24132 kPa)
(100-111°C) fJ MAIN RELIEF VALVE (Electrical Controlled),
E) COLD FLUID BY-PASS VALVE, 297 PSI Normal Operation; 2200 PSI (15159 kPa)
(2048 kPa) High Hor$epower Operation; 3000 PSI
8 PORT BLOCK (20685 kPa)
8 CH ARGE BY-PASS VALVE,.. . 110 PSI 8 ORIFICE
. (758 kPa) 9 ELECTRICAL SELECTOR VALVE
8 ORIFICE ... Motor Case Drain 0.217" G, *RELIEF VALVE, 300 0 PSI (20 685 kPa)
(5, 5 mm) Diameter 9 UN-LOADING SPOOL
8 H YDROSTATIC MOTOR 9 FLOW CONTROL SPOOL
E) PRESSURE SWITCH ( Dual Function), 9 BUCKET POSITION VALVE
Hourmeter Starts @ 19-23 PSI (132-158 • FLOW ADJUSTMENT VALVE
kPa) Warning Light Turns off @ 17-21
e
fi) FILTER, ........ Hydraulic #4 Element
PSI (118-144 kPa)
BY-PASS VALVE, .... 72 PSI (496 kPa)
f) H YDR AULIC PUMP, Gear Type - Rated 9 OIL COOLER
@ 2700 RPM @ 1050 PSI (7239 kPa)
a. Hydraulic Pump, 16.2 GPM (61,3 Umin.) G) FILTER, _ .....Hydrostatic #3 Element
b. Charge Pump, 10.8 GPM (40,9 Umin.) e) DIAGNOSTIC COUPLER
c. Auxiliary Hydraulic Pump, 6.9 GPM 9 PRESSURE SWITCH, Differential 40 PSI
(26,1 Umin.) (276 kPa)
d. *Relief Valve, 3000 PSI (20685 kPa) G BY-PASS VALVE, ....50 PSI (345 kPa)
8 AUXILIAR Y COUPLER , Case Fluid Drain 8 BREATHER CAP, ..........5 Micron
• AUXILIARY COUPLER S, ........High 9 SCREEN, ............... 100Mesh
Horsepower Flow 8 DIFFUSER
8 TILT CYLINDER 8 STEERING SERVO CONTROL
t) LIF T CYLINDER S 9 HYDROSTATIC PUMPS
0, LOAD CHECK VALVES, ........... 3 G HIGH PRESSURE RELIEF VALVES, 3500
Q ANTI-CAVITATION VALVE PSI (24133 kPa)
0 AUXILIARY QUICK CO UPLERS
4D HYDR AULIC CONTROL VALVE
8 SOLENOID VALVE, ..High Horsepower
Control
6570916 (8-90) {Sheet 2 Of 21 Printed in U.S.A.

WIRE DIAGRAM LEGEND WIRING DIAGRAM
PARTS LEGEND--·-
NO.'s COLOR GAUGE
12G Orange/White 16 [!] Harness Connector
SOR Black 16
SORA Black 16 I!] Switch
sos Black 16 @] Solenoid Co�ileclors
SOY Black 16
54E Dk. Green 16 � Ground
S4EA Dk. Green 16
S4F Dk. Green 16
54G Dk. Green 16
CHECKING & ADJUSTING MAIN RELIEF

VALVE (DUAL PRESSURE)
Adjustment
1. Lift and block the loader. Screw
2. Connect the hydraulic tester to the quick

couplers 0
3. Disconnect the electrical connectors
ea and eb .
4. Start the engine. Check the main relief
valve ED
pressure.
Access Plug
5. Engage the high flow hydraulics switch f) .
NOTE: If the pressure relief setting is adjusted,
it will effect the standard relief pressure.
Always adjust the high pressure setting first.
6. If adjustment is needed, loosen the jam nut and

adjust the high flow relief valve pressure by
turning in to increase pressure or out to decrease
pressure. The correct setting is 2950-3030 PSI
H;ghP,essL Adjustment
(20340-21030 kPa).
Screw
Adjustment
7. Disengage the high flow hydraulics. Stop the
engine. tighten the jam nut to 35 ft.-lbs. (47 Nm)
torque. MC-1253
8. Remove the access plug or loosen the jam nut

on the main relief valve . ED 11. To check the relief valve in the hydraulic
d
pump f) end section: connect the hydraulic
9. Start the engine. Use an allen wrench and turn c
tester into the outlet line of the pump e .By
the screw in to increase pressure or out to
restricting the flow, with the hydraulic tester, the
decrease pressure. The correct setting is
pressure should be 3000 PSI (20685 kPa) at the
2150-2250 PSI (14824-15514 kPa).
relief valve f) .
d
10. Stop the engine. Install the access plug or tighten

the jam nut . Disconnect the hydraulic tester.
AND WIRING DIAGRAM BLUE - - - - - -
GREEN - - - - -
Low Pressure
For Model c:::J ORANGE - - - - Charge Pressure
843H (With Pilot Operated Main Relief) c:::J LT. ORANGE - Bucket Position Fluid Flow
Go
r.:==I�======�
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J J��I==
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=l==:i
lc:===o===
'--- 50V --�- � : ---�
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54G

�bobcat
HYDRAULIC / HYDROSTATIC �YSTEM OPER.ATfONS
To Be Used With
HYDRAULIC / HYDROSTAT IC FLOW CHAR T AND WIRING DIAGRAM
For Model
843H (With Pilot Operated Main Relief)
========== CHART LEGEND ==========
0 RESER VOIR, Cap.: ..... 3.5-4.0 Gals. 9 HYDR AULIC CONTROL VALVE
(13,2-15,1 L) 9 ORIFICE, . . . 0.024" (0,61 mm) Dia.
f) SCREEN,. . . . . . . . . . . . . . . 60 Mesh 0 SOLENOID VALVE, . High Horsepower
f) BREATHER CAP,. . . . . . . . . 5 Micron a. Forward Flow Fluid Control (High Flow)
8 DIFFUSER b. Reverse Flow Fluid Control (Low Flow)
0 TEMPER ATURE SWITCH, . 225-232 ° F. � ANTI-CAVITATION VALVE
(100-111 ° C.) 9 LO ADER CHECK VALVES, . .. . . . . . 3
(t COLD FLUID BY-PASS VALVE, 297 PSI f) ORIFICE
(2048 kPa) G MAIN RELIEF VALVE, Pilot Operated
8 PORT BLOCK Normal Operation;
8 CH ARGE BY-PASS VALVE, 180-200 PSI 2250-2400 PSI (15514-16548 kPa)
(1241-1379 kPa) High Flow Control;
f) ORIFICE,. . . Motor Case Drain 0.217" 3000 PSI (20685 kPa)
(5,5 mm) Diameter 9 PORT RELIEF VALVE,. .. . . 3500 PSI
e
G) HYDROSTATIC MOTOR (24133 kPa)
G HYDR AULIC PUMP,. Gear Type-Rated ELECTRICAL SELECTOR VALVE
@ 2700 RPM 9 UN-LOADING SPOOL/ PRESS. RELIEF
a. Hydraulic Pump, 16.2 GPM (61,3 Umin.) VALVE
b. Charge Pump, 10.8 GPM (40,9 Umin.) f) FLOW CONTROL SPOOL
c. Auxiliary Hydraulic Pump, G
e
FLOW ADJUSTMENT VALVE
6.9 GPM (26,1 L/min.) CHECK VALVE
f> PRESSURE SWITCH (Dual Function), G BUCKET POSITION VALVE
Hourmeter Starts @ 19-23 PSI
G FILTER,. . . . . . . Hydraulic #4 Element
(131-159 kPa); Warning Light Turns
Off @ 17-21 PSI (117-145 kPa)
fl BY-PASS VALVE,. . . 72 PSI (496 kPa)
I) OIL COOLER
G) RELIEF VALVE, 3000 PSI (20685 kPa)
G) FILTER, . . . . . Hydrostatic #3 Element
fD HIGH PRESSURE RELIEF/REPLENISHING G) DI AGNOSTIC COUPLER
VALVES (4),. . 3500 PSI (24133 kPa)
49 HYDROSTATIC PUMPS 8 PRESSURE SWITCH, . . . . . Differential
G AUXILI ARY COUPLER, . . . Case Drain
40 PSI (276 kPa)
$ BY-PASS VALVE, . .. 50 PSI (345 kPa)
4D AUXILI ARY QUICK COUPLERS
G) AUXILI ARY COUPLERS, . . . . . . . High
Horsepower Flow
G) TILT CYLINDER
� LIFT CYLINDERS
9 STEERING SERVO CONTROL
WIRE LEGEND PARTS LEGEND
NO.'s COLOR GAUGE [!] Harness Connector
12G Orange/White 16
SORA Black 16 el Switch
sos Black 16 Ground
SOY Black 16 [!)
sow Black 16 � Solenoid Connector (Forward Flow)
S4E Dk. Green 16
S4EA Dk. Green 16 I!] Solenoid Connector (Reverse Flow)
S4EB Dk. Green/Yellow 16 Electrical Selector Valve Connector
54G Dk. Green 16 �

1. Lift & block the loader.
couplers Q . All tests are done with
engine speed at full RPM.
3. Start the engine. Check main relief valve
pressure. T he correct pressure for the low
setting is 2250-2400 PSI (15514-16548
kPa).
4. Engage the "high pressure" function &
check the high flow pressure. The correct
pressure for the high setting is 3000 PSI MC·1654
(20685 kPa) .
NOTE: If adjustment is necessary , adjust 6. When the low pressure setting is correct,
the low pressure setting before
adjusting the high pressure setting. adjustment of the main relief valve
use the following procedure:
e,
the next step is to set the high pressure
5. Stop the engine. To adjust the low

pressure on the main relief valve
the following procedure:
e'
use a. Stop the engine. Disconnect the pilot
hose & remove the adapter.
b. Use a 1/4" alien wrench (Item 1) to
a. Disconnect the pilot hose & remove press the push pin (Item 2) in until it
the adapter fitting. bottoms out against the shoulder ;
b. Remove the high pressure adjustment stop (Item 3) !ID.
housing (Item 1) �. c. Turn the adjusting guide (Item 4) in
c. Use a 1/4" allen wrench (Item 2) to to increase or out to decrease the
turn the adjusting screw (Item 3) in
to increase or out to decrease
pressure lru. One turn is equal to ·
approximately 390 PSI (2689 kPa) .
pressure � . One turn is equal to d. Install the adapter & connect the pilot
approximately 490 PSI (3379 kPa). hose.
d. Install the high pressure adjustment e. Start the engine. Engage the "high :
housing & adapter. Connect the pilot horsepower" function and check for
hose.
e. Start the engine and check the
the correct pressure. Repeat the i
proceddure until the pressure setting !
pressure setting. Repeat the is correct.
procedure until the pressure setting
is correct.
========FLUID FLOW EXPLANATION========
Hydraulic fluid flows from the reservoir Oand enters the inlet port of the triple (3 section)
gear pump G G
. The larger section a of the pump supplies fiow to the inlet of the hydraulic
control valve EB O
. The pump pressure is controlled by the main relief valve . The control
EB
e
valve is a four-section, open center, closed port, series type valve. Wilen all four spools
are in neutral position, the fluid goes through the control valve and to the hydraulic
filterG.
When the lift arms are raised, the hydraulic pump G
a fluid flow is directed to the base
end of the lift cylinders G) . The fluid from the rod end of the lift cylinders e) returns to
the bucket position valveG and is directed to the center of the flow-control spool e.
The
flow-control spool f) and flow adjustment valve G) direct this flow. A percentage of the
fluid is directed over the flow adjustment valve G) to position the bucket. The rest of the
e
e
fluid is directed through the orifice in the flow-control spool and onto the return port
of the control valve (lift section).
The fluid flow from the flow-control spool G

and flow adjustment valve G) are against
the un-loading spool/pressure relief valve G . The un-loading spool/pressure relief
valve G moves to allow extension of the tilt cylinder G) as the lift cylinders O
raise the
lift arms.
The Un-loading spool/pressure relief valve e

is to relief fluid from the base end of the tilt
cylinder G) if the bucket is fully rolled out and the lift cylinders e) are still extending.
G
e.
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 G or oil cooler by-pass valve The oil
cooler by-pass valve 9
will open when the fluid temperature is cold or if there is excessive
G , then through the hydrostatic
e
fluid pressure. The fluid flows through the oil cooler
filter • and past the pressure switch to supply the front and rear hydrostatic
pump 8 with charge pressure and on to the charge by-pass valve C). The pressure
switch 8 has a dual function, it starts the hourmeter and turns the warning light off. The
charge pressure fluid flows into each pump 8 and motor G to cool, lubricate and replenish
the fluid supply which has been lost through case drain. Also fluid from the four-way cross
fitting supplies fluid to actuate the steering servo controls ED and the electrical
solenoids fl for high horsepower operation. The return fluid from the steering servo
controls EDand electrical solenoids fl flows to the port block 8 .
There are two hydrostatic pumps 8
and two hydrostatic motors G) . One pump and one
The swash plates of the hydrostatic pumps 8 are angled by the steering servo
9 8 force fluid, under pressure, to the motors G) .
1
controls in either direction, the pumps
The motors G) turn and push the low pressure fluid back to the pumps 8 to be used again.
The motors G) contain a shuttle valve which allows some fluid from the drive loop to go
to the port block 8and back to the reservoir O . The hydrostatic pumps G) contain four
high pressure relief/replenishing valves 4D 4D
. There are two valves for drive on each side
relief/replenishing valves 4Dhave a dual function. The valve cartridges 4D are pushed off
pumps 8 and motors G) . 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 CD onto the seat. The high pressure replenishing valve CD will open
allowing the drive pressure to relieve into the charge loop to be used again- if excessive
pressure is generated by the pumps 8 .
Excess charge pressure fluid which is relieved over the charge by-pass valve E) goes through
the port block 8 and joins the hydrostatic motors G) case drain and flows to the reservoir
through the diffuser O O
. Fluid from the cold oil by-pass valve flows into the port
block 8 and back to the reservoir O
under conditions of cold fluid or excess flow.
The hydraulic filter G has a by-pass valve G

to protect the system if the filter element
becomes plugged. The hydrostatic filter G) has a by-pass valve G
to protect the system
if the filter element becomes plugged and a pressure differential switch CD
which indicates
the condition of the filter element.
The diagnostic coupler G) provides a quick access for checking the charge pressure in the
system.
HIGH FLOW OPERATION
Turning the switch II] "ON" for high flow operation will activate the following functions:
it will energize the electrical solenoid fJ a, and the electrical selector valve G. When the
electrical solenoid fJ a is energized the charge pressure will shift the control valve
spool 9 to allow the fluid flow from the hydraulic pump • a to flow to the electrical
selector valve G where the fluid joins with the fluid from the auxiliary hydraulic pump G c.
This fluid than flows to the high flow quick coupler E) at the front of the loader. The return
fluid flows to the control valve 9 and to the hydraulic filterG . Case drain fluid (Example:
Planer) will return through the coupler 49
and back to the port block 8 to join the fluid
going to the reservoir O .
When the high flow operation is engaged; it will engage the pilot operated main relief
valve f) which will increase the relief pressure to 3000 PSI (20685 kPa). The relief
valve • in the auxiliary hydraulic pump • C and main relief valve e
will open to relieve
excessive pressure.
The fluid from the auxiliary hydraulic pump • c when not in use, flows to the electrical
selector valve G and returns to the hydraulic filter . G
Turning the switch II] "REV" for reverse operation will active the electrical solenoid fJ b
and shift the control valve spool 9to allow fluid flow from the hydraulic pump • a to
flow to the high flow coupler 4D . The return fluid goes to the control valve 9
and to the
hydraulic filterG G
. The electrical selector valve is not energized in this function.
� AND WIRING DIAGRAM BLUE - - - - - - Low Pressure
� .,,_ For Model GREEN - - - - - Case Drain & Reservoir
•'�bobcat
77 c::J ORANGE - - - - Charge Pressure
843H (S/N 50450 & Above) C=:J LT. ORANGE - Bucket Position Fluid Flow
tG t
G
J
>
0
IO
MCl259
50RA
MC 1548

�bobcat
HYDRAULIC / HYDROSTATIC SYSTEM OPERATIONS
To Be Used With
HYDRAULIC / HYDROSTATIC FLOW CHART AND WIRING DIAGRAM
For Model
843H (S/N 50450 & Above)
===========CHART LEGEND ==========
8 RESERVOIR, Cap.:. . .. . 3.5-4.0 Gals. fJ HYDR AULIC CONTROL VALVE

(13,2-15,1 L) G ORIFICE, .. . 0.024" (0,61 mm) Dia.
f) SCREEN,... . . . .. . . . . . . . 60 Mesh fJ SOLENOID VALVE, . High Horsepower
E) BREATHER CAP, . . . . . . . .. 5 Micron a. Forward Flow Fluid Control (High Flow)
0
e
DIFFUSER b. Reverse Flow Fluid Control (Low Flow)
C, TEMPER ATURE SWITCH,. 225-232 ° F. ANTI-CAVITATION VALVE
(100-111 °C.) 9 LOADER CHECK VALVES, . . . . . . . . 3
8 COL D FLUID BY-PASS VA LVE, 297 PSI G ORIFICE
(2048 kPa) t) MAIN RELIEF VALVE, (Electrical Controlled)
8 POR T B LOCK Normal Operation;
9 CH ARGE BY-PASS VALVE, 180-200 PSI 2200-2300 PSI (15159-15859 kPa)
(1241-1379 kPa) High Flow Control;
f) ORIFICE,. . . Motor Case Drain 0.217" 3000 PSI (20685 kPa)
(5,5 mm) Diameter � PORT RELIEF VALVE, . . . .. 3500 PSI
G) HYDROSTATIC MOTOR (24133 kPa)
G) HYDR AULIC PUMP, . Gear Type-Rated G ELECTRICAL SELECTOR VALVE
@ 2700 RPM 0 UN-LOADING SPOOL / PRESS. RELIEF
e
a. Hydraulic Pump, 16.2 GPM (61,3 Umin.) VALVE
b. Charge Pump, 10.8 GPM (40,9 L/min.) FLOW CONTROL SPOOL
c. Auxiliary Hydraulic Pump, G FLOW ADJUSTMENT VALVE
6.9 GPM (26,1 L/min.) G CHECK VALVE
f) PRESSURE SWITCH (Dual Function), G BUCKE T POSITION VALVE
Hourmeter Starts @ 19-23 PSI
G FILTER,. . . . . . . Hydraulic #4 Element
(131-159 kPa); Warning Light Turns
G BY-PASS VA LVE,. . . 72 PSI (496 kPa)
Off@ 17-21 PSI (117-145 kPa)
G OIL COOLER
G)
0
RELIEF VALVE, 3000 PSI (20685 kPa)
HIGH PRESSURE RELIEF/REPLENISHING
G FILTER, ... .. Hydrostatic #3 Element
G) DIAGNOSTIC COUPLER
VALVES (4),. . 3500 PSI (24133 kPa)
'9 HYDROSTATIC PUMPS
G PRESSURE SWITCH, . . . . . Differential
40 PSI (276 kPa)
G) AUXILIARY COUPLER,. .. Case Drain
f) BY-PASS VALVE,... 50 PSI (345 kPa)
4D AUXILIARY QUICK COUPLERS
G) AUXILIARY COUPLERS, . .. . . . . High
Horsepower Flow
G) TILT CYLINDER
9 LIF T CYLINDERS
@ STEERING SERVO CONTROL
6720945 (9·911 (Sheet 2 Of 2) Printed in U.S.A.

NO.'s COLOR GAUGE D Harness Connector ---
12GA
SOR
Orange/White
Black
16
16
D Switch
SORA Black 16 D Solenoid Connectors
sos Black 16 a. Forward Fluid Flow
sov Black 16 b. Reverse Fluid Flow
sow 16
54[
Black
Dk. Green 16 D Ground
54EA Dk. Green 16
54EB Lt. Green/Yellow 16
54F Dk. Green 16
54G Dk. Green 16

Adjustment
Screw
1. lift & block the loader.

couplers 4D.
3. Disconnect the electrical connectors

11a and IJb.
4.
5.
e
Start the engine. Check the main relief
valve pressure.
Engage the high flow hydraulic system 28

t
Jam Nut
Access Plug
NOTE: If the high pressure relief setting is

adjusted, it will effect the standard
relief pressure. Always adjust the
high pressure setting first.
6. If adjustment is needed, loosen the jam Adjustment

nut and adjust the high flow relief valve High Pressure Screw
pressure by turning in to increase Adjustment
pressure or out to decrease pressure. The
MC-1253
correct setting is 2950-3050 PSI
(20340-21030 kPa).
10. Stop the engine. Install the access plug
7. Disengage the high flow hydraulics. Stop or tighten the jam nut. Disconnect the
the engine. Tighten the jam nut to 35 ft. hydraulic tester.
lbs. (47 Nm) torque.
11. To check the relief valve G)in the
e.
8. Remove the access plug or loosen the hydraulic pump end section: connect the
jam nut on the main relief valve hydraulic tester into the outlet of the
pump. c. By restricting the flow, with
9. Start the engine. Use an allen wrench and
the hydraulic tester, the pressure should
turn the screw in to increase or out to
be 3000 PSI (20685 kPa) at the relief
decrease pressure. The correct setting is
valve G).
2150-2250 PSI (14824-15514 kPa).
Hydraulic fluid flows from the reservoir O

and enters the inlet port of the triple (3 section)
G G
. The larger section a of the pump supplies flow to the inlet of the hydraulic
e.
gear pump
The pump pressure is controlled by the main relief valve f) . The control
e
control valve
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 G) a_nd to the hydraulic
filterG.
When the lift arms are raised, the hydraulic pump G
a fluid flow is directed to the base
end of the lift cylinders f) . The fluid from the rod end of the lift cylinders f> returns to
the bucket position valve9 and is directed to the center of the flow-control spool G
. The
flow-control spool 9and flow adjustment valve Gdirect this flow. A percentage of the
fluid is directed over the flow adjustment valve G
to position the bucket. The rest of the
fluid is directed through the orifice in the flow-control spool f> and onto the return port
of the control valve e (lift section).
The fluid flow from the flow-control spool G

and flow adjustment valve Gare against
the un-loading spool/pressure relief valve G . The un-loading spool/pressure relief
valve G moves to allow extension of the tilt cylinder G) as the lift cylinders G
raise the
lift arms.
The un-loading spool/pressure relief valve G

is to relief fluid from the base end of the tilt
cylinder G) if the bucket is fully rolled out and the lift cylinders G are still extending.
G
e.
The fluid from the charge pump b flows to the four-way cross fitting and is called "charge
G
e
pressure fluid". The fluid flows to the oil cooler 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 G
, then through the hydrostatic
filter8 and past the pressure switch f) to supply the front and rear hydrostatic
pump Q with charge pressure and on to the charge by-pass valve E) . The pressure
switch f) has a dual function, it starts the hourmeter and turns the warning light off. The
charge pressure fluid flows into each pump 8
and motor G) to cool, lubricate and replenish
the fluid supply which has been lost through case drain. Also fluid from the four-way cross
fitting supplies fluid to actuate the steering servo controls f) and the electrical
solenoids O for high horsepower operation. The return fluid from the steering servo
controls G, and electrical solenoids O flows to the port block G .
There are two hydrostatic pumps 8
and two hydrostatic motors G) . One pump and one
The swash plates of the hydrostatic pumps 8 are angled by the steering servo
controls 9 in either direction, the pumps 8 force fluid, under pressure, to the motors G) .
The motors G turn and p.ush the low pressure fluid back to the pumps 8 to be used again.
The motors G) contain a shuttle valve which allows some fluid from the drive loop to go
to the port block 8 and back to the reservoir O . The hydrostatic pumps G) contai11 four
high pressure relief/replenishing valves O G
. There are two valves for drive on each side
relief/replenishing valves G have a dual function. The valve cartridges O are pushed off
pumps G) and motors G) . In forward or reverse (when the swash plates are angled), the
fluid has a higher pressure the charge fluid. This pressure difference forces the high pressure
replenishing valve 0, onto the seat . The high pressure replenishing valve f>
will open
e.
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 E) goes through
the port block Gand joins the hydrostatic motors G) case drain and flows ·to the reservoir
through the diffuser 8.Fluid from the cold oil by-pass valve 0
flows into the port
block G and back to the reservoir O under conditions of cold fluid or excess flow.
The hydraulic filter G has a by-pass valve ED

to protect the system if the filter element
becomes plugged. The hydrostatic filter G) has a by-pass valve f)
to protect the system
if the filter element becomes plugged and a pressure differential switch CD
which indicates
the condition of the filter element.
The diagnostic coupler$ provides a quick access for checking the charge pressure in the
system.
HIGH FLOW OPERATION
Turning the switch fl "ON" for high flow operation will activate the following functions:
it will energize the electrical solenoid9 e
a, the main relief valve and the electrical selector
valve El) . When the electrical solenoid 9
e
a is energized the charge pressure will shift the
e
control valve spool Gto allow the fluid flow from the hydraulic pump a to flow to the
electrical selector valve where the fluid joins with the fluid from the auxiliary hydraulic
pump G c. This fluid than flows to the high flow quick coupler CB) at the front of the loader.
The return fluid flows to the control valve f) and to the hydraulic filter f; .Case drain
fluid (Example: P laner) will return through the coupler G and back to the port block G to
join the fluid going to the reservoir O.
When the high flow operation is engaged; it also energized the main relief valve e
which
e
will increase the relief pressure to 3000 PSI (20685 kPa). The relief valve G) in the auxiliary
hydraulic pump • C and main relief valve Will open to relieve excessive pressure.
Gf
e
The fluid from the auxiliary hydraulic pump c when not in use, flows to the electrical
selector valve and returns to the hydraulic tilter G.
Turning the switch fl "REV" for reverse operation will active the electrical solenoid eb
and shift the control valve spool 9to allow fluid flow from the hydraulic pump a to a,
8. The return fluid goes to the control valve f) and to the
e
flow to the high flow coupler
hydraulic filterG. The electrical selector valve e>
and the main relief valve are not
energized in this function.
HYDRAULIC / HYDROSTATIC FL OW CHART RED - - - - - - - High Pressure
For Model BLUE - - - - - - low Pressure
� GREEN - - - - - Case Drain & Reservoir
� 8438 c:::=J
• bobcat
ORANGE - - - - Charge Pressure
Chart #6720555 {Printed September 1992) c:::=J LT. ORANGE - Bucket Position Fluid Flow
G
l
I
•
NOTE
Chart shows oil flow in Forward
Drive Position and with Hydraulic
Cylinders Partially Extended. For
Hydraulic/Hydrostatic System
Operation, refer to Sheet 2 of this
publication.

• bobcat
-
To Be Used With
HYDRAULIC / HYDROSTATIC FLOW CHART
For Model
8438
===========CHART LEGEND==========
• BREATHER CAP, . . . . . .. . . 5 Micron 9 FLOW CONTROL SPOOL
8 SCREEN, ............. 100 Mesh t) FLOW ADJUSTMENT VALVE
6) RESERVOIR, fi CHECK VALVE
e
Cap acity
3.5 -4.0 G als. (13,2 -15,1 l.) BUCKET POSITION VALVE (OPT.)
8 DEFUSER fJ HYDR AULIC FILTER, ... .. 10 Micron
C, TEMPER ATURE SWITCH, 225-232 ° F. f! BY-PASS_ VALVE, .. 72 PSI (496 kPa)
(108-111 ° C.l f}) HYDROSTATIC FILTER, . . #3 Element
Q COLD FLUID BY-PASS VALVE, 9 DIAGNOSTIC COUPLER
297 PSI (2048 kPa)
9 DIFFERENTIAL PRESSURE SWITCH,
8 PORT BLOCK 40 PSI (276 kPa)
C, CH ARGE BY-PASS VALVE, f) BY-PASS VALVE, . . 50 PSI (345 kPa)
110 PSI (758 kPa)
G OIL COOLER
E) ORIFICE, . . . . ... . Motor Case Drain
G HYDROSTATIC PUMPS
G) HYDROSTATIC MOTOR
0.217" (5,5 mm)
9 HIGH PRESSURE/REPLENISHING RELIEF
VALVES, .... 3500 PSI (24133 kPa)
G, PRESSURE SWITCH (Dual Function)
Hourmeter Starts@ 19-23 PSI (131 -159
kPa); Warning Light Turns Off@ 17-21
PSI (117-145 kPa)
4D HYDR AULIC PUMP, . . ... Gear Type
Rated@ 2700 RPM &
1050 PSI (7239 kPa)
a. C harge Pump, 11.5 GPM (43,5 Umin.)
b. Hydraulic Pump, 16.1 GPM (60,9) Umin.)
G) TILT CYLINDER
fD LIFT CYLINDERS
8 AUXILI ARY QUICK COUPLERS (OPT.)
0 LO AD CHECK VALVES (3)
4D ANTI-C AVITATION VALVE
G) HYDR AULIC CONTROL VALVE
G) ORIFICE
f) M AIN RELIEF VALVE,
2250 -2400 PSI (15514 -16558 kPa)
G PORT RELIEF VALVE,
3500 PSI (24133 kPa)
f) UN-LOADING SPOOL/PRESSURE
RELIEF VALVE
6720555 (9-921 (Sheet 2 Of 21 Printed in U.S.A.
Hydraulic fluid flows from the reservoir f) to the infet port of the tandem (2 section) gear
pump 8 . The larger section 4D b
of the hydraulic pump suppiies pressure to the inlet of
the hydraulic control valve G) . The pump pressure is controlled by the main relief valve C's) .
The control valve G) is a three-section, open center, closed port, serie� �ype valve. When
all three spools are in neutral position, the fluid goes through the control valve e to the
hydraulic filter 9.
If one of the spools is activated, the fluid goes out the respective port to either the base
end, or the rod end of the cylinder(s} G) e . As the fluid goes into one end of the
cylinder(s) G) 4D the fluid from the other side of the cylinder flows back into the control
valve G) . ALSO SEE BUCKET POSITIONING SYSTEM OPERATION (OPTIONAL).
When the cylinder(s) G) e reach the end of the stroke, the fluid reaches the setting of
the main relief valve C's) , it will open and let the fluid by-pass the-hydraulic circuit (internally)
and go back to the reservoir e .
The fluid flows from the charge pump 9a to either the oil cooler 9 or the cooler by-pass
valve 8 which will open when there is cold fluid or if there is excessive fluid pressure.
The fluid flows through the oil cooler 9 , then through the hydrostatic filter • and into
the four-way block. The fluid flows past the pressure switch G to the charge by-pass
valve E) . The pressure switch G has a dual function, it starts the hourmeter and turns
the warning light "OFF".
Normal flow of fluid is through the four-way block to the front and rear hydrostatic
pumps G . This fluid flow is called "charge pressure" and supplies the hydrostatic
pumps G and hydrostatic motors G) with charge fluid. The charge fluid is used by the
pumps and motors, but as the charge pressure increases, the charge by-pass valve G will
open to prevent excessive pressure build-up.
The charge fluid flows into each pump G and motor G to cool, lubricate and replenish
the fluid supply which is lost through case drain. Case drain from the pumps G flows into
the inlet side of the hydraulic pump e through internal porting.
There are two hydrostatic pumps G and motors G . 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 swashplates of the hydrostatic pumps G are angled to either direction, the
pumps G force fluid, under pressure, to the motors G . The motors G turn and push the
low pressure fluid back to the pumps 9 to be used again. The motors G) contain a shuttle
valve which allows some fluid from the "drive loop" to go to the port block 8 and back
to the reservoir e.
The hydrostatic pumps G) contain four high pressure relief /replenishing valves G . There
are two valves G for drive on each side of the loader.:. one for forward travel ��d -�-;e for
reverse travel. The high pressure relief/replenishing valves G have.a dual function. In neutral
the valve cartridges G are pushed off their seats to allow fluid flow from the charge loop
to cool, lubricate and replenish the pumps e and motors G . 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 G against the seat. The high pressure
replenishing valves G also act as a high pressure relief valve for the pumps G) . The high
pressure replenishing valves G will open allowing the "drive pressure" to relieve into the
charge loop to be used again if excessive pressure is generated by the pumps G.
Excess charge pressure fluid which is relieved over the charge by-pass valve O goes through
the port block 8 and joins the hydrostatic motors G case drain fluid and flows to the
reservoir f) through the defuser 8 . Fluid from the cold fluid by-pass valve 9 flows into
the port block • and back to the reservoir e.
Both the hydraulic filter G and hydrostatic filter f) have a by-pass � e . The hydrostatic
filter 9 also has a pressure differential switch ED which indicates the condition of the filter.
The diagnostic coupler G provides a quick access for checking the charge pressure.
BUCKET POSITIONING SYSTEM OPERATION (OPTIONAL)
The lift and tilt section of the control valve G) work together to position the bucket as
the lift arms are being raised. When the lift arms are being raised, the hydraulic
b
pump 4D flow is directed to the base end of the lift cylinders G> . The fluid from the rod
end of the lift cylinders • returns to the bucket position valve e and is directed to the
center of the flow-control spool f! . The flow-control spool f! has an orifice at each end.
Some of the fluid flow is directed to the base end of the tilt cylinder G) and the other portion
of the fluid is directed through the opposite end of the flow-control spool e to the return
port of the lift section of the control valve G) .
The fluid flow from the flow-control spool e is against the Un-loading spool e and flow
adjustment valve 9 . An increase in fluid pressure causes the flow adjustment valve 9 to
open which allows the flow of the fluid to the base end of the tilt cylinder G) . The fluid
•from the rod end of the tilt cylindere is contained by the Un-loading spool e and allows
the rod end fluid to return into the control valve G) . The pressure relief valve e is to relief
fluid from the base end of the tilt cylinder e if the bucket is fully rolled out and the lift
cylinders I> are still being extended.
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 lift arms come down with tl"}e 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
HYDRAULIC SYSTEM INFORMATION Mark a Line on Nut
Flats of Both Nuts
IMPORTANT
Always keep hydraulic and hydrostatic parts clean. Tighten to Correct
Clean outside of all assemblies before beginning repairs. Amount from Chart
Use plugs and caps to cover open ports. Dirt can quickly
damage the system.
1-2021-0284
A-1897
_!J
Flare Connections
Tube Size Rotate No.

Use the following procedure to tighten the flare fitting:
Wrench Size Outside Dia. Thread Size of Hex Flats
Tighten the nut until it makes contact with the seat. 5/8" 5/16" 1/2" - 20 2-1/2
Make a mark across the "flats" of both the male and female
11/16" 3/8" 9/16" - 18 2
parts of the connection [!]. 7/8" 1/2" 3/4" - 16 2
1" 5/8" 7/8" - 14 1-1/2 - 2
1-1/4" 3/4" 1-1/16" - 12 1
Use the chart to find the correct tightness needed [ID.
1-3/8" 1" 1-5/16" - 12 3/4 - 1
If the fitting leaks after tightening, disconnect it and inspect 2" 1-1/4" 1-5/8" - 12 3/4 - 1
the seat area for damage.
2-1/4" 1-1/2" 1-7/8" - 12 1/2 - 3/4
Straight Thread 0-ring Fitting
When installing this fitting, the 0-ring must be first lubricated.

Loosen the jam nut, install the fitting into place, then tighten
the jam nut. Tighten the jam nut until it and the washer are tight
against the surface [g.
Tubelines 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
LIFT CYLINDER
Checking the Lift Cylinder(s)
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) � (left side) Ii]. 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. 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
Start the engine and push the top (toe) 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 Installation
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 lg.
Installation: Tighten the lock bolt to 8-10 ft.-lbs. (11-14 Nm) B-8495
torque.
Remove the rod end pin [Q].
843 Loader
LIFT CYLINDER (Cont'd)
Remove the lock bolt at the base end pivot pin.
Remove the base end pivot pin l!] .
B-4395
Slide the cylinder forward a small amount. Disconnect the hoses

from the cylinder !ID.
Remove the lift cylinder from the loader.
See Page 2-13 for Hydraulic Cylinder Repair.
B-4391
843 Loader
-2-4- SP-rvir.P- Manual
TILT CYLINDER
Checking the Tilt Cylinder
Remove the bucket. Roll the Bob-Tach fully backward. Stop the
engine. Activate the tilt pedal to release the hydraulic pressure.
11
Disconnect the hose which goes to the base end of the tilt
cylinder � -
Put a plug in the hose. Remove Hose from Base

g __End of Tilt Cylinder
A
B-2790
·WARNING
I
W-2074-1285
Start the engine and push the bottom (heel) of the tilt pedal.
\ B-4400
If there is leakage from the open port, remove the tilt cylinder
for repair.
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 tilt cylinder [ID.
Remove the lock bolt at the rod end pin [£].
Installation: Tighten the lock bolt to 8-10 ft.-lbs. (11-14 Nm)

torque.
Remove the rod end pin � .
843 Loader
TILT CYLINDER (Cont'd)
Remove the lock bolt at the base end pin I!].
B-4402
Remove the pin at the base end of the tilt cylinder [ID.
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 �.
C
B-4405
Use two pieces of shim stock, to install the rod end of the
cylinder, so there is no damage to the seals �.
843 Loader
TILT CYLINDER (CESSNA)
T he tools listed will be needed to do the following procedure:
MEL-1074 - 0-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.
B-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 (Item 1) in the end cap �.
Lift the retainer ring (Item 21 out of the cylinder barrel �.
Put a wrench on the fitting and turn the end cap

counterclockwise to remove the retainer ring [ID.
Remove the cylinder end cap, piston and rod assembly from the
cylinder barrel [g.
B-3897
Put the rod end of the rod in a vise. Remove the piston from
the rod IQ].
843 Loader
TILT CYLINDER (CESSNA) (Cont'd)
Remove the 0-ring from the end of the rod I!] .
Remove the cushion sleeve from the rod I!] .
Remove the end cap from the rod.
B-3902
Remove the wiper seal �.
B-3905
Remove the oil seal [g.
B-3911
Remove the 0-ring (Item 1) and back-up washer (Item 2) from

the end cap [Q].
B-3912
843 Loader
Assembly
_ -Remove the teflon seal and the 0-ring from the piston [!].
Wash all the parts in clean solvent. Dry with air only. Destroy
old seals and 0-rings.
B-3689
B-3703
Install the piston on the tool [ID.
Install the 0-ring on the piston using the tool [ID.
Install the teflon seal over the tool and on the piston [£) .
NOT E: 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 piston size diameter.
B-3677
B-3673
Install the oil seal in the end cap � -
B-3899
843 Loader
Install the wiper seal, with the lip toward the outside of the end
cap IA].
B-3907
Install the back-up washer (Item 1) and 0-ring (Item 2) on the

end cap [!].
B-3908
Put oil on the oil and wiper seal and install on the rod �.
Install the cushion sleeve, with tapered end toward the end cap
�-
Install the 0-ring on the end of the rod.
Remove the piston from the tool.
Install the piston on the shaft, with the recessed edge toward
the 0-ring �.
B-3902 B-3915
843 Loader
TILT CYLINDER (CESSNA) (Cont'd}
Tighten the piston to 400-455 ft.-lbs. (542-617 Nm) torque�
Lubricate the teflon seal and 0-ring.
B-4460
Install the piston into the cylinder barrel and work the teflon seal
and 0-ring past the slot in the barrel [ID.
Install the rod and end cap assembly into the cylinder barrel lg.
B-3894
Install the end cap into the barrel, work the 0-ring past the slot
[Q].
Rotate the end cap until the small hole in the end cap can be
seen in the slot.
8-3910
843 Loader
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.
B-2604
Push down on the retainer ring and make sure it is seated

correctly 00 .
Push the cylinder rod in and out the full length. It must travel
freely through the full stroke.
B-3913
843 Loader
HYDRAULIC CYLINDER REPAIR
NOTE: The following procedure can be used for the lift and
tilt cylinders.
Disassembly
T he tools listed will be needed to do the following procedure:
MEL-1074 - 0-ring Seal Hook

MEL-1033 - Rod Seal Installation Tool
MEL-1075 - Gland Nut Wrench
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 � .
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 [!].
Remove the piston from the rod � .
B-3683
Remove the end cap from the rod [Q].
843 Loader
HYDRAULIC CYLINDER REPAIR (Cont'd)
Remove the 0-ring and back-up washer from the end cap �.
Remove the wiper seal from the end cap [ID.
Remove the oil seal from the end cap lg.
Remove the teflon seal and 0-ring from the piston [Q] .
Wash all the parts in clean solvent. Dry with air only. Destroy
all the old seals and 0-rings.
B-3703
843 Loader
-2-14- Service Ma[lual
Assembly
Inspect the parts for scratches, nicks, bent, etc. Replace the
parts as needed.
Install the piston on the tool I!].
Install the 0-ring on the piston using the tool I!].
B-3675
Install the teflon seal over the tool and on the piston [!I.
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.
/
/
/
B-3677
/ / B-3673
Install the seal on the seal tool lg.
Install the seal in the end cap lg.
/
//
B-3702
B-3671
Install the wiper seal with the lip toward the outside of the end
cap [Q].
NOTE: T he 0-ring side of the oil seal goes toward the inside
of the cylinder.
843 Loader
Install the back-up washer and 0-ring on the end cap �.
B-3679
B-3681
Put oil on the wiper seal and install the end cap on the shaft �
NOTE: On tilt cylinder with tapered sleeve, install the sleeve

with the taper toward the eye end of the rod.
B-3685
Remove the piston from the tool and install the piston on the
shaft 1£1.
NOTE: On tilt cylinder with tapered piston, install 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.-lbs.

(203-217 Nm)
Tilt Cylinder (Tapered Sleeve) - 330-360 ft.-lbs.

(447-488 Nm)
Tilt Cylinder (Tapered Piston) - 478-550 ft.-lbs.

(638-745 Nm)
843 Loader
Inspect the cylinder barrel bore for scratches.
Put oil on the seals, 0-rings and end cap threads I!].
Install the assembly into the cylinder barrel.
B-3691
Tighten the end cap with the special tool [ID.
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
� .. rv;,.,.,. M,.n,.,.I
HYDRAULIC CONTROL VALVE (CESSNA)
Checking the Main Relief 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 IK].
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 Umin.) free flow.
The correct pressure for the main relief valve is 2150-2400 PS I

(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 beginning repairs.
damage the system.
1-2021-0284
843 Loader
HYDRAULIC CONTROL VALVE (CESSNA) (Cont'd)
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
procedure).
Clean the area around the control valve.
Loosen the main relief valve IA].
B-4372
Remove the main relief valve from the control valve [!I.
B
Installation: When installing the main relief valve, always use
NEW 0-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.
B-4373
Stop the engine. Activate the hydraulic controls to release the

hydraulic pressure.
procedure).
procedure).
Remove the front panel (See Page 3-3 for the correct
_ procedure).
Clean the area around the control valve. B-4374
Remove the hose from the control valve which goes to the port
block lg.
Disconnect the pedal control linkage at the valve spool (Q].
B-4375
843 Loader
Disconnect all the control linkage from the control valve l!].
B-4376
Disconnect all the tubelines from the control valve [!].
Installation: When installing the tubelines, make sure the,

restrictor orifice is :located in the port [!l.
,\::
B-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.-lbs. (34-38 Nm)

torque.
Remove the control valve from the loader.
B-4379
843 Loader
HYDRAULIC CONTROL VALV E (CESSNA) (Cont'd)
Disassembly
IMPORTANT
damage the system. B-4286
1-2021-0284
Mark each section of the control valve for identification for

correct assembly IA].
Remove the control valve thru-bolts �.
Remove the end section lg.
B-4290
Remove the auxiliary, lift and tilt sections [Q].
Remove all the 0-rings and destroy them.
NOTE: Disassembly, repair and assembly must be done to one

valve section at a time.
B-4295
843 Loader
Inlet Section
Remove the main relief valve � -
B-4296
Remove the 0-ring, back-up washer and 0-ring from the port
[ID.
B-4297
Remove the 0-ring from the main relief valve lg.
Clean and inspect the main relief valve and inlet section. Replace
the parts as needed.
B-4298
Installation: Make sure to install NEW 0-rings and back-up

washer in the inlet section [Q] .
B-4300
843 Loader
Tilt Section
Remove the bolts from the end cap [!].
Installation: Tighten the bolts to 10-13 ft.-lbs. (14-17 Nm) torque.
B-4301
Remove the end cap [ru.
Remove the valve spool assembly [£].
Installation: CAREFULLY install the spool from the rear of the

valve section to prevent damage to the 0-rings.
Installation: Check the valve spool, it must move freely in the

bore. If not, rotate it 180 ° .
B-4305
Remove the 0-ring from the valve spool �.
Remove the 0-rings from the valve spool bore � .
Installation: Always use NEW 0-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 (See Page 2-28 for the correct procedure).
843 Loader
Remove the plug for the load check valve �.
Remove the spring and poppet �.
Remove the plug for the check valve [ID.
Remove the spring and poppet [ID.
Remove the plug at the unloading valve [£:I.

,
,t>
B-4315
B-4317
Remove the spring and unloading valve �.
Clean and inspect all the parts.
Replace the parts as needed.
Remove and destroy all the 0-rings.
Always use NEW 0-rings when assembling the valve section.
B-4318
843 Loader
HYDRAULIC CO NTROL VALV E (CESSNA) (Cont'd)
Lift Section
Remove the bolts from the end cap IA].
B-4320
Remove the end cap [!] .
NOTE: When installing the end cap, make sure the detent holds
the spool.
B-4321
Remove the valve spool assembly � -
B-4322
Remove the 0-ring from the valve spool � .
Installation: Check the valve spool so it operates freely in the

bore. If not, rotate the spool 180 ° .
Remove the 0-rings at both ends of the valve spool bore in the
valve section.
unless the spring is broken. If the bolt is to be removed,
(See Page 2-28 for the correct procedu�e).
B-4307
843 Loader
HYDRAULIC CON TROL VALV E (CESSNA) (C ont'd)
Remove the port relief valve I!].
Remove the 0-ring, back-up washer and 0-ring I!] .
B-4324
B-4326
Remove the plug at the load check valve �.
(lJ - 0·-4329
B-4327
Remove the plug at the flow divider valve 1£] .

Large Hole
to the
Remove the flow divider valve and 0-ring 1£].
,9-(1
C,
·
Small Hole
Toward the
Plug
B-6568
B-4331
Remove the self-level valve [Q].
Remove the 0-rings and back-up washers from the self-level

valve [Q].
Clean and inspect all the parts. Replace the parts as needed.
Remove and destroy all the 0-rings and back-up washers.
NOTE: Always use NEW 0-rings and back-up washers when

assembling the valve section.
Ooo•�• B-4336
B-4338
843 Loader
Auxiliary Section
Remove the bolts from the end cap � -
Remove the end cap.
NOTE: When installing the end cap, make sure the detent holds
the spool.
B-4342
Remove the valve spool assembly [ID.
Installation: Check the valve spool so it operates freely in the

bore. If not, rotate the spool 180 °.
B-4345
Remove the 0-ring from the valve spool �.
Remove the 0-rings at both ends of the valve spool bore in the
section.
unless the spring is broken. If the bolt is removed See
Page 2-28 for the correct procedure.
B-4307
Remove the plug at the load check valve �.
B-4347
B-4348
843 Loader
_')_')"7_
Remove the flow plug � .
Clean and inspect all the parts. Replace the parts as needed.
Remove and destroy all the 0-rings.
Always use NEW 0-rings when assembling the auxiliary section.
Valve Spool Bolt
To remove the spool bolt, follow this procedure:

B-4350
IMPORTANT
Remove This
The spool bolt is held tightly by Loc-tite. Failure to heat
the spool will cause breakage of the spool bolt.
1. Heat the spool where the spools bolt turns into the spool
to about 400 ° F (205 ° C) [ru.
Heat This Area to

2. Use a deep socket and remove the spool bolt.
'400 ° F (205 ° C) to Remove
the Spool Bolt B-3508
3. Install a NEW 0-ring (Item 1) on the spool lg.
4. Install the washer (Item 21. spring cap (Item 3), spring (Item
4) and spring cap (Item 5).
5. Put Loctite on the spool bolt (Item 6) and install it in the

spool lg.
B-4341
6. Tighten the spool bolt to 60-96 in.-lbs. (6,8-10,8 Nm) torque

�-
Tighten to
60-96 in.-lbs. (6,8-10,8
Nm)
Torque Only
B-3512
843 Loader
HYDRAULIC C ONTROL VALVE (CESSNA} (Cont'd}
Assembly
NOTE: Use vaseline or grease to hold the 0-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) �.
Install the lift section (Item 2) �.
Install the tilt section (Item 1) [ID.
B-4357
Install the end section (Item 1) lg.
Install the thru-bolts (Item 2) 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.
B-4358
Tighten the bolts to 22 ft.-lbs. (30 Nm) torque [Q].
843 Loader
HYDRAULIC CONTROL VALVE (MELROE)
Checking the Main Relief Valve
MEL-1238 - Hydraulic Tester

Stop the engine. Activate the right steering lever (auxiliary

hydraulics) to release the hydraulic pressure.
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 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 Umin.) free flow.
The correct pressure for the main relief valve is 2250-2400 PSI
(15514-16548 kPa) measured at the quick couplers.
If not, stop the engine.
Replace or adjust the main relief valve (See Page 2-31).
IMPORTANT
Clean outside of all assemblis before beginning repairs.
damage the system.
1-2021-0284
843 Loader
HYDRAULIC CONTROL VALVE (MELROE ) (Cont'd)
M ain 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 00.
Installation: When installing the main relief valve, always use

NEW 0-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 1) from the main relief valve �. Using
an alien wrench, adjust the relief valve until the pressure is
correct.
B-9316
NOTE: The 8438 loader control valve is a 3 spool valve, but

'
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 [g.
Disconnect the auxiliary linkage from the control valve spool

�-
843 Loader
Revised Sept_ 90 -2-31- Service Manual
HYDRAULIC CONTROL VALVE (MELROE) (Cont'd)
Disconnect the lift and tilt linkage from the control valve
spools �.
Disconnect all the tubelines from the control valve � [g .
Disconnect the inlet and outlet hoses from the control

valve [Q].
Remove the mounting bolts from the control valve. Remove the
control valve from the loader.
Installation: Tighten the mounting bolts to 180-200 in.-lbs.

(21-23 Nm) torque.
843 Loader
INLET
Disassembly and Assembly

Fl
The 8438 control valve is a 3 spool valve. The D3 rear DI GI
auxiliary section is NOT there, but the procedure for

disassembly and assembly is the same. 02
03
Mark each spool and section for correct assembly.
Check the control valve layout before disassembly for correct D4 G4

identification and location of the parts @ .
OUTLET
A1 Lift Cylinder, Rod End D2 Tilt Spool

A2 Tilt Cylinder, Rod End D3 Rear Auxiliary Spool
A3 Rear Auxiliary D4 Front Auxiliary Spool
A4 Front Auxiliary E1 Anti-Cavitation Valve
B1 Lift Cylinder, Base End E2 Plug
B2 Tilt Cylinder, Base End F1 Main Relief Valve
B3 Rear Auxiliary F2 Port Relief Valve
B4 Front Auxiliary F3 Anti-Cavitation Valve
C1 Lift Load Check F4 Plug
C2 Tilt Load Check G1 Lift Detent
C3 Rear Auxiliary, Load Check G2 Tilt Centering Mechanism
C4 Front Auxiliary, Load Check G3 Rear Aux. Centering Mechanism
D1 Lift Spool G4 Front Auxiliary Detent
B-6581
Remove the load check valves (Item 1) from the four center ports
[ID.
B-6886
Remove the port relief valve from the lift section [g .

1. ReHef Valve
Remove the 0-rings and back-up wasHer. 2. 0-ring
3. Back-Up Washer
Assembly: Always use NEW 0-rings and back-up washer. 4. 0-ring
Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
cp cpqxp
-0-o-o
E-1509
843 Loader
Revised Sept. 90 -2-33- Service Manual
HYDRAULIC CONTROL VALVE (MELROE ) (Cont'd)
1. Anti-Cavitation Valve
Remove the anti-cavitation valves from the spool end of the lift 2. 0-ring
section and base end of the tilt section. 3. Back-Up Washer
4. 0-ring
cpcp1
Remove the 0-rings and back-up washer [Al .
Assembly: Always use NEW 0-rings and back-up washer.

Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
cp
Remove the plugs from the spool end and base end of the front
auxiliary section. -0-a-o--
E-1509
Remove the 0-rings and back-up washer [ID.

1. Plug
Assembly: Always use NEW 0-rings and back-up washer. 2. 0-ring
Tighten to 35-40 ft.-lbs. (47-54 Nm) torque. 3. Back-Up Washer
cpf�
4. 0-ring
cp
-O-o-o--
E-1509
Remove the main relief valve from the control valve [g.
Remove the 0-rings and back-up washers [g.

1.
Assembly: Always use NEW 0-rings and back-up washers. 2.
Tighten to 35-40 ft.-lbs. (47-54 Nm) torque. 3.
4.
5.
-0-0-0-0..cD B-6887
E-1509
Remove the screws which fasten the rubber boot retainer to

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

torque.
B-6888
843 Loader
-2-34- Service M anual
I HYDRAULIC CONTROL VALVE (MELROEJ (Cont'd)
I Remove the retainer, rubber boot and bronze filter � .

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
I
The lift spool and the front auxiliary spool have a detent and
float position. Use the following procedure to disassemble and B-6889
assemble the detent assembly for either the lift or auxiliary
spool.
The detent sleeves are not the same:
Lift detent has a inside depth of 1.160" (29,5 mm).

Auxiliary detent has a inside depth of 1.061" (26,9 mm).
Remove the snap ring and washer [iJ .
I Remove the screws securing the detent cap [g .

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 [QI .
NOTE: Carefully remove the centering spring bolt, because

there is spring pressure.
Remove the spool from the bore.
Remove the front and rear 0-rings. B-6894
843 Loader
NOTE: It is not necessary to remove the spool from the bore 1111111111111111111111
completely on the counter-bored valve with a bushing
�-
Bushing Quad-Ring
B-13345
Install a NEW 0-ring in the groove at the front of the control

valve [iJ.
*
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 0-ring can be installed [g.
Install the NEW rear 0-ring [QI . *

Push the valve spool back into the control valve until it is even
with the rear machined surface of the control valve.
B-9294
843 Loader
Put the detent adapter into a vise.
Install the detent spring � .
Put grease on the jaws of the detent tool. Put the detent balls
on the jaws of the detent tool I!] .
Hold the detent balls in position. Install the spring end cap over
the detent adapter lg .
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.-lbs. (10-11 Nm) torque.
I install the detent spring into the detent adapter [QI.
B-9298
843 Loader
* Revised Sept. 90 -2-37- Service Manual
Hold the detent balls in position with the detent tool and slide
the detent sleeve into position � .
Install the detent cap. Tighten the screw to 90-100 in.-lbs. (10-11
Nm) torque.
Install the washer and snap ring on the end of the detent sleeve.
Centering Mechanism
I 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 rn:J . *

B-9297

torque.
Remove the cap. Remove the centering spring bolt [g .
A WARNING
Wear safety glasses to prevent eye injury when any of
• Tools are being used.
W-2019-1285
Assembly: Tighten the centering spring bolt to 90-100 in.-lbs.

(10-11 Nm) torque.
NOTE: Carefully remove the centering spring bolt, because

there is spring pressure.
B-6897
Remove the spring caps, spring and adapter [QI .

*�
f
1. 0-ring 4. Centering Spring
Remove the spool and the front and rear 0-rings from the bore. 2. Bushing 5. Spring Cap
(Early Models) 6. Adapter
Install the front 0-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 0-ring can be installed.
Install the rear 0-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
HYDRAULIC PUMP (SINGLE STAGE)
Checking the Output of the Hydraulic Pump
I OEM-1238 - Hydraulic Tester

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.
procedure). B-4381
I 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 [Al.
IMPORTANT
Connect the INLET hose of the tester to the outlet of the I
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 relief 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 fully
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 (60 ° C) by turning the

restrictor knob on the tester to about 1000 PSI (6895 kPa). D O
NOT exceed system relief pressure.
Open the restrictor and record the free flow (GPM) at full RPM.
I 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.
B-4382
843 Loader
HYDRAULIC PUMP (SINGLE STAGE) (Cont'd)
IMPORTANT
damage the system.
B-4389
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 [ID.
Installation: Tighten the bolts to 25 ft.-lbs. (34 Nm) torque.
B-4390
Remove the hydraulic pump and the 0-ring [g.
B-4416
Put the pump in a vise.
Make a mark across the body for correct assembly.
Remove the bolts from the pump [QI .
Assembly: Tighten the bolts to 23 ft.-lbs. (31 Nm) torque.
843 Loader
-2-40- Serv ice Manual
Remove the pump housing [!].
Remove the 0-ring.
B-4419
Remove the idler and drive gears I!].
B-4420
Remove the wear plate [g.
Remove the spring and steel ball from the pump housing �.
IMPORTANT
Make sure to mark the port where the SJ)f'ing and steel
baH are removed. If the ball and spring are instaHed in
the wrong port, damage will result to the complete
hydrostatic pumps. Only one ball and spring must be
installed on the high pressure side of the pump or the
lower port as it is attached to the hydrostatic pumps.
843 Loader
-2-41· Service Manual
Remove the back-up gasket .and diaphragm seal from the

housing [!I .
Inspection
Clean and dry the parts.
Inspect the drive gears [!I.
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.
B-4426
Check the I.D. of the bearings·in the front and back housing �
If the bearings are more than 0.691" (17,5 mm), the housing
must be replaced (bearings are not available as a separate
items).
B-4429 B-4428
Oil grooves in the bearings at both housings must be in

alignment with the dowel pin hole and 180 ° apart. This put the
oil grooves closest to the correct dowel pin @.
Check the body gear area for wear @.
Replace as needed.
B-4427 B-4430
843 Loader
HYDRAULIC PUMP (DOUBLE STAGE)
The hydraulic pump is a two stage (double gear) pump, each
section of the pump must be checked separately.
I OEM-1238 - Hydraulic Tester

Checking the Output of the Hydraulic Pump
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.
procedure).
procedure).
Connect the jumper start switch (See Page 1-9 for the correct
procedure). B-9370
Small Section of the Pump Only: Disconnect the outlet hose

from the pump � - Connect the inlet hose of the tester to the
' outlet of the pump � . Connect the outlet of the tester to the
hose which was removed from the pump � . Disconnect the
hose which goes to the port block (at the hydraulic pump). Put
plugs in the hose and the fitting on the pump.
II 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 [j]. Connect the inlet hose of the tester to the
outlet of the pump [j]. Connect the outlet of the tester to the
IMPORTANT
hose which was removed [j] .
Be careful when turning the flow control restrictor at
NOTE: Make sure that the restrictor valve on the tester is fully
open. the hydraulic tester. When the tester is connected this
I
way there is no relief 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, all the way.
is connected correctly. If no flow is indicated on the tester, the
hoses are connected wrong.
I
Increase the engine speed to full RPM*. Warm the hydraulic fluid
to 140 ° F (60 ° C) by turning the restrictor knob on the tester
to about 1000 PSI (6895 kPa). 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 (GPM) at full RPM.
I Large Section of the Pump Only: Use the right steering lever
to engage the auxiliary hydraulics. Record the highest pressure
and flow at full RPM.
I
The highest 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 form the system.
I *Refer to the Specifications (Section 8) for system relief

pressure and full RPM. The system relief pressure must be per
specifications before test is run.
B-9372
843 Loader
HYDRAULIC PUMP (DOUBLE STAGE) (Cont'd)
procedure).
Raise the lift arms and have a second person install a lift arm
stop (See Page 1-4 for the correct procedure).
Stop the engine. Raise the operator cab {See Page 1- 7 for the
correct procedure).
IMPORTANT
damage the system.
1-2021-0284
Disconnect the charge pressure hose at the front of the pump

[!].
Disconnect the hose at the charge pressure sender �-
Disconnect the charge tubeline at the charge pressure sender

�-
-
B-9348
Disconnect the charge pressure tubeline from the hydrostatic

pump�.
Remove the tubeline.
843 Loader
Disconnect the hose from the rear section of the pump IA].
Remove the tee fitting at the front section � -
Disconnect the inlet hose at the bottom fitting of the hydraulic

pump 1£].
Loosen the clamp at the inlet hose � .
843 Loader
Remove the mo unting bolts from the pump flange � -

torque.
Turn the pump so the inlet fitting at the bottom is to the side
and slide the pump from the hydrostatic pump �.
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.-lbs. (34-38 Nm) torque.
Remove the bolts from the pump �.
8-8815
843 Loader
Separate the pump body from the end plate �.
Remove the 0-ring.
B-8816
Remove the pressure plate at the gears �.
Remove the large section from the pump [g.
Remove the 0-ring.
B-8818
Remove the large idler gear [Q].
843 Loader
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 [ID.
B 8820
Remove the small section of the pump �.
Remove the 0-ring.
B-8822
Remove the small drive and idler gear [Q].
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 0-rings when assembling the hydraulic pump.
843 Loader
BUCKET POSITION VALVE (S/N 15001 & Above)
Stop the engine. Operate the hydraulic controls to release the

hydraulic pressure.
Open the rear door.
Disconnect all the tube lines at the bucket position valve �.
Remove the bolts and nuts and remove the bucket position valve
[ID.
Installation: Put Loctite on the treads of the tubeline fittings
before tightening.
__...J B-9310
NOTE: Make sure to mark the plugs and valves for correct
assembly.
Remove the plug, 0-ring , spring and spool lg.
I
• B-7993
On the other side, remove the plug and 0-ring [QI .

D
B-8022
843 Loader
BUCKET POSITION VALVE (S/N 15001 & Above)
Remove the plug, 0-ring , spring and spool �.
B-8059
On the other side, remove the plug and 0-ring [ID.

B�
B-8041
Remove the flow divider plug and 0-rings 19.

Clean and check all the parts for wear, replace as needed.
Always use new 0-rings and back-up washers when assembling

the bucket position valve.
B-7992
843 Loader
PORT BLOCK (S/N 14999 & Below)
40 Micron Filter (Bronze)
T he tool listed will be needed to do the following procedure:
MEL-1177 - Filter Removal Tool
Replace the bronze (40 micron) filter every 500 hours of loader
operation.
IMPORTANT
damage the system.
1-2021-0284
Raise the operator cab.
Disconnect the hose at the fitting �.
8-4481
Remove the fitting from the port block 00.
Install the filter removal tool on the filter �.
8-5083
Remove the filter, spring and sleeve from the port block � .
8-5084
843 Loader
PORT BLOCK (S/N 14999 & Below) (Cont'd)
Remove the filter removal tool from the filter l!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 l!l.

B-5085
Install the assembly into the port block [ID.
Remove the tool. Install the fitting and connect the hose.
Neutral By-Pass Valve
Disconnect the hose from the fitting [g.
Remove the fitting.
Remove the spring and by-pass poppet from the port block [g.
Clean the parts. Check the valve seat in the port block. Replace
B-4484
B-4485

D
}..
Remove the hoses from the port block [QJ.
843 Loader
Disconnect the charge tubelines at the front of the port block

��-
8-4457
8-4458
Disconnect the charge tubeline at the rear of the hydrostatic

pump lg.
B-4488
Disconnect the charge tubeline at the front of the hydrostatic

pump�-
843 Loader
Disconnect the tubeline which goes to the hydraulic/hydrostatic

reservoir � .
Remove the bracket from the port block [ID.
Installation: Tighten the bolt to 25-28 ft.-lbs. (34-38 Nm) torque.
B-4492
Remove the large bolt from the port block and remove the port
block from the hydraulic pump lg.
Clean all the parts in solvent. Use air pressure to dry them.
Always use NEW 0-rings when assembling the port block.
�! ,.t'(.'------�111
843 Loader
PORT BLOCK (S/N 15001 & Above)
Remove the front and side panels (See Page 3-9 for the correct
procedure).
Disconnect the wire at the temperature switch I!].
Disconnect the fitting at the tubeline from the reservoir [!].
Disconnect both hydraulic hoses lg.
Remove the mounting bolt.
Remove the port block from the loader � .
843 Loader
PORT BLOCK (S/N 15001 & Above) (Cont'd)
Charge By-Pass
Remove the fitting [!I.
Remove the poppet and spring [ID.
Install a NEW 0-ring before installing the fitting.
Cold Oil By-Pass
Remove the fitting �.
Remove the poppet and spring [Q] .
Install a NEW 0-ring before installing the fitting.
843 Loader
HYDRAULIC FLUID FILTER HOUSING (S/N 15001 & Above)
A�

procedure).
Disconnect and remove the throttle rod linkage at the throttle

lever.
Disconnect the tubeline at the filter housing � -
Remove the mounting bolt and nut �-
B-9335
Pull the filter housing away from the loader frame.
Disconnect the hoses from the filter housing lg.
By-Pass Valve
Remove the plug, spring and poppet � .
Clean all the parts.
Check the poppet and seat for scratches.
Always use a NEW 0-ring when installing the by-pass valve.
B-8582
843 Loader
HYDRAULIC/HYDROSTATIC RESERVOIR (S/N 21514 & Below)

procedure).
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 2-55). B-9341
IMPORTANT
I

damage the system.
1-2021-0284
Disconnect the high pressure hoses at the hydrostatic motor

�-
Disconnect the high pressure hoses at the hydrostatic pumps

and remove them from the loader [!].
Remove the dipstick and tube from the reservoir lg.
Remove the filler neck from the reservoir � -
843 Loader
HYDRAULIC/HYDROSTATIC RESERVOIR
(S/N 21514 & Below) (Cont'd)
Loosen the clamp at the outlet hose for the reservoir �.
NOTE: It may be easier to disconnect and remove the hose

from the reservoir at the hydraulic pump. Turn the
hydraulic pump about 90 ° so the hose comes off the
inlet fitting at the hydraulic pump.
Remove the bolts at the holding strap [ID.
B-9356
Slide the reservoir forward and to the side and remove it from
the loader lg.
843 Loader
HYDRAULIC CONTROLS PEDALS (S/N 14999 & Below)
Disconnect the linkage at the pedal IA].
B-4684
Remove the hair pins at the pivot pins [ID.
Remove the pedal from the bracket.
B-4469
Remove the bushing from the pedal, using a vise, install the new
bushing in the pedal lg.
Adjustment
Loosen the nuts at the mounting bracket [Q].
Slide the mounting bracket backward or forward until there is

about 1-1/2" (38 mm) under the rear edge of the pedal.
Tighten the nuts to 25-28 ft.-lbs. (34-38 Nm) torque.
B-4478
843 Loader
HYDRAULIC CONTROL PEDALS (S/N 15001 & Above)
Remove the bolt and nut at the linkage I!).
Check the rubber bushing in the pedal for wear and replace as
needed.
Remove the two mounting bolts [ID.
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 IQ].
843 Loader
PEDAL LOCK LINKAGE
- ·l· .
Adjustment
=----�
Check the pedal lock linkage so it is free and lock the pedals
I!]. �:
ll
D-1548
Check that the tab goes into the slot at the lock [ID.
If not, loosen the bolts (Item 1) and adjust the tab for
engagement [ID.
A WARNING
Adjust locking tabs on pedal control linkage so that lift B-4043
and tilt control pedals are locked in neutral when seat
bar is up.
W-2104-1285
843 Loader
HYDROSTATIC SYSTEM
Page
Number
FRON T AN D SIDE PANELS (S/N 19999 & Below )

I FRON T AN D SIDE PANELS (ONE PIECE )

(S/N 20001 & Above ) & 8438
HYDROSTATIC FLUID FILTER HOUSING HYDROSTATIC

Removal and Installation........................ 3-53 SYSTEM
HYDROSTATIC MOTOR
Inspection ................................... 3-41
Removal and Installation........................ 3-3 6
Timing the Hydrostatic Motor..................... 3-42
High Pressure Hose Routing...................... 3-42
HYDROSTATIC PUMPS
Checking Charge Pressure....................... 3-44
Checking the High Pressure Relief/Replenishing Valves.. 3-42
Hydrostatic Pump Rear Mount.................... 3-52
Inspection ................................... 3-50
Tow Valves .................................. 3-51
HYDROSTATIC SYSTEM INFORMATION

High Pressure Relief/Replenishing Valve Function...... 3-2
PIN T LE LEVER ARMS (S/N 2 6 000 Thru 298 6 9)

SERVO CONTROL
STEERING LEVERS (S/N 1 6 191 & Below )

Repairing the Steering Levers..................... 3-5
I STEERING LEVERS (S/N 1 6 192 & Above ) & 8438

Removal and Installation....................... : 3-12
Repairing the Steering Levers...................... 3-13
I ST L 61 e
�;��I !��;t!�� 0� - �� .� _s_ �� - .............
)
Repairing the Pintle Lever........................

3-7
3-8
Steering Linkage Adjustment..................... 3- 6
STEERING L INKAGE (S/N 1 6 192 Thru 25999) & 8438

Repairing the Pintle Lever........................ 3-1 6
Steering Linkage Adjustment..................... 3-14
843 Loader
Service Manual
Revised Sept. 90
HYDROSTATIC SYSTEM (Cont'd)
Page
Number
STEERING LINKAGE (S/N 26000 Thru 29869)

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

Creep Centering Spring Mechanism................ 3-29
Description .................................. 3-27
Neutral Adjustment ............................ 3-27
Pint le Arm ................................... 3-29
Steering Lever Centering Spring Mechanism.......... 3-29
STEERING LINKAGE (S/N 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
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
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
HYDROSTATIC SYSTEM INFORMATION
IMPORTANT
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
High Pressure Relief/Replenishing Valves Function
The high pressure relief replenishing valves are used both in

forward and reverse travel I!].
FUNCTION 2 Valve Stays on Seat
The functions of the high pressure relief replenishing valves are
as follows: to Hold High Pressure
for Drive
1. Give replacement fluid to the low pressure side of the
closed hydrostatic circuit (Function 1) I!].
2. To keep the high pressure flow of fluid out of the low

pressure side of the closed hydrostatic circuit (Function 2)
I!]. 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
FRONT AND SIDE PANELS (S/N 19999 & Below)

procedure).
Remove the bolts from the front of the panel [Al .
Remove the front panel.
Remove the bolt from the foot rest (both sides) 00.
B-4436
Remove the bolts and remove the side shields (both sides) [g.
_/ B-4435
Remove the bolts from the steering lever shields (both sides)
�-
Remove the shields from the steering levers.
843 Loader
'STEERING LEVERS (S/N 16191 & Below)
A
Disconnect the steering linkage from the steering levers � .
IMPORTANT
damage the system.
1-2021-0284
Disconnect the charge tubelines from the port block 00 .
Disconnect the auxiliary linkage from the right steering

lever [g.
Remove the nuts and bolts from the left side pivot bearing [QI.
Installation: Tighten the bolts to 25 - 28 ft.lbs. (34 - 38 Nm)

torque.
B-4442
843 Loader
lsTEERING LEVERS (S/N 16191 & Below) (Cont'd)
Remove the nuts and bolts from the right side pivot bearing �.

torque.
Remove the steering lever assembly from the loader [!].
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 1£].
Install new teflon bushings into the steering levers � .
Check the pivot bearings and replace as needed.
843 Loader
I STEERING LINKAGE (S/N 16191 & Below) (Cont'd)
Steering Linkage Adjustment
procedure).
Loosen the nuts from the pintle lever � .
Loosen the nuts on the steering levers [i:] .
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.
f B-4455
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 [QI .
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
I STEERING LINKAGE (S/N 16191 & Below) (Cont'd)
Disconnect the steering linkage from the steering levers and

pintle levers � .
Disconnect the springs from the centering bar [ID.
Slide the centering bar toward the rear and lift up and remove
it from the transmission [g.
B-4465
Loosen the bolt on the pintle lever mi .

Installation: Install the key in the pintle shaft mi. Tighten the
pintle lever bolt to 18-20 ft.-lbs. (24-27 Nm) torque.
B-4474
843 Loader
Revised Sept. 90 -3-7- Service ManlAJI
STEERING LINKAGE (S/N 16191 & Below) (Cont'd)
Remove the guide, bushing and pintle lever �.
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 [!I .
-�� ·----·---·
)_____ .f----··--
Remove the rubber bushing from the pintle lever.
11
re��-::::-��-x__k--.. ··- . ---
"� / B-4476
Install new rubber bushing into the pintle lever �.
B-4388
Press the rubber bushing into the pintle lever, using two sockets
and a vise [QJ.
843 Loader
I FRONT AND SIDE PANEL (ONE PIECE) (S/N 20001 & Above)
& 843B
Raise the lift arms and have a second person install a lift arm
stop (See Page 1-4) for the correct procedure).
Stop the engine.
Raise the operator cab (See Page 1-7) for the correct
procedure).
Remove the nuts from the parking brake pedal � .

B-8829
Remove the brake pedal [ID.
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

[Q].
843 Loader
I FRONT AND SIDE PANEL (ONE PIECE)
(S/N 20001 & Above) & 843B (Cont'd)
Remove the bolts from the bottom of the front panel (both
sides) [Al.
B-8839
Remove the hydrostatic motor cover (both sides) [i] .
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) [QI .
843 Loader
I FRONT AND SIDE PANEL (ONE PIECE) (S/N 20001 & Above)
& 8438 (Cont'd)
IAl -
1
Lift and remove the front panel from the loader frame
Remove the steering levers (See Page 3-4 for the correct
procedure).
al
Remove the bolts and remove the side panel from the loader
frame I!].
843 Loader
1 STEERING LEVERS
843 (S/N 16192 thru 25999)

843 (Starting with S/N 34222)
843B
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 00].
Remove the bolts and nuts from the pivot bearings [g .
Lift and remove the steering lever assembly from the loader [QI.
843 Loader
1 STEERING LEVERS (Cont'd)
843 (S/N 16192 thru 25999)

843B
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
843 Loader
1 STEERING LINKAGE
843 (S/N 16192 thru 25999)

843B
Steering Linkage Adjustment
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 [Al .
Connect a remote start switch (See Page 1- 9 for the correct
I
procedure).
Loosen the bolts from the front bar [@] .
Loosen the bolts from the rear bar.
Start the engine and run at idle.
I
Stand clear of the tires. Move the steering lever for the rear arm,
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 ft.-lbs. (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 [g .
Tighten the bolts at the pintle bar to 28 ft.-lbs. (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.-lbs. (31 Nm) torque.
843 Loader
STEERING LINKAGE (Cont'd)
1 843 (S/N 16192 thru 25999)

8438
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 00 .
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 00 .
Slide the centering bar toward the front and lift up and remove
it from the transmission [g .
I Loosen the bolt on the pintle lever [Q] .
Installation: Install the key in the pintle shaft. T ighten the pintle
lever bolt to 18 - 20 ft.lbs. (24 - 27 Nm) torque.
843 Loader
1 STEERING LINKAGE (Cont'd)
843 (S/N 16192 thru 25999)

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 00 .

Installation: Tighten the bolt to 25 - 28 ft.-lbs. (34 - 38 Nm)
torque.
Remove the rubber bushing from the pintle lever.
Install a new rubber bushing into the pintle lever [£].
B-4388
Press the rubber bushing into the pintle lever, using two sockets
and a vise � .
7 B-4471
843 Loader
Revised Sept. 90
Description
A hydraulic servo control cylinder {Item 11 is used to stroke each

hydrostatic pump pintle lever I!] . The hydraulic servos are
controlled by steering levers and the fluid to activate them
comes from the charge circuit I!] .
The steering levers are centered by two centering spring

mechanisms {Item 21 � . Neutral setting for the hydrostatic
pumps is achieved through the servo spool adjustment on the
centering spring mechanism {Item 31 for the pintle levers �.
Neutral Adjustment
I 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 41 and steering
linkage {both sides) I!].
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 11 and turn them in
or out �- When there is no more free play in the centering
spring mechanism, lock the jam nuts together.
NOTE: If there is any free play in the centering spring

mechanism, the correct adju�tment of positive neutral
can not be obtained.
5. Position the steering lever by loosening the jam nut {Item

21 and turning the centering rod {Item 3) in or out of the
ball joint �- When the steering lever is in a perpendicular
position, lock the jam nut {Item 21 �- Check the centering
spring mechanism again to make sure that the adjustment
{no free play) has been maintained.
843 Loader
STEERING LINKAGE (S/N 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) I!]. 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) I!].
8. Connect the Remote Start Switch (See Page 1-9). Start

the engine and run at low idle.
A WARNING
AVOID INJURY
9. Adjust the wheel creep to neutral by turning the centering

rod (Item 3) in or out of the connector rod end I!].
NOTE: Always maintain at least 3/8" (9,5 mm) thread contact

in the rod end.
10. Check the neutral setting by hand stroking the servo spool
(Item 4) I!]. 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. T ighten the jam nut (Item 2) I!]. Connect the steering
linkage to the servo spool.
12. Loosen the lock nut on the servo spool (Item 5) I!].
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. Turn 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. T ighten the jam nut (Item 5) on the servo spool I!].
16. Repeat the Steps 3 through 15 to adjust natural for the

other side of the loader.
843 Loader
I STEERING LINKAGE (S/N 16000 Thru 298691 (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 [!J.
Remove the centering spring assembly 1£).
Remove the lock nuts Im.

Installation: Tighten the lock nuts to 16-20 ft.-lbs. (22-27 Nm)
torque.
843 Loader
Revised Sept. 90
Remove the spring rod and rod end assembly �.
Remove the spring [ID .
Remove the bushings lg.
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
Remove the rod end washer I!].
Remove the lock nuts �.
Installation: Tighten the lock nuts to 16 - 20 ft.-lbs. (22-27 Nm)

torque.
Remove the spring rod and rod end assembly �.
Remove the centering spring and washers [QJ.
843 Loader
Remove the bolts and nuts from the centering spring mounting
bracket I!] .
Installation: Before tightening the bolts and nuts, install the

spring rod and align the rod end hole and the hole in the pintle
lever[!].
Remove the centering spring mounting bracket lg.
I
NOTE, The centering spring mechanism must be adjusted for
neutral after installation, See Page 3-17 for the
correct procdure.
843 Loader
SERVO CONTROL
I Remove the centering spring mechanism (Page 3-20).

Remove the bolt and nut from the piston rod end I!].
Disconnect the linkage from the spool end of the servo control
[ru.
Installation: Tighten the bolt and nut to 25 ft.-lbs. (34 Nm)

torque.
Disconnect both hoses from the servo control 1£].
Remove the bolt and nut from the pintle arm and servo control
body�-
Installation: Tighten the bolt and nut to 100 - 110 ft.-lbs. (136
- 149 Nm) torque.
843 Loader
Revised Seot. 90
SERVO CONTROL (Cont'd)
Remove the servo control and spacer (Item 1) I!].
I See Page 3-17 for neutral adjustment of the servo controls and
steering linkage.
Use a snap ring plier, remove the snap ring from the housing
[ID.
Remove the rod and piston assembly [ID.
B-8633 B-8632
Remove the cap from the servo housing. Use an allen wrench
and remove the plug lg.
Remove the spool from the housing IQ].
Clean and inspect all the parts for wear or damage. Replace
Always use new 0-rings and seals when assembling the servo
control.
843 Loader
PINTLE LEVER ARMS (S/N 26000 Thru 29869)
I
Remove the servo control (Page 3-23).
Remove the three screws from the pintle lever arm � .
Installation: Tighten the screws to 60 - 65 in.-lbs. (6,8 - 7,3

Nm) torque. Re-torque several times until screws stay at 60
- 65 in.-lbs. (6,8 - 7,3 Nm) torque.
Install the three screws in the holes next to the ones they were
removed from 00.
Turn the screws in to remove the pintle lever arm from the hub
lg.
Remove the pintle lever arm �.
843 Loader
PINTLE LEVER ARMS (S/N 26000 Thru 29869) (Cont'd)
Remove the hub from the pintle lever shaft �.
Installation: Use solvent to clean the pintle shaft & hub. Put
loctite (P/N 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 � -
NOTE: Thread locking adhesive must cure at room

temperature for 8 hours without primer (or 3 hours with
primer (P/N 6649655).
843 Loader
Revised Sept. 90 -3-2 6- Service Manual
I STEERING LINKAGE (S/N 29870 Thru 31863)
Description
A hydraulic servo control cylinder (Item 1) is used to stroke each

hydrostatic pump pintle lever I!]. 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 sides) [!I.
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
-3-27- Service M"1ual
Revised Sept. 90
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
I
WARNING
AVOID INJURY
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 rn] . 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
[g. Install and tighten the lock nut.
NOTE: Always maintain at least 3/8" (9,5 mm) thread contact

in the rod end.
843 Loader
I STEERING LINKAGE (S/N 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.
I
11. Repeat the above steps to adjust neutral of the other pump.
Steering Lever Centering Spring Mechanism
T he remove and disassemble the steering lever centering spring

mechanism, See Page 3-19 (S/N 2600 thru 29869) for the
procedure.
Creep Centering Spring Mechanism
I
To remove and disassemble the spring mechanism, See Page
3-20 (S/N 26000 thru 29869), the photo's may look different
but the procedure is the same [i] .
Pintle Arm
I
To remove and install the hydrostatic pump pintle arm See Page
3-25 (S/N 26000 thru 29869), the photo's may be different
by the procedure is the same [i] .
843 Loader
STEERING LINKAGE (S/N 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.
T his steering linkage adjustment procedure is for 843 loaders

(S/N 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.
procedure).

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
R•:n,icorl dnril Qfi -3-30- Service Manual
STEERING LINKAGE (S/N 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 [i]. DO NOT remove

the bolt.
Check for freeplay in the hydrostatic pump centering spring

mechanism [g.
NOTE: Freeplay will exist in the centering spring adjustment

rod (Item 1 I if the adjusting nut is too loose, or in the
centering spring bushing if the adjusting nut is too tight
[g.
To remove the freeplay, adjust the hydrostatic pump centering

spring by loosening the jam nut (Item 11 and turning the
adjusting nut in or out � .
Adjust the centering spring mechanism so there is no freeplay.
T ighten the jam nut after the adjustment is made.
Re-tighten the hydrostatic pump linkage bolt.
843 Loader
Revised April 96 -3-31- Service Manual
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 procedure).
Locate the neutral band (Item 1) on the servo control spool �.
B-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 l 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 �.
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
Revised April 96
STEERING LINKAGE (S/N 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 00 .
Turn the adjusting nut in or out to adjust the centering spring

mechanism so there is no freeplay [g .
T ighten 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
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 �.
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 � -
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
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 00 .
Install the jam nut and tighten [g .
Install a mechanical stop on the steering lever centering

mechanism (slow side) [QI .
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 [QI .
NOTE: DO NOT over tighten or the wheel RPM will be reduced.
Release the steering lever.
Install the jam nut and tighten.
843 Loader
HYDROSTATIC MOTOR
IMPORTANT
damage the system.
1-2021-0284
procedure).
Use a floor jack, remove the motor cover bolts, and lower the
motor cover �.
Remove the case drain hose [!].
Use a crowsfoot wrench and remove the high pressure hoses

�-
Remove the bolts from the motor mounting flange �.
I
torque.
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 [!] .
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 [ID.
Assembly: T ighten the bolts to 65 - 70 ft.-lbs. (88 - 95 Nm)

torque.
Lift the valve housing straight up. If done carefully, the springs
and balance plate will stay on the valve lg .
Remove the 0-rings.
B-8692
Remove the plug from the shuttle valve � .
843 Loader
Added Sept_ 90 -3-37- Service Manual
Remove the spring and sleeve � .
Remove the shuttle valve spool [!I.
Use a punch, through the housing and remove the poppet,

spring, 0-ring and plug from the other side of the housing �-
B-8696
I Assembly: Make sure all the parts are cleaned and check for
wear. Assemble as shown � .
D-1526
843 Loader
Remove the balance plate I!].
B-8731
Remove the inner seal from the balance plate [ID.
Assembly: Put grease on the inner seal and install as shown [ID.
Outer
Seal
B-8733
Pin B-3046
Remove the outer seal from the balance plate � -
Assembly: Put grease on the outer seal and install as shown �-
Pin Inner Seal Pin B-3046
Remove the valve � .
B-8738
843 Loader
I HYDROSTATIC MOTOR (Cont'd)
NOTE: See Page 3-42 for timing the motor when installing
the valve, valve drive and geroler.
Remove the valve plate I!].
B-8737
Remove the valve drive [ID.
B-8729
Remove the geroler 1£].
B-8739
Remove the drive shaft [Q].
B-8736
843 Loader
Remove all the 0-rings from the motor I!].
NOTE: Always use new 0-rings when assembling the

hydrostatic motor.
� -(1
I B-8730
Inspection
Before the motor is assembled check the following items:
1. Check the geroler roller and rotor for wear and scratches
oo.
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. B-8743
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 lg.
---===,.,.. ,
B-8690
843 Loader
Rotate Valve Clockwise
T iming 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 outs;de of Val
�
1. Geroler (Item 1) I!].
2. Valve Drive (Item 2) @.
3. Valve Plate (Item 3) @.
4. Valve (Item 4) @.
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 0-rings.
Install the valve drive I!].
Align the drain hole in the valve plate with the drain hole in the
geroler. Install the valve plate with the 0-ring toward the geroler. eroler 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 �.
Front Of
Loader
C-2970
843 Loader
HYDROSTATIC PUMPS
IMPORTANT
I

damage the system.
1-2021-0284
Checking the High Pressure Relief/Replenishing valve
procedure).
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 � [g .
Remove the high pressure relief valves from the top and bottom
and switch them around rn:J [QJ .
Install the plugs and tighten.
Start the engine and check the drive.
I If the loss of drive goes to the other side, the relief/replenishing

valve which controls that side of the loader must be replaced.
843 Loader
HYDROSTATIC PUMPS (Cont'd)
Checking Charge Pressure
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:
S/N 12999 & Below: 120 - 140 PSI (827 - 965 kPa)
S/N 24001 & Above: 180 - 200 PSI (1241 - 1379 kPa)
NOTE: If the hydrostatic pumps need repairing, See Page

3-45 for the procedure.
procedure).
procedure).
Disconnect the steering linkage at the steering levers (both

sides) I!].
Disconnect the steering linkage at the pintle levers [g .
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
Disconnect all the hoses from the hydraulic pump.
Disconnect the hoses and wire from the charge pressure switch
fitting [Al .
Remove the nuts from the front mounting bolts Ii] .
Remove the four bolts and nuts from the rear mounting flange
for the pumps [g .
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.
IMPORTANT
damage the system.
1-2021-0284
Remove the two bolts from the center section [QJ.

torque.
843 Loader
Pull the front and rear pumps apart � -
Remove the 0-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.
B-8874
Remove the plugs from the high pressure relief valves 00 .
Remove the high pressure relief replenishing valves (both sides)

[£].
Remove the bolts from the center section [Q] .

torque.
B-8845
843 Loader
Remove the section from the pump housing �.
Remove the rotating group 00.

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.
B-8848
Front Pump
Remove the snap ring and spacer �.
843 Loader
Remove the drive shaft and bearing from the housing �.
B-8850
Remove the snap ring from the pintle shaft cover [i] .
Remove the pintle shaft cover 1£].
Remove the 0-ring �.
843 Loader
HYDROSTATIC PUMPS (CONT'D)
Remove the bearing from the pintle shaft I!].
Assembly: When installing the bearing, make sure the number

side of the bearing is toward the outside.
B-8854
\- ------
Remove the snap ring from the camplate shaft on the other side.
Remove the cover I!].
B-8849
Remove the 0-ring lg .
Remove the bearing and race � .
Assembly: When installing the race make sure the chamfer side
is toward the camplate.
Added Sept. 90 -3-49-

d B-8856
843 Loader
Service Manual
Remove the camplate from the housing �.
B-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 � . 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 B-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 �. All the pins must be � ....
the same length and must not be bent. Check the spherical
washer for sharp edges, wear or scratches �.
B-8860
Check the piston shoes for scratches. Check the end play of
each piston assembly [QI. Measure the thickness of each shoe.
All shoes must be within 0.001" (0,025 mm) of each other [QI
. 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.
DO NOT use cloth or paper because small pieces of material
Piston
�1
can get into the system and cause damage.
DO NOT use sandpaper or a file to remove scratches.

hoe ust Swivel Smoothly on Bell
End Play Must Not Exceed .003" (0,076 mm) A-1850
843 Loader
4.rll'IAl'I SAnt _ 90 -3-50- Service Manual
Tow Valves
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:

procedure).
Remove the high pressure relief plug [Al .
Remove the high pressure relief valve [!] .
Install the tow bar and tighten the plug [g .
Remove the other high p'ressure relief plug � .
843 Loader
Remove the high pressure relief valve � .
Install the tow bar and tighten the plug [!J.
The loader can now be moved. Be sure to remove the tow bars
before operating the loader.
Hydrostatic Pump Rear Mount (S/N 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 [g . MEL-1395-4 - Rear Spacer (843)
MEL-1395-9 - Shim (8431
1. Remove the engine from the loader (Page 7C-17).
2. Install the spacer (Item 3) [gin 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) (gin 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 [g .
5. Install the shaft (Item 2) into the main frame [g .
6. Install the tool into the loader so the slot (Item 2) � fits 0 0
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 s-12557
843 Loader
*Revised Feb. 94 -3-52- Service Manual
0
FRONT 0
8. Loosen the pump mounting bolts. Slide the tool shaft
forward and rotate until its aligned with the pump coupler. 0 0 0 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 1) as needed [jJ. Tool Slot Here Tool Fits Here
10. Remove the alignment tool. Engine

Mounting
REAR Plate ,J
B-12564
HYDROSTATIC FLUID FILTER HOUSING

t
11.52"
�
(292,6 mm) Engine Mounting
Plate
IMPORTANT � B-6938

Use P.lugs and caps to cover open ports. Dirt can quickly
damage the system.
1-2021-0284
procedure).
Open the rear door.
Disconnect the wire from the sending switch.
1Disconnect the tubelines from the filter housing [g .
*
IRemove the mounting bolts [Q) .
Installation: Tighten the mounting bolts to 25 ft.-lbs. (34 Nm)

torque.
JRemove the differential pressure switch [Q) .
Inspect all the parts for damage and replace as needed.
NOTE: 843 (S/N 20992 & Above) use a higher pressure rating
of the switch. Make sure to install the correct switch
if it is replaced (See Parts Microfiche).
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
PARKING BRAKE
Adjustment .................................. 4-1
Block and Pucks.............................. 4-2
REDUCTION GEARCASE DRIVE

Checking Reduction Gearcase.................... 4-11 SYSTEM
Reduction Gearcase Seal........................ 4-17
843 Loader
Service Manual
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 I!].
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.-lbs. (88-95
Nm) torque.
B-5188
I
Install the front panel.
Readjust the brake as outlined above.
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 �.
843 Loader
Revised J11lv RR
PARKING BRAKE (Cont'd)
Remove the snap rings at the discs I!).
�::: . \
: ,
··,
.·.··
:'
_-
·. ' . .. -
·.:·:.:
':·. .-..-· -
. ···:,
. -.....
. . ,. -
...... \ .. \ ,
.
'-::. •:. ,_.-.
, ,
B-8666
Remove the brake discs [ID.
Check the brake disc for damage. Replace the discs as needed.
DO NOT grind the discs.
Block and Pucks
Remove the brake lever [g.
B-5174
Remove the bolts which fasten the block to the cover �.
Installation: Put Loctite on the bolts and tighten to 65- 70 ft.

lbs. (88-95 Nm) torque.
843 Loader
PARKING BRAKE (Cont'd)
Remove the pucks form the block � -
Check the pucks for wear or damage. The pucks can be turned
180 ° 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 0-Ring on the cam pin I!].
B-5208
Clean and dry the block and put a bead of R.T.V. sealant on the
brake block � .
Install the center cover on the brake block �.
Install the bolts and tighten.
B-5204
843 Loader
AXLES, SEALS AND BEARINGS
Removal
NOTE: The removal and installation of the four axles use the
same procedure.
MEL-1242 - Port- a-Power
I MEL-1053 - Axle Seal Tool

MEL-1202C - Axle Bearing Race Service Set
procedure).
Remove the wheel and tire assembly.
procedure).
procedure).
....
I' I•:,
.....
'•
'�: � '",.:
' .·.
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).
'·· .. .'... B-8766
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 [ID.
Loosen the bolt (inside the chaincase) at the sprocket by turning

at the axle hub.
'
Installation: Put Loctite on the bolt and tighten to 475-52 5 ft.-
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 [Q]. Remove the bearing cup from
the axle tube.
B-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 [ID.
Bearing
B-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
C-2528
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

wear ring in its correct location.
Lubricate the axle seal (Item 2) and install the seal on the axle
with the open side toward the chaincase �.
B-3986
843 Loader
Service Manual
AXLES, SEALS AND BEARINGS (Cont'd)
A
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.
B-3981
Install the outer bearing cup using the correct size bushing driver
[ID.
Install a long threaded bolt into the axle tube.
Install the correct size cup driver.
Install a washer and nut.
B-3982
Inside the chaincase, install the new bearing cup, the bearing
cup driver tool, washer and nut lg.
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
AXLES, SEALS AND 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].

Install the inner halves of the installation tool behind the
out axle seal [A].
8--04531
Install the outer halves of the tool on the inner halves [B].
Install the spring on the tool [B].
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.
8--04560
8--04559
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 [D]. Remove the inner halves from the
axle [D]. D
Tighten the sprocket bolt to the correct torque. Check the
axle end play. It must be between 0.00 - 0.1 O" (0,254
mm).
If not, replace the washer, at the sprocket bolt to get the
correct end play.
8--04567
843 Loader
FINAL DRIVE CHAIN
Removal
A
MEL1269 - Chain Breaker
MEL1037 - Chain Link Press
MEL1049 - Chain Puller Tool
Lift and block the loader. (See Page 1-2 for the correct
procedure.)
procedure.)
Remove the front panel (See Page 3-3 or 3-9 for the
correct procedure.)
B--03969
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
B
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 [B].
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 [D].
Put the drive chain over the reduction gearcase sprocket

and pull the ends out and above the chaincase.
843 Loader
Revised June 96 --4-8- Service Manual
FINAL DRIVE CHAIN (Cont'd)
Put a flat bar under the chain across the chaincase IKJ.
Clamp the bar to the chaincase.
Install the connector link and plate [ID.
Install the chain link press �.
Tighten the chain link press to 180 ft.-lbs. (244 Nm) torque to
press the connector plate into position �.
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.-lbs. (300-330 Nm)
torque.
B-4657
843 Loader
REDUCTION GEARCASE
procedure).
Remove the hydrostatic motor (See Page 3-17 for the correct
procedure).
procedure).
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 IA].
Remove the bolts which fasten the gearcase to the chaincase

[ID.

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) �.

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.-lbs.
(285-305 Nm) torque.
Complete the installation of the reduction gearcase.
843 Loader
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" (0,0 254 mm). If not the following
parts may need replacing: Bearing, bearing cups, gear or
gearcase housing.
Install the dial indicator on the output shaft [i]. The end play
must be between 0.00 - 0.010" (0,0 254 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 ± 0,0 25 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 I.D. or Run-Out) is not within
the specifications, replace the gearbox.
,,,,�
8-8673
T he tool listed will be needed to do the foliowing procedure:
Remove the bolts from the end plate � .
8-8705
843 Loader
Remove the end plate �.
B-8704
Remove the dust cap [ID.
Installation: Put "Boretite" sealant on the edge of the dust cap

before installing it.
B-8728
Remove the bolt from the output shaft [g.
Installation: Put Loctite on the bolt and tighten to 210-235 ft.

Remove the bolt and washer [Q] .
843 Loader
Remove the bolt at the disc hub �.
Installation: Put Loctite on the bolt and tighten to 210-235 ft.

Remove the bolt and washer [ID.
Remove the disc hub and key [9.
Put the gearcase housing in the press and remove the output
shaft [Q].
B-8682
843 Loader
Remove the bearing I!] .
Remove the spacer l!J ·
Remove the output shaft 1£l .
Remove the large gear �.
-4-14-
Remove the bearing at the input shaft I!].
Use a press and remove the input shaft [ID.
B-8679
Remove the input shaft assembly from the housing [£].
B-8744
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
Installation
Install a new Quad-ring. Install the back-up washer �.
B-8675
Install the new seal using the seal installation tool [!I.
843 Loader
Reduction Gearcase Seal
It is not necessary to remove the reduction gearcase to replace

the seal at the input shaft, use the following procedure.
procedure).
Remove the hydrostatic motor (See Page 3-17 for the correct �B-8676
procedure).
Use a punch and hammer and bend the edge of the seal inward
I!].
Use a screwdriver, pry the seal from the housing 00.
B-8674
Remove the washer. Replace the Quad-ring lg.
Install the new seal using the seal installation tool IQ].
--=
B-8734
843 Loader
--
--
-
Y-ME.&.ROE--ME.&.ROE-ME.&.ROE--MEL.
,« _w,-_.,,-_w,- ,
MAIN FRAME
Page
Number
BOB.:Y-ACH
Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . 5-13
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 5-11
T ilt Cylinder Rod End Seal. . . . . . . . . . . . . . . . . . . . . . . 5-12
FUEL TANK (S/N 19999 & Below)

FUEL TANK (S/N 20001 & Above)

Fuel Tank Sender Switch . . . . . . . . . . . . . . . . . . . . . . . . 5-17
LIFT ARMS
OPERAT OR CAB (S/N 19999 & Below)

OPERAT OR CAB (S/N 20001 & Above) MAIN

Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 5-3 FRAME
I
OPERAT OR CAB GAS CYLINDER

REAR DOOR
Door Latch Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . 5- 8
843 Loader
Service Manual
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5 MAIN FRAME
OPERATOR CAB (S/N 19999 & Below)
procedure).
Disconnect the electrical harness I!].
Fasten a chain and chain hoist to the operator cab [ID.
C-2630
Remove the bolt and nut at the spring block. Remove the spring
block (both sides) 1£].
Installation: Tighten the bolt and nut to 65-70 ft.-lbs. (88-95

Nm) torque.
�--==�=,=,
l =-=, =,,=\ ,=-, B-4542
Remove the nuts at the pivot bolt for the operator cab (both
sides) IQ].

Nm) torque.
1
, B-4054
843 Loader
OPERATOR CAB (S/N 19999 & Below) (Cont'd)
With the chain hoist tight.
Use a punch and hammer and remove the bolts (both sides) at
the pivot bracket � .
�1 1 I
I I I
!
Use a pry bar, pry the springs out of the operator cab [ID.
Lift the operator cab with the chain hoist and remove it from
the loader.
1(\ \ \ B-4047
( \I
II I I B-4057
843 Loader
OPERATOR CAB (S/N 20001 & Above)
Remove the stop blocks at the rear of the operator cab I!].
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.

procedure).
Disconnect the electrical harness [ID.
Remove the electrical harness clamp [g.
Install a bar through the operator cab balance point. Install a

chain and chain hoist @ .
843 Loader
OPERATOR CAB (S/N 20001 & Above) (Cont'd)
Remove the clip at the upper pivot pin for the gas cylinder �.
B-8511
Remove the upper pivot pin for the gas cylinder (both sides) �-
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 lg.
Remove the lower pivot pin (both sides) [Q].
843 Loader
OPERATOR CAB (S/N 20001 & Above) (Cont'd)
Remove the gas cylinder (both sides) �.
Remove the nuts from the pivot bolts [ID .
Installation: Tighten the pivot bolts to 25-35 ft.-lbs. (34-4 7 Nm)

torque.
/
/;
/
/
;1, B-8553
Use a punch to remove the pivot bolt (both sides) lg.
Lift the operator cab from the loader using the chain hoist.
843 Loader
OPERATOR CAB GAS CYLINDER
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.

procedure).
Remove the clip and the upper pivot pin at the gas cylinder [ID.
B-8510
B-8511
Remove the clip and lower pivot pin at the gas cylinder [g.
Installation: Install the lower pivot pin first, use a screwdriver

to hold the gas cylinder down and install the top pivot pin.
B-8516
B-8517
Remove the gas cylinder from the mounting bracket [Q].
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
REAR DOOR
Door Latch Adjustment
Loosen the set screw �.
B-5772
Loosen the nut (Item 1) [ID.
Turn the bolt {Item 2) in or out [ID, until the door contacts both
the top and the bottom of the loader frame (Item 1) with the
lever in the latched position lg.
NOTE: It takes approximately 50 lbs. of force to push the lever

down when the latch is correctly adjusted.
B-7385
Lubricate the wear surface (Item 2) lg.
NOTE: With the set screw up, the flanges at the bolt (Item 3)
must be to the side so that the set screw aligns with
the flat surface at the end of the bolt lg.
Tighten the set screw �.
Tighten the nut (Item 1) to 65-70 ft.-lbs. (88-95 Nm) torque [ID.
843 Loader
REAR DOOR (Cont'd)
Install a chain hoist on the rear door [Kl .
Use a punch and remove both hinge pins [ID.
Lift the rear door from the loader frame.
843 Loader
LIFT ARMS
procedure).
Roll the Bob-Tach fully forward.

hydraulic pressure.
Remove the Bob-Tach from the lift arms (See Page 5-11).
Fasten chains and a chain hoist to the lift arms �. B-2801
Put a floor jack under the lift arms �.
Raise the lift arms, with the floor jack, until the pivot pin at the
rod end of the lift cylinders can be removed.
B-4543
Remove the lock nut and bolt �.

Nm) torque.
Remove the pins at the rod end of the lift cylinders (both sides)
[QJ.
Lower the lift arms. Remove the floor jack.
843 Loader
LIFT ARMS (Cont'd)
Remove the lock nut and bolt at the pivot pins for the lift arms
(both sides) �.

Nm) torque.
Tighten the chain hoist.
B-4544
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
808-TACH
Tilt the Bob.:Y-ach fully forward until the front edge is on the floor
�-
hydraulic pressure.
B-2791
Remove the lock nut and bolt at the rod end of the tilt cylinder
[ID.
Nm) torque.
Remove the pivot pin at the rod end of the tilt cylinder lg.
Loosen the bolt at the Bob.:Y-ach pivot pin [Q]. DO NOT remove
the bolt.
Installation: Tighten the bolt at the pivot pin to 220-245 ft.-lbs.

(298-332 Nm) torque.
C
B-4546
843 Loader
BOB-TACH (Cont'd)
Remove the grease fitting at the pivot pins l!l -

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.:rach frame.
Put a rag over the grease fitting hole.
B-4547
Hit the bolt to start the pivot pin into the Bob-Tach frame [ID.
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 Jg.
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.:rach with a floor jack � .
B-4404
843 Loader
BOB-TACH (Cont'd)
Install the new seals at the rod end l!J.
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.:rach frame [ID.
Remove the shim stock and finish installing the Bob.:rach
Put the Bob.:rach on a work bench.
Remove the bolt at the Bob.:rach lever lg.
::.
-
Using a punch and hammer, remove the Bob.:rach wedge and

spring assembly from the frame [Q:J.
B-4552
843 Loader
BOB-TACH (Cont'd)
Put the wedge and lever assembly in the vise.
Remove the bolt at the lever I!].
Assemble: Tighten the bolt to 25-28 ft.-lbs. (34-38 Nm) torque.
B-4557
Remove the block from the wedge bolt [ru.

*
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
Remove the nut and the spring from the bolt lg.
B-4556
Remove the plastic guides from the Bob-Tach frame �.
Clean and inspect all the parts for wear and damage, replace
843 Loader
* Revised Feb. 87
FUEL TANK (S/N 19999 & Below)
procedure).
Turn the fuel shut-off valve (Item 1) to the "OFF" position I!].
Use a transfer pump and remove all the fuel from the tank.
Disconnect the hoses (Item 2) from the fuel tank I!].
Disconnect the wires from the sending unit (Item 3) I!].
Remove the bolts (Item 4) at the holding strap (Item 5) I!].
Remove the fuel tank from the loader.
I �,�
&---.;, D-1556
843 Loader
FUEL TANK (S/N 20001 & Above)

procedure).
I \
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 [ru.

'''" ---
Disconnect the wires at the fuel sender lg.
Turn the fuel shut-off valve to the "OFF" position.
B-8484
Disconnect the fuel hose at the shut-off valve [QJ.
B-8497
843 Loader
FUEL TANK (S/N 20001 & Above) (Cont'd)
Remove the bolts from the holddown strap [!J.
Remove the fuel tank from the loader.
J'
Fuel Tank Sender Switch
Remove the top plate from the fuel tank [[).
Remove the screws from the sender switch lg.
B-8811
Remove the sender switch from the fuel tank �.
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 Alternator Regulator.................... 6-4
Checking Alternator Wiring Harnes................. 6-4
Disassemby and Assembly....................... 6-6
BAT TERY
Checking the Battery........................... 6-2
ELECTRICAL SYSTEM INFORMATION

Description .................................. 6-1
MANDO ALTERNATOR
STARTER
Checking the Starter........................... 6-12
Replacing the Brushes.......................... 6-15 ELECTRICAL
SYSTEM
TROUBLESHOOT ING
Chart ...................................... 6-1
843 Loader
Service Manual
COMPANY
A BUSINESS UNIT OF CLqRK EQUIPMENT COMPANY

WIRING DIAGRAM (P/N 6722195)
BUCKET POSITION VALVE LOCKOUT (OPTIONAL)
Model 753, 7753, 843, 843B & 853
(Printed April 1992)
MC-1450
MC-1118

WIRE NO. COLOR CONNECTS TO 8 Switch Cover
12S-A Orange loader Wiring Harness
Fused & Switched Power
8 Switch
12S-B Orange Switch f) Solenoid
59E-A Orange
8 Terminal
Switch
59E-B Orange Solenoid
SO-A
50-B
Black
Black
Solenoid
Ground 8 Connector
0 Bucket Position Valve
8 Wiring Harness
CAB HARNESS
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CAB HARNESS
NO.'s COLOR GAUGE NO.'s COLOR GAUGE 0 Harness Connectors G, Fuse - Ignition
1
2
Black
Black
16
16
34
35
Dk. Blue
Black
16
16
f) Operator Cab Ground 9 Ignition Switch
3
4
Orange
Orange
16
12
36
37
Black
Black
16
16
9 Fuel Sender 9 Glow Plug Indicator
(543 Only)
5 Orange/White 16 38 Brown 16 0 Back-Up Alarm (Opt.) 9 Shut-Down Module (Opt.)
6
7
White
Lt. Blue
16
16
39
40
Black
Brown
16
16 e Rear Lamp
8 Orange/Green 16 41 Yellow 16 C, Tail Lamp
9 Yellow/Black 18 42 Purple 16 • Tee splice
10 Yellow 18 43 White 16 G Left Flasher Lamp (Opt.) Butt splice
11 White/Purple 18 44 Lt. Blue 16 0
E) Left Front Lamp
e
12 Purple 18 45 Red 16
13 Lt. Blue/Black 16 46 Orange (Not Used) 16
Wiper Motor (Opt.)
14 Yellow 18 47 Grey (Not Used) 16
15 Purple 18 48 Brown (Not Used) 16 G) Flasher (Opt.)
16 Orange 16 49 Black 16
17 Orange 16 G Right Front Lamp
White/Orange
18
19 Orange/Dk. Blue
16
16 4D Right Flasher Lamp (Opt.)
20
21
Orange
Black
18
16
4D Hourmeter
22 Orange 18 G, Light Switch
23 Orange 18
24 Dk. Green/Yellow 16 G, Fuse • Accessory
25
26
Orange
Black
18
16 G Wiper Switch (Opt.)
27
28
Orange/Black
Orange/Black
16
16
4D Fuel Gauge
29 Orange/Dk. Blue 16 E) Trans. Warning Light
30 Orange/Dk. Blue 16
G) Engine Warning Light
e
31 White/Dk. Blue 16
32 Pink 16 Voltmeter
33 Brown 16
l'trl, 1rm -�3�..-e
4
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an .-0
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25,--------2H ENGINE
.�'---
ENGINE HARNESS
----
ENGINE HARNESS

NO.'s COLOR GAUGE 0 Harness Connectors G) Frame Ground
1
2
Black
Black
16
16 G Unfused & Live Accessories G) Diode
3
4
White/Orange
Orange
16
12
6) Fuse and Live Accessories
5 White/Green 16 0 Engine Connector
6 White/Black 16
7 Orange/Green 16 C, Back-Up Alarm Switch (Opt.)
8 Yellow/Black 16 C, Trans. Oil Temperature
9 Yellow 16
10
11
Purple
Lt. Blue/Black
16
16
0 Trans. Charge Pressure
12 Orange 12 E) Brake Switch
13 White/Lt. Green 16
14 White 12 E) Starter
15 Lt . Green 16 G) Engine Oil Pressure
16 Orange 12
1·7 Orange 12 G Fuel Shut-Off Solenoid
18
19
White/Orange
White/Green
16
16 49 T hermo-Start or Glow Plug
20 Lt. Blue/Orange 8 E) Engine Coolant Temperature
21 Red Cable
22
23
Black Cable 4D Alternator
Red Cable
24 Red Cable fD Batteries
25 Black Cable
Cs, Pre-Heat Relay
4D Start Relay
843 (S/N 13001 Thru 19999)
(Printed December 1985)
o,
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CAB HARNESS

NO.'s COLOR GAUGE NO.'s COLOR GAUGE 0 Harness Connectors 9 Voltmeter
1D Red 12 41 Pink 16
f) Operator Cab Ground
e
� Ignition Switch
1F Red 16 42FL Dk. Blue 16
10A Black 12 42FR Dk. Blue 16 E) Fuel Sender Hourmeter
108 Black 12 42R Dk. Blue/White 16
0 Back-Up Alarm (Opt.)
e
12 Orange 16 46 Brown 16
12A Orange 18 46L Brown 16
128 Orange 16 46R Brown 16 Rear Lamp • Tee splice
12C
12F
Orange
Orange
16
18
49F
49T
Gray
Gray
16
16
8 Tail Lamp 0 Butt splice
12L
12T
Orange
Orange
18
18
49V
60W
Gray
Black
16
16
0 Left Flasher Lamp (Opt.)
19C Red/White 16 63 Orange/Black 16 C, Left Front Lamp
19F Red/White 16 66 Orange/Green 16
19H Red/White 18 E) Wiper (Opt.)
19L Red/White 16 E) Flasher (Opt.)
19S Red/White 16
19W Red/White 16 4D Right Front Lamp
21R White 16
49 Right Flasher Lamp (Opt.)
e
23F White/Black 16
26 Lt. Blue 16 Engine Temperature Gauge
28 Lt. Blue/Black 16
30 Black 16 G, Fuel Gauge
30F Black 16
30G Black 16 C9 Light Switch
30T
31P .
Black
Yellow/Green
16
18 '9 Wiper Switch (Opt.)
32PT
35H
Yellow
Yellow/Brown
18
18
4D Trans. Warning Light
36 Purple 16 '9 Engine Warning Light
36T Purple/White 18
G)
e
40FL Black 16 Fuse • Ignition
40FR Black 16
Fuse • Accessory
40R Black 16
e
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ENGINE HARNESS

NO.'s COLOR GAUGE 0 Harness Connectors 4D Start Relay
0
1
Black
Red
Cable
Cable f) Unfused & Live Accessories G, Frame Ground
1A Red 8 C, Engine Connector G) Engine Ground
18 Red 12
lC Red 12 0 Back-Up Alarm Switch (Opt.)
1D Red
10A Black
12
12 9 Trans. Oil Temperature Switch
12C White/Orange 16 C, Trans. Charge Pressure
14F Lt. Green 16 Switch
14R Lt. Green/White 16
21R White 16 0 Starter
21S White/Green 12
23F White/Black 16 C) Engine Oil Pressure Switch
28 Lt. Blue/Black 16 E) Fuel Shut-Off Solenoid
288 Lt. Blue/Orange 8 (Internal)
28S Lt. Blue/Yellow 16
31P Yellow/Lt. Green 16 G) Hydraulic Fluid Filter
32F Yellow/Dk. Blue 16 Pressure Switch
32PT Yellow
32T Yellow/Black
16
16 4D Glow Plugs
35H Yellow/Brown
36T Purple/White
16
16
8 Engine Coolant Temp. Sender
608 Black 16 f) Diode
66 Orange/Green 16
4D Alternator
e
e
Batteries
Pre-Heat Relay
843 (S/N 20001 Thru 23999)
(Printed July 1988)
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CAB HARNESS

NO.'s COLOR GAUGE NO.'s COLOR GAUGE 0 Harness Connectors G)
e
Fuse • Accessory
1D
1F
Red
Red
12
16
40FL
40FR
Black
Black
16
16
G Operator Cab Ground Voltmeter
10A Black 12 40R Black 16 E) Fuel Sender 9 Ignition Switch
9 Hourmeter
108 Black 12 41 Pink 16
12 Orange 16 42FL Dk. Blue 16 G Back-Up Alarm (Opt.)
16
12A Orange
128 Orange
18
12
42FR
42R
Dk. Blue
Dk. Blue/White 16 C, Rear Lamp
12C Orange
12F Orange
16
18
46
46L
Brown
Brown
16
16
C, Tail Lamp • Tee splice
12L Orange
Orange
18 46R
49F
Brown
Gray
16
16
G Left Flasher Lamp (Opt.) 0 Butt splice
12 T 18
19C Red/White 16 49 T Gray 16 C) Left Front Lamp
19F Red/White 16 49V Gray 16
19H Red/White 18 60W Black 16
E) Wiper (Opt.)
19L Red/White 16 66 Orange/Green 16 G) Wiper Switch (Opt.)
G Shut Down Module (Opt.)
19S Red/White 16
19W Red/White 16
21R White
21RM White
16
16 8 Flasher (Opt.)
23F White/Black 16 G) Right Front Lamp '
26 Lt. Blue 16
28 Lt. Blue/Black 16 G, Right Flasher Lamp (Opt.)
30 Black 16
30F Black 16 G, Engine Temperature Gauge
30G Black 16
30 T Black 16
G) Fuel Gauge
31FP Yellow
31P Yellow/Green
16
18
4D Light Switch
32FPT Yellow 18 4D Trans. Warning Light
32PT Yellow 18
35H Yellow/Brown 18 G) Engine Warning Light
36 Purple 16 � Fuse • Ignition
36 T Purple/White 18
--- --- �-o
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ENGINE HARNESS

NO.'s COLOR GAUGE 0 Harness Connectors
0
1
Black
Red
Cable
Cable
f) Back-Up Alarm Switch (Opt.)
1A Red 12 E) Trans. Fluid Temp. Switch
18 Red 10
1C Red 12 8 Trans. Charge Pressure
Switch
1D Red 12
10A
12C
Black
White/Orange
12
16
C, Starter
14F
14R
Lt. Green
Lt. Green/White 16
16 C, Injection Pump Shut-Off
21R White 16 0 Hydrostatic Filter Switch
21S White/Green 12
23F White/Black 16 E) Engine Oil Press. Switch
28 Lt. Blue/Black 16 E) Engine Coolant Temp. Sender
288 Lt. Blue/Orange 8
28S Lt. Blue/Yellow 16 G) Engine Glow Plugs
31P
32F
Yellow/Lt. Green 16
Yellow/Dk. Blue 16 G Diode
32P
32T
Yellow
Yellow/Black
16
16
49 Alternator
35H Yellow/Brown 16 G, Battery
36T Purple/White 16
608 Black 16 4D Start Relay
66 Orange/Green 16
49 Pre-Heat Relay
Ce, Harness Connectors
843 (S/N 24001 Thru 25999)
(Printed July 1988)
T
9
G -..
r 4
46R ,,---
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� 6570913 (7-88)
CAB HARNESS
NO.'s COLOR GAUGE NO.'s COLOR GAUGE 0 Harness Connectors ED Fuse • Accessory
1D Red 12 40FL Black 16
9 Operator Cab Ground
e
� Voltmeter
lF Red 16 40FR Black 16
10A Black 12 40R Black 16 E) Fuel Sender Ignition Switch
9 Hourmeter
108 Black 12 41 Pink 16
12 Orange 16 42FL Dk. Blue 16 G Back-Up Alarm (Opt.)
12A Orange 18 42FR Dk. Blue 16
128 Orange 12 42R Dk. Blue/White 16 C, Rear lamp
12C Orange 16 46 Brown 16 C) Tail lamp • Tee splice
12F Orange 18 46L Brown 16
12L Orange 18 46R Brown 16 G Left Flasher lamp (Opt.) 0 Butt splice
12 T Orange 18 49F Gray 16
19C Red/White 16 49 T Gray 16 C, Left Front lamp
E) Wiper (Opt.)
G Shut Down Module (Opt.)
19S Red/White 16
19W Red/White 16
21R White
21RM White
16
16 8 Flasher (Opt.)
23F White/Black 16 E) Right Front lamp
26 Lt. Blue 16
28 Lt. Blue/Black 16 4D Right Flasher lamp (Opt.)
30
30F
Black
Black
16
16 Ct, Engine Temperature Gauge
30G Black 16
30 T Black 16 G, Fuel Gauge
31FP Yellow
31P Yellow/Green
16
18
4D Light Switch
32FPT Yellow 18 G) Trans. Warning Light
32PT Yellow 18
35H Yellow/Brown 18 G) Engine Warning Light
36 Purple 16 � Fuse • Ignition
36 T Purple/White 18
"'
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28
I lC
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36T
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z
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L 1C D �
32F Ll-----,---
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ENGINE HARNESS
NO.'s COLOR GAUGE O Harness Connectors 4D Start Relay

0
1
Black
Red g:::: f) Unfused & Live Accessories '9 Frame Ground
1A Red 8 E) Engine Connector G) Engine Ground
18 Red 10
1C Red 12 8 Back-Up Alarm Switch (Opt.)
1D Red 12
10A Black 12 v
A Trans. Oil Temperature
Switch
12C White/Orange 16
14F Lt. Green 16 C, Trans. Charge Pressure
14R Lt. Green/White 16 Switch
21R White
21S White/Green
16
12 0 Starter.
23F White/Black 16
C, Engine Oil Pressure Switch
288
28S
Lt. Blue/Orange
Lt. Blue/Yellow
8
16
E> Fuel Shut-Off Solenoid
(Internal)
31P Yellow/Lt. Green 16
32F Yellow/Dk. Blue 16 Ci) Hydraulic Fluid Filter
32PT Yellow 16 Pressure Switch
32T Yellow/Black
35H Yellow/Brown
36T Purple/White
!!
16
G Glow Plugs
4D Engine Coolant Temp. Sender
CS, Diode
608 Black 16
66 Orange/Green 16
C, Alternator
4D Battery
G Pre-Heat Relay
843 (S/N 26001 Thru 28134)
(Printed July 1988)
r f
9
4
-- -------
e -... �46R ,.--
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.,_1_______
:
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121 ,I II
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108
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111 ,
66
35 H
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6570914 (7-88)
CAB HARNESS.

NO.'s COLOR GAUGE NO.'s COLOR GAUGE 0 Harness Connectors G, Fuse - Accessory
1D Red 12 40FL Black 16
f) Operator Cab Ground
e
� Voltmeter
1F Red 16 40FR Black 16
10A Black
108 Black
12
12
40R
41
Black
Pink
16
16
9 Fuel Sender Ignition Switch
12 Orange 16 42FL Dk. Blue 16 8 Back-Up Alarm (Opt.) 9 Hourmeter

12A Orange
128 Orange
18
12
42FR
42R
Dk. Blue
Dk. Blue/White
16
16 C, Rear Lamp
12C Orange
12F Orange
16
18
46
46L
Brown
Brown
16
16
C, Tail Lamp • Tee splice
12L Orange 18 46R Brown 16 0 Left Flasher Lamp (Opt.) Butt splice
e
0
12T Orange 18 49F Gray 16
19C Red/White 16 49T Gray 16 Left Front Lamp
E) Wiper (Opt.}
19S Red/White 16
19W Red/White 16 4D Shut Down Module (Opt.)
21R White
21RM White
16
16 CD Flasher (Opt.)
23F
26
White/Black
Lt. Blue
16
16
G, Right Front Lamp
28
30
Lt. Blue/Black
Black
16
16
0 Right Flasher Lamp (Opt.)
30F Black 16 G, Engine Temperature Gauge
30G Black 16
30T Black 16
G) Fuel Gauge
31FP Yellow
31P Yellow/Green
16
18
4D Light Switch
32FPT Yellow 18 E) Trans. Warning Light
32PT Yellow 18
G)
e
35H Yellow/Brown 18 Engine Warning Light
36 Purple 16 Fuse • Ignition
36T Purple/White 18
� (''� -\.
·�,r,·) ... ...
'' - --
\
\
\
'> - --.ir-w,re 26LT IS connected to wire 26
when module is not used.
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w w WIN
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18
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ENGINE _____J E-1820
ENGINE HARNESS
ENGINE HARNESS
NO.'sCOLOR GAUGE 0 Harness Connectors 4D Start Relay

0
1
Black
Red
Cable
Cable
8 Unfused & Live Accessories G) Frame Ground
1A
18
Red
Red 10
8 9 Engine Connector G) Engine Ground
1C Red 12 8 Back-Up Alarm Switchs (Opt.)
10 Red 12
10A Black 12 C, Trans. Oil Temperature
Switch
12C White/Orange 16
14F Lt. Green
16 C, Trans. Charge Pressure
Switch
21R White
21S White/Green
16
12 G Starter
23F White/Black 16
E) Engine Oil Pressure Switch
288 Lt. Blue/Orange 8 E) Fuel Shut-Off Solenoid
28S Lt. Blue/Yellow 16 (Internal)
31P Yellow/Lt. Green 16
32F Yellow/Dk. Blue 16 E) Hydraulic Fluid Filter
32PT Yellow 16 Pressure Switch
32T Yellow/Black
35H Yellow/Brown
16
16
G Glow Plugs
36T Purple/White 16 49 Engine Coolant Temp. Sender
60BA Black 16
608 Black 16 E) Diode
66 Orange/Green 16
G, Alternator
C9 Battery
G) Pre-Heat Relay
CAB HARNESS

843 {S/N 28135 & Above) & 8438
(Printed September 1990)
o-. F ::� ------ l I

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10A
C 36 ----------- I
J
\
"-- -10AB ___) L,os __J -r
(.) "----10A
6570915
CAB HARNESS
NO.'s COLOR GAUGE NO.'s COLOR GAUGE 0 Harness Connectors G) Fuel Gauge
1D
1F
Red
Red
12
16
36T
40R
Purple/White
Black
18
16
8 Ground � Hourmeter
10A Black 12 40FL Black 16
16
8 Fuel Sender 0 Fuse (Ignition)
8 Back-Up Alarm (Opt. 843B 9 Fuse (Accessory)
108 Black 14 40FR Black
e
10AB Black 12 41 Pink 16
12A Orange 18 42FL Dk. Blue 16 Only)
16 Light Switch (Opt. 84�
128 Orange 16 42FR Dk. Blue
C, Rear Light (Opt. 843B Only)
e
12C Orange 16 42R Dk. Blue/White 16 Only)
12F
12L
Orange
Orange
16
18
46
46L
Brown
Brown
16
16
C, Tail Light (Opt. 843B Only) Ignition Switch
12T Orange 18 46R Brown 16 G Left Flasher Light (Opt.)
12V
19C
19F
Orange
Red/White
Red/White
18
16
16
49F
49T
49V
Gray
Gray
Gray
18
18
18
e Left Front Light (Opt. 843B
Only)
19L Red/White 16 66 Orange/Green 16 E) Wiper Switch (Opt.)
19S Red/White 16
19W Red/White 16
G) Wiper (Opt.)
21R White 16 G Shut Down Module (Opt.)
21RM
23F
White
White/Black
16
16 49 Flasher (Opt.)
26 Lt. Blue 16
26A Lt. Blue 16 G) Right Front Light (Opt. 843B
28 Lt. Blue/Black 16 Only)
30.
30G
Black
Black
16
16
0 Right Flasher Light (Opt.)
30T
31
Black
Yellow
16
18
Ct, Trans. Warning Light
31P Yellow/Green 18 G, Engine Warning Light
32
32PT
Yellow
Yellow
18
18 4D Voltmeter
35H Yellow/Brown 18 G) Temperature Gauge
36 Purple 16
,:�
l
<\#
.....
V- -- -
-�
....,..... 7
1 i
' '
\ 11·�
fi 0 OCD b�G)
_ _ __ _ ___ . __ --····-'-·-.t ._.._ ,·. �re 26
when module is not used.
w w WIN
u, N cnoo
��-i
::c .., -4
1=14R �+--8 r;:�:'�" r&lQ:o��

� l /0 ·--:J.
c,: '•
.....
N
=l::t =_==-
.,, "V 32T�.+-V .
--. .23 F
I
'
1
1-
t:
-===-
!o
-3 2P _ 35�·
3 T/
2
_,___
�/oT
·-- ..
�\"�
:I�
----32 F
1-t-�1��
2
,2151- 3F -
-32F - -�-\!
1 -lOA
--- -36T
i-� f 0
\
�'i' �i : I en)/••. A � ..... 0
�
lftr
4D-+-10r
28B V .,, �
;--lA \n---1 ......., 0
1-------4-_J
-·1 I
32F .--- ,,
'-------28B
i� �
1B
36T J
ENGINE HARNESS -- ·--··--------
ENGINE
-- --- ·---·----··_J
- - -- --· ·----
E-1820
---· ---· - ---·--
-----·--·-·- - - .
. . .. ·--- ··-· - -------------------·· -·- -· -· ·- .. .. --· -·
ENGINE HARNESS

NO.'s COLOR GAUGE O Harness Connectors '9 Battery
0
1
Black
Red g:::: 8 Unfused & Live Accessories G) Pre-Heat Relay
1A
18
Red
Red
8
10
E) Engine Connector. 4D Start Relay
lC Red 12 0 Back-Up Alarm Switch (Opt.) CB) Frame Ground
1D Red 12 A
10A Black 12 w Trans. Fluid Temp. Switch G) Engi�e Ground
12C
14F
White/Orange
Lt. Green
16
16
C, Trans. Charge Pressure
Switch
16 0 Starter
e
21R White
21S White/Green 12
23F White/Black 16 Engine Oil Pressure Switch
28 Lt. Blue/Black 16 E) Fuel Shut-Off Solenoid
288 Lt. Blue/Orange 8 (Internal)
28S Lt. Blue/Yellow 16
31P Yellow/Lt. Green 16 G) Hydraulic Filter Pressure
32F Yellow/Dk. Blue 16 Switch
32PT
32T
Yellow
Yellow/Black
16
16 4D Glow Plugs
35H
36T
Yellow/Brown
Purple/White
16
16
4D Engine Coolant Temp. Sender
60BA Black 16 G) Diode
60B
66
Black
Orange/Green
16
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.
W-2003-1285
components for starting the engine.
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
1. Alternator belt is loose or damaged.

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.
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 Aoril 96 -6-1- Service Manual
BATTERY
Checking the Battery
MEL-10004 - Battery Tester
To make a safe and complete check of the battery see the Clark
Battery Manual (P/N 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 burns 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
for several minutes and get medical attention.
W-2065-1285
DO NOT remove the vent caps from the battery while charging
the battery. The battery has vent caps which will decrease the
possibility of the battery being exploded by an external spark.
Disconnect the battery cables. Always remove the negative (-)

cable first to prevent sparks �.
Remove the nuts and bolts from the holddown clamp and
remove the holddown clamp �.
Remove the battery from the loader lg.
843 Loader
ALTERNATOR
Alternator Belt Adjustment
Open the rear door.
Remove the bolts from the belt shield.
Remove the belt shield from the engine � .
B-5782
Loosen the adjustment bolt 00].
Move the alternator to set the belt tension at 1/4" (6,5 mm)
deflection with 5 lbs. pressure � -
Tighten the adjustment bolt 00].
Install the belt shield.
B-5783
843 Loader
ALTERNATOR (Cont'd)
---- No. 1 Terminal
Checking the Alternator Wire Harness
Turn the key switch to the "ON" position and make the checks
as follows I!].
Connect a voltmeter between ground and No. 1 terminal.
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
procedure).
Disconnect the "BAT" terminal at the alternator [ID.
Connect the "BAT" wire to one side of the ammeter. Connect

the other side to the "BAT" terminal of the alternator [g.
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. @ 2100 RPM) lg.
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 [Q] .
The ammeter 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
ALTERNATOR (Cont'd)
Remove the belt shield at the engine.
Disconnect the negative (- I cable at the battery.
Disconnect the wire at the "BAT' terminal � -
Disconnect the No. 1 & 2 terminals [ID.
Remove the adjustment bolt 1£:l .
B-4516
Remove the mounting bolt [Q] ·
Remove the alternator from the engine.
B-4!iJ8'
843 Loader
10
1. Pulley
2. Bolts
3. Case Halves
4. Rotor
5. Nuts
6. Stator
7. Diode Trio
e-t-@HID- @-cca:q)
8. Rectifier
9. Capacitator QJ---(0)- -,---------1
10. Brush Holder
11. Regulator I I �·---.�
-=� - - �
-=�--1)�
0
==,---_--m4- �
�=--� In\
I
f L--4 � @--@)
0::,-�-�--ID--1-
-'� - -®- --@�@
C-1802
ALTERNATOR (Cont'd)
Disassemble the alternator as shown IA].
Connect an ohmmeter as follows to check the rotor [ID.
Between one slip ring and the shaft. Check the other slip ring.
There must be maximum resistance.
Between both slip rings. There must be 2.4 to 3.0 ohms.

resistance. B-8068
Connect a battery powered test light as follows to check the

stator �.
Between the center wire and an outside wire. Light must come
"ON".
Between center wire and the other outside wire. Light must
come "ON".
Between one of the wires and frame. Light must NOT come
"ON".
843 Loader
ALTERNATOR (Cont'd)
A
Connect a D.C. test light as follows to check the diode trio I!].
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. Insulated
Connect a test light as follows to check the rectifier I!].
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.
B-2101
Between one connection and the grounded heat sink. Connect B-2102
test light in opposite direction. The light must come "ON" in
one direction, but not in the other direction.
Insulated Washers
Assembly: Reverse the order of disassembly.
Also if regulator was removed, install new insulated washers

and spacers lg.
B-2128
When installing the brushes, put a piece of straight wire through

the housing to hold the brushes in the up position � .
Then install the rotor, when in position pull the wire out to seat
the brushes.
B-2097
843 Loader
MELROE ALTERNATOR
Checking the Alternator Output
A WARNING
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 wire.
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 wire.
Start the engine and run at 2600 R.P.M.
The ammeter reading should be between 45 & 55 amps. @

B-9570
2600 RPM.
If the reading is low, disconnect the battery and connect a

jumper wire from the alternator output terminal (Item 1) to the
regulator terminal (Item 2).
Connect the battery cable, start the engine and check the
ammeter. If the reading is within the rated amperage (45-55
amps. @ 2600 RPM) replace the diode trio �.
843 Loader
Revised Mar. 86 -6-8- Service Manual
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
W-2017-0286
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 reading is low, stop the engine and disconnect the battery.
Remove the screws and pull the regulator cover away from the
alternator. Connect the jumper wire from the ground stud (Item
1) to the brush terminal (Item 2) (the tan wire) 00.
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)
Disconnect the negative cable from battery.
Disconnect the wire terminals from the back of the alternator

�-
B-9381
Disconnect the battery terminal [ID.
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
843 Loader
Revised Mar. 86 -6-8.2- Service Manual
�-ai-
"
-1
1. Nut
2. Pulley
1
I
ii-�-��
-�-1- vI :: ®-
_
- -3- -__8__ J 9
3. Fan
4. Bolt --
5. Case Half (Front)
__ _ _____ 1 ' I I
rl _-__r---:. , �, t � �
- ___ __ _
-__-_1
6. Bearing
7. Rotor I 'ID®
1
8. Slip Ring
9. Stator
____
\!.I
_
:
_
: � .
10. Heat Sink I+ l j
-----
11. Heat Sink ( - l
12. Case Half (Rear)
13. Condenser Assy.
14. Brush Holder Kit
15. Regulator Kit
__ ,I
I
I
I
I
I
I
I
I
I
- --
_
__
__ __ _ .J
- -
_
- - -
-- ---
--- -- -
- - - - - - - -- --
,r
I
I
14
I _.
I
L---
I
I
tt;--·--
I
I
\
� D-1760
Disassemble the alternator as shown � -
Remove three (3) bolts (Item 4) holding halves together.
Pry halves apart.
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
hammer or press..
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.
Use the following procedure with an ohmmeter to test the rotor:
Touch both probes on the slip rings. There must be a 3 to 5 ohm

reading [ID.
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
Use the following procedure with an ohmmeter to test the

stator:
Touch to (21 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 �.
B-9378
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
lg.
Reverse the probes and check the other direction. There must
be no continuity �.
*
843 Loader
MANDO ALTERNATOR (Cont'd)
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 [ID.
Check the brushes for wear. The maximum length of exposed

brushes should be .125" (3 mm).
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.-lbs. (70 Nm) torque [g.
B-9383
843 Loader
STARTER
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 "M" terminal and the "BAT"
terminal [ID.
If the starter turns, the defect is in the solenoid.
If the starter does not turn , the starter is defective.
A-1991
Disconnect the negative (-) cable at the battery.

\
Disconnect the wire at the "BAT" terminal of the solenoid lg.
Disconnect the wires at the solenoid [!!I.
843 Loader
STARTER (Cont'd)
Remove the bolts at the starter bracket �.
Remove the starter mounting bolts �.
B-8753
Remove the starter from the engine lg.
843 Loader
C-1802
STARTER (Cont'd)
Disassemble the starter as shown IA].
A WARNING
Wear safety glasses to prevent eye injury when any of
A-1995
• 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_ T he

solvent will remove the lubricant and the drive will slip.
A-1994
843 Loader
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.
T he 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
[ID.
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. T he 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. T he lamp should
not light [ID.
Also check:
Broken or burned insulation
Brush connections
Brushes
Drive Gear
Worn teeth
Tooth engagement (Drive gear must engage ring gear by 1/2
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
ENGINE SERVICE
Section
Number
ENGINE SERVICE (Perkins 2.5 Liter Diesel Engine) .. 7A-1
ENGINE SERVICE (Perkins 2.5 Liter TK200 Diesel Engine).. 7B-1
ENGINE SERVICE (Isuzu 2.8 Liter Diesel Engine) ...... 7C-1
Bobcat 843 Serial Numbers 502012999 & Below Section 7A-1

Perkins 2.5 Liter Four Cylinder Diesel
Bobcat 843 Serial Numbers 5026 13001 to 23999 Section 7B-1

Bobat 843 Serial Numbers 24001 and up Section 7C-1

Isuzu 2.8 Liter Diesel
ENGINE
SERVICE
Perkins 2.5 Liter
Perkins 2.5 Liter

TK200 Series
Isuzu 2.8 Liter

ENGINE SERVICE (Perkins 2.5 Liter Diesel Engine)
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
ENGINE
ENGINE BLOWER HOUSING
Removal and Installation ........................ 7A-20
ENGINE COMPRESSION
Checking .................................... 7A-3
ENGINE FLYWHEEL & U-JOINT
Flywheel Ring Gear............................ 7A-21
ENGINE MUFFLER ENGINE
Removal and Installation........................ 7A-19 SERVICE
{PERKINS 2.5L )
ENGINE TIMING TO INJECTION PUMP
{USING DIAL INDICATOR)
Procedure ................................... 7A-8
USING TIMING TOOL)
Procedure ................................... 7A-9
FUEL FILTER
Water Trap .................................. 7A-4
FUEL INJECTOR NOZZLE
Checking .................................... 7A-12
FUEL INJECTION PUMP
FUEL INJECTION PUMP DRIVE GEAR
843 Loader
Worldwide Parts Source LLC Phone: 269 673 2313 email: PartsAndGaskets@gmail.com
Service Manual
ENGINE SERVICE (Perkins 2.5 Liter Diesel Engine) (Cont'd)
Page
Number
FUEL LIFT PUMP
Checking.................................... 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
OIL PUMP
Checking.................................... 7A-47
Disassembly and Assembly ...................... 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
REMOVING AIR FROM THE FUEL SYSTEM
Procedure ................................... 7A-6
ROCKER ARMS
Assembly ................................... 7A-28
Disassembly ................................. 7A-28
TIMING CASE
THERMOSTAT
Installation .................................. 7A-51
Removal .................................... 7A-51
Testing the Thermostat ......................... 7A-51
TROUBLESHOOTING
Chart ...................................... 7A-1
VALVES
Checking Valve Springs......................... 7A-26
Installing Valve Guides.......................... 7A-25
Installing the Valves............................ 7A-24
Reconditioning the Valve & Valve 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
843 Loader
Service Manual
7A ENGINE SERVICE - Perkins 2.5 Liter Diesel Engine
TROUBLESHOOTING
PROBLEM CAUSE
Slow cr anking speed. 1, 2, 3, 4
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 30, 31, 32
Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 23, 28, 30, 31, 32
No power from engine. 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 23, 24, 25, 26, 30, 31, 32
Engine is mis-firing. 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 24, 25, 27, 28, 29, 31
Too much fuel consumption. 11, 13, 14, 18, 19, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32
Bl ack exhaust. 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32
Blue/white exhaust. 4, 11, 18, 19, 20, 24, 26, 30, 32, 33, 53
Low oil pressure. 4, 34, 35, 36, 37, 38, 40, 42, 55
Engine knocking. 9, 14, 16, 18, 19, 22, 25, 27, 28, 30, 32, 34, 43, 44, 56
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 25, 27, 28, 29, 32, 43, 56
Vibration. 1a 1� 2� 2� 25, 28, 29, 32, 43, 45, 46
High oil pressure. 4, 36, 39
Overheating. 11, 13, 14, 16, 18, 19, 23, 24, 43, 47, 48, 49, 50, 54
Too much crankcase pressure. 25, 30, 32, 33, 43, 52
Poor compress ion. 11, 19, 24, 27, 28, 30, 31, 32, 33, 44, 56
Start and stop. 10, 11, 12
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 clearance adjustment with engine stopped and

cold.
Put the correct size feeler gauge between the rocker arm and
the valve stem and turn the adjustment bolt until the clearance
is correct � .
The correct clearance is 0.012" (0,30 mm) with the engine cold
oo.
Use the following sequence to set the valves:
a. With the rocker arm rocking on No. 4, set clearance at

No. 1 valves.
b. With the rocker 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 B-4123
at No. 2 valves.
843 Loader
ENGINE COMPRESSION
Checking
MEL-10630 - Engine Compression Kit
The engine must be at operating temperature.
Remove the fuel injectors (See Page 7A-11) [ru.
B-4697
Install the correct compression adapter into the engine.
Connect the compression gauge [ID.
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.
Worldwide Parts Source LLC Phone: 269 673 2313 email: Parts@WwPartsSource.com
843 Loader
FUEL FILTER
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) �
Remove the fuel filter element (Item 2) �.
Lubricate the 0-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.
843 Loader
FUEL LIFT PUMP
Checking
Install a gauge to the outlet side of the lift pump. Turn the engine
for 10 seconds.
ST ANDARD PRESSURE - 6 PSI (41 kPa)

MINIMUM PRESSURE ACCEPT ED - 3.75 PSI (26 kPa)
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 I!].
NOTE: Make sure to "Open" the fuel shut-off valve at the fuel
tank after installation is completed.
843 Loader
REMOVING AIR FROM FUEL SYSTEM
Procedure
Loosen the bolt (Item 1) at the top of the fuel filter I!].
B-4325
Loosen the plug at the top (Item 1) and the side (Item 2) of the
fuel injection pump 00.
Operate the fuel 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.
t
+
When all the air is removed from the fuel system, close the vents
in the following order:
a. Final Fuel Filter (Item 1) I!].
b. Injection Pump side plug (Item 2) 00.

c. Injection Pump top plug (Item 1) 00.
B-3873
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 fittings. T ighten the fittings
to 15 ft.-lbs. (20 Nm) torque.
843 Loader
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
B-4299
done.
1-2028-0284
B
Disconnect the throttle control linkage (Item 1) at the pump I!].
Disconnect the linkage (Item 2) from the electrical fuel shut

off solenoid I!] .
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.-lbs. (20 Nm) torque.
Disconnect the low pressure lines at the fuel filter and injection
pump.
Remove the cover at the timing cover I!].
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) jg. Align the timing marks
on the outside of the mounting flange, tighten the nuts �.
843 Loader
-7A- 7- Service Manual
(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 � -
Put the head of the exhaust on top of the piston crown. Install
a dial indicator at the valve stem I!].
Rotate the crankshaft backward and forward a small amount

to find TDC 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. A-2347
T he"C" line on the rotor of the fuel injection pump must be in

alignment with the edge of the snap ring �.
NOTE: DO NOT move the snap ring in the pump. It is put in

this position by the manufacturer.
If the timing is not correct, do the following:
a. Loosen the nuts at the mounting flange.
b. Turn the pump to align the timing marks �.
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.
843 Loader
(USING TIMING TOOL)
Procedure
MEL-1056 - Timing Tool
Remove the valve cover. Turn the engine crankshaft until No.
1 cylinder is at TDC, compression stroke (both rocker arms are
moving at No. 4 cylinder).
Align the TDC bolt with the mark in the front pulley I!].
B-4701
Remove the fuel injection pump (See Page 7A- 7).
Loosen the screw (Item 1) on the timing tool [ID. 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
B-8069
LJ42 281 290 18
LJ44E 281 290 18
LJ47 281 290 18
LJ51 281 290 18
Install the adapter into the gear lg. 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�- Turn
the timing tool in opposite direction of engine rotation to remove
gear play.
The engine flange timing mark must be in alignment with the

B-4702
V-notch of the timing tool plate.
NOTE: If the marks are 180 ° apart. the No. 1 cylinder is not
at TDC.
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 TDC bolt out of the front pulley
after the timing procedure is done.
843 Loader
CHECKING TIMING MARK ON INJECTION PUMP FLANGE
Procedure
Loosen the screw (Item 1) and install the shaft (Item 2) into the
timing 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 �.
Operate the test pump until the pressure is at 440 PSI (3033
kPa) maximum .
Turn the tool in the normal rotation of the pump. When the pump
reaches the No. 1 port there will be resistances or will not turn.
- 8-7842
Move the plate over the mounting flange [g.
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
FUEL INJECTOR NOZZLES
A WARNING
cardboard or wood to find leaks. Do not use bare hand.
Wear safety goggles. If fluid enters skin or eyes, get
immediate medical attention. C-2635
W-2074-1285
12 ft.-lbs.
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.
Remove the high pressure fuel lines (Item 1) �.

A-2668
IMPORTANT
1-2029-0284
Remove the fuel return line (Item 2) �.
Remove the nuts from the mounting flange (Item 3) �.
Installation: Tighten the nuts to 12 ft.lbs. (16 Nm) torque JID.
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 lg.
843 Loader
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
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:
SETTING PRESSURE - 2205 PSI (15203 kPal

WORKING PRESSURE - 1985 PSI (13687 kPal
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 PSI
(5163 kPa).
I
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 �:
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
ENGINE
procedure).

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]. B-4288
Disconnect the ground wire at the left side of the engine.
Remove the air cleaner hose at the intake manifold. B
Remove the bolts and nuts at the air cleaner clamps [ID.
B-4289
Remove the air cleaner assembly from the engine compartment

lg.
B-4291
Disconnect the throttle linkage at the throttle lever �.
B-4378
843 Loader
ENGINE (Cont'd)
Disconnect the throttle linkage at the injection pump I!].
B-4299
Remove the bolt and nut at the cross lever � .
Remove the throttle linkage assembly.
Remove the rear grill.
Remove the radiator cap.
B-9281
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 �.
843 Loader
ENGINE (Cont'd) Fuel Tank
Turn the fuel shut-off valve to the "OFF" position at the fuel
tank �.
Disconnect the fuel line at the water trap filter.
Disconnect the fuel return hose at the fuel injector nozzles.
B-4304
Remove the exhaust pipe at the muffler [ID.
Remove the exhaust pipe at the exhaust manifold lg.
B-4314
Remove the rear engine mounting bolts, washers and nuts (both
sides) [Qi.
'Installation: Add liquid adhesive (LOCTITE) to the bolt threads

and tighten to 125 - 140 ft.-lbs. (169 - 190 Nm) torque.
843 Loader
ENGINE (Cont'd)
Remove the front engine mount bolts, washers and nuts (both
sides) � -
Installation: Add liquid adhesive (LOCTITE) to the bolt threads

'
and tighten to 125-140 ft.-lbs. (169-190 Nm) torque.
Lift the rear of the engine over the edge of the loader frame
with pry bars.
8-4316
Slide the engine out of the loader 00 .

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.
843 Loader
Revised Feb. 94
RADIATOR
Remove the bolts at the cover on the blower housing. Remove

the cover from the blower housing � -
B-4335
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 oil cooler (See Page 7A-18).
Disconnect the radiator hoses (both sides) [£].
Remove the bolts at the bottom of the radiator.
B-4337
Lift the radiator up and over the muffler shield [Q].
Remove the radiator from the loader.
843 Loader
OIL COOLER
Remove the engine from the loader (See Page 7A-13).
Disconnect the tubelines from the oil cooler (both sides) I!].
8-4537
Remove the four bolts at the side brackets of the oil cooler [ID.
B-4536
Drop the oil cooler down and pull it towards you to remove it
from the loader lg.
B-4538
843 Loader
ENGINE MUFFLER
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 �.
Remove the bolts at the bottom of the muffler.
Remove the muffler from the loader �.
843 Loader
Remove the engine from the loader (See Page 7A-13).
Remove the cover at the blower housing.
Remove the bolts along the top edge of the blower housing�-
In
�
B-4344
Remove the bolt at the bottom of the blower housing IID.

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 � .
843 Loader
Remove the four bolts at the u-joint mounting flange I!].

torque.
Remove the u-joint from the flywheel [ID.
Remove the bolts from the flywheel lg.

torque.
Remove the washer IQ] .
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 ° C.).
F it the ring gear over the flywheel. Make sure the gear is on
its seat correctly.
843 Loader
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
'k
_i_:t'_1:1.'r'�
0.012" (0,305 mm)
.. ... . .1Si-____-'r' �
�·-·--rGIDij
radiator hoses.
0____:
Remove the fuel injectors and fuel tubelines (See Page 7A-11).
t -····
0.003" 0.006" 0.006"
(0,08 mm) (0,15 mm)
Remove the fuel filter and bracket. (0,15 mm)
Remove the valve cover.

Pl-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 I!].
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
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.
B-3207
Tighten the bolts in the correct sequence [ID. Do this in a three

step procedure to 85 ft.-lbs. (115 Nm) torque.
Example: First tighten all bolts to 30 ft.-lbs. (41 Nm) torque, then
65 ft.-lbs. (88 Nm) 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.-lbs. (115 Nm) torque
A-2646
Adjust the valve clearance (See Page 7A-2).
Install the valve cover.
Install the fuel injector nozzles and fuel tubelines.
Install the fuel filter and bracket.
Install radiator hoses.
Add coolant to the engine and radiator.
843 Loader
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
[ID.
Remove the valve spring and valve from the head lg.
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 Inner Spring
Put each valve in its correct location. �M Spring Spring
� Var
�-�· ··::� -�t� ••
Assemble the valve springs and cups lg.
The intake valve is fitted with a rubber seal.
Use a valve spring compressor and install the valve springs and ti
,..,. t r
valve stem locks.
Tap the valve stem with a hammer a small amount to seat the Intake Outer Seal Locks
valve stem lock. Valve Spring
B-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
0
IQ]. 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)
Worldwide Parts Source LLC Phone: 269 673 2313 email: PartsAndGaskets@gmail.com 843 Loader
VALVES (Cont'd)
Installing Valve Guides
Check the valve guides for wear with a dial indicator l!J. If the
movement is more than the listed specification, replace the
guide:
INTAKE & EXHAUST - 0.024" (0,6 mm)
NOTE: Make sure to check the valve stem for wear before
replacing the valve guide [!I.
I
0.501/0.5018 in.
(12,73/12.74 mm)
4.503/4,521 in.
EXH. & IN. 0.312/0.313 in. )114,38/114.83 mm)
(7,92/7,95 mm)
15!:]�
�m1
[
l
�,
m•
�rooo •• ,
oo,.,-0oo
1 0.638/0.662 in.
(16.2/16,8 mm)
0.500/0.50
(12.7/12.73 mm)
Remove the guide with a hydraulic press or hand operated tool

lg.
B-1887
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.

Phone: 269 673 2313
email: Parts@WwPartsSource.com
843 Loader
VALVES (Cont'd)
Checking the Valve Springs

1.74 in.
The valve springs for the intake and exhaust valves are the same. (44,19 mm)
Check the spring ends for damage and check the specifications
�-
1.49 in.
(37,84 mm)
VALVE SPRING OUTER

1.59 in.
(40,38 mm) Pl-2371

Phone: 269 673 2313
843 Loader
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 lg. 1 .372/1.374 in.
(34,86/34,90 mm)
Fl
i-
q
0.425/0.4281 ;n.
110.79/10.87mm)---1---'r-
�II � ..
1
10,07mm)
(34,92/34.96 mm) 0.002 in.
r4
0 0
Pl-2376
Use a hammer and punch to set the expansion washer in

position to hold the insert in the cylinder head [QJ.
_o cB-3330
ROCKER ARMS
Disassembly
Mark the rocker arms and support bracket for correct assembly.
Remove the snap rings (Item 1) form each end of the shaft (Item
2) I!].
Remove the rocker arm (Item 3), bracket (Item 4) and spring
(Item 5) I!].
Inspect the rocker arm bushings for wear � -

0.7188/0.7196 in.
118,26/18,28 mm)
0.7199/0.7207 in.
118.29/18.30 mml
8.5102/8,5412 in.
1216,16/216,94 mm)
0.247/0.25 in.
16.27/6,35 mml
Pl-2595
Assembly
Align Oil Feed Holes
When installing a new bushing in the rocker arms, make sure
the oil holes are in alignment �.
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.
A-2352

Phone: 269 673 2313
843 Loader
A
;
Removal
Remove the cylinder head (See Page 7A-22). 0

� � � �
(?�,too oo() O ' O N
Remove the oil pan and oil pump (See Page 7A-47}. 2
O 0
o D oUo
Remove the ridge and carbon deposits at the top of the cylinder
oLio
o
bore with a ridge reamer.
CD CD CO o
Make sure the pistons have identification marks � . Oo OOo OOo OOo Oo
B-3248
Rotate the crankshaft until a pair of connecting rods are at

bottom dead center. Make sure the cab and rod have
identification marks [ID.
Remove the nuts and remove the bearing cap �.

C
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.

Phone: 269 673 2313
.....\,',II_
/ '
"
B-3317
843 Loader
PISTON AND CONNECTING RODS (Cont'd)
Disassembly O.OOZ/0.004111,
(D.05/0,10nwnl
Remove the rings from the pistons. •0.00054/0.0017Sln.

r-0.o,1-o.04 • • 1
r - _ ----,
Remove the piston pin. 0.002210.oO<l 111.10,0510, 10mml

0.093/0.9381n.12,38/2,38mm)
1.2497811.24998111,
131,74131.75mrnl 0.098/0.097,n,12,44J2.38mml
NOTE: If the piston pin does not come out easily, do not drive 0.083/0.938in.(2,38/2,38mm)
it out. Warm the piston in oil to a temperature of 0.002210.004in.

(0,06/0,10mmJ
1.2496/Ul!SOitl.
0.0022/0.0041n.f0,05/0,10mm)
0.1895/0.19051n.C4,8114.8'mmJ
120 ° F. (50 ° C.) and push the pin out. C31,74131,75mml

'-- -'-+ ---' 0.1888/0.18751n.(4.74J4,78mmJ
• 0.189510.190!> In, (4,81/4,84mml
0.1885/0.1875111,
14,74J4,78fflml
Inspection
Pl-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 !ID.
B-3334
Make sure the specifications are correct 1£].
A--�===;+=
l}-�---=u
0.01 4/0.019 in.
(0,35/�. 4 8 mm)
,� v· 1� 0.011,0.0,s;n.
(0, 2 8/0. 4 1 mm)
Pl-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. 1.3785/1 .380 in.
-0.00054/+ 0.00175 in.
{36.01/35,05 mm)
1·0,01/+ 0.04 mml
-0.0025/-0.005 in,
(·0,06/·0.13 mm} 0.00074/0.0059 in.
Use the correct size reamer to fit the new bushing to the piston 1.375/1.376 in. (0.0187/0.1280 mml
134,92/34,95 mm)
pin.

Phone: 269 673 2313
f,ff-·�-·
�
31,74131,75 mml
1,2505/1.2515 in.
131,76131.79 mml
email: Parts@WwPartsSource.com 1.047/1.055 in.

{26.59/26.80 mml
Pl-2396R
843 Loader
PISTON AND CONNECTING RODS (Cont'd) 5 in.
(127 mm)
Check the connecting rod alignment I!].
Installation
Install the piston pin by putting the piston in clean oil at a

temperature of 120 ° F. (50 ° C.). ±0.01 in. ±0.01 in.
(±0,254 mm) (±0,254 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.

Pl-2375
Install the piston rings using a expanding tool to prevent the

ring from breaking �.
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 �.
Put oil on the bearings. Install the bearing cap [£].
Tighten the nuts on the connecting rod [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.

Phone: 269 673 2313
45 ft.-lbs.
(61 Nm)
B-3325
843 Loader
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.
The standard bore of the cylinder liner is 3.501 - 3.502" (88,92

- 88,95 mm). When the bore dimension is 0.006" (0,15 mm)
over standard dimensions the liner must be replaced.
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
�.
Follow the same procedure for the other cylinder liners.
Hone the cylinder bore to standard dimensions �.

,�·:ui,�: �?� [,,o.o,.,o.o,, �-
I �1
·[o.35/0,57 mml
-
0.001/0.0031n.
L
-,..---�---t-< 10,03/0,08mml
r,',":i'N,'
' ' mm
0
'"; �
3.814513.8156 in.
I
0 150/0 152 In
196,89/96,91mm)
1:i,a113,88mmi
3.99013.995 In
1101.35/101,47 mml
-,
3.8125/3.8135 in.
196,84196,88 mm)
0.028/0.0311n.
Worldwide Parts Source LLC 10,88/0,79 mm)
Phone: 269 673 2313

Pl-2373
843 Loader
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-47).
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 !ID.
On the center main bearing, remove the cap and thrust washers
from each side of the cap lg .
Remove the top half of the bearing and thrust washer by pushing
on one side of the bearing and rotating the crankshaft [Q] .

Phone: 269 673 2313
843 Loader
MAIN BEARINGS (Cont'd)
0
Installation
Check the crankshaft journals before installing the main bearings

(See Page 7A-35). 0
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.
0
Install the other bearing half in the main bearing cap. Lubricate
the bearing and install it on the engine block. 85 ft.-lbs
(115 Nm)
Install the bolts and tighten to position the cap, then loosen B-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 �or a

dial indicator lg.
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.

Phone: 269 673 2313
843 Loader
CRANKSHAFT
Removal
Remove the oil pan. Remove the oil pump (See Page 7A-47).
Remove the crankshaft pulley, timing case cover, timing gears

and timing case (See Page 7A-38).
Remove the flywheel (See Page 7A-21).
Remove the rear main seal (See Page 7A-37).
Remove the connecting rod caps {See Page 7A-30).
Remove the bolts and main bearing caps (See Page 7A-3).
Lift the crankshaft out of the engine block for inspection.
Checking
Using a micrometer, check the crankshaft for correct

dimensions IA] .
1 .391/1.421in. 1.391/1.412 in.

(35.4/36.1 mml (35.4/36.1 mm)
0.003/0.015 in.
(0.08/0,38 mml
I
�------ 0.050/0.080 in.

,._.,_---,- (1,27/2,03 mml
STD
0.0896/0.0915 in.
(2,26/2 .32 mml
OVERSIZE
0.0966/0.0985 in.
(2 ,45/2 ,50 mml
.
1 2495/1.251 in.
0.0025/0.0045 in. 1/8 / 9/64 in. _ _i_n_--0
_ 2
0.0-82 . +in.� (31.74/31.77 mml
- -5
(0.06/0, 11 mm) 3,2/3,57 mml (2.09 mml (12 ,7 mml 3.9985/3.9995 in.
L
2.2 485/22.49 in. (101.56/101.59 mml
0.0822 in.
(2 .09 mml (57,10/57. 12 mml
�
2.7515/2.753 in.
(69.89/69.93 mml ,
2.7845/2 .749 in.

1---,.____ (69.81/69.82 mml
1.122/1.130 in.
(28,5/28,7 mm)
1. 122/1.130 in.
(28.5/28,7 mml
9/64 / 5/32 in.
1.3725/1.3741 in. 13,57/3,7 mml
2.7845/2.749 in. (34,86/34,9 mml
(69,81/69.82 mml
Pl-2370R
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 SA-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-37).
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-21).

Phone: 269 673 2313
843 Loader
REAR MAIN OIL SEAL
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.-lbs. (5 - 8

Nm) torque �.
Tighten the bolts (Item 4) to 12 ft.-lbs. (16 Nm) torque and then
tighten the bolts (Item 6) to 12 ft.-lbs. (16 Nm) torque �.

Phone: 269 673 2313
843 Loader
TIMING CASE COVER
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 [!I .
Put a new gasket on the cover. Install the cover, be careful! 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 B-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 � .

Phone: 269 673 2313
B-3325
843 Loader
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 [!I.
Remove the idler gear hub 00 . T he idler gear hub is an

interference fit, use a soft hammer to remove it.
Check the idler gear and hub lg.

-0.00071-0.0027 in.
1-0.02/-0,07 mm) 0.001/0.0023 in.
Replace the parts as needed. 1.1320/1.1340 in.
(28,75/28,80 mm)
(0,00/0,06 mm)
Installation 0.0014/0.0034 in.
Make sure the oil passage is clean in the hub.

1.8898/1.8908 in.
(48148,02 mm)
..JI "�\
Turn the engine crankshaft until No. 1 piston is at TDC,
compression stroke.
,_1321,,.1337 in.
Install the idler gear hub 00. /
144,01/44,04 mm)
1.8915/1.8924 in.
(48,04/48,07 mm) 1.140/1.144 in.
(28,95/29,0ti mml
Pl-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 �.

Phone: 269 673 2313
843 Loader
IDLER GEAR AND HUB (Cont'd)
Install the retainer plate. 40 - 50 ft.-lbs. 19 - 21 ft.-lbs.

(54 - 68 Nm) Torque (26 - 28 Nm) Torque
Tighten the nuts to the correct torque I!].
21 ft.-lbs.
(28 Nm) Torque
B-3346
Check the clearance for end play at the idler gear [ID.
The correct end play is 0.006 - 0.012" (0,15 - 0,30 mm).
Check the clearance at the gear teeth [g for the correct

dimensions � .
Replace any worn parts that do not meet specifications.
Install the timing case cover (See Page 7A-38).
843 Loader
CAMSHAFT GEAR 0
Removal

C
MEL-1054 - Puller
Remove the idler gear (See Page 7A-39).
Remove the bolt, tab washer and retainer washer.
Install the puller to remove the camshaft gear �.
Remove the camshaft gear [ID.
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.-lbs. (54 - 68 Nm) torque.
Install the idler gear (See Page 7A-39).
Install the timing case cover (See Page 7A-38).
843 Loader
Remove the fuel injection pump (See Page 7A- 7).
Remove the three bolts � -
Installation: Tighten the bolts to 19 - 21 ft.-lbs. (26 - 28 Nm)

torque.
Remove the gear from the hub.
B-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.

Phone: 269 673 2313
843 Loader
TIMING CASE
Remove the camshaft gear (See Page 7A-41).
Remove the fuel injection pump drive gear (See Page 7A-42).
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 [!].

Phone: 269 673 2313
843 Loader
Removal
Remove the camshaft gear (See Page 7A-41).
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 I!] .
Remove the camshaft from the engine block [ID.
Remove the tappets from the engine block [g.
�
B-3294

Phone: 269 673 2313
843 Loader
CAMSHAFT AND TAPPETS (Cont'd)
D -0.0007I+ 0.0007 in. 1 .O in. - 1.0 in.

(-0,02/ + 0,02mm) (25,4mm) (25,4mm)
0.2374/0.240 in. 2.045/2.0252 in.

(6,03/6,10mm) (51,41/51,44mm)
1.125/1.1257 in.
(28,58/28,59 mm)
Pl-2397
Inspection
Check the camshaft and the bearings I!].
Use the correct tools for removal and installation of the

camshaft bearings.
Installation
Lubricate the tappets before installation.
Lubricate the camshaft. Carefully install the camshaft to prevent

damage to the bearings.
After rocker arms are installed, make sure to set the valve
clearance (See Page 7A-2).

Phone: 269 673 2313
843 Loader
LUBRICATION SYSTEM
Description
SPLASH AND OIL MIST TO VALVE
The figure shows the engine oil lubrication system �. AND GUIDE ASSEMBLIES
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.
OL
"::SURE
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 Pl-2369R
by-pass valve which prevents the engine from going without
lubrication if the filter element becomes plugged.

Phone: 269 673 2313
843 Loader
OIL PUMP
Remove the oil pan. Remove the bolts (Item 1) that fasten the
oil tube (Item 2) to the block I!].
Loosen the locknut (Item 3) at the bolt (Item 4) that holds the
oil pump in the block. Remove the oil pump.
Remove the bolts (Item 5) and tube (Item 2) I!].
Remove the bolts (Item 6) and oil screen (Item 7) I!].
Remove the bolts (Item 1) and the end cover (Item 2) [ID.
Remove the relief valve plunger and spring (Item 3) [ID.
Remove the outer rotor (Item 4) [ID.
Use a puller and remove the gear (Item 5) [ID.
Remove the shaft and inner rotor (Item 6) [ID.
Checking
Check the clearance between the outer rotor and housing lg.
Check the clearance between the inner rotor and outer rotor
[Q].
See Page 7A-48 for the specifications.

Phone: 269 673 2313
B-4110
843 Loader
OIL PUMP (Cont'd)
Check the relief valve and plunger [!].

0.00 1 5/0.003 In.
I0,04/0,08mm)
0.0013/0.002 1 In.
10.03/0.05=1
±
0.823/0,8235 In.
Jr.I :,.E...,,Jt5:�··��
...r ��..
Jf-1 bJ
�-o· �
0.4965/0.497 In.
, -1
0.825/0,8ZS in.
� 0,78125 In.
1 1 2,81/ 1 2,82 mml 1 1 5,871 1 5,90 mm) 119,84mml
0.5585/0.559& in,
0.5805/0,582 1 In. 1 1 4, 1 8/ 1 4,2 1 mml
(14,24/ 1 4,28 mml 1.�
0.00 1 /0,0038 In.
0.00210.oos in. co.0210.01 -,
10.05/
0.389/0.406 In,
(9,88/ 1 0,29 mml"'l_
�
,1111\ili,1
�I- o.a,2,n.
120,82 mmJ
�
�
0.0052/0.0 1 0 in,
1.6625in.
139,89mm)
10.13/0,25mml
Pl-2592
Installation: Check the end play of the shaft and inner rotor [ID
and then install the outer rotor �.

Phone: 269 673 2313
843 Loader
WATER PUMP
Remove the coolant from the cooling sy stem. 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 � .
Installation: Clean the block surface. Put gasket cement on the

engine block and install a new gasket. 2
Disassembly
Remove the snap ring (Item 1) l!J.

Press the complete assembly out of the impeller end of the
housing.
Remove the snap ring (Item 2) I!].

B-3206
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 l!J.

Phone: 269 673 2313
843 Loader
WATER PUMP (Cont'd)
Checking
Check the water pump as listed in the specifications I!].
Replace the seals and worn parts.
{S.-,m,0.030,0
�-"-
Pl-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 00.
Put a support under the shaft, 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 B-3206
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.
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 lg.
843 Loader
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 [!J.
Testing the Thermostat
Put the thermostat in water and heat the water.
The thermostat valve must start to open at 179 - 183 ° F. (81

- 85 ° C.) and must be fully open to 0.315" (8 mm) at 185 - 200 °
F. (88 - 94 ° 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.

Phone: 269 673 2313
843 loader
ENGINE SERVICE
Page
Number
Inspection ................................... 78-47
Installation .................................. 78-47
Removal .................................... 78-46
CAMSHAFT GEAR
Installation ................................. . 78-43
Removal .................................... 78-43
Removal and Installation ....................... . 78-28
CRANKSHAFT
Checking .................................... 78-36
Installation .................................. 78-37
Removal .................................... 78-36
CRANKSHAFT GEAR
Removal .................................... 78-44
CYLINDER HEAD
Cylinder Head Surface Alignment ................. . 78-23
Installing the Cylinder Head...................... 78-24
Removing the Cylinder Head..................... 78-23
CYLINDER LINERS
Checking .................................... 78-33
ENGINE
ENGINE COMPRESSION
Checking .................................... 78-3
Flywheel Ring Gear ............................ 78-22 ENGINE SERVICE
Removal and Installation........................ 78-22 Perkins 2.5 Liter
TK200 Series
ENGINE MUFFLER I
Removal and Installation ........................ 78-20

FUEL FILTER (S/N 13315 & Below)
Water Trap ................................... 78-4
FUEL FILTER (S/N 13316 & Above)
Water Trap ................................... 78-4
FUEL INJECTOR NOZZLE
Checking .................................... 78-12
FUEL INJECTION PUMP
Maximum and Installation....................... 78-8
GLOW PLUGS
Checking .................................... 78-13
IDLER GEAR AND HUB
Installation .................................. 78-42
Removal .................................... 78-41
843 Loader
�oruiro M==-n•r�I
ENGINE SERVICE
Perkins 2.5 L TK200 Series Four Cylinder Diesel - continued
Page
Number
LUBRICATION SYSTEM
Description .................................. 78-48
MAIN BEARINGS
Crankshaft End Play ........................... . 78-35
Installation .................................. 78-35
Removal .................................... 78-34
OIL COOLER
OIL FILTER ADAPTER HOUSING
OIL PUMP
Inspection ................................... 78-50
Disassembly ................................. 78-31
Inspection ................................... 78-31
Installation .................................. 78-32
Removal .................................... 78-30
REAR MAIN OIL SEAL
RADIATOR
REMOV ING AIR FROM THE FUEL SYSTEM
(S/N 13315 & Below)
Procedure ................................... 78-5
REMOV ING AIR FROM THE FUEL SYSTEM
(S/N 13316 & Above)
Procedure ................................... 78-6
ROCKER ARMS
Assembly ................................... 78-29
Disassembly ................................. 78-29
TIMING CASE
TIMING CASE COVER
Front Seal................................... 78-40
TIMING THE FUEL INJECTION PUMP
Procedure ................................... 78-9
THERMOSTAT
Installation .................................. 78-54
Removal .................................... 78-54
Testing the Thermostat ......................... 78-54
TROUBLESHOOTING
Chart ..
, .................................... 78-1
VALV ES
Checking Valve Springs......................... 78-27
Installing Valve Guides.......................... 78-26
Installing the Valves............................ 78-25
Reconditioning the Valve & Valve Seats ............. 78-25
Removal of the Valves.......................... 78-25
VALV E CLEARANCE
Adjustment .................................. 78-2
WATER PUMP
Assembly ................................... 78-53
Checking .................................... 78-53
Disassembly ................................. 78-52
Service Manual
7B ENGINE SERVICE - PERKINS 2.5 Liter Diesel TK200 Series
TROUBLESHOOTING
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 30, 31, 32
Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 23, 28, 30, 31, 32
No power from engine. 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 23, 24, 25, 26, 30, 31, 32
Engine is mis-firing. 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 24, 25, 27, 28, 29, 31
Too much fuel consumption . 11, 13, 14, 18, 19, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32
Black exhaust. 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32
Low oil pressure. 4, 34, 35, 36, 37, 38, 40, 42, 55
Engine knocking. 9, 14, 16, 18, 19, 22, 25, 27, 28, 30, 32, 34, 43, 44, 56
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 25, 27, 28, 29, 32, 43, 56
Vibration. 13, 1� 2� 2� 25, 28, 29, 32, 43, 45, 46
Overheating. 11, 13, 14, 16, 18, 19, 23, 24, 43, 47, 48, 49, 50, 54
Poor compression. 11, 19, 24, 27, 28, 30, 31, 32, 33, 44, 56
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.
1200 Series) 843 Loader
VALVE CLEARANCE
Adjustment

cold.
the valve stem and turn the adjusting bolt until the clearance
is correct � .
[ID.
Use the following sequence to set the valves:
a. With 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 rocker arms rocking at No. 1, set clearance

at No. 4 valves.
d. With the rocker arms rocking at No. 3, set clearance

at No. 2 valves.
Perkins 2.5 Liter Diesel TK200 Series 843 Loader

-7B-2- Service Manual
ENGINE COMPRESSION
Checking
MEL-10630 - Engine Compression Kit
Remove the fuel injectors (See Page 78-11 ).
Install the correct compression adapter into the engine.
Connect the compression gauge � -
The compression must be between 300 - 500 PSI (2069 - 3448

kPa), with no more than 50 PSI (345 kPa) difference between
cylinders.
(Perki ns 2.5 Li ter Di esel TK200 Series) 843 Loader

FUEL FILTER (S/N 13315 & Below)
See the Service Schedule (Page 1-1) for the correct service
sequence when replacing 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
filter. 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 �
Tighten the thumb screw when all the water is removed.
FUEL FILTER (S/N 13316 & Above)
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 lg.
Remove the bolt (Item 21 at the top of the filter, while holding
the nut below the filter bowl. Remove the filter element (Item
3) and bowl lg.
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 lg.
Perkins 2.5 Liter TK200 Series) 843 Loader

REMOVING AIR FROM THE FUEL SYSTEM (S/N 13315 & Below)
Procedure
Loosen the vent plug (Item 11 I!].
Operate the priming pump (Item 2) until the fuel, which flows
from the vent, shows no air bubbles.
Holding the priming pump down, tighten the vent plug (Item
1) I!].
Loosen the tubeline connection (Item 1) at the fuel injection

pump [ID.
Operate the priming pump (Item 21 until the fuel which flows
from the tubeline 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.
B-5793
T ighten the fittings at the high pressure lines to 15 ft.-lbs. (20

Nm) torque lg.
Perkins 2.5 Liter TK200 Series) 843 Loader

Service Manual
(S/N 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) [ID.
Operate the hand pump until the fuel flows from the tubeline
connection with no air bubbles.
Start the engine. When the engine runs smoothly, tighten the
tubeline connection [ID.
(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
IMPORTANT
personnel. adjustment or maintenance must not be B-5822
done.
J-2028-0284
MEL-1200 - Puller
Disconnect the throttle control linkage (Item 1) from the injection

pump�.
Disconnect the wire at the fuel shut-off solenoid 00:J. �B-5794
Disconnect the high pressure fuel lines at the injection pump.

I\�
\
��})!/\
----
IMPORTANT
1-2029-0284
Remove the pump support bracket at the bottom of the pump / B-5790
�-
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 [QJ.
(200 Series) 843 loader

-7B- 7- Service Manual
FUEL INJECTION PUMP (Cont'd)
Remove the gear nut and spring washer � -
Installation: Tighten the nut to 50 ft.-lbs. (69 Nm) torque.
Remove the nuts at the pump mounting flange.
With the injection pump supported, loosen the pump gear using
the special tool [ID.
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

� . 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 �.

TIMING THE FUEL INJECTION PUMP
Procedure
T he tool listed will be needed to do the following procedure:
Turn the engine crankshaft until No. 1 piston is at TDC on the

compression stroke. Both valves at No. 4 cylinder are moving.
Loosen the adjustment bolt at the rocker arm intake valve IKJ.
B-5805
Remove the snap ring at the end of the rocker arm shaft and
remove the rocker arm [ID.
B-5806
Remove the valve spring lg.
Put the valve head on the top of the piston crown.
B-5798
Install a dial indicator on the top of the valve stem IQ].
Turn the engine crankshaft backward and forward a small

amount to find TDC (maximum piston height) and zero the dial
indicator.
Remove the high pressure fuel lines from the injection pump.

Phone: 269 673 2313

TIMING THE FUEL INJECTION PUMP (Cont'd)
Remove the plug and washer at the rear of the injection pump
�-
Install the timing 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) [ID.
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 dial 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 mm),

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.

Phone: 269 673 2313

I
A WARNING
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
C-2635
W-2074-1285
Problems caused by faulty injector nozzles:
Rough engine operation and idle.
The engine will not have full power.
The engine exhaust smoke is black, white or blue.
Remove the high pressure fuel lines (Item 1) � -
IMPORTANT
1-2029-0284
Remove the fuel return line (Item 2) �.

A-2668
Remove the nuts from the mounting flange [!].
Installation: Tighten the nuts to 12 ft.-lbs. (16 Nm) torque lg.
Remove the fuel injector nozzles from the cylinder head.
Installation: Always replace the copper washer (Item 1) with a

new copper washer when installing the fuel injector nozzle �-
Phone: 269 673 2313
A-2846
A
Checking
IMPORTANT
Do not _disassemble or test the fuel injector nozzles
unless y6u have the correct service and testing tools.
1-2027-0284
A-2513

MEL-10018 - Injector Nozzle Tester
MEL-10019 - Accessory Set
CORRECT WRONG
Connect the nozzle to a test pump in a down position �.
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.
W-2075-1285
Checking nozzle spray pattern �:
Does not come out the side of nozzle. Worldwide Parts Source LLC
Phone: 269 673 2313
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.

GLOW PLUGS
Checking
IMPORY,ANT
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 pos1t1ve ( +) 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��
Installation: T ighten the glow plug to 11 ft.-lbs. (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.

Phone: 269 673 2313

ENGINE
procedure).

procedure).
Remove the batteries from the loader (See Page 6- 2 for the
correct procedure).
Disconnect the engine wiring harness �.
Disconnect the wires at the two solenoids �.
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 [g.
Disconnect the throttle linkage at the fuel injection pump [Q].
Remove the bolt and nut at the cross lever and remove the
throttle linkage assembly.

Phone: 269 673 2313
B-5822
(200 S�ries) 843 Loader

ENGINE {Cont'd)
A
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.
Disconnect the radiator hoses at the engine and radiator [ID[g.
B-5823
Remove the coolant pipe and radiator hose Im.
\\
0\
\
il1\
I ; Il J B-5824
\
\�
�-
B-5825

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 [i].
Remove the front engine mounting bolts, washers and nuts [g.
Installation: Add liquid ahesive (LOCTITE) to the bolt threads

'
and tighten to 125 - 140 ft.-lbs. (169 - 190 Nm) torque.
Lift the rear of the engine over the edge of the loader frame.
B-4316
Slide the engine out of the loader [Q] .
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 splines of the hydrostatic pump
shaft, while the engine is moved toward the front of the loader.
B-5826

Revised Feb_ 94 -78-16- Service Manual
RADIATOR
Remove the rear grill IA].
--=== B-8336
Remove the radiator cap �.
Open the coolant drain (Item 1) at the side of the engine block
and drain the coolant into a container lg.
B-4256
Disconnect both radiator hoses at the radiator �.

RADIATOR (Cont'd)
Remove the radiator holddown bracket at the right side of the

frame�-
B-8763
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 �.
- --� .... -·
B-8672

OIL COOLER
Remova I and Installation
Remove the panels above the eng1·ne on the blower housing .
.
Remove the radiator (See Page 7 8-17).
. ht side of the oil cooler IAl

Disconnect the tubeline at the rig �-
.
Disconnect the tubehne .
at the left side of the oil cooler [ID.
Remove the bolts at the n"ght SI"de bracket for the oil cooler lg.
Remove the bolts at the left side bracket for the oil cooler [Q].
Remove the o1·1 cooler from the moun ting frame.
1200 Series)
-7B-19-
ENGINE MUFFLER
Remove the bolts from the plate which covers the muffler I!].
a
B-8740
Remove the four bolts inside the engine compartment [ID.
B-8693
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.
B-8764
Remove the muffler from the loader �.

Remove the bolts along the top edge of the blower housing �-
Use a punch and hammer and remove the rivet from the blower
housing [ID.
Remove the blower housing from the loader lg.
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 [QJ .
B-8760

Remove the four bolts at the u-joint mount flange � .

torque.
Remove the u-joint from the flywheel !ID.

torque.
Remove the washer � .
Flywheel Ring Gear
The ring gear on the flywheel is an interference fit . Heat the

to remove it.
Clean the outer surface of the flywheel to give it a smooth fit.
Clean the new ring gear and heat it to a temperature of 450

- 500 ° F. (232 - 260 ° C.).
F it the ring gear over the flywheel. Make sure the gear is on
its seat correctly.

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 ::JtT{E:?.:!{I :'_-d.t� �------�$:fil �..___GJJ)faj
T_...
radiator hoses.
0.004" 0.010" 0.010"
(0,1 mm) (0,25 mm) (0,25 mm)
Remove the fuel injectors and fuel tubelines (See Page 7B-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.

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 7B-25 for removing and reconditioning the valves.
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 head.

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 [!]. Do this in a three

stop procedure to 85 ft.-lbs. (115 Nm) torque.
EXAMPLE: First tighten all the bolts to 30 ft.-lbs. (41 Nm) torque,
then 65 ft.-lbs. (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.-lbs. (115 Nm) Troque
brackets.
Adjust the valve clearance (See Page 7B-2).
Install the valve cover.
Install the fuel injectors and fuel tubelines.
Add coolant to the engine and radiator.

Phone: 269 673 2313

VALVES
Removing the Valves
Mark the valves so they are put in the original position on

assembly I!].
8-1855
Use a valve spring compressor and remove the valve spring locks
[ID.
Remove the valve springs and valve from the cylinder head.
Repeat this procedure for each valve.
Installing the Valves
Make sure the cylinder head is clean.
8-5798
Assemble the valve springs and cups 1£].

Outer
i
Spring Inner
Spring Locks
i
The intake valve is fitted with a rubber seal. Spring
�=4
Set
Exhaust Valve Spring Cup /
Use a valve spring compressor and install the valve springs and
valve stem locks. ! �
Tap the valve stem with a hammer a small amount to seat the ��
valve stem locks.
IJ• fl
t
Intake Valve t t Seal
Fil
Spring
Outer Inner
Spring Cup
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 ° [QJ.

Phone: 269 673 2313
INLET EXHAUST
(90 ° Included Angle)
45 ° 8-4125

VALVES (Cont'd)
�-
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 [ID. If the
movement is more than the listed specifications, replace the
guide.
INTAKE & EXHAUST: 0.024" (0,6 mm)
NOTE: Make sure to check the valve stem for wear before
replacing the valve guide [g . Minimum Dia.
INT.
0.3102 in.
(7,88 mm)
� EXH.
r[l.....
0.3097 in.
(7,87 mm)
Maximum Clearance
INT.
0.00 5 in.
(0,13 mm)
EXH.
0,00 55 in.
(0,14 mm)
r--J
��(16, I- 5 mm) -l .3145/0.3155 in.
(7.99/8,0 1 mm) Pl 2372
Remove the guide with a hydraulic press or hand operated tool

[Q].

Phone: 269 673 2313
B-1887

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" 116,5 mm) is above
the cylinder head.
Checking the Valve Springs

28 lbs.± 1.5 lbs.
(12,7 kg.± 0,65 kg)
r·1
The valve springs for the intake and exhaust valves are the same. 1.74 in.
(44,19 mm)
Check the spring ends for damage and check the specifications
[!). 3! i
c
-L--+-..__ �--.L�:_ _ __j
VALVE SPRING INNER
1.49 in.
(37,84 mm)
1.81 in. 40 lbs.± 2.0 lbs.
�1,
(45,97 mm) (18,1 kg± 0,91 kg)
...L-4,.--'--��-__J
VALVE SPRING OUTER
1.59 in.
(40,38 mm) Pl-2371

Phone: 269 673 2313

Remove the inserts, using a punch through the injector nozzle

bore and hit the punch with a hammer � -
J)_B-3284
Position the new insert by putting the expansion washer in the

correct position �.
Make sure to check the height of the insert to the cylinder head
as shown lg.
1
0.002 in.
10.07mmJ
r9
Pl-2376
Use a hammer and punch to set the expansion washer in

position to hold the insert in the cylinder head [Q].

Phone: 269 673 2313

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) �-
Remove the rocker arm (Item 3), bracket (Item 4) and spring
(Item 5) �-
Inspect the rocker arm bushings for wear [!].
Assembly
When installing a new bushing in the rocker arms, make sure

the oil holes are in alignment [g. 8.5102/8.5412 in.
0. 0006 /0. 0024
in.
1216.16/216.94 mm) . (0,01/0,06 mm)
0.247/0 .25 m.
-=n
�
Reverse the order of disassembly and make sure that each set (6,27/6 ,35 mm) · _J
Q . 0. 6 234/0. 6244 in.
of rocker arm pair has the correct off-set. (15,83/15,86 mm)
0. 625/0. 62cl ..
(15,87/15,89 mm)
Put oil on all the parts for protection.
Pl-2595
Align Oil Feed Holes
A-2352

Phone: 269 673 2313

*Revised Feb. 94 -7B-29- Service Manual
Removal
'--
Q ---
Remove the cylinder head (See Page 7B-23).
� � � �
o
' 00�0
°
Remove the oil pan and oil pump (See Page 7B-49). ��to
2 00
0
bore with a ridge reamer. o Uo o ol/o
o CD CD0 CD o
Make sure the pistons have identification marks �.
0 0 OOo OOo 000 Oo
B-3248
Rotate the crankshaft until a pair of connecting rods are at

bottom dead center. Make sure the cab and rod have
identification marks [ID.
/¢;
60
Remove the nuts and remove the bearing cap [g.

Using a hammer handle, push the piston and rod assembly out
of the block �.

Phone: 269 673 2313
- -
..
_ � , ' �--•
; '
B-3317

-7R-�O- Service Manual
PISTON AND CONNECTING RODS (Cont'd)
*
Disassembly
0.002/0.004 in.
(0,05/0,10 Ihm)
Remove the rings from the pistons. 0.00054/0.00175 in.
0.096!0.097 In, 12,44/2.46 mml
(0,01/0,04 m�m�)---�
Remove the piston pin. 0.0022/0.004 in. (0.05/0,10 mm)

0.09310.938 In, (2,3612.38 mm)
.24976/1.24996 inJ=J
NOTE: If the piston pin does not come out easily, do not drive (31. 74/31. 75 mm) L.:::1_ 0.096/0.097 in. (2.44/2,38 mm)
it out. Warm the piston in oil to a temperature of 120° F. 0.0022/0.004 in. g:gi�f;g_��!'� /�:�:'.�:;i ;;:;;:/
0.1895/0.1905 In. 14.81/4,84 mm!
(50° C.) and push the pin out. (0,05/0,10 mm) 1.2495/1.250 in.
(31, 74/31.75 mm)'��,-� 0.1868/1.1875 In. 14.74/4,76 mm)
0.1865/0.1875 in. 0.002/0.0036 in. (0,05/0,10 mm)
Inspection (4,74/4,76 mm)
0.1895/0.1905 in
(4,81/4,84 mm)
Clean all the parts in clean solvent. Pl-2393
• Piston Diameter Measured at 90 ° of Piston Pin Bore
Check the clearance of the new rings in the piston grooves�-
Check the ring gap in the cylinder bore [ID.
��-=--�
Maximum Ring Gap
0.060' (1,5 mm) B-3334
Make sure the specifications are correct lg.

*
0.011/0.016 in.++-----<
(0,28/0.41 mm
Pl-2394
Check the piston and pin bushing [Q].
Replace the bushings with a hydraulic press. Remove all metal 1.3785/1.280 in.
burrs from the piston bore before installing the new bushings. (38,01/35,05 mm) 0.00054/+0.00175 in.
(0,01/+0,04 mm)
0.0025/0.005 in.
LDJ
(0,0610,13 mm) 0.00074/0.0059 in.
Use the correct size reamer to fit the new bushing to the piston 1.375/1.376 in.
(0,017/0,149 mm}
T
pin. (34,92/34,95 mm)
. � 1.2495/1.250 in.
I I I
� (31,74/31,75 mm)
w
Worldwide Parts Source LLC •1.24976/1.24996 in.
Phone: 269 673 2313 (31,74/31,75 mml
. 1.2505/1.2515 in.
email: PartsAndGaskets@gmail.com 1.047/1.055 in.
(31' 76/31'78 mm)
(26,59/26,80 mm)
Pl-2396

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 ° F. (50 ° C.). ±0.01 in. ±0.01 in.
(±0.254 mm) (±0,254 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.

Pl-2375
Install the piston rings using a expanding tool to prevent the

ring from breaking 00.
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 00.
Put oil on the bearings. Install the bearing cap lg.
Tighten the nuts on the connecting rod � .

bottom dead center. Repeat the procedure to install the other
pair of pistons.

Phone: 269 673 2313
60 ft.-lbs.
(82 Nm) B-3325

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.
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.
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�
Follow the same procedure for the other cylinder liners.
Hone the cylinder bore to standard dimensions � . *

3.972/3.976 in.
(100,0/10 1 mm) 0.0 14/0 .023
in.
,35/0,57 mm)
0.148/0.150
-�
inT
(3,76/3,8 1 mm)
u=3. 8 145/3.8 155 in.]
(96,89/96,91 '!'ml
l°';J 00 1/0.003 in.
�,03/0,08 mm)
0 .150/0 .152 in.

I 3.990/3.995 ,n. -i
13• 8 113• 86 mm)
(10 1,35/10 1,47 mm) 1 1
3.8 125/3.995 in.
Phone: 269 673 2313 196,84196,86 mm) 0.026/0.03 1in.
email: PartsAndGaskets@gmail.com (0,66/0,79 mm)
3.50 1/3.502 in.

(88,92/88,95 mm)
0.000/0 .004in.
(0,00/0,10 mml
Pl-2373

MAIN BEARINGS
Center
The crankshaft has five main bearings. The end play is controlled Front 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 I!] .
location.
Removal
Remove the oil pan. Remove the oil pump (See Page 78-49).

C>
Remove the main bearing cap and remove the bearing from the
cap half.
\
the bearing and rotating the crankshaft [ID.
__o______o
_______o_____ B-1865
On the center main bearing, remove the cap and thrust washers
from each side of the cap lg.
Remove the top half of the bearing and thrust washer by pushing
on one side of the bearing and rotating the crankshaft [Q] .

Phone: 269 673 2313
B-3289

MAIN BEARINGS (Cont'd)
0
Installation
Check the crankshaft journals before installing the main bearings

(See Page 7B-36). 0

0
Install the other bearing half in the main bearing cap. Lubricate
the bearing and install it on the engine block.
85 ft.-lbs.
Install the bolts and tighten to position the cap, then loosen
1115 Nm)
B-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 l!] .
Crankshaft End Play
The end play can be checked by either a feeler gauge [!]or a

dial indicator lg.
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.

Phone: 269 673 2313

CRANKSHAFT
Removal
Remove the oil pan. Remove the oil pump (See Page 78-49).
Remove the crankshaft pulley, timing case cover, timing gears

and timing case (See Page 78-39).
Remove the flywheel (See Page 78-22).
Remove the rear main seal (See Page 78-38).
Remove the connecting rod caps (See Page 78-31).
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 Phone: 269 673 2313
dimensions � . email: PartsAndGaskets@gmail.com
*
1 .39 1/ 1.4 21 in. 1 .39 1/1.4 12 in.
(35.4/36.1 mm) 135.4/36,1 mm)
1.4265/1.4385 in.
(36.49/36,54 mm) 0.003/0.0 1 5 in.
(0,08/0,38 mm)
Ii
i
__;;
(2,
STD
:::�:::
m) e· •
0.0896/0.0915 in.. �-------
�----- 0.050/0.080 in.
...__�-- (1,27/2.03 mm)
0.0966/0.0985 in.
1 2.45/2,50 mm)
2.211/2.212 in.
156,16/56,18 mm) 1.2495/1.251 in.
mm)
0.0025/0.0045 in. 1 /8/ 9/64 in. 0.0822 in. 0_5 in. 131,74/31,77
10,06/0,11 mm) 13.2/3,57 mm) (2,09 mm) 112,7 mm) 3.985/3.9995 in.
in. 1 10 1,56/101,59 mm)
2 .2485/2.2.49
0.0822 in
12 .09 mm) 57,10/57.12 m!II)
�
L
2.7515/2.753 in.
169,89/69,93 mm) I
1 .122/1.130 in.
(28,5/28.7 mm) ,l,!lc=l.-��1
9/64 I 5/32in.
13,57/3,97 mm) 9/64 I 5/32 in.
1 .372/ 1 .374
in. (3.57/3,7 mm)
2.7845/2.749 in. (34,86/34,9 mm)
(69,8 1/69,82 mm)
Pl-2370R

* Revised Feb. 94
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 SB-7 for the correct specifications).
Installation
clean and open.
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 78-34).
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 78-35).
Install the rear oil seal (See Page 78-38).

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 7B-39).
Install the flywheel (See Page 78-22).

Phone: 269 673 2313

REAR MAIN OIL SEAL
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.If it is

found to be grooved, the seal must be pressed further into the
housing I!]. 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.
B-5810

Phone: 269 673 2313

TIMING CASE COVER
Remove the alternator and belt.
Remove the crankshaft pulley bolt � .
Installation: Tighten the bolt to 180 ft.-lbs. (245 Nm) torque I!].
B-3325
Remove the pulley from the crankshaft lg.
Remove the bolts and nuts from the cover.
Remove the timing case cover from the engine �.
Clean the timing case cover and timing case back plate.
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
pulley to center the front seat on the pulley hub.
Tighten the bolts and nuts. Remove the pulley to tighten the
bolts behind the pulley.

Phone: 269 673 2313 B-5811
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 �.
I
Make sure it is seated to the correct specifications [ID.
; •.
so,o.,oo
?/35/7 , 62 mm}
B-3194

Phone: 269 673 2313
(2 00 Series) 843 Loader

IDLER GEAR AND HUB
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 IA].
B-3205
Remove the idler gear [ru.
B-3202
Remove the idler gear hub lg.
The idler gear hub has an interference fit. Use a soft hammer
to remove it.
B-3238
Check the idler gear and hub as the specifications shown �-

Phone: 269 673 2313 0.0014/0.0034 in.
1p�-,
1/
t.
A-
0.006/0.012 in.
(0,15/0,30 mm)
Pl-2593

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 IA] .
Install the retainer plate.
Install the nuts and tighten to the correct torque [[].
B-3346
Check the end play for the idler gear�- The correct end play
is 0.008 - 0.012" (0,20 - 0,030 mm).
Check the clearance at the teeth of the gears �.
B-3196
The correct specification is shown in figure �. 0.04 in. -------�
��

Phone: 269 673 2313
B-3188

CAMSHAFT GEAR
Removal
The tool listed will be needed to the following procedure:

C
MEL-1054 - Puller
Remove the idler gear (See Page 7B-41).
Remove the bolt and washer from the gear.
Install the puller to remove the camshaft gear I!]. B-3200

,0,_�
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.-lbs. (54 - 68 Nm) torque.
Install the idler gear (See Page 7B-41).
Install the timing case cover (See Page 7B-39).

Phone: 269 673 2313

MEL-1200 - Puller
Remove the timing case cover (See Page 78-39).
Remove the idler gear (See Page 78-41).
Remove the bolt from the gear I!] .
Installation: Tighten the bolt to 50 ft.-lbs. (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.

Phone: 269 673 2313

TIMING CASE
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 IA].
Installation: Check that the bottom of the timing case is even C-2475R
with the face of the oil pan attaching surface [ru.

Phone: 269 673 2313

Removal
Remove the idler gear (See Page 7B-41 ).
Remove the camshaft gear (See Page 7B-43).
Remove the rocker arm assembly and push rods.
Turn the engine over and remove the oil pan and oil pump (See
Page 7B-49).
Remove the thrust plate at the camshaft �.
Remove the camshaft from the engine [ID.
Remove the tappets from the engine block lg.

Phone: 269 673 2313

CAMSHAFT AND TAPPETS (Cont'd)
� L_
�
%
§§
�
§§
�
�
�
�
IA I
\Ir
2.043112.0448 in.
(51,91/51,94mm)
2.0339/2.035 in. 0.0012/0.0071 in.
(51,66/51,69mm) (0,03/0,18 mm)
D
2.045/2.0252 in.
(51,41/51,44mm)
2.0142/2.0154 in.
(51,15/51,19mml
Pl-2397
Inspection
Check the camshaft and the bearings as the specifications

shown I!].
Use the correct tools for removal and installation of the

camshaft bearings.
Installation
Lubricate the camshaft. Carefully install the camshaft to prevent

damage to the bearings.
After rocker arms are installed, make sure to set the valve
clearance (See Page 78-2).

Phone: 269 673 2313

-7R-47- Service Manual
LUBRICATION SYSTEM
Description
SPLASH AND OIL MIST TO VALVE
ANO GUIDE ASSEMBLIES
The figure shows the engine oil lubrication system I!].
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.
PAEik\JAE
GAUG
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 Pl-2369R
by-pa'ss valve which prevents the engine from going without
lubrication if the filter element becomes plugged.

Phone: 269 673 2313

OIL PUMP
Remove the oil pan.
Remove the bolts which fasten the oil tube to the engine block
IA].
��
B5B12
Loosen the locknut at the bolt which holds the oil pump in the
block �-
Remove the bolt and remove the oil pump.
�I B-5814
Remove the bolts (Item 1) and remove the tube (Item 2) �.
Remove the bolts (Item 3) and remove the tube (Item 4) with
the screen �.
B-4105
Remove the relief valve plunger and spring [Q].

Phone: 269 673 2313
B-5815

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 [!].
Check the clearance between the outer rotor and the housing
[!l.
B-4109 B-4110
The correct specifications are shown in figure 1£].
nif
Jr
�� 1
-, I
.
F'F� 5Jr �
.J..
,,}l� bl
(0.012 in.
0,30
1-_...,
i '�-
1.6 in.
0.012 in.
(0,30 mm) (40 mm) Pl-2592
Check the end play � .
If any of the clearances are over specifications, the oil pump

must be replaced as an assembly.

Phone: 269 673 2313

OIL FILTER ADAPTER HOUSING
Use a filter wrench and remove the oil filter (Item 1) l!l.
Remove the hoses (Item 2) from the adapter housing l!l.
B-5776
Remove the bolt and the adapter housing 00.

Installation: Clean the surface of the adapter housing and install
a new 0-ring before installation.
B-5816

Phone: 269 673 2313

"'1D_r:;:1_ S<>rvir.<> Manual
WATER PUMP
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 IA] .
Installation: Clean the block surface. Put gasket cement on the

engine block and install a new gasket.
Disassembly
Remove the snap ring (Item 1) [ID.
Press the complete assembly out of the impeller end of the

housing.
Remove the snap ring (Item 2) [ID.
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 [ID.

Phone: 269 673 2313

-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
Press the two bearings and spacer (between the bearings) on

the shaft. Pl-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) [ID.
Put a support under the impeller end of the shaft. Press the hub
on the shaft and install the snap ring (Item 1) [ID.
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) [ID.
B-3206
Press the impeller on the shaft. Check the clearance to make

sure there is 0.015 - 0.030" (0,38 - 0, 76 mm l between the
impeller and the housing lg.

Phone: 269 673 2313
B-3285

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 I!].
Testing the T hermostat
Put the thermostat in water and heat the water. The thermostat
valve must start to open at 179 - 183 ° F. (81 - 85 ° C.) and must
be fully open to 0.315" (8 mm) at 185 - 200 ° F. (88 - 94 ° 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.

Phone: 269 673 2313

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
CYLINDER LINERS
Checking .................................... 7C-41
Installation .................................. 7C-41
Removal .................................... 7C-41
ENGINE
ENGINE COMPRESSION
Checking .................................... 7C-3
Flywheel Ring Gear............................ 7C-26
ENGINE MOUNTS
ENGINE MUFFLER
ENGINE OIL AND FILTER
Procedure ................................... 7C-9
FUEL FILTER
Fuel Filter Element ............................. 7C-4
Water Trap .................................. 7C-4
Checking .................................... 7C-12
Removal and Installation........................ 7C-11 ENGINE SERVICE
FUEL INJECTION PUMP (ISUZU)
FUEL INJECTION PUMP IDLER GEAR
Bearing Installation ............................ 7C-53
GLOW PLUGS
IDLER GEAR & HUB
Checking .................................... 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
OIL PAN
Installation .................................. 7C-59
Removal .................................... 7C-59
OIL PUMP
Checking .................................... 7C-60
Gear Replacement ............................. 7C-61
Oil Pump Relief Valve .......................... 7C-62
Rotor Replacement ............................ 7C-62
PISTON & CONNECTING ROD
Assembly ................................... 7C-39
Disassembly ................................. 7C-35
Inspection ................................... 7C-36
Installation .................................. 7C-40
Removal .................................... 7C-35
RADIATOR
Procedure ................................... 7C-5
ROCKER ARMS
Disassembly and Assembly ...................... 7C-34
THERMOSTAT
Inspection ................................... 7C-66
TIMING CASE
TIMING CASE COVER
TIMING CASE COVER SEAL
TROUBLESHOOTING
Chart ...................................... 7C-1
VALVES
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
WATER JACKET TUBE
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 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. 2, 5, 6, 7, 8, 9, 11, 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, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 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
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 39, 52
Engine knocking. 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
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 51
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53

1. Battery capacity low. 28. Worn valves and seats.
2. Bad electrical connections. 29. Broken, worn or sticking piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the oil pan.
6. Fuel tank empty. 33. Switch is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Pressure relief valve is sticking open.
9. Plugged fuel filter. 36. Pressure relief valve is sticking closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
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.
17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in the water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem oil deflectors.
24. Incorrect tappet adjustment. 51. Coolant level too low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect high pressure fuel pipes. 53. Broken valve spring.
27. Worn cylinder bores.
843 Loader
-7C-1- Service Manual
VALVE CLEARANCE
Adjustment

cold.
I �-
B-4123
the valve stem. Turn the adjustment bolt until the clearance
is correct [ID .
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

TDC on compression stroke
0 0 0 0
Piston in No. 4 cylinder is at 0 0 0 0

TDC on compression stroke
843 Loader
* Revised Feb. 87 -7C-2- Service Manual
ENGINE COMPRESSION
Checking
I MEL-10630-1
- Engine Compression Kit
MEL-1268 - Compression Gauge Test Adapter
Remove the glow plugs (See Page 7C-14 for the correct
procedure) [!I .
Install the correct compression adapter into the cylinder head.
Connect the compression gauge [iJ.
The compression must be between 300 and 500 PSI (2069 -

3448 kPa) with no more than 50 PSI (345 kPa) difference
between cylinders.
The engine has an open crankcase ventilation system.
T he ventilation hose comes from the valve cover tube (Item 1)

and passes down the side of the engine block [iJ.
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 [Al , until all the water is removed from the filter. ( /
B-11080
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.
I Loosen 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 [Al .
Operate the priming bulb until fuel flows from the plug with no
air bubbles showing 00 .
I Close the plug at the top of the filter housing.
Loosen the plug at the fuel injection pump (Item 1) [g.
Operate the priming bulb until fuel flows from the plug with no
air bubbles showing 00 .
Tighten the plug at the fuel injection pump.
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
IMPORTANT
personnel, adjustment or maintenance must not be
done.
1-2028-0284
Disconnect the throttle linkage.
Disconnect the shut-off wire � .
Rotate the engine until No. 1 piston is at TDC. Both valves at

No. 1 cylinder are not moving and have clearance 00 .
* TDc:5
The 4th mark on the front pulley is at TDC [g .
Remove the oil fill pipe at the timing case cover.

INSET
B 8944
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
IMPORTANT
them on the injection pump or the injectors.
1-2029-0284
Disconnect the high pressure fuel lines at the injection pump

�-
Disconnect the fuel lines at the injectors [ID.
I Installation: Tighten the fittings on the high pressure fuel lines

to 14-29 ft.-lbs. (19-39 Nm) torque.
¾-,
Remove the high pressure fuel lines from the engine �.
� /v----==----
.1�-=--= -
Remove the bolts at the rear of the injection pump and remove
the bracket � .
843 Loader
Revised July 88 -7C-7- Service Manual
Remove the bolts at the front of the timing case cover [Kl.
Installation: Tighten bolts & nuts to 10-1 7 ft.-lbs. ( 14-23 Nm)

torque.
Remove the fuel injection pump [!].
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
Procedure
Rotate the engine until No. 1 piston is at TDC. Both valves at

No. 1 cylinder are not moving and have clearance [!].
/
�
_/ ,,
B-8935
The mark on the front pulley is at TDC [!].
Remove the plug at the rear of the injection pump lg.
Install timing tool and dial indicator [Q].
/ B-8977
843 Loader
ENGINE TIMING TO INJECTION PUMP (Cont'd)
Rotate the engine counterclockwise so the front pulley mark

goes 30 ° to 40 ° before TDC [!].
30 ° - 40 °
Set the dial indicator to zero [ID.
I Rotate the engine back to 17 ° BTDC mark on the front pulley

[!l.
The dial indicator must read approximately 0.020" (0,50 mm)

[ID.
If not, loosen the bolts at the bracket � and 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 ° BTDC.
Repeat the procedure until the timing is correct.
* Revised July 88 843 Loader

A WARNING
W-2074-1285
Some problems caused by faulty injector nozzles:
Rough engine operation and idle.
The engine will not have full power.
The engine exhaust smoke is black, white or blue.
IMPORTANT
� /!v�-�
�

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.-lbs. (19-39 Nm) torque.
Disconnect the fuel lines at the fuel injectors [!I.
Remove the high pressure fuel lines from the engine lg.
Remove the low pressure hoses from the fuel injector nozzles
[Q].
843 Loader
Remove the nut at the fuel injector holddown clamp I!].
Installation: Tighten the nuts to 23-32 ft.-lbs. (31-43 Nm)

torque.
Use a screwdriver and pry the injector from the cylinder head
[ID.
Remove the injector nozzle from the head lg.
Checking
IMPORTANT
DO NOT disassemble or test the injector nozzle unless
you have the correct service and testing equipment.
1-2027-0284
OEM-1064 - Injection Nozzle Tester

OEM-1065 - Accessory Set
Connect the nozzle to the test pump, in a down position [Q].
Injection Pressure: 2630 PSI (18134 kPa)
843 Loader
If the pressure is not correct, do the following:
�. ,
Disassemble the injector nozzle and clean. I\
I\
Replace the shim (Item 6) I!].
0-+-I ' ,
��
\
Check the pressure again.
\
\
A
I
\
WARNING \
\
\
\
\
Do not disassemble or test fuel injector nozzles unless
\,
you have correct service and testing tools. Keep away \ I
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
I
3. Spacer
Assembly: Tighten the retaining nut (Item 1) to 29-32 ft.-lbs. 4. Push Rod
(39-43 Nm) torque I!]. 5. Spring
6. Adjusting Shim
7. Nozzle Holder
B-8959
Checking nozzles spray pattern Ii]. _!J CORRECT 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

nozzle. Clean or replace any injector nozzle that does not
operate correctly.
B-8895
843 Loader
GLOW PLUGS
Disconnect the negative (-) cable at the battery.
Remove the electrical bar holddown nuts at the glow plugs I!].
Remove the electrical connector bar �.
Loosen the glow plug [g.
Remove the glow plug from the cylinder head [Q].
843 Loader
ENGINE OIL AND FILTER
See the Service Schedule (Page 1 -1) for the correct service
interval.
Check the oil level every day IA].
Add the correct oil as needed.
Al B-11092
Use recommended engine oil [!J. RECOMMENDED SAE VISCOSITY NUMBER

(LUBRICATION OILS FOR ENGINE CRANKCASE)
c• -34 -29 -23 .,a -13 -7 ., +4 +10 +1s +21 +21 +32 +38
SAE 10W·3 l4u
. AE 5W-30
SAE15W-40
r
SAE30
.SAE 20W/20
... r
SAE10W
F0 -30 -20 ·10 0 +10 +20 +30 +40 +50+60 +70 +80 +90 +100
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
(GASOLINE: USE API CLASSIFICATION SE or SF)
(DIESEL: USE API CLASSIFICATION CC or CD)
Pl-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 lg .
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-2108-0986
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
ENGINE OIL AND FILTER (Cont'd)
*
Remove the cap (Item 1) at the end of the hose I!].
Drain the oil into a container.
Install the cap on the end of the hose and tighten I!] .
B-11778
Remove the filler cap 00.
Fill to capacity lg (See Specification, Section 8C-2).
Start the engine and let it run for about 5 minutes. Check for
leaks at the filter.
Stop the engine. Check the oil level.
Add oil until the level is at the "FULL" mark on the dipstick.
Install the filter cap 00.
NOTE: Do Not overfill the crankcase.
843 Loader
* Revised July 88 -7C-16- Service Manual
ENGINE
Remove the battery (See Page 6-2 for the correct procedure).
Lift the rear grill and remove the radiator cap I!].
B-8334
Open the valve at the side of the engine block and drain the
coolant�-
*
Disconnect the throttle linkage at the fuel injection pump.
Remove the four bolts at the exhaust manifold �.
Remove the exhaust pipe � -
843 Loader
ENGINE (Cont'd)
Disconnect the radiator hose �.
Disconnect the radiator hose �.
Remove the holddown band for the coolant recovery tank [g.
C
B-8714
Remove the coolant recovery tank [QJ.
843 Loader
ENGINE (Cont'd)
Disconnect the wire harness connectors IA].
Disconnect the wires from the solenoid IA].
Disconnect the inlet and return fuel hoses [!].
Disconnect the air cleaner hose at the intake manifold 1£].
Disconnect the wire at the hydrostatic filter sending switch �-
843 Loader
ENGINE (Cont'd)
Remove the four engine mounting bolts and nuts I!].
Remove the panels over the oil cooler [!].
B-11083
The lift hook at the rear of the engine is in a down position jg.
Remove the lift hook and put it in the up position for removal
of the engine [QJ.
843 Loader
ENGINE (Cont'd)
Hook the chain hoist into the front lift hook I!].
Lift the engine just enough to make clearance at the rear edge
of the frame.
Slide the engine out of the frame until the chain hoist can be
hooked into the rear lift hooks [!I.
Remove the engine from the loader.
Installation: Make sure to make alignment of the Li-joint to the

spline on the hydrostatic pump shaft when installing the engine
in the Feller Buncher.
843 Loader
RADIATOR
Remove the rear grill I!].
_ B-8336
Remove the radiator cap !ID.
Open the valve at the side of the engine block and drain the
coolant lg.
Disconnect both radiator hoses at the radiator.
l
Remove the radiator holddown bracket at the right side of the
frame�.
I
B-8763
843 Loader
RADIATOR (Cont'd)
Remove the holddown bracket at the left side of the frame �

\�
Remove the bolts under the radiator.
B-8757
Lift the radiator up and remove it from the loader [ID.
0
-�B-8672
843 Loader
OIL COOLER
Remova I and Installation
Remove the P anels above the eng1·ne on the blower housing.
.
Remove the radiator (See Page 7C -22).
.
Disconnect the tubelme at the right
. SI·de of the oil cooler !Al
�.
.
Disconnect the tubeline at the left side of the oil cooler [ID.
.
Remove the bolts at the right side oil cooler brae ket lg·
.
Remove the bolts at the left side o1·1 cooler bracket [Q].
Remove the o1·1 cooler from the mou nting frame.
-7C-24-
ENGINE MUFFLER
/�1
Removal and Installation 0----=
Remove the bolts from the plate which covers the muffler I!].
B-8740
Remove the four bolts inside the engine compartment [ID.
�- B-8693
Remove the shield from the muffler lg.
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].
------�:=:
-� ::J -
B-8720
843 Loader
ENGINE FL VWHEEL & U-JOINT
Remove the four bolts at the u-joint mount flange � -

torque.
Remove the u-joint from the flywheel [ID.

torque.
Remove the washer [Q].
Flywheel Ring Gear
The ring gear on the flywheel is an interference fit. Heat the

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 ° C).
Fit the ring gear over the flywheel. Make sure the gear is on
its seat correctly.
843 Loader
ENGINE BLOWER HOUSING - ' '--::::::---
Use a punch and hammer and remove the rivet from the blower
housing �.
Remove the bolts along the top edge of the blower housing.
Remove the blower housing from the loader [ID.
After the blower housing is installed, install the rivet in the

bottom of the blower housing and hit it with a hammer � -
843 Loader
ENGINE MOUNTS
Lift the engine with a chain hoist.
Remove the flywheel (See Page 7C-26).
Remove the bolts around the crankshaft flange [!].

torque.
B-8715
Remove the bolts around the engine block 00.

torque.
\
B-8716
Remove the bolts at the crankshaft pulley end of the engine 1£].

torque.
Lift the engine from the mounts.
843 Loader
CYLINDER HEAD
3
Removal and Installation �
I
The tools listed will be needed to do the following procedure: 1� I
MEL-1267 - Cylinder Head Bolt Wrench
Clean all the debris from the cylinder head and engine.
Remove the coolant from the engine and radiator. Remove the
radiator hoses.
Remove the fuel injectors and fuel tubelines (See Page 7C- 11
for the correct procedure). B-8186
Remove the valve cover nuts in the correct sequence �.
Installation: Tighten the nuts to 6-13 ft.-lbs. (8-17 Nm) torque

in the correct sequence � .
Remove the rocker arm assembly bolts in the correct sequence

[ID.
Installation: Tighten the bolts in the correct sequence to 36-43
ft.-lbs. (49-58 Nm) torque.
B-8188
Remove the cylinder head bolts in the correct sequence �.
Installation: Lubricate the bolts and tighten them in two steps

' as listed, in the correct numerical sequence �.
Step 1 Step 2 B-8189

New Bolts 29 ft.-lbs. (39 Nm) 59-67 ft.-lbs.
(80-91 Nm)
Used Bolts 62 ft.-lbs. (83 Nm) 72-80 ft.-lbs.
(97-108 Nm)

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).
B-8189
843 Loader
Check the surface of the head with the straight edge �.
�B-8198
Check the head at six different directions �.
The standard distrotion is 0.002" (0,05 mm) and the maximum

limit is 0.008" (0,20 mm).
When the head distrotion exceeds the maximum limit, regrind

the head with a maximum limit of 0.012" (0,30 mm).
B-8197
Exhaust Manifold
If the exhaust manifold has been removed, use the correct 4 8 5 l

torque sequence and tighten the bolts to 10-17 ft.-lbs. (14-23
Nm) torque �.
3 7 6 2
B-8187
843 Loader
VALVES

1. Spring Seat 15
®>-1
I
The tools listed will be needed to do the following procedure: 2. Springs
3. Valve I
�>
MEL-1266 - Valve Stem Seal Installer 4. Oil Seal g
5. Spring Seat
Mark the valves and parts so they are returned to their original I 2
position when assembling.
I
Remove the valve spring locks I!], using a spring compressor
�-4
[!]. I
5-� I
Remove the valve springs, spring seats, oil seal and valve I!].
Before reassembly, check the valves, valve seats and guides.
Installation: Make sure the head is clean.
Put each valve in the correct location.

I
Install the valve springs, spring seats and oil seals I!]. I
NOTE: Install the valve springs with their closed pitched
1-3
(painted side) end toward the cylinder head.
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.
8-8193
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 ° lg.
The valve head thickness is as listed lg:
Standard - 0.071" (1,8 mm)

Limit - 0.059" (1,5 mm)
8-8202
843 Loader
VALVES (Cont'd)
the valves and seat. The correct specifications are as follows Contact
I!]: Width
Intake - Standard 0.029" (0,73 mm)

Limit 0.05" (1,28 mm)
Exhaust - Standard 0.028" (0,70 mm)
Limit 0.047" (1,20 mm)
Check the valve seat contact width I!]:
Intake - Standard 0.067" (1,70 mm)

Limit 0.087" (2,20 mm) B-8199
Exhaust - Standard 0.079" (2,0 ml
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 [!]. 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"

(10mm)
-- _l
MEL-1259 - Valve Guide Remover
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 mm) B-8205
Exhaust - Standard 0.0025-0.0038" (0,064-0,96 mm)

Limit 0.010" (0,25 mm)
i i --
�
t t
NOTE:
t
Make sure to check the valve stem for wear before
replacing the valve guide [Q] .
Intake 0.3128-0.3134" Limit 0.310"

Standard [7,946-7,961 mm) (7, 88mm)
Exhaust 0.31 19-0.3124"

Standard (7,921-7,936mm)
B-8204
843 Loader
VALVES {Cont'd)
Remove the guide �.
Install the new guide [ID.
The height of the valve guide top edge to the cylinder is 0.51"
(13 mm).
Valve Springs
Check the free length and inclination lg.

C r Inclination
Std. Limit
Inner 1.783" 1.748"

(45,3 mm) (44.4 mm)
Free Length
Outer 1.957" 1.898"
(49,7 mm) (48,2 mm)
Inner - - - 0.118" Square

(3,0 mm)
B-8208
Inclination
Outer -- - 0.126"
(3,2 mm)
Check the valve spring tension [Q].
Set Length Std. Limit
Inner 1.46" 13 lbs. 11 lbs.

(37 mm) (5,9 kg) (5,02 kg)
Outer 1.54" 46 'lbs. 40 lbs.

(39,0 mm) (2q,9 kg) (18,1 kg)
B-8209
843 Loader
ROCKER ARMS
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. B-8191
Inspect all the parts for wear or damage.
Standard - 0.7478-0.7486" (18,98-19 mm)

Limit - 0.7427" (18,85 mm)
B-8214
Check the rocker arm lg.
Rocker arm diameter.
Standard - 0.7489-0.7497" (19,01-19,03 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)
B-8215
Push Rods
Check the push rods for run-out [Q].
Limit - 0.012" (0,3 mm)
843 Loader
PISTON AND CONNECTING ROD
Removal
0� G0 �
° 0 ()()Co{
Remove the cylinder head (See Page 7C-29).
Remove the oil pan (See Page 7C-59).

0
0 0 ()0
O�OC2\0GO�O
° 0 ()0
bore with a ridge reamer. oUoLJoLJoUo
o0 CD CD CD o
Make sure the pistons have identification marks [!]. o OOo OOo OOo Oo
Rotate the crankshaft until a pair of connecting rods are at the
bottom dead center. Make sure the connecting rod caps and B-3248
the rods have identification marks.
Remove the nuts and remove the bearing caps � -

A-2344
Using a hammer handle, push the piston and rod out of the block
�-
B-8909
Disassembly
Remove the rings from the pistons [Q].
B-8194
843 Loader
PISTON AND CONNECTING ROD (Cont'd)
Remove the piston pin snap ring � -
Drive out the piston pin using a brass rod � -
--- B-8196
Inspection
Clean all the parts in clean solvent.
Check the clearance of the new rings in the piston grooves �-
Standard Limit
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)
Check the piston diameter �.
Pistons are available in two sizes.
Piston Grade A 3.6608-3.6616"

(92,985-93,004 mm)
Piston Grade C 3.6616-3.6624"
(93,005-93,024 mm) 2.9"
(74mm)
B-8227
843 Loader
Check the ring gap in the cylinder bore � .
Standard Limit
Compression 0.008-.016" 0.059"
(0,2-0,4 mm) (1,5 mm)
Oil 0.004-0.012" 0.059"
(0,1-0,3 mm) (1,5 mm)
B-8229
Check the piston pin diameter �.
Standard -1.220" (31 mm)

Limit - 1.219" (30,97 mm)
B-8230
Check the clearance between piston pin and piston pin bore [g
Clearance - 0.00008-0.0006"
(0,002-0,015 mm)
Q
B-8231
Check the connecting rod alignment 00] .
Standard - 0.002" (0,5 mm) or less

Limit - 0.0079" (0,2 mm)
B-8232
843 Loader
Revised April 96 -7C-37- Service Manual
Check the connecting rod small end bushing �.
Standard - 1.2208-1.2211" (31,008-31,015 mm)
B-8233
Check the clearance between the piston pin and connecting

rod [ID.
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 �.
B-8200
After installation of a new bushing, finish the bushing bore to

the correct specifications [QJ .
843 Loader
Assembly
Heat the piston to about 140 ° F {60 ° C) � -
I Assemble the piston and connecting rod �.
C-2936
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 lg.
B-8252
I install the piston pin. Install the snap rings �. *
843 Loader
I PISTON AND CONNECTING ROD (Cont'd)
Install the rings on the piston l!l.

The face with the mark "NPR" or "TOP" must be turned up
* Marked Side Up
1st Comp.
for the 1st and 2nd compression rings.
n
� B-8253
Installation *
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 00.
I Put oil on the bearings. Install the bearing cap 1£]. *
Tighten the nuts to 58-65 ft.-lbs. (78-88 Nm) torque �. *

bottom dead center. Repeat the procedure and install the other
pair of pistons.
58 - 65 ft.-lbs.
(78 - 88 Nm) B-3325
843 Loader
CYLINDER LINERS
Checking
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 [Al.
Measuring point is done approximately 0.75" (20 mm) below

the top of the cylinder bore. B-8223
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 [ID .
There is only one size liner available.
Installation B-8224
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 1103 lbs. (500 kg) using a hydraulic press.
NOTE: Do Not use a hammer to install the cylinder liners.
Then, apply a final load of 5513 lbs. (2500 kg). Push the liner
in until O - 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
0 0 0 0
The crankshaft has five 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 I!]. FRONT
location.
Removal
Remove the oil pan (See Page 7C- 59).
Remove the oil pump (See Page 7C-60).
Remove th main bearing cap and remove the bearing from the
cap half.

the bearing half and rotating the crankshaft � -
B-1865
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.
843 Loader
MAIN BEARING (Cont'd)
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 !ID.
B-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 �.

Install the other bearing half in the bearing cap. Lubricate the r..---No Oil Groove
bearing and install the cap on the engine block. and Hole
(Lower Side) B-8254
Lubricate the bolts, install them finger tight only.
Install the center main bearing and thrust washers �.
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
MAIN BEARING (Cont'd)
Tighten the crankshaft bearing cap bolts in the correct sequence

[!].
Torque - 116-130 ft.-lbs. (157-176 Nm).
B-8257
Crankshaft End Play
The end play can be checked by either a feeler gauge �or dial
indicator 1£].
Std. Limit
End Play 0.004" (0,1 mm) 0.012" (0,3 mm)
The fitting of oversize thrust washer can be used to correct the

end play if it is over the specifications.
B-3291
843 Loader
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-59). No testing solution near
\ the oil hole.
Remove the oil pump (See Page 7C-60). ........ /\
'
The sliding surface of -.,_,_..""'-- /
/ ;
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-35).
B-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

5/10% solution at the test location I!].
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.
lmmediatley 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.
Checking
Check the crankshaft connecting rod journals [ID.
Standard - 2.0833-2.0839" (52,915-52,930 mm)

Limit - 2.0829" (52,906 mm)
B-8244
843 Loader
CRANKSHAFT (Cont'd)
Check the crankshaft main bearing journals [!].
Standard - 2.7526-2.7532" (69,917-69,932 mm)

Limit - 2.7524" 169,910)
B-8246
Check the clearance between connecting rod bearing and

crankshaft journal �.
Install the bearing and cap and tighten nuts to 58-65 ft.-lbs.
(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)
B-8245
Check the clearance between main bearings and crankshaft

journals©-
Install the main bearing and caps and tighten the bolts to
116-130 ft.-lbs. (157-176 Nm) 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" 10,11 mm)
Check the crankshaft run-out �.
Standard - 0.0019 (0,05 mm) or less

Limit - 0.003" 10,08 mm)
B-8248
843 Loader
CRANKSHAFT (Cont'd)
Crankshaft Gear
MEL-1263 - Crankshaft Gear Installer

MEL-1264 - Crankshaft Rear Oil Seal
Use a puller to remove the gear � -
Use the correct size driver tool to install the gear [ID.
Installation
clean and open.
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-44).
Install a new rear oil seal [g. Using the correct size driver tool.

rod caps (See Page 7C-35).
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-49).
Install the flywheel (See Page 7C-26).
843 Loader
TIMING CASE COVER SEAL
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 I!].
Installation: Tighten the bolt to 123-152 ft.-lbs. (167-206 Nm)

torque. B-8945
Install a standard puller and remove the crankshaft pulley I!].
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 �.
843 Loader
TIMING CASE COVER
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.-lbs. ( 167-206 Nm)

torque.
B-8945
Use a puller to remove the crankshaft pulley � -
Remove the bolts which fasten the noise dampening shield to

the timing case cover lg.
Remove the noise dampening shield �.
843 Loader
TIMING CASE COVER (Cont'd)
Remove the bolts from the timing case cover �.
oo.
Use a Allen wrench to remove the alien head bolt from the cover
Installation: Tighten the bolt to 11-17 ft.-lbs. (1 5-23 Nm)

torque.
Remove the timing case cover � -
B-8974
Installation: Put the 0-ring gasket in the groove and hold it in

position using Form-A-Gasket so it will not fall out when
installing the cover IQ] .
843 Loader
IDLER GEAR AND HUB
Remove the timing case cover (See Page 7C -49).
Remove the bolts at the tube for gear lubrication I!] .
Remove the tube [ID.
Remove the bolts at the idler gear lg.

torque.
Remove the idler gear and hub [Q] .
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
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).
843 Loader
FUEL INJECTION PUMP IDLER GEAR
Remove the timing case cover (See Page 7C-49).
Remove the idler gear (See Page 7C-51).
Remove the bolt at the fuel injection pump idler gear I!].

torque.
Remove the idler gear and bearing I!].
If the bearing needs replacement, remove the snap ring at the

bearing �-
Use a press to remove and install the new bearing.
B-8955
Bearing Installation
When installing the new bearing, make sure the projection and
height is correct � .
Projection
Projection - 0.016-0.024" (0,4-0,6 mm)
Height - 0.933-0.945" (23,7-24 mm)
Height
f
B-8896
843 Loader
CAMSHAFT GEAR
Remove the bolt at the camshaft gear � .

torque.
Install the puller and remove the gear �.
Remove the bolts at the retainer plate 1£].

torque.
Remove the retainer plate � .
Installation: Check the camshaft end play.
Standard - 0.002-0.0045" (0,05-0, 114 mm)

Limit - 0.0079 (0,2 mm)
843 Loader
TIMING CASE
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 bolts at the timing case �.

torque.
Remove the timing case �.
Installation: After the timing case cover is installed with the

new gasket, cut the excess gasket at the engine block � .
843 Loader
CAMSHAFT
Remove the rocker arm cover, rocker arm assembly and the
push rods (See Page 7C-29).
Remove the oil pan and oil pump (See Pages 7C-59 &
7C-60).
Remove the camshaft from the engine. B-8217
Checking
Check the camshaft journals IAJ. B

Standard - 1.9662-1.9675" (49,945-49,975 mm) 0
Limit - 1.9528" (49,60 mm)
Check the bearing inside diameter �.

�o
Standard - 1.9685-1.9697" (50,0-50,03 mm)
Clearance between camshaft journal and bearing.

B-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 �.
Standard - 1.654" (42,02 mm)

Limit - 1.640" (41,65 mm)
843 Loader
CAMSHAFT (Cont'd)
A -�
'�
Camshaft Bearings

-
MEL-1260 - Camshaft Bearing Remover/Installer
0 0 @J 0
Use the correct tool to remove the bearings IA]. 0
B-8219
When installing the new bearings, make sure to align the oil
hole in the bearing with the hole in the engine block (Item 1 l
[!].
Tappets
Remove the tappets from the engine block. Mark the cylinder
number on each tappet after removal �.
B-8190
Inspect the tappets for wear, damage or abnormal conditions

�-
Pitted Crack Normal Contact
Irregular Contact
B-8210
843 Loader
CAMSHAFT (Cont'd)
Check the diameter of the tappets � -
Standard - 0.51091-0.51142" (12,977-12,990 mm)

Limit - 0.50984" (12,950 mm)
B-8211
Clearance between tappet and engine block bore as listed [!I.
Standard - 0-0012" (0,03 mm)

Limit - 0-0039" (0,09 mm)
0 0 o__
,,_- __ _o__ o o c
® to�o") {e�o�l1(0�-
Jl.�---TI�TI,___��-- 1· B-8212
Installation
Lubricate the camshaft bearings and journals_ Install the

camshaft, carefully not to damage the bearings_
Install the camshaft gear (See Page 7C-54).
Check the camshaft end play using a feeler gauge lg.
Standard - 0.0002-0-0045" (0,05-0,114 mm)

Limit - 0_0079" (0,2 mm)
After the rocker arm assembly is installed, make sure to set

the valve clearance (See Page 7C-2). B-8216
843 Loader
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 ft.-lbs.

(19-26 Nm) torque.
Installation
C!ean the surface on the oil pan and engine block.
Put Three Bond (TB-12078) at the front and rear main bearing
caps (Item 1) I!], lg.
Put liquid gasket on the oil pan surface area of the engine block.
B-8911
I Install the oil pan. Install and tighten the bolts in the sequence
shown@.
B-12200
843 Loader
Revised December 87 -7C-59- Service Manual
OIL PUMP
Remove the bolts at the oil pump IA].

torque.
Remove the oil pump assembly from the engi� block �.
Checking
Disassemble the oil pump as illustrated �.

1. Oil Pipe
2. Strainer
3. Pump Cover
4. Vane
B-8420
843 Loader
OIL PUMP (Cont'd)
Check the clearance between vane and body I!].
Standard - 0.0008-0.0028" (0,02-0,07 mm)

Limit - 0.0059" (0,15 mm)
8-8421
Check the clearance between the rotor and vane �.
Standard - 0.0055" (0,14 mm) or less
Check the clearance between the vane and pump body �.
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 � -
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
�.
Installation: Install the gear and new pin. Peen the end of the
pin after installation.
8-8425
843 Loader
OIL PUMP (Cont'd)
Rotor Replacement
Remove the pin at the rotor using a punch and hammer IA].
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 IA] .
After the oil pump is assembled, put oil into the pump and turn
the shaft to prime the pump.
B-8426
B-8427
Oil Pump Relief Valve
Remove the relief valve from the oil filter housing J!].
Check the relief valve and clean. Replace as needed.
-//
843 Loader
WATER PUMP
Remove the alternator belt.
Remove the water pump pulley �.
Remove the water pump bolts 00.

Installation: Tighten the bolts to 11-18 ft.-lbs. ( 1 5-24 Nm)
torque.
Remove the water pump from the engine block �-
Disassembly
Remove the hub for the pulley using a press �.
B-8429
843 Loader
C:.o.l'ui,-..o. I\Jl-!3on11�I
WATER PUMP (Cont'd)
Disassemble the water pump � -
B-8428
Check the bearing for abnormal noise, binding or wear l!J.

Assembly
Apply a thin coat of liquid gasket cement to the outer surface

of the seal unit before assembly �.
B-8432
Press the bearing assembly into position by aligning the set

screw hole in the bearing with that in the pump body � -
B-8431
843 Loader
WATER PUMP (Cont'd)
After installation, check that the rear face of the impeller has
the correct height I!} .
Height - 0.98" (25 mm)

r
B-8433
Check the distance between the pulley hub and pump body �
Distance - 3.13 ± 0.01" (79,5 ± 0,3 mm).
B-8434
843 Loader
THERMOSTAT
Remove the bolts from the thermostat housing I!] .

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)
B-8435
If the thermostat housing assembly is removed, tighten the

bolts to 10-17 ft.-lbs. (14-23 Nm) torque (Item 1) 1£].
B-8419
843 Loader
WATER JACKET TUBE
A
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 timing case (See Page 7C-55).
Remove the water pump (See Page 7C-63).
Grip the ed�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 [ID.
843 Loader
TECHNICAL DATA
Section
Number
TECHNICAL DATA (Perkins Engine).................. 8A-1
TECHNICAL DATA (200 Series Perkins Engine)......... 8B-1
TECHNICAL DATA (Isuzu Engine)................... 8C-1
GENERAL SPECIFICATIONS....................... 8-1
TECHNICAL
DATA
SPECIFICATIONS
(Perkins)
SPECIFICATIONS
((200 Series Perkins)
SPECIFICATIONS
(Isuzu)
GENERAL
SPECIFICATIONS
843 Loader
Service Manual
GENERAL SPECIFICATIONS
Page
Number
DECIMAL & 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
GENERAL
SPECIFICATIONS
843 Loader
T
Seat Bar, F uel Tank & Panel Group
Ref. Torque
�-·---]:..,,::...G)-.
r- "Ill
1. 16-20 ft.-lbs. !
(21-27 Nm)
2. 40-45 ft.-lbs.
(54-61 Nm)
3. 9-11 ft.-lbs.
(12-15 Nm)
4. 25-28 ft.-lbs.
(34-37 Nm)
5.* 7-8 ft.-lbs.

(9-10 Nm)
e' t
,/�·/
fi)
I
(@
/ I
l ____ -, /
I
/ I
I I
I ,f.J I
I
l _____
____ -,
I
I
(ibll I
I
@
I I
I I
�i
I I
I I
I I
L____
I I ____ -,
I I
I
I
I I
I I
I I
I )
/
I /
I /
I /
/
I
I
I
I
I
I
I
--J
' 0-1596
0-1548
* Put Lock-Tite on the Treads 0-1696
843 Loader
TORQU E SPECIFICATIONS (Cont'd)
Steering Levers Linkage & Pedal Group

'
Ref. Torque
1. 25-28 ft.-lbs.
(34-38 Nm)
-----:-
11-13 ft.-lbs.
(15-18 Nm)
E-1525
* Put Lock-Tite on the Treads E-1617
843 Loader
-8-2- .
Service Manual
TORQUE SPECIFICAT IONS (Cont'd)
Brake, Axle & Chaincase Group
Ref. Torque
1. 65-70 ft.-lbs.
(88-95 Nm)
2.* 65-70 ft.-lbs.

(88-95 Nm)
3.* 475-525 ft.-lbs.

(645-710 Nm)
,,
!!
4. 16-20 ft.-lbs.
(21-27 Nm)
0
5. 220-234 ft.-lbs. ®--en-en- CD- CD- 0--
0
(300-330 Nm)
-@
-CD-1-1-®
r--
___ J
----e----
cp
----- --•- �
0-1553
* Put Lock-Tite on the Treads

C-2528
0-1524
843 Loader
TORQUE SPECIFICATIONS (Cont'd)
Operator Guard, L1"ft Arm & Main Frame

Group
Ref. Torque
1. 65_ 70 ft.-lbs.
(88-95 Nm)
2. 20_40 ft.-lbs.
(27-55 Nm)
Required to push the
handle into lock
position
3. 55_ 70 ft.-lbs.
(75-95 Nm)
4. 15_17 ft.-lbs.
(21-23 Nm)
5. 15_20 ft.-lbs.
(21-27 Nm)
6. 25_28 ft.-lbs.
(34-38 Nm)
7. 220-245 ft.-lbs.
(300-330 Nm)
8. 18_20 ft.-lbs.
(24-27 Nm)
9. 105-115 ft.-lbs.
(142-156 Nm)
��n·
vAV \ .
(D\
c•
\
' '
t:::::ii
' -- - _J
,! '
'
J.�ijb---J:
8 ,: ,.· ·
. .• +
: ) (7) ·,.·
<
___ :, __ ., . --c:r=n E-i322
... � E-1618
D-1522
843 Loader
Hydraulic/Hydrostatic Group
Ref. Torque
·q
1. 65-70 ft.-lbs.
(88-95 Nm)
QJ
rij___\�
2. 12-15 ft.-lbs.
(16-20 Nm)
�
3. 25-28 ft.-lbs. 5
(34-38 Nm)
4. 16-20 ft.-lbs.
(21-27 Nm)
5. 40-50 ft.-lbs.
(54-68 Nm)
6. 40-45 ft.-lbs.
(54-61 Nm)
7. 15-17 ft.-lbs.
(21-23 Nm)
E-1726
E-1806
E-1725
843 Loader
(Cont'd) Engine Group
Perkins 2.5 Liter Diesel
Ref. Torque
1. 125-140 ft.-lbs.
(169-190 Nm)
2. 25-28 ft.-lbs.
(34-38 Nm)
3. * 40-45 ft.-lbs.
(51-54 Nm)
4. 75-80 ft.-lbs.
(102-108 Nm)
5. 16-20 ft.-lbs.
(21-27 Nm)
-6,:�-------l
6. 65-70 ft.-lbs.
(88-95 Nm)
7. 15-17 ft.-lbs.
(21-23 Nm)
: ----------! 0
,•\ ---'=".)�
f '
------., I
'
' '
$
843 Loader
Revised June 87 -8-6- Service Manual
Eng ine Group Perkins 2.5 Liter Diesel
Ref. Torque
1. 15-17 ft.-lbs.
(21-23 Nm)
2. 25-28 ft.-lbs.
(34-38 Nm)
3. 16-20 ft.-lbs.
(21-27 Nm)
4. 75-80 ft.-lbs.
(102-108 Nm)
5. * 25-28 ft.-lbs.
(34-38 Nm)
6. * 23-25 ft.-lbs.
(31-34 Nm)

E-1339
843 Loader
Engine Group 2.5 Liter TK200 Series Perkins)
�I
/--------
.-
Ref. Torque I
/
I
/
I
1. 125-140 ft.-lbs.
I
/
I
(169-190 Nm) I
I
I
n{/ �
,, ''
;e:,,J/ I
/'
/ ,
2. 25-28 ft.-lbs. I
/ ,/ / CO--�-
I - •-,7
(34-38 Nm)
(
I ,
I (,,, , -= ,,,/
': ' ,,,,.." ,

I
I
:
I
-�
•
I
3. * 40-45 ft.-lbs. I
I '
(51-54 Nm) '
I
4. 75-80 ft.-lbs.
(102-108 Nm)
5. 16-20 ft.-lbs.
(21-27 Nm)
6. 65-70 ft.-lbs.
(88-95 Nm)
7. 15-17 ft.-lbs.
(21-23 Nm)

E-1626
843 Loader
Revised June 87 -8-8-
Service Manual
Engine Group 2.5 Liter TK 200 Series Perkins)
Ref. Torque
1. 15-17 ft.-lbs.
(21-23 Nm)
2. 25-28 ft.-lbs.
(34-38 Nm)
3. 16-20 ft.-lbs.
(21-27 Nm)
4. 75-80 ft.-lbs.
(102-108 Nm)
5. * 25-28 ft.-lbs.
(34-38 Nm)
6. * 23-25 ft.-lbs.
(31-34 Nm)
843 Loader
Engine Group (Isuzu)
Ref. Torque
1. 125-140 ft.-lbs.
(169-190Nml
2. 25-28 ft.-lbs.
(34-38Nm)
3. * 40-45 ft.-lbs.
(51-54 Nm)
4. 75-80 ft.-lbs.
(102-108Nm)
5. 16-20 ft.-lbs.
(21-27 Nm)
6. 65-70 ft.-lbs.
(88-95 Nm)
7. 1 5-17 ft.-lbs.
(21-23 Nm)
---
--�-;.� �
�
843 Loader
Engine Group (Isuzu)
Ref. Torque
1. 15-17 ft.-lbs.
(21-23 Nm)
2. 25-28 ft.-lbs.
(34-38 Nm)
3. 16-20 ft.-lbs.
(21-27 Nm)
4. 75-80 ft.-lbs.
(102-108 Nm)
5.* 25-28 ft.-lbs.

(34-38 Nm)

E-1701
843 Loader
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
NOTES _________
Specifications
Use Melroe hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not
available, use 10W-30 or 10W-40 SAE Motor Oil (5W-30 for 0 ° F [-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
(indicated by "TRANS" light "ON") will cause transmission damage in less then 60
seconds time.
Stop the engine if the " TRANS" light

comes "ON" and stays "ON". The light
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
1/16 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 41/64 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 -23.019
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" 0.001" = 0.0254 mm
U.S. TO METRIC CONVERSION
TO CONVERT INTO MULTIPLY BY

LINEAR Miles Kilometers 1.609
MEASUREMENT Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Millimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
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) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Pounds/Sq. In. Kilopascal 6.895
WORK Foot-pounds Newton-Metre 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPERATURE Fahrenheit Celsius 1. Subtract 32 °
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 GRADES SAE GRADES
INCH. .250 80-90 110-120

LBS. (9-10) (13-14)
(Nm) 215-240
.3125 180-200
(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) (240-260)
FOOT .750 220-245 300-330
LBS. (300-330) (410-450)
(Nm) 475-525
.875 330-360
(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) (2720-2980)
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 8 7 -8-14- Service Manual
TECHNICAL DATA
Page
Number
ENGINE SPECIFICATIONS
Cooling System & Water Pump Dimensions.......... SA-8
Crankshaft & Main Bearing Dimensions............. BA-5
Cylinder Block & Liner Dimensions................. SA-5
Cylinder Head Dimensions....................... SA-3
De-Rating for Altitude.......................... SA-9
Engine Torque................................ SA-9
Fuel System Specifications...................... SA-8
Grinding Specifications for Crankshaft.............. SA-10
Oil Pump Dimensions........................... SA-7
Piston & Connecting Rod Dimensions............... SA-4
Timing Case, Camshaft & Drive Dimensions .......... SA-6
LOADER SPECIFICATIONS
Capacities ................................... SA-2
Drive System................................ SA-2
Electrical .................................... SA-2
Engine...................................... SA-1
Loader Hydraulics............................. SA-2
Specifications ................................ SA-1
Tire ........................................ SA-2
SPECIFICATIONS
(Perkins 2.5 Liter
Diesel)
843 Loader
SA LOADER SPECIFICATIONS
Where applicable, specifications

conform to SAE standards.
r-62.4
Specifications are subject to
/";«,,..:. t 1584) --1
change without notice. // 1 99° 155.2
(3941) I ( I
[ ::-::�)�f,�jr--.. \
--r---1 ----,,'-/<-<?"
�
./<>··.-_-:::�' L
.aC·::-��-->'- �,-::·o_,:)�----�
..
119.6
/ / 370 '•,, \
: : ·, , (3037)
----=
�';- '·""'�---�
94.5
(2399)
80.4
(2042)
32.8
38.6 (833)
(980)
104.5
(2654) _________...
------- 131.4
(3338) ____
Pl-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 NOTES _________
Weights
Operating Weight .............................. 6500 lbs. (2 95 1 kg)
Rated Operating Capacity ......................... 1 700 lbs. (772 kg)
T ipping Load (SAE) ............................. 3400 lbs. ( 1 544 kg)
Travel Speed ............................. 0.0 to 6.3 MPH ( 1 0,1 km/hr.)
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
Main Drive ...................... . ................... Hydrostatic
Brakes ....................... . .. Mechanical disc,foot-operated pedal.
ENGINE
Make ........................... . ...................... Perkins

Model ....................... .........................2.5 Liter
Fuel . ...... ............................................. Diesel
Horsepower .................................. . . . . 54 HP (40,3 kW)
Maximum Governed RPM ................................. 2 600 RPM
Torque ............................. 1 1 3 ft.-lbs. ( 1 5 3 Nm) @ 1800 RPM
Number of Cylinders ........................................... 4
Bore/Stroke ................................. 3.50 (88,9)/4.00 ( 1 0 1 ,6)
Displacement ............................... 15 3.9 cu.in. (2522 cm 3)
Cooling System ............................................ Liquid
Crankcase Ventilation .............................. Open PCV System
f,.ir Cleaner .................. Dry replaceable paper element, dual element
IL.ow Idle .............................................. 1 150 RPM
High Idle .... ..................................... 2725-2775 RPM
Revised Feb. 94 -SA-1- Service Manual
LOADER SPECIFICATIONS (Cont'd)
NOTES _________
LOADER HYDRAULICS
Pump ........... ..................................... Gear type

Pump Capacity .................... 15.4 GPM (58,3 Umin.)@ 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.
@ 0 ° F (-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
sealed chaincase with oil lubrication.
Total Engine to Wheel Reduction:
Gear Reduction ... ....... . ..... . ......... . ............... 3.54:1
Chain Reduction .. ....................... . ............... 31.11:1
Fluid Type ... . .. Clark Bobcat Fluid (P/N 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 .............................. 9.5 qts. (9 L)
Chaincase . ....... ........................ . . . ....... 9 gals. (34 L)
Hydraulic/Hydrostatic Reservoir ...... . .......... . . . .... 15.5 qts. (14,7 L)
TIRES
Standard ...... . ... . ........... 8.25 x 15, 6 Ply Rating, Nylon W/Bar Lug
Pressure ............................ . .... 45-50 PSI (310-345 kPa)
Flotation ....... . ................... . . . ..... . 12 x 16.5, 6 Ply Rating
Pressure ......... . .................. . . . .. 45-50 PSI (310-345 kPa)
-SA-2- Service Manual
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 °
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 ...................... 0.001/0.0042 (0,025/0,106)
Insert Thickness ......................... 0.4252/0.426 (10,80/10,82)
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 (7,99/8,01)
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 °
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 (7,92/7,95)
Clearance Fit of Stem in Guide ............. 0.0015/0.0035 (0,038/0,089)
Valve Head Diameter ....................... 1.3937/1.4016 (35,4/35,6)
Valve Face Angle .......................................... 45 °
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 ............ 28 lbs. ± 1.4 lbs. (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 lbs. ± 2.0 lbs. (18,1 kg ± 0,908 kg)
Free Length ........................................ 1.81 (45,97)
Rocker Arms:
Bore Diameter .......................... 0.7188/0.7196 (18,26/18,28)
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) 0.625/0.6528 (15,88/15,90)
ENGINE SPECIFICATIONS (Cont'd)
NOTES _________
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 (0,01/0,06)
Lubrication ....... ...... ........... ...... No. 1 Bracket T hrough 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 .. ... ... .... 0.000/0.004 (0,00/0,102)
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) ..... .. .. ... . 0.096/0.097 (2,44/2,46)
Ring Groove Width (4th & 5th) .......... ... ... 0.1895/0.1906 (4,81/4,84)
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 (0,056/0,102)
Ring Width (4th) .. ...... .. .......... ...... 0.1868/0.1875 (4,74/4,76)
Ring Clearance in Groove . ...... .. .......... 0.002/0.0038 (0,05/0,097)
Ring Width (5th) .... .................. .... 0.1865/0.1875 (4,74/4,76)
Ring Clearance in Groove .. .. ........ .... .... 0.002/0.004 (0,05/0,102)
Ring Gap (Top) . .. .. ...... .. ... ........ .. ... 0.014/0.019 (0,36/0,48)
Ring Gap (2nd & 3rd) ... ...................... 0.011/0.016 (0,28/0,41)
Ring Gap (4th) ..... ........... ............. 0.014/0.019 (0,36/0,48)
Ring Gap (5th) .... .. .. ................. ..... 0.011/0.016 (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 (0,0251 above 3.501 (88,931.
Piston Pins:
Type .. .. . ..... ......... ............ ...... . ..... .. Fully Floating
Outside Diameter .. .... ......... .. ..... 1.24976/1.24996 (31,74/31,75)
Clearance in Rod End .... .... .......... 0.00054/0.00175 (0,014/0,044)
Connecting Rods:
Type ...... .......... .......... ...... .............. "H" Section
Big End Bore ............. .. ............ 2.395/2.3955 (60,83/60,85)
Small End Bore .. ........ .. .... .. .. .. .. .. . 1.375/1.376 (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 (0,24/0,33)
Big End Bolt Size ........ ........ ... . . .. .. ...... .. .... 7/16 (11,11)
T hread 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 (31,76/31,79)
NOTES ________
parenthesis.
Piston and Connecting Rod Dimensions (Cont'd)
Connecting Rod Bearings:

Type ............................. Steel Backed, Aluminum T in Lined
Width ................................. 1.1208/1.1280 (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 (0,036/0,076)
Cylinder Block and Liners Dimensions
Cylinder Block:
Total Height of Cylinder Block ................ 11.177/11.181 (283,9/284,0)
Bo re Diameter for Cylinder Liner ............ 3.8125/3.8135 (96,84/96,86)
Liner Flange Depth in Block .................... 0.150/0.152 (3,81/3,86)
Cylinder Block Recess Bore ................. 3.990/3.995 (101,35/101,47)
Main Bearing Bore ......................... 2.916/2.917 (74,07/74,09)
No. 1 Bore for Camshaft ................... 2.0472/2.0484 (52,0/52,03)
No.2 Bore for Camshaft .................. 2.0374/2.0386 (51,75/51,78)
No.4 Bore for Camshaft ................... 2.0177/2.0189 (51,25/51,28)
Tappet Bore Diameter ................... 0.5625/0.56375 (14,29/14,32)
Crankshaft T hrust 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 .. 0.001/0.003 (0,025/0,076)
Liner Finish Bore .......................... 3.501/3.502 (88,93/88,95)
Liner Flange Thickness ........................ 0.148/0.150 (3,76/3,81)
Depth of Flange BELOW Top Face of
Cylinder Block ........................... 0.000/0.004 (0,00/0,102)
Liner Flange Diameter .................... 3.972/3.976 (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 .............. 1.4335/1.4415 (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)
Crankshaft Pin Fillet Radius .......................1/8 - 9/64 (3,2/3,57)
Surface Finish, All Journals ............ 15 micro. max. (0,4 microns max.)
Crankshaft Journals & Pins Grinding ............... 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)
Crankshaft Flange Width ................................. 0.5 (12,7)
Crankshaft End Play ........................ 0.001/0.015 (0,025/0,38)
NOTES _________
parenthesis.
Crankshaft and Main Bearings Dimensions (Cont'd)
Type ............................. Steel Backed,Aluminum Tin Lined

Shell Width for all Journals ..................... 1.122/1.130 (2 8,5/2 8,7)
Outside Diameter ................................... 2.917 (74,09 1
Inside Diameter ........................... 2.75/2.753 (69,8 9/69,93)
Bearing Running Clearance ................. 0.0025/0.0045 (0,064/0,114)
Crankshaft Thrust Washer:

Type ............................. Steel Backed,Aluminum Tin Lined
Position on the Crankshaft ....................... Center Main Bearing
Thrust Washer Thickness (STD) .............. 0.0 8 96/0.0915 (2,2 8/2,32)
Thrust Washer Thickness (0/S)............... 0.0966/0.09 8 5 (2,45/2,50)
Thrust Washer Diameter ..................... 3.7 4 4/3.756 (95,09/95,4)
Timing Case, Camshaft and Drive Dimensions
Camshaft:
Journal Length, No. 1 ...................... ........... 1.1 8 (29,97 1
Journal Diameter, No. 1 ................... 2.0437/2.044 8 (51,91/51,94 1
Journal Clearance Fit, No. 1 ................. 0.0024/0.0047 (0,06/0,119 1
Journal Length, No. 2 ................................... 1.0 (25,4)
Journal Diameter, No. 2 .................... 2.0339/2.035 (51,66/51,69)
Journal Diameter, No. 3 ................... 2.0241/2.0252 (51,4 / 15,1 44)
Journal Clearance Fit, No. 3 ................. 0.0024/0.0 0 47 (0,06/0,119)
Journal Diameter, No. 4 .................... 2.0142/2.0154 (5 , 1 16/51,19)
Cam Lift .................................. 0.2 8 0/0.2 8 2 (7,11/7,16 1
Lift Pump Cam ............................. 0.095/0.09 8 (2,41/2,49)
Camshaft Flange for Gear ......... . ........ 1.1251/1.1257 (2 8,5 8/2 8,59)
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 Pla y ........................ 0.00 12/0.0071 (0,625/0,1 8)
Camshaft Gear:
Inside Diameter of Gear ..................... 1.1251/1.126 (2 8,5 8/2 8,60)
Gear Fit on Camshaft Flange ......... 0.0007 interference/0.0009 clearance
(0,01 8/0,023)
Fuel Injection Pump Gear:

Inside Diameter of Gear for Fuel Injection
Pump Flange ........................... 1.750/1.75 1 (44,45/44,4 8)
Idler Gear and Hub:

Idler Gear Bore Diameter .................. 1.8 8 9 8/1.8 90 8 (4 8,00/4 8,02)
Idler Gear Bushing Outside Diameter .......... 1.8 9 5
1 /1.8 924 (4 8,04/4 8,07)
Interference Fit of Bushing ................ 0.0007/0.0027 (0,0 17/0,06 8)
Idler Gear Bushing Bore ................... 1.7327/1.7337 (44,01/44,04)
Outside Diameter of Hub .................. 1.7303/1.73 13 (43,95/43,9 8)
Clearance Fit of Bushing in Gear on the Hub ... 0.0014/0.0034 (0,035/0,0 8 6 1
Idler Gear Width .... ..................... 1.1320/1.1340 (2 8,75/2 8,8 0)
Hub Width ........ ....................... 1.140/1.144 (2 8,96/29,06)
NOTES _________
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 ..... 1.731/1.732 (43,97/43,99)
Size & Clearance Fit of Flange in
Cylinder Block Bore ..... ....... . ........... 0.000/0.002 (0,00/0,05)
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 ...... ....... ...... 1.2496/1.2505 (31,74/31,76)
Crankshaft Flange for Gear Diameter ........ .. . 1.2494/1.250 (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 (0,01/0,05)
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 ................... 0.625/0.626 (15,87/15,90)
Outside Diameter of Shaft .................. 0.623/0.6235 (15,82/15,84)
Running Clearance of Shaft in Bore ....... ...... 0.0015/0.003 (0,04/0,08)
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 .............. 0.0013/0.0021 (0,03/0,05)
Drive Gear Backlash ....................... 0.0155/0.0019 (0,39/0,48)
Oil Pump Relief Valve:

Type .... .................................. Spring-Loaded Plunger
Pressure Setting ................... ........ 36/44 PSI (248/303 kPa)
Relief Valve Bore ........................ 0.5605/0.5621 (14,24/14,28)
Outside Diameter of Plunger ................ 0.5585/0.5595 (14,18/14,21)
Clearance of Plunger in Bore ................. 0.001/0.0036 (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)
NOTES _________
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 (19,94/19,96)
Interference Fit of Pulley Hub on the Shaft ..... 0.0016/0.0027 (0,04/0,068)
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 .................. 0.000/0.005 (0,00/0,13)
Impeller Bore ............................ 0.497/0.4975 (12,62/12,64)
Outside Diameter of Shaft for Impeller .......... 0.498/0.499 (12,65/12,671
Interference Fit of Impeller on Shaft ........... 0.0005/0.002 (0,013/0,051)
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
T hermostat:
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
Fuel Injection Pump:

Manufacture ............................................ C. A.V.
Type .................................................. D.P.A.
Pump Rotation ........................... Clockwise (from drive end)
Timing Letter, Mechanically Governed ........................... "C"
No. 1 Cylinder Outlet ....................................... "W"
Static T iming:
Mechanically Governed ................................ 18 ° B.T.D.C.
0.125 (3,18) Piston Displacement
Fuel Injectors:
Manufacture ............................................ C. A.V.
Injector Body ..................................... BKB35SD5247
Injector Nozzle ..................................... BDN4SD6346
Working Pressure ............................. 1980 PSI (13,652 kPa)
Setting Pressure ............................. 2200 PSI (15,169 kPa)
Identification Code Letter ..................................... CJ
Starting Aid:,
Manufacture ............................................ C.A.V.
Type ...................................... T hermostart Type 357
Voltage ............................................... 12 Volt
Maximum Current ........................ . .. 12.9 amps. @ 11.5 volts
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
0 - 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 Torque
The following figures will apply with the bolts and/or nuts having a light coat of oil
before assembly.
Ft.-Lbs. Nm Page
Rear Main Seal Mounting Bolts ............. 4-6 5-8 7A-37

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.
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parenthesis.
Perkins 2.5 Liter Four Cyl inder Diesel - Grinding Specifications for Crankshaft
F C D C C
A
A
R1 Rl
E E
Pl-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 (3,71/3,99) All Journals
R2 0.126/0.142 (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.
Independent Readings:
Crankshaft Pulley Rear Oil Seal Flywheel Flange
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
Service Manual
TECHNICAL DATA Pe rkins 2.5 Lite r TK200 Se rie s
Page
Number
Cooling System & Water Pump Dimensions.......... 8B-5
Crankshaft & Main Bearing Dimensions............. 8B-4
Cylinder Block & Liner Dimensions................. 8B-4
Cylinder Head Dimensions....................... 8B-3
De-Rating for Altitude .......................... 8B-6
Engine Torque ............................... . 8B-6
Fuel System Specifications...................... 8B-6
Grinding Specifications for Crankshaft.............. 8B-7
Oil Pump Dimensions........................... 8B-5
Piston & Connecting Rod Dimensions ............... 8B-3
Timing Case, Camshaft & Drive Dimensions.......... 8B-5
Capacities .................................. . 8B-2
Drive System ................................ 8B-2
Electrical .................................... 8B-2
Engine ...................................... 8B-1
Loader Hydraulics ............................. 8B-2
Specifications ................................ 8B-1
Tire ........................................ 88-2
SPECIFICATIONS
TK 200 Series Perkins
843 Loader
Service Manual
8B LOADER SPECIFICATIONS
r-
Where applicable, specifications
62.4
Specifications are subject
/;«...;:: t (1584) --,
change without notice.
i
,./· : 990 155.2
I I
•
(3941)
//<> ,,�;i:-\1 119.6
/,<, <]?'
13037)
1
94.5
(2399)
80.4
(2042)
I
8.4 6.18 32.8
(212) 38.6 1157) (833)
(980)
104.5 _______
(2654)
131.4
�------(3338) ____
Pl-2585
SPECIFICATIONS
Weights
Operating Weight .............................. 6500 lbs. (2951 kg)
Rated Operating Capacity ......................... 1700 lbs. (772 kg) NOTES _________
T ipping Load (SAE Rating) ........................ 3420 lbs. (1551 kg)
Travel Speed .................... lnfinately Variable 6.3 MPH (10,1 km/hr.)
Controls
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.
Engine ............ Hand lever throttle; key type starter switch & shutdown
Main Drive .......................................... Hydrostatic
Brakes .......................... Mechanical disc, foot-cperated pedal.
ENGINE
Make . .... ................................... Perkins (TK200 Series)
Model ........................... ..................... 2.5 Liter
Fuel .. .................................................. Diesel
Horsepower ...................................... 54 HP (40,3 kW)
Maximum Governed RPM ................................. 2600 RPM
Torque ............................. 113 ft.-lbs. (153 Nm) @ 1800 RPM
Number of Cylinders ........................................... 4
Bore/Stroke ................................. 3.50 (88,9)/4.00 (101,6)
Displacement ............................... 153.9 cu. in. (2522 cm3)
Cooling System ............................................ Liquid
Crankcase Ventilation .............................. Open PCV System
Air Cleaner .................. Dry replaceable paper element, dual element
ILow Idle .............................................. 1150 RPM
High Idle .. ........................................... 2720 RPM
843 Loader
_s:u�_,_ Service Manual
LOADER SPECIFICATIONS (Cont'd)
NOTES _________
LOADER HYDRAULICS
Pump ................................................ Gear type

Pump Capacity (S/N 15000 & Below) ..... 16 GPM (61,3 Umin.) @ 2700 RPM
(S/N 14999 & Below) .... 15.5 GPM (58,7 Umin.) @ 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 (850,9)
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.
Fluid Lines ........................ SAE standard tubes, hoses & fittings

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.
@ 0 ° F (-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 ............................... 39.4:1
Fluid Type ...... Clark Bobcat Fluid (P/N 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)
Chaincase .......................................... 36 qts. (34 L)
Hydraulic/Hydrostatic 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)
-SB-2- Service Manual
ENGINE SPECIFICATIONS Perkins 2.5 Liter TK200 Series
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed
NOTES _________
by parenthesis.
Cylind er Head Dimensions
Cylinder Head:
Grinding Allowance ................................ DO NOT GRIND

Valve Seat Angle (Intake) .................... 45 ° (90 ° Included Angle)
(Exhaust) .................. 30 ° (120 ° Included Angle)
Valve Seat Width ................................. 0.079 (2,0 mm)
Combustion Chamber Inserts:

Height of Insert in Relation to Cylinder Head Face ..... 0.001 (0,025) Above
0.0029 (0,073) 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 (0,13)
Minimum Valve Head T hickness .......... ............... 0.053 (1,35)
Valve Face Angle ............... .............. ............. 45 °
Valve Stem Seal ....... ................... Synthetic Rubber Deflector
Valve Clearance (Cold) ... ........................... .. 0.012 (0,30)
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 T hickness ......................... 0.053 (1,35)
Valve Face Angle .......................................... 30 °
Valve Stem Seal ........ ..................... . ......... Not Used
Valve Clearance (Cold) ................................. .012 (0,30)
Valve Springs, Inner:

Fitted Length ....................................... 1.49 (37,85)
Load at Fitted Length ........... .. 28 lbs. ± 1.5 lbs. (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 lbs. ± 2.0 lbs. (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 (0,08)
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)
Worldwide Parts Source LLC Phone: 269 673 2313 email: PartsAndGaskets@gmail.com ) 843 Loader
ENGINE SPECIFICATIONS (Cont'd) Perkins 2.5 Liter TK200 Series
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by NOTES _________
parenthesis.
Piston and Connecting Rod Dimensions (Cont'd)
Pistons Rings:
Compression (T op) .................................. Chrome Inlay
Compression (2nd) .................... Internally stepped chrome faced
Scraper (3rd) ................... . ..... Coil Spring Loaded, Oil Control
I
Maximum Clearance in Groove ...... . .................. 0.0 1 2 (0,30)
*Ring Gap (New Rings) ................. 0.0 1 4 - 0.022 (0,356 - 0,559)
(Maximum)................................ 0.060 ( 1 ,52)
* T he 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 ........... 0.0006/0.001 6 (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 T in Lined
Rod Bearing Running Clearance............... 0.001 4/0.003 (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................... 2.0472/2.0484 (52,0/52,03)
No. 2 Bore for Camshaft .................. 2.0374/2.0386 (51,75/51,78)
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 lnterence 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)
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 (69,81/69,83)
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)
Main Journal & Rod Journal Diameter Out-of-Round Premitted . 0.0005 (0,013)
Crankshaft End Play ....................... 0.003/0.015 (0,080/0,038)
Maximum End Play ................................... 0.01 6 (0,41)
Main Bearing:
Type . . ........................... Steel Backed, Aluminum T in Lined
Main Bearing Running Clearance .............. 0.0025 /0.0045 (0,06/0,11)
Maximum Clearance .................................. 0.005 (0,13)
ENGINE SPECIFICATIONS (Cont'd) Perkins 2.5 Liter TK200 Series
NOTES _________
parenthesis.
Crankshaft and Main Bearings Dimensions (Cont'd)
Crankshaft Thrust Washer:

Type .................................. Steel Backed, Aluminum Tin
Position in Cylinder Block ........................ Center Main Bearing
Thrust Washer Oversize ............................... 0.007 (0,18)
Timing Case, Camshaft and Drive Dimensions
Camshaft:
Journal Diameter, No. 1 ............... .... 2.0437/2.0448 (51,91/51,94)
Minimum Journal Diameter, No. 1 ...................... 2.0434 (51,90)
Journal Diameter, No.2 .................... 2.0339/2.035 (51,66/51,69)
Journal Diameter, No. 3 ................... 2.0241/2.0252 (51,41/51,44)
Journal Diameter, No. 4 .................... 2.0142/2.0154 (51,16/51,19)
Minimum Journal Diameter, No. 4....................... 2.0139 (51,15)
Maximum Journal Running Clearance ...................... 0.006 (0,15)
Maximum Camshaft Runout ............. ............... 0.003 (0,08)
Minimum Cam Height ............................... 1.6727 (42,49)
Camshaft End Play......................... 0.0012/0.0071 (0,03/0,18)
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 (0,020/0,30)
Maximum End Play................................... 0.015 (0,38)
Timing Gears:
All Gears Backlash ............................ 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 on Camshaft
Clearance of Inner to Outer Rotor ........................ 0.012 (0,30)
Clearance of Outer Rotor to Pump Housing ................. 0.012 (0,30)
Rotor End Play ...................................... 0.006 (0,15)
Oil Pump Relief Valve:

Type ...................................... Spring-Loaded Plunger
Spring, 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 ° /78.5 ° C)
Fully Open Temperature .............................. 194 ° F (90 ° C)
Minimum Travel at Full Open .............................. 0.3 (7,6)
-88-5- Service. Manual
NOTES _________
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
0 - 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 Bolts & Nuts ............. 125-140 169-190 78-16

U-Joint Mounting Bolts ................... 25-28 34-38 78-22
Cylinder Head Bolts (Also Rocker Arm Brackets) 85 115 78-24
Main Bearing Bolts ...................... 85 115 78-35
Connecting Rod Nuts* ................... 60 82 78-32
Flywheel Bolts ......................... 83-90 113-122 78-22
Crankshaft Pulley Retaining Bolt ............ 180 244 78-39
Camshaft Gear Bolt ..................... 40-50 54-68 78-43,
78-42
Idler Gear Hub to Cylinder Block Nuts ........ 21 28 78-42
Fuel Injection Pump Drive Gear Nut ......... 50 58 78-8,
78-42,
78-44
Fuel Injector Nuts ....................... 12 16 78-11
High Pressure Tubeline Fittings ............. 15 20 78-5
Glow Plugs ....... .................... 11 15 78-13
* Once the Connecting Rod Nuts are removed, they must be replaced.
Revised July 88 -8B-6- Service Manual
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parenthesis.
Perkins 2.5 Liter TK200 Series Grinding Specifications for Crankshaft

F C D C C
A A
R1 Rl
E E
Pl-2598
0.010 (0,25) 0.020 (0,51) 0.030 (0,76)

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)
8 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 (36,731 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 (3,71/3,99) All Journals
R2 0.126/0.142 (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.
Independent Readings:
Crankshaft Pulley Rear Oil Seal Flywheel Flange
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
TECHNICAL DATA (Isuzu}
Page
Number
EN GIN E SPECIFICATIONS Isuzu 2.8L

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
Capacities ................................... 8C-2
Drive System ................................ 8C-2
Electrical .................................... 8C-2
Engine ...................................... 8C-1
Loader Hydraulics............................. 8C-2
Specifications ................................ 8C-1
Tire ................................... · · · · · 8C-2
SPECIFICATIONS
(Isuzu)
843 Loader
I SC LOADER SPECIFICATIONS Isuzu 2.8L -, // i 990
t
155.2
i--
I
62.4
(1584) ----!
I
//':: b:::i�\}, '
Where applicable, specifications (3941)
�1 ----'-�
Specifications are subject to 119.6
change without notice. (3037)
94.5
(2399)
80.4
(2042)
I
6.18 32.8
8.4
(212) 38.6 (157) (833)
(980)
104.5 _______
(2654)
I+------- 131.4 _____,
(3338) Pl-2585
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 NO TES _________
Weights
Operating Weight .............................. 6480 lbs. (2939 kg)
Rated Operating Capacity ......................... 1700 lbs. (772 kg)
Bucket Capacity (SAE) (60" Dirt) .................. 12.5 cu.-ft. (0,35 m3)
Travel Speed ....................Infinitely variable 0-6.3 MPH (10 km/hr.)
Controls
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
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.-lbs. (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 2 - 750 RPM
843 Loader
Revised Feb. 94 -SC-1- Service Manual
LOADER HYDRAULICS Isuzu 2.8L
NOTES _________
Hydraulic Pump (Rear)
Type .................................... Engine driven, gear type
Capacity .... 16.2 GPM (61,3 L/min.) @ 2700 RPM @ 1050 PSI (723 9 kPa)
Charge Pump (Front)
Type ......................................Engine driven, gear type
Capacity .... 10.8 GPM (40, 9 L/min.) @ 2700 RPM @ 1050 PSI (723 9 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 (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, 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

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.
@ 0 ° F (-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 1 OW-30 or 1 OW-40 Class SF Motor Oil
CAPACITIES
Cooling System ..................................... 22 qts. (21 L)

Fuel ............................................. 22 gals. (83 L)
Chaincase .......................................... 36 qts. (34 L)
Hydraulic/Hydrostatic Reservoir ....................... 15.5 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
-SC-2- Service Manual
ENGINE SPECIFICATIONS Isuzu 2.8L
NOTES _________
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 Width

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 (0,70)
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 0.010 (0,25)
Valve Guide Height.. . .................................. 0.51 (13)
Valve Springs
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.... ..................................... Limit 0.118 (3,0)
Outer...... , .................................. Limit 0.126 (3,2)
Tension
Inner-Set Length.................... 1.46 (37) Std. 13 lbs. (5,9 kg)
Limit 11 lbs. (5,02 kg)
Outer-Set Length......... . ..... . .. 1.54 (39) Std. 46 lbs. (20,9 kg)
Limit 40 lbs. (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,-03)
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
-SC-3- Service Manual
ENGINE SPECIFICATIONS Isuzu 2.8L (Cont'd)
NOTES _________
All dimensions are given in inches. Respective metric dimensions are given in millimet ers 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.D.
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 O.D .. .. .. .. .... .......... ........ .... .. 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)
Small End Bushing I.D... .. .. ....... Std. 1.2208-1.2211 (31,008-31,015)
Clearance Between Piston Pin &
Small End Bushing... .. ........ ... Std. 0.0003-0.00079 (0,008-0.20)
Limit 0.0002 (0,05)
Clearance Between Crankshaft Journal &
Bearing .. ... . .................. .. Std. 0.001-0.0026 (0,029-0,066)
Limit 0.004 (0,10)
Cylinder Liners
Cylinder Liner I.D. ........ .... ..... 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 I.D.
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
Gear Backlash ........ ...... ........... Std. 0.004-0.007 (0,10-0,17)

Limit 0.012 0,3)
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
ENGINE SPECIFICAT IONS Isuzu 2.8L (Cont'd)
NOTES _________
parenthesis.
Camshaft (Cont'd)
Clearance ..................................... Std. 0.0 0 2 0 (0,05)

Limit 0.0 0 47 (0,12)
Camshaft Run-Out ............................... Limit 0.0 0 39 (0,1)
Cam Lobe Height ............................... Std. 1.65 4 (4 2,0 2)
Limit 1.6 4 0 (4 1,65)
NOTE: Crankshaft is Tuffride coated and cannot be re-ground.
Crankshaft
End Play........................................ Std. 0.0 0 4 (0,1)

Limit 0.0 12 (0,31)
Connecting Rod Journal O.D.......... Std. 2.0833-2.0839 (5 2,915-5 2,930)
Limit 2.082 9 (5 2,90 6)
Main Bearing Journal 0.D............ Std. 2.75 2 6-2.75 32 (6 9,917-6 9,932)
Limit 2.75 2 4 (6 9,910)
Clearance Between Journal & Main Bearing Std. 0.0 0 14-0.0 0 4 1 (0,0 35-0,080)
Limit 0.0 0 4 3 (0,11)
I Crankshaft Run-Out ......................... Std. 0.0 0 2 (0,05) or less
Limit 0.0 0 3 (0,08)
Idler Gear
End Play....................................... Std. 0.0 0 3 (0,07)

Limit 0.0 08 (0,2)
Backlash ............................. Std. 0.0 0 4-0.0 07 (0,10-0,0 17)
Limit 0.0 12 (0,3)
Idler Gear Hub 0.D................. Std. 1.7 6 95-1.77 07 (44,945-4 4,975)
Limit 1.7 65 6 (4 4,845)
Clearance Between Hub & Gear .......... Std. 0.0 0 0 9-0.0 0 3 (0,0 25-0,085)
Limit 0.0 07 9 (0,2)
Bearing Replacement
Projection ................................. 0.0 16-0.0 2 4 (0,4-0,6)
Height ................................. 0.933-0.945 (2 3,7-24,0)
Oil P ump
End Play Between Vane & Body........... Std. 0.0 0 08-0.0 0 28 (0,0 2-0,07)
Limit 0.0 05 9 (0,15)
Clearance Between Rotor & Vane .............. Std. 0.0 055 (0,14) or less
Clearance Between Vane & Body........... Std. 0.0 07 9-0.0 105 (0,2-0,27)
Clearance Between Rotor Shaft & Body............... Std. 0.0 0 16 (0,0 4)
Limit 0.0 07 9 (0,2)
Oil Pump Pressure ............... 57-7 1 PSI (393-4 90 kPa) @ 14 0 0 RPM
2 1 PSI (145 kPa) @ Idle RPM
Fuel System
Pump Type ........................................... Bosch VE

Nozzles .......... . ............. . ....... Bosch Multi-hole (4 orifices)
Injector Pressure (Opening)...................... 2 6 30 PSI (18134 kPa)
Supply Pump Pressure
Idle RPM ..................................... 37 PSI (255 kPa)
High Idle RPM ................................. 7 1 PSI (4 90 kPa)
Injection Pump T iming .................................. 17 ° BTDC
843 Loader
Revised Feb. 94 -BC-5- Service Manual
ENGINE SPECIFICATIONS Isuzu 2.8L (Cont'd)
NOTES�.,_________
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-11
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 (Hollow) .............. 9-12 12-16
*Lubricate Thread with Oil
843 Loader
D .... ui£!'.o.rl l11lu gg -BC-6- Service Manual
Notes:
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Bobcat 843 Service Manual

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Available Formats

Bobcat 843 Serial Numbers 502012999 & Below

Perkins 2.5 Liter Four Cylinder Diesel

Bobcat 843 Serial Numbers 5026 13001 to 23999

Bobat 843 Serial Numbers 24001 and up

Worldwide Parts Source LLC

CORRECT CORRECT CORRECT

B-10731a B-12365 B-7469

B-11799 B-15231 B-15280

B-6590 B-6580 B-6589

Revised Aug. 97 843 Loader

2. Check that ROPS mounting 10. Bob-Tach wedges and

5. Machine signs must be legible 13. Check hydraulic fluid level,

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

18. Check the electrical charging

19. Check tires for wear and

20. Inspect for loose or broken

21. Operate the loader and check ) )

all functions. ) )))l)))))))>) ))JJ

22. Check for any field

23. Check for correct function of

Recommend to the owner that all

LOADER SERIAL NUMBER

The loader serial number plate is located on the inside of

Explanation of loader Serial Number:

ENGINE SERIAL NUMBER

The Delivery Report must be filled out by the dealer and

is delivered. An explanation of the form must be given to = ------

REAR LIGHT (Opt.)

LIFTING AND BLOCKING THE LOADER

REMOTE START SWI TCH

TRAN SPORTING THE LOADER

USING AND EXTRA BATTERY (JUMP STA RT)

Instructions are necessary before operating or servicing machine. Read Operator's

100 250 500 1000

LIFTING AND BLOCKING THE BOBCAT LOADER

Always park the loader on a level surface.

Put floor jack under the rear of the loader.

Put floor jack under the front of the loader.

NOTE: Make sure the jackstands do not touch the tires.

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

Lower the lift arms and bucket to the transport vehicle.

Stop the engine. Engage the parking brake.

Fasten chains to the uprights as shown �.

Fasten chains to the front as shown lg.

The operator cab fastening bolts and nuts must be tight � -

Seat Bar System

Seat Bar Inspection

Sit in the seat and fasten the seat belt snugly.

Seat Bar Maintenance

Disconnect the two front fasteners �.

If the lift arms are up, stand beside the loader lg .

Slowly raise the cab until it is all the way up [IDor lg .

Lowering the Operator Cab

Stand on the safety tread A or beside the loader lgand slowly C

Install the fasteners �before operating the loader.

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

5. Start the engine.

6. Immediately remove the negative(-) cable(Item 41 from

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

8. Remove the cables from the extra battery.

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

This remote start switch is required when the serviceman is