Bobcat 853H Service Manual

6720755 (6–99) Printed in U.S.A. © Melroe Company 1999ServiceManual853853H(S/N 508411001–508417999)(S/N 509711001–509717999)(S/N 510250001 & Above

iv853, 853H LoaderService Manual

PEDAL INTERLOCK LINKAGERemoval And InstallationRaise the lift arms and install an approved lift arm supportdevice. (See Page 1–1.)Raise the operator c

PEDAL INTERLOCK LINKAGE (Cont’d)Removal And Installation (Cont’d)Remove the panel from the loader frame [A].Install the mounting bolts (Item 1) [B] th

HYDROSTATICSYSTEM853, 853H Loader–3–1– Service ManualHYDROSTATIC SYSTEMCOLD OIL BY–PASS VALVERemoval And Installation 3–21. . . . . . . . . . . . . .

–3–2–853, 853H LoaderService Manual

TROUBLESHOOTINGChartThe following troubleshooting chart is provided forassistance in locating and correcting problems which aremost common. Many of th

Replenishing Valve FunctionThe functions of the replenishing valves are:HYDROSTATIC SYSTEM INFORMATIONWhen making repairs on hydrostatic andhydraulic

FRONT PANELRemoval And InstallationPut jackstands under the front axles and rearcorners of the frame before running the enginefor service. Failure to

FRONT PANEL (Cont’d)Removal And Installation (Cont’d)Remove the steering cable U–bolt (Item 1) [A].Disconnect the steering cable ball joint (Item 2) [

STEERING LEVERSDisassembly And AssemblyRemove the front panel/steering lever assembly. (SeePage 3–5.)Remove the steering shaft centering mechanism bol

STEERING LEVERS (Cont’d)Disassembly And Assembly (Cont’d)Check the nylon bushing (Item 1) [A] and replace asneeded.Assembly: Make sure the wave washer

SAFETY INSTRUCTIONSW–2003–0299Instructions are necessary before operating or servicing machine. Read and understand the Operation &Maintenance Man

STEERING LEVERS (Cont’d)Neutral Pre–Adjustment ChecksRead this adjustment completely to become familiar withthe procedure before beginning the adjustm

STEERING LEVERS (Cont’d)Adjusting Lever FreeplayRead this adjustment completely to become familiar withthe procedure before beginning the adjustment.U

STEERING LEVERS (Cont’d)Adjusting The Wheel RPM Forward Compared ToReverse TravelRead this adjustment completely to become familiar withthe procedure

STEERING LEVERS (Cont’d)Adjusting The Wheel RPM Forward Compared ToReverse Travel (Cont’d)5. Move the lever to the neutral position. Measure thedistan

DP–077241STEERING LEVERS (Cont’d)Adjusting The Steering Neutral SettingRead this adjustment completely to become familiar withthe procedure before beg

STEERING LEVERS (Cont’d)Adjusting The Wheel RPM Left Compared To RightSide1. Loosen the bolts at the stop (Item 1) [A] and lowerthe lever stops (both

STEERING LEVERS (Cont’d)Hydrostatic Pump Neutral AdjustmentWhen working on the left side of the hydrostaticpump, Be Careful to keep your fingers and t

DP–02866STEERING LEVERS (Cont’d)Hydrostatic Pump Neutral Adjustment (Cont’d)3. Clamp the control lever to the neutral adjustmentbracket with a small l

HYDROSTATIC MOTORRemoval And InstallationLift and block the loader. (See Page 1–1.)Raise the operator cab. (See Page 1–1.)Remove the front tire/wheel

HYDROSTATIC MOTOR (Cont’d)Removal And Installation (Cont’d)Remove the hydrostatic motor from the gearcase.Installation: Replace the large O–ring (Item

P–3705ASAFETY INSTRUCTIONS (Cont’d)• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hea

HYDROSTATIC CHARGE OIL FILTERRemoval And InstallationDisconnect the temperature switch wire from thehydrostatic filter [A].Disconnect the differential

HYDROSTATIC CHARGE OIL FILTER (Cont’d)Removal And Installation (Cont’d)Remove the four mounting bolts [A].Installation: Tighten the mounting bolts to

COLD OIL BY–PASS VALVERemoval And InstallationNever work on a machine with the lift arms upunless the lift arms are secured by an approvedlift arm sup

COLD OIL BY–PASS VALVE (Cont’d)Removal And Installation (Cont’d)Disconnect the oil cooler outlet tubeline (shown) and thefront auxiliary valve charge

HYDROSTATIC PUMPRemoval And InstallationRemove the hydrostatic pump/engine assembly from theloader. (See Page 7–1.)Remove the belt shield clips (Item

HYDROSTATIC PUMP (Cont’d)Removal And Installation (Cont’d)Remove the two mounting bolts (Item 1) [A] and nuts(Item 1) [B].Installation: Tighten the m

HYDROSTATIC PUMP (Cont’d)Replenishing/High Pressure Relief ValveThere are four replenishing/high pressure relief valves(Item 1) [A] in the hydrostatic

DRIVE BELT SHIELDRemoval And InstallationStop the engine.Open the rear door.Remove the three belt shield holddown clips (Item 1) [A].Remove the belt s

DRIVE BELT Replacing The Drive BeltRaise the operator cab. (See Page 1–1.)Remove the belt shield. (See Page 3–26.)Loosen the bolt (Item 1) [A] on the

E–02296SPRING LOADED TENSIONER PULLEYParts Identification 1. Cover 2. Bolt 3. Washer 4. Pins 5. Washer 6. Spring 7. Snap Ring 8. Snap Ring 9.

SERIAL NUMBER LOCATIONSAlways use the serial number of the loader whenrequesting service information or when ordering parts.Early or later models (ide

SPRING LOADED TENSIONER PULLEY (Cont’d)DisassemblyRemove the grease cover (Item 1) [A].Remove the bolt (Item 1) [B], the flat washer (Item 2) [B],the

SPRING LOADED TENSIONER PULLEY (Cont’d)AssemblyInstall the spring (Item 1) [A] on the pulley (Item 2) [A] asshown.Install the shaft from the bracket a

SPRING LOADED DRIVE BELT TENSIONER PULLEY(Cont’d)Assembly (Cont’d)Install the first retainer washer (Item 1) [A] and springwasher (Item 2) [A] over th

SPRING LOADED TENSIONER PULLEY (Cont’d)Adjusting The Drive BeltWhen adjusted correctly the spring loaded idler assemblywill increase the service life

FIXED TENSIONER PULLEYRemoval And InstallationRemove the three belt shield holddown clips (Item 1) [A].Remove the belt shield.Loosen the tensioner pul

FIXED TENSIONER PULLEY (Cont’d)DisassemblyNOTE: Be careful, the pulley hub is full of oil.Remove the cap [A].Remove the bolt and washer [B].Install a

FIXED TENSIONER PULLEY (Cont’d)Disassembly (Cont’d)Install a bearing puller behind the seal and wear sleeve[A].PHOTO CLARITY ONLY: If the bearing pull

FIXED TENSIONER PULLEY (Cont’d)AssemblyNOTE: The bearings, cups and spacers are amatched set and must be replaced as a unit.If the spacer is replaced,

FIXED TENSIONER PULLEY (Cont’d)Assembly (Cont’d)Put sealant (P/N 6633538) around the diameter of theshaft where the wear sleeve is installed [A].Put g

FIXED TENSIONER PULLEY (Cont’d)Assembly (Cont’d)Install the small bearing spacer [A].Install the taper roller bearing pushing on the I.D. of thebearin

* TIRES – Flotation tires are shown. The Bobcat loader is based–equipped with standard tires.BUCKET – Several different buckets and other attachments

FIXED TENSIONER PULLEY (Cont’d)Assembly (Cont’d)Tighten the bolt to 25–28 ft.–lbs. (43–38 Nm) torque [A].Use only 15W/50 synthetic oil (Example: Mobil

FIXED TENSIONER PULLEY (Cont’d)Checking Pulley End PlayInstall the pulley/mounting bracket assembly in to vise.Install a dial indicator on the pulley

FIXED TENSIONER PULLEY (Cont’d)Adjusting The Drive BeltSee the SERVICE SCHEDULE Page 1–1 for the serviceinterval.To adjust the drive belt between the

OIL COOLERRemoval And InstallationDisconnect the tubeline (Item 1) [A] from the oil cooler.Disconnect the tubeline (Item 1) [B] from the oil cooler.In

DRIVESYSTEM853, 853H Loader–4–1– Service ManualDRIVE SYSTEMAXLE SEALRemoval And Installation 4–9. . . . . . . . . . . . . . . . . . . . . . . . . . .

–4–2–853, 853H LoaderService Manual

PARKING BRAKE PEDALAdjustmentWhen the parking brake is in good condition and adjustedcorrectly, it will keep the loader from moving when thesteering l

PARKING BRAKERemoval And InstallationRaise the operator cab. (See Page 1–1.)Remove the bolt and nut from the lift pedal linkage [A].Disconnect the lif

PARKING BRAKE (Cont’d)Removal And Installation (Cont’d)Remove the nuts from the brake linkage rod [A].Disconnect the brake lever spring and remove the

PARKING BRAKE (Cont’d)Brake Block And PadsRemove the brake lever [A].Loosen the brake pad bolts and remove the bolts [B].Installation: Tighten the bol

PREVENTIVEMAINTENANCE853, 853H Loader–1–1– Service ManualPREVENTIVE MAINTENANCEAIR CLEANER SERVICEReplacing Filter Element 1–12. . . . . . . . . . . .

PARKING BRAKE (Cont’d)Brake Block And Pads (Cont’d)Remove the brake block [A].Installation: Clean and dry the brake block. Put a beadof R.T.V. sealant

FRONT CHAINCASE COVERRemoval And InstallationDisconnect the brake pedal/linkage rod assembly [A].Remove the front cover mounting bolts [B].Remove the

AXLE SEALRemoval And InstallationLift and block the loader. (See Page 1–1.)Remove the tire/wheel assembly.Installation: Tighten the wheel nuts to 105–

AXLE SEAL (Cont’d)Removal And Installation (Cont’d)Install a slide hammer (Item 1) [A] with a screw tip end intothe axle seal.Remove the axle seal.The

AXLE, SPROCKET AND BEARINGSRemoval And InstallationThe tools listed will be needed to do the followingprocedure:MEL1242 – Port–a–PowerMEL1202B – Axle

AXLE, BEARINGS AND SPROCKET (Cont’d)Removal And Installation (Cont’d)Push the axle out until the ram is at the end of the stroke.Add a spacer and push

AXLE, BEARINGS AND SPROCKET (Cont’d)Removal And Installation (Cont’d)Use the tools provided in the (MEL1202B) Axle BearingService Set for bearing cup

AXLE, BEARING AND SPROCKET (Cont’d)Removal And Installation (Cont’d)Use the bearing cup installation tools (Item 1) [A] & (Item1) [B].Put the inne

REDUCTION GEARCASEReduction Gearcase SealThe tool listed will be needed to do the followingprocedure:MEL1047 – Seal Installation ToolLift and block th

REDUCTION GEARCASE (Cont’d)Removal And InstallationLift and block the loader. (See Page 1–1.)Raise the operator cab. (See Page 1–1.)Remove the front p

–1–2–853, 853H LoaderService ManualPREVENTIVE MAINTENANCE (Cont’d)REMOTE START SWITCHProcedure 1–29. . . . . . . . . . . . . . . . . . . . . . . . . .

REDUCTION GEARCASE (Cont’d)Checking Reduction GearcaseBefore disassembly of the gearcase do the followingchecks:Install a dial indicator on the input

REDUCTION GEARCASE (Cont’d)Disassembly (Cont’d)Remove the end plate [A].Remove the dust cap [B].Loosen the bolt from the output shaft [C].Remove the b

REDUCTION GEARCASE (Cont’d)Disassembly (Cont’d)Remove the bolt from the disc hub [A].Remove the bolt and washer [B].Remove the disc hub and key [C].Pu

REDUCTION GEARCASE (Cont’d)Disassembly (Cont’d)Remove the bearing [A].Remove the spacer [B].Remove the output shaft [C].Remove the large gear [D].AB–0

REDUCTION GEARCASE (Cont’d)Disassembly (Cont’d)Remove the bearing at the input shaft [A].Use a press and remove the input shaft [B].Remove the input s

REDUCTION GEARCASE (Cont’d)AssemblyUsing a press and bearing cup tool, install the bearing cupin the housing.Install the input shaft [A].Install the b

REDUCTION GEARCASE (Cont’d)Assembly (Cont’d)Install the spacer [A].Install the bearing [B].Put LOCTITE on the bolt.Install the bolt and washer [C].Tig

REDUCTION GEARCASE (Cont’d)Assembly (Cont’d)Install the key and hub on the input shaft [A].Put LOCTITE #242 adhesive on the bolt threads.Install the b

REDUCTION GEARCASE (Cont’d)Assembly (Cont’d)Install the end plate bolts and tighten to 13–14 ft.–lbs.(Nm) torque [A].Install a new quad ring. Install

DRIVE CHAINRemoval And InstallationNOTE: It is necessary to remove the rear axle anddrive chain [A]. If the front chain has to beremoved.Lift and bloc

853, 853H Loader–1–3– Service ManualCheck wheel nut torque every 8 hours for the first 24 hours.Also replace hydraulic/hydrostatic filter element when

CHAINCASE FLUIDRemoving The Fluid From The ChaincaseTo drain the oil from the chaincase, remove the cover(Item 1) [A] which is installed over the drai

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MAINFRAME853, 853H Loader–5–1– Service Manual PageNumberBOB–TACHBob–Tach Lever And Wedge 5–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

–5–2–853, 853H LoaderService Manual

OPERATOR CAB GAS CYLINDERRemoval And InstallationCylinder contains high pressure gas. Do notopen. Opening cylinder can release rod andcause injury or

OPERATOR CAB GAS CYLINDER (Cont’d)Disassembly And AssemblyRemove the clevis (Item 1) [A] and washer (Item 2) [A]from the end of the gas cylinder.Remov

OPERATOR CABRemoval And InstallationRemove the cab nut and holddown plate (Item 1) [A] (bothsides).Installation: Tighten the nut to 40–50 ft.–lbs. (54

OPERATOR CAB (Cont’d)Removal And Installation (Cont’d)Remove the nut (Item 1) [A] from the pivot bolt (bothsides).Installation: Tighten the pivot bol

BOB–TACHRemoval And InstallationTilt the Bob–Tach forward, so it is parallel to the floor. Putblocks approximately 3 inches thick under each side ofth

BOB–TACH (Cont’d)Removal And Installation (Cont’d)Installation: Use two pieces of shim stock (lightcardboard) to protect the seals during installatio

Instructions are necessary before operating orservicing machine. Read and understand theOperation & Maintenance Manuals, Handbookand signs (decals

BOB–TACH (Cont’d)Removal And Installation (Cont’d)Install the Bob–Tach mounting bolt (Item 1) [A] into thepivot pin (Item 2) [A]. Remove the pivot pin

BOB–TACH (Cont’d)Bob–Tach Lever And Wedge (Cont’d)Using a punch and hammer, remove the roll pin (Item 1)[A] from the Bob–Tach wedge and spring, bolt a

LIFT ARMSRemoval And InstallationRoll the Bob–Tach (Item 1) [A] fully forward.Stop the engine.Remove the Bob–Tach (Item 1) [A] from the lift arms(Page

REAR GRILLRemoval And InstallationRaise the rear grill.Support the rear grill.Remove the nut (Item 1) [A] to disconnect the gascylinder from the rear

AP–050411REAR DOORRemoval And InstallationOpen the rear door, disconnect the wiring harnessconnector (Item 1) [A].Remove the nuts (Item 2) [A] from th

REAR DOOR (Cont’d)Hood Removal And InstallationRemove the rear lights harness from the rear door hoodif so equipped.Remove the mounting bolts from the

FUEL TANKRemoval And InstallationRemove the cover (Item 1) [A] which is installed over thedrain plug.Remove the drain plug (Item 1) [B].Drain the fuel

FUEL TANK (Cont’d)Removal And Installation (Cont’d)Remove the mounting plate (Item 1) [A] for the batteryholddown plate.Lift the fuel tank and remove

ELECTRICALSYSTEM853, 853H Loader–6–1– Service ManualELECTRICAL SYSTEMALTERNATORAssembly 6–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

–6–2–853, 853H LoaderService Manual

TRANSPORTING THE LOADERProcedureW–2058–0494Adequately designed ramps of sufficientstrength are needed to support the weight ofthe machine when loading

853, 853H Loader–6–3– Service Manual

–6–4–853, 853H LoaderService Manual

C114C216MC2561 (5-25-99)S/N 508411001-11010(Printed June 1999)MC2561853 BOSS - WIRING SCHEMATICSTARTRUNOFFACC21PUR/WHTRNGRNGDBL/WHTRNGWHTBLKRED/WHTIGN

C114MC2562 (5-25-99)S/N 508411011-11353(Printed June 1999)MC2562853 BOSS - WIRING SCHEMATICSTARTRUNOFFACC21PUR/WHTRNGRNGDBL/WHTRNGWHTBLKRED/WHTIGNITIO

MC2566 (5-25-99)853 BOSS - WIRING SCHEMATICS/N 508411354-11714S/N 509711001-11094(Printed June 1999)MC2566ABBLKRNGBLKBLKDGN/REDC414C415C407C408BLKRNGC

AABBDGN/REDDGNRNGBLKLGN/PNKDGN/YELRNGLGN/DBLRNG/DBLRNGYEL/WHTYELRNGBLKBLKDGN/REDDGN/LGNCONTROLS MODULEDGN/REDBCCONTROLS HARNESS - 6703878C414C415C407C

C114C124MC2567 (5-25-99)S/N 508412361-12460S/N 509711309-11334(Printed June 1999)MC2567853 BOSS - WIRING SCHEMATICSTARTRUNOFFACC21PUR/WHTRNGRNGDBL/WHT

RED = REDRNG = ORANGEBLK = BLACKLBL = LIGHT BLUEDBL = DARK BLUELGN = LIGHT GREENDGN = DARK GREENYEL = YELLOWPNK = PINKBRN = BROWNTAN = TANPUR = PURPLE

C115C124MC2564 (5-25-99)S/N 508415056-15187S/N 509715097-15221S/N 510250162-50448S/N 510375093-75213(Printed June 1999)MC2564853 BOSS - WIRING SCHEMAT

C120853 BOSS - WIRING SCHEMATICMC2571 (5-25-99)S/N 508415188-15215S/N 509715222-15292S/N 510250449-50691S/N 510375214-75404(Printed June 1999)MC257121

• Before lifting, check fasteners on four pointlift.• Never allow riders in the cab or bystanderswithin 15 feet (5 meters) while lifting themachine.LI

AUX.FRONTATTACHMENTHERE OR TOC460ATTACHMENTHERE OR TOC460C441C457REAR AUX.TURNSIGNALBACDGNBRNYELRNGYEL/LGNYEL/REDWHTRNG/WHTHORNSKI CONTROLBACABBAATTAC

RED = REDRNG = ORANGEBLK = BLACKLBL = LIGHT BLUEDBL = DARK BLUELGN = LIGHT GREENDGN = DARK GREENYEL = YELLOWPNK = PINKBRN = BROWNTAN = TANPUR = PURPLE

853 WITHOUT BOSS - WIRING SCHEMATICS/N 510125240-26110(Printed June 1999)MC2569MC2569 (5-14-99)WHTDBL/WHTPNKBLKPUR/WHTHRFCGBDEAHSTARTER RELAYWIRES CON

RED = REDRNG = ORANGEBLK = BLACKLBL = LIGHT BLUEDBL = DARK BLUELGN = LIGHT GREENDGN = DARK GREENYEL = YELLOWPNK = PINKBRN = BROWNTAN = TANPUR = PURPLE

RNGDGNYELRNG/WHTLBLBRNREDBLKRNG/WHTLBLWHTYELDGNDBLBRNBRN/YELYEL/WHTYEL/REDYEL/LGNRNGDGNDGN/YELLGN/WHTBLKYELDGNRNGWHTDBLRNGYEL/REDYEL/LGNDGNDGNBLKLGNBR

RED = REDRNG = ORANGEBLK = BLACKLBL = LIGHT BLUEDBL = DARK BLUELGN = LIGHT GREENDGN = DARK GREENYEL = YELLOWPNK = PINKBRN = BROWNTAN = TANPUR = PURPLE

RED = REDRNG = ORANGEBLK = BLACKLBL = LIGHT BLUEDBL = DARK BLUELGN = LIGHT GREENDGN = DARK GREENYEL = YELLOWPNK = PINKBRN = BROWNTAN = TANPUR = PURPLE

1. Alternator belt is loose or damaged. 2. Battery connections are dirty or loose. 3. Battery is damaged. 4. The cable & wire connection are

ELECTRICAL SYSTEM INFORMATIONDescriptionThe loader has a 12 volt, negative ground alternatorcharging system. The electrical system is protected byfuse

BATTERYRemoval And InstallationOpen the rear door.Disconnect the negative(–) cable (Item 1) [A] from thebattery.Disconnect the positive (+) cable (Ite

LIFT ARM SUPPORT DEVICEW–2059–0991Never work on a machine with the lift arms upunless the lift arms are secured by a lift armsupport device. Failure t

BATTERY (Cont’d)Removal And Installation (Cont’d)Always clean the terminals and cable ends wheninstalling a new battery [A] and [B].When installing th

BATTERY (Cont’d)Using A Booster Battery (Jump Starting)If it is necessary to use a booster battery to start theengine, BE CAREFUL! There must be one p

ALTERNATORAlternator Output TestPut jackstands under the front axles and rearcorners of the frame before running the enginefor service. Failure to use

When an engine is running in an enclosedarea, fresh air must be added to avoidconcentration of exhaust fumes. If the engineis stationary, vent the exh

ALTERNATORRemoval And Installation• Engine is operated with battery cablesdisconnected.• Battery cables are connected when using afast charger or when

ALTERNATOR (Cont’d)Disassembly (Motorola or Prestolite 30 Amp., Enclosed)Disassemble the alternator as shown in Fig. [A].Remove the regulator cover an

ALTERNATOR (Cont’d)Rotor Continuity TestTouch the probes to the slip rings [A].The ohmmeter should read between 3.0–33.0 ohms.If there is no continuit

ALTERNATOR (Cont’d)AssemblyReverse the order of disassembly.Place the rotor in soft jaws when tightening the shaft nut.Tighten to 50 ft.–lbs. (68 Nm)

STARTERChecking The StarterThe key switch must be in the OFF position.The battery must be at full charge.The cable connections on the battery must be

STARTER (Cont’d)Removal And InstallationDisconnect the negative (–) cable from the battery.Disconnect the positive (+) cable (Item 1) [A] and starterw

LIFT ARM SUPPORT DEVICE (Cont’d)Disengaging The Lift Arm Support DeviceRemove the pin from the lift arm support device.Connect the spring (Item 1) [A]

D–02119STARTER (Cont’d)Parts Identification 1 Screw 2. Solenoid 3. Bolt 4. Lever 5. Washer 6. Nut 7. Plug 8. Washer 9. Housing Drive10. Washe

STARTER (Cont’d)Disassembly And AssemblyRemove the starter thru–bolts [A].Remove the screws for the brush holders [B].Remove the starter end cap [C].R

STARTER (Cont’d)Disassembly And Assembly (Cont’d)Remove the armature and brushes from the starterhousing [A].Remove the bolts from the reduction gear

STARTER (Cont’d)Cleaning And InspectionUse a brush and air pressure to clean the drive, field coils,armature and starter housing.NOTE: DO NOT use solv

STANDARD INSTRUMENT PANELRemoval And InstallationPry the rubber light mount loose from the operator cab(both sides) [A].Lower the light from the opera

FRONT LIGHTSRemoval And InstallationThe front lights are mounted in the upper corners of theoperator cab [A].Pry the rubber light mount free from the

STEERING LEVER CONTROL HANDLE (Early Series)Disassembly And AssemblyRemove all the screws and nuts from the control handle[A].Remove one side of the c

ENGINESERVICE853, 853H Loader–7–1– Service ManualENGINE SERVICEAIR CLEANER HOUSINGRemoval And Installation 7–8. . . . . . . . . . . . . . . . . . . .

–7–2–853, 853H LoaderService ManualENGINE SERVICE (Cont’d)FAN GEARBOX/BLOWER HOUSINGRemoval And Installation 7–13. . . . . . . . . . . . . . . . . . .

853, 853H Loader–7–3– Service ManualENGINE SERVICE (Cont’d)OIL PUMPChecking 7–82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATOR CABDescriptionThe Bobcat loader has an operator cab (ROPS andFOPS) as standard equipment to protect the operatorfrom rollover and falling obj

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1. Battery capacity low. 28. Worn valve and seats. 2. Bad electrical connections. 29. Broken, worn or sticking piston rings. 3. Faulty starter mot

ENGINE SPEED CONTROLRemoval And InstallationRaise the operator cab. (See Page 1–1.)Remove the two mounting bolts (Item 1) [A] and nuts fromthe speed c

ENGINE MUFFLERRemoval And InstallationOpen the rear door.Raise the rear grill.Remove the air cleaner. (See Page 7–8.)Loosen the exhaust pipe clamp (It

AIR CLEANER HOUSINGRemoval And InstallationLoosen the hose clamp (Item 1) [A].Disconnect the hose from the intake manifold.Loosen the hose clamp (Item

COOLANT RECOVERY TANKRemoval And InstallationOpen the rear door.Raise the rear grill.Lift the coolant recovery tank from the bracket [A].Disconnect th

RADIATORRemoval And InstallationOpen the rear door.Remove the rear grill. (See Page 5–1.)Remove the oil cooler. (See Page 3–1.)Remove the engine muffl

RADIATOR (Cont’d)Removal And Installation (Cont’d)Disconnect the over–fill hose (Item 1) [A].If so equipped, disconnect the wires from the water level

FAN DRIVE TENSION PULLEYRemoval And InstallationRemove the fan drive belt.Remove the idler pulley bolt (Item 1) [A].Remove the spacers, bolt and washe

FAN GEARBOX/BLOWER HOUSINGRemoval And InstallationRaise the operator cab. (See Page 1–1.)Remove the mounting bolts (Item 1) [A] from the gascylinder m

OPERATOR CAB (Cont’d)Lowering The Operator CabNOTE: Make sure the seat bar is fully raised orlowered when lowering the cab.Pull down on the bottom of

FAN GEARBOX/BLOWER HOUSING (Cont’d)Removal And Installation (Cont’d)Installation: Use R.T.V. sealant to reseal the blowerhousing to the loader frame

FAN GEARBOX/BLOWER HOUSING (Cont’d)Removal And Installation (Cont’d)Remove the lock nut and spacer [A].Installation: Tighten the nut to 45–55 ft.–lbs.

FAN GEARBOX/BLOWER HOUSING (Cont’d)Removal And Installation (Cont’d)Early S/N Loaders:Use the following procedure to remove the fan from theshaft:Use

1. Seal 2. Snap Ring (Small) 3. Shims (1.0 inch O.D.) 4. Bearing 5. Shaft (Long) 6. Shims (2.0 inch O.D.) 7. Long Key 8. Shaf

FAN GEARBOX (Cont’d)DisassemblyNOTE: When repairing the gearbox order thefollowing as needed:Remove the fan and blower housing mounting plate. (SeePag

FAN GEARBOX (Cont’d)Disassembly (Cont’d)Remove the small shims [A].NOTE: The gear and the other bearing (pulley end)will be removed with the shaft.Rem

FAN GEARBOX (Cont’d)Disassembly (Cont’d)Short HousingRemove the end cap [A].Use care not to damage the housing.AVOID INJURY OR DEATHWear safety goggle

FAN GEARBOX (Cont’d)Disassembly (Cont’d)Remove the screw and washer (Item 1) [A] from theshaft.Remove the snap ring from the cap end of the housing[B]

FAN GEARBOX (Cont’d)Disassembly (Cont’d)Press the bearing, shims and gear from the shaft [A].Remove the key (Item 1) [B] from the shaft.AssemblyLong H

FAN GEARBOX (Cont’d)Assembly (Cont’d)Install the small snap ring in the groove above the shims[A].Install the gear key in the flange end of the shaft

SEAT BAR RESTRAINT SYSTEMDescriptionThe seat bar restraint system has a pivoting seat bar witharm rests and has spring loaded interlocks for the lift

FAN GEARBOX (Cont’d)Assembly (Cont’d)Short HousingInstall a bearing in the flanged end of the housing [A].Install the large shims on the bearing (flan

FAN GEARBOX (Cont’d)Assembly (Cont’d)After the gear is seated, drive the key down inside thegear key way [A].NOTE: This will prevent damage to the shi

FAN GEARBOX (Cont’d)Assembly (Cont’d)Install the snap ring in the groove above the bearing [A].Install the washer (Item 1) [B] on the shaft. Put liqui

FAN GEARBOX (Cont’d)Checking BacklashNOTE: If square shims are used, put a small amountof the liquid adhesive on both sides of allshims.Install the fo

FAN GEARBOX (Cont’d)Checking Backlash (Cont’d)Put the fan nut (Item 1) [A] on the shaft and tighten snugly.Install a locking pliers on the fan nut and

FAN GEARBOX (Cont’d)Checking Backlash (Cont’d)When the backlash is correct, install the seals, cap andgear oil as follows:Remove the bolts from the fl

ENGINERemoval And InstallationRaise the operator cab. (See Page 1–1.)Disconnect the case drain hose (Item 1) [A] and drain thehydraulic fluid into a c

ENGINE (Cont’d)Removal And Installation (Cont’d)Disconnect the wires (Item 1 & 2) [A] at the filter.Disconnect the electrical harness connectors (

ENGINE (Cont’d)Removal And Installation (Cont’d)Disconnect the steering cables (Item 1) [A].Installation: See Page 3–1 for transmission neutraladjust

ENGINE (Cont’d)Removal And Installation (Cont’d)Remove the battery. (See Page 6–1.)Remove the air cleaner housing. (See Page 7–8.)After the air cleane

AIR CLEANER SERVICEReplacing Filter ElementSee the SERVICE SCHEDULE, Page 1–3 for the intervalto service the air cleaner system.WITH CONDITION INDICAT

ENGINE (Cont’d)Removal And Installation (Cont’d)Disconnect the electrical connector (Item 1) [A].Remove the coolant recovery tank and bracket (Page7–9

ENGINE (Cont’d)Removal And Installation (Cont’d)Remove the left rear engine mount bolt and nut [A].Remove the right rear engine mount bolt (Item 1) [B

ENGINE (Cont’d)Removal And Installation (Cont’d)The engine lift eye bracket (Item 1) [A] has been turneddown for clearance at the exhaust pipe. Turn t

FLYWHEELRemoval And InstallationRemove the drive belt. (See Page 3–1.)Remove the bolts (Item 1) [A] from the flywheel.Installation: Put LOCTITE on the

BELT SHIELDRemoval And InstallationRemove the mounting bolt (Item 1) [A] from thethermostat housing.Remove the mounting bolt (Item 2) [A] from the cyl

ENGINE MOUNTSRemoval And InstallationThere is a kit available to replace the existing enginemounts in older model 853 loaders.Use the following proced

GLOW PLUGSRemoval And InstallationDisconnect the negative (–) cable from the battery.Remove the electrical bar holddown nuts at the glowplugs [A].Remo

VALVE CLEARANCEAdjustmentMake the valve clearance adjustment with enginestopped and cold.The correct clearance is 0.016 inch (0,41 mm) with theengine

FUEL INJECTION PUMPDescriptionThe injection pump contains parts which have a veryclose tolerance and its operation has a direct effect on theperforman

FUEL INJECTION PUMP (Cont’d)Removal And Installation (Cont’d)Use the parting line (off–set) (Item 2) [A] or (Item 1) [B]of the timing case cover to ma

AIR CLEANER SERVICE (Cont’d)Replacing Filter Element (Cont’d)Remove the wing nut (Item 1) [A] at the large air filterelement.Remove the large filter e

FUEL INJECTION PUMP (Cont’d)Removal And Installation (Cont’d)Do not bend the high pressure fuel injectiontubes when removing or installing them.I–2029

FUEL INJECTION PUMP (Cont’d)Removal And Installation (Cont’d)Remove the fuel injection pump [A].Installation: After the injection pump is installed, t

FUEL INJECTION PUMP (Cont’d)Timing The Injection PumpThe tools listed will be needed to do the followingprocedure:MEL1201 – Timing ToolRemove the valv

FUEL INJECTION PUMP (Cont’d)Timing The Injection Pump (Cont’d)Install the timing tool and dial indicator [A].Rotate the engine counterclockwise so the

FUEL INJECTOR NOZZLESRemoval And InstallationDiesel fuel or hydraulic fluid under pressurecan penetrate skin or eyes causing seriousinjury. Fluid leak

FUEL INJECTOR NOZZLES (Cont’d)Removal And Installation (Cont’d)Remove the nut at the fuel injector holddown clamp [A].Installation: Tighten the nuts t

FUEL INJECTOR NOZZLES (Cont’d)Checking (Cont’d)If the pressure is not correct, do the following:Disassemble the injector nozzle and clean.Replace the

CYLINDER HEADRemoval And InstallationThe tools listed will be needed to do the followingprocedure:MEL1267 – Cylinder Head Bolt WrenchClean all the deb

CYLINDER HEAD (Cont’d)Cylinder Head Surface AlignmentCheck the surface of the head with the straight edge [A].Check the head at six different directio

VALVES, VALVE SEAT AND GUIDERemovalThe tools listed will be needed to do the followingprocedure:MEL1266 – Valve Stem Seal InstallerMark the valves and

FUEL SYSTEMFuel SpecificationsUse only clean, high quality diesel fuel, Grade No. 1 orGrade No. 2 .The following is one suggested blending guideline w

VALVES, VALVE SEAT AND GUIDE (Cont’d)Reconditioning The Valve And Valve Seats (Cont’d)Check the valve head depth in the cylinder head aftergrinding th

VALVES, VALVE SEAT AND GUIDE (Cont’d)Valve Guide (Cont’d)Remove the guide [A].Install the new guide [B].The height of the valve guide top edge to the

ROCKER ARM AND SHAFTDisassembly And AssemblyMark the rocker arms and support brackets for correctassembly.Remove the snap ring (Item 1) [A] from each

PISTON AND CONNECTING RODRemovalRemove the cylinder head. (See Page 7–51.)Remove the oil pan. (See Page 7–81.)Remove the ridge and carbon deposits at

PISTON AND CONNECTING ROD (Cont’d)Disassembly (Cont’d)Remove the piston pin snap ring [A].Drive out the piston pin using a brass rod [B].CheckingClean

PISTON AND CONNECTING ROD (Cont’d)Checking (Cont’d)Check the ring gap in the cylinder bore [A].Standard LimitCompression 0.008–0.016 inch 0.059 inch(0

PISTON AND CONNECTING ROD (Cont’d)Checking (Cont’d)Check the connecting rod small end bushing [A].Standard – 1.2208–1.2211 inch (31,008–31,015 mm)Chec

PISTON AND CONNECTING ROD (Cont’d)AssemblyHeat the piston to about 140°F (60°C) [A].Assemble the piston and connecting rod [B].Install the piston to t

PISTON AND CONNECTING ROD (Cont’d)Assembly (Cont’d)Install the rings on the piston [A].The face with the mark NPR or TOP must be turned upfor the 1st

CYLINDER LINERSChecking The Cylinder BoreThe tools listed will be needed to do the followingprocedure:MEL1180 – Puller SetMEL1261 – Cylinder Liner Rem

FUEL SYSTEM (Cont’d)Removing Air From The Fuel SystemAfter replacing the fuel filter element or when the fuel tankhas run out of fuel, the air must be

MAIN BEARINGSDescriptionThe crankshaft has five main bearings. The end play iscontrolled by a thrust washer on both sides of the centermain bearing.Ea

MAIN BEARINGS (Cont’d)InstallationCheck the bearing spread as listed [A].Limit – 2.93 inch (74,5 mm)Check to see if the bearing has enough tension, so

MAIN BEARINGS (Cont’d)Installation (Cont’d)Tighten the crankshaft bearing cap bolts in the correctsequence [A].Torque – 116–130 ft.–lbs. (157–176 Nm).

CRANKSHAFTRemoval And InstallationRemove the oil pan. (See Page 7–81.)Remove the oil pump. (See Page 7–82.)Remove the crankshaft pulley, timing gearca

CRANKSHAFT (Cont’d)Checking The Crankshaft (Cont’d)Check the crankshaft main bearing journals [A].Standard – 2.7526–2.7532 inch (69,917–69,932 mm) Li

CRANKSHAFT GEARRemoval And InstallationThe tools listed will be needed to do the followingprocedure:MEL1263 – Crankshaft Gear InstallerMEL1264 – Crank

TIMING GEARCASE COVER SEALRemoval And InstallationThe tool listed will be needed to do the followingprocedure:MEL1265 – Crankshaft Front Oil Seal Inst

TIMING GEARCASE COVERRemoval And InstallationRemove the alternator and belt. (See Page 6–1.)Remove the bolt at the crankshaft pulley [A].Installation:

TIMING GEARCASE COVER (Cont’d)Removal And Installation (Cont’d)Remove the bolts from the timing gearcase cover [A].Installation: Tighten the bolts to

IDLER GEAR AND HUBRemovalRemove the timing gearcase cover. (See Page 7–71.)Remove the bolts at the tube for gear lubrication [A].Remove the tube [B].R

MAINTENANCE SAFETYWARNINGInstructions are necessary before operating or servicing machine. Read andunderstand the Operation & Maintenance Manual,

ENGINE LUBRICATION SYSTEMChecking Engine OilCheck the engine oil level every day.Before starting the engine for the work shift, open the reardoor. Rem

IDLER GEAR AND HUB (Cont’d)InstallationInstall the idler gear on the hub.Make sure the timing marks are in alignment with thecrankshaft, camshaft and

FUEL INJECTION PUMP IDLER GEARRemoval And InstallationRemove the timing gearcase cover. (See Page 7–71.)Remove the idler gear. (See Page 7–73.)Remove

CAMSHAFT GEARRemoval And InstallationRemove the timing gearcase cover. (See Page 7–71.)Remove the idler gear. (See Page 7–73.)Remove the bolt at the c

TIMING GEARCASERemoval And InstallationRemove the timing gearcase cover. (See Page 7–71.)Remove the idler gear. (See Page 7–73.)Remove the fuel inject

CAMSHAFTRemoval And InstallationRemove the rocker arm cover, rocker arm assembly andthe push rods. (See Page 7–56.)Remove the timing gearcase cover. (

CAMSHAFT (Cont’d)Camshaft BearingsThe tools listed will be needed to do the followingprocedure:MEL1260 – Camshaft Bearing Remover/InstallerUse the cor

CAMSHAFT (Cont’d)Tappets (Cont’d)Check the diameter of the tappets [A].Standard – 0.511–0.5114 inch (12,98–12,99 mm) Limit – 0.510 inch (12,95 mm)Cle

OIL PANRemovalRemove the oil drain plug and remove the oil.Remove the fastening bolts and nuts from the oil pan [A].InstallationClean the surface on t

OIL PUMPRemoval And InstallationRemove the oil pan. (See Page 7–81.)Remove the bolts at the oil pump [A].Installation: Tighten the bolts to 10–17 ft.–

OIL PUMP (Cont’d)Checking (Cont’d)Check the clearance between vane and body [A].Standard – 0.0008–0.0028 inch (0,02–0,07 mm) Limit – 0.0059 inch (0,1

ENGINE LUBRICATION SYSTEM (Cont’d)Replacing Oil And Filter (Cont’d)Put 8 qts. (7,6 L) of oil in the engine. (See Oil Chart, Page1–16.)Start the engine

OIL PUMP (Cont’d)Rotor ReplacementRemove the pin at the rotor using a punch and hammer[A].Installation: When installing the new pin in the rotor,make

WATER PUMPRemoval And InstallationRemove the alternator belt.Remove the water pump pulley [A].Remove the water pump bolts [B].Installation: Tighten th

WATER PUMP (Cont’d)Disassembly (Cont’d)Disassemble the water pump [A].Check the bearing for abnormal noise, binding or wear[B].Replace the parts as ne

WATER PUMP (Cont’d)Assembly (Cont’d)After installation, check that the rear face of the impellerhas the correct height [A].Height – 0.98 inch (24,8 mm

THERMOSTATRemoval And InstallationRemove the bolts from the thermostat housing [A].Installation: Tighten the bolts to 10–17 ft.–lbs. (14–23Nm) torque.

WATER JACKET TUBERemoval And InstallationRemove the timing gearcase cover. (See Page 7–71.)Remove the idler gear and hub. (See Page 7–73.)Remove the f

–7–90–853, 853H LoaderService Manual

SYSTEMSANALYSIS853,853H Loader–8–1– Service ManualSYSTEM ANALYSISBOSS® DIAGNOSTIC TOOLProcedure 8–3. . . . . . . . . . . . . . . . . . . . . . . . . .

–8–2–853, 853H LoaderService Manual

BOSS® DIAGNOSTIC TOOLProcedureThe tool listed will be needed to do the followingprocedure:MEL1400 – Diagnostic ToolStop the engine.Lift and block the

ACD–10853ENGINE COOLING SYSTEMChecking The Coolant LevelCheck the cooling system every day to preventover–heating, loss of performance or engine damag

RPM SENSORAdjustmentContinuity Resistance of 3000–3500 ohms.Disconnect the connector [A] from the engine harness.Loosen the jam nut (Item 1) [A] on th

SERVICE CODES ChartThe following list references the defect codes that aretransmitted to the instrument panel display which canoccur. Some service pro

SUBJECT DISPLAY READSHydrostatic Charge HF1–2 WARNING, High Restriction Filter Condition HF1–6 Sensor No SignalHydrostatic Fluid HP 1 SHUTDOWN, Pres

12 volt supply andBOSS failure.Sensor No Signal orNo RPM’s.Lack of 5.0 voltsregulated power.Low voltage (5.0)triggered reset.The display is not faultt

BOSS® UNITRemoval And InstallationRaise the loader operator cab. (See Page 1–1.)Loosen the nuts (Item 1) [A] from the sensing system unit(Item 2) [A].

BOSS® INSTRUMENT PANELRemoval And InstallationPry the rubber light mount from the operator cab (bothsides) [A].Lower the light from the operator cab a

–8–10–853, 853H LoaderService Manual

SPECIFICATIONS853, 853H Loader–9–1– Service ManualSPECIFICATIONSDECIMAL & MILLIMETER EQUIVALENTSChart 9–17. . . . . . . . . . . . . . . . . . . .

–9–2–853, 853H LoaderService Manual

Operating Weight 6497 lbs. (2950 kg). . . . . . . . . . . . . . . . . . . Rated Operating Capcity 1700 lbs. (772 kg). . . . . . . . . . . . . Tipping

ENGINE COOLING SYSTEM (Cont’d)Replacing The CoolantDo not remove radiator cap when the engine ishot. You can be seriously burned.W–2070–1285Open the r

Hydraulic SystemPump Engine driven gear type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Capacity 18.0 GPM (68,1 L/min.) @ 2750 RP

ENGINE SPECIFICATIONSAll dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.Cylinder HeadDi

ENGINE SPECIFICATIONS (Cont’d)All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.Piston

ENGINE SPECIFICATIONS (Cont’d)All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.NOTE:

TORQUE SPECIFICATIONS FOR LOADERSpecificationsItem Ft.–Lbs. NmAir Cleaner Mounting Bolts 25–28 34–38. . . . . . . . . . . . . . . . . . . . . . . . .

TORQUE SPECIFICATIONS FOR LOADER (Cont’d)Specifications (Cont’d)Item (Cont’d) Ft.–Lbs. NmThermostat Housing Bolts 10–17 14–23. . . . . . . . . . . . .

INCH. .250 80–90 110–120LBS. (9,0–10,2) (12,4–13,6)(Nm).3125 180–200 215–240(20,3–22,6) (24,2–27,1).375 25–28 35–40(34–38) (47–54).4375 40–45 60–65(54

MaterialThread Size(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10M 5 x 0.8 3–4 ft.–lbs.(4–5 Nm)M 6 x 1.0 6–7 ft.–lbs. 6–9 ft.–lbs.(8–9 Nm) (8–12

AB–07575BA–01852NutNutWasherWasherO–ringO–ringCTS–0161912–9–12–853, 853H LoaderService ManualHYDRAULIC CONNECTION SPECIFICATIONSO–ring Face Seal Conne

BTS–0161912Hex Flat Tightening Method853, 853H Loader–9–13– Service ManualHYDRAULIC CONNECTION SPECIFICATIONS (CONT’D)O–ring Flare FittingThe flare is

ALTERNATOR BELTAdjusting The Alternator BeltStop the engine.Raise the operator cab. (See Page 1–8.)Loosen the alternator mounting bolt (Item 1) [A].Lo

AP–13572Copper Bonnet Orifice1–9–14–853, 853H LoaderService ManualHYDRAULIC CONNECTION SPECIFICATIONS (CONT’D)O–ring Flare Fitting (Cont’d)NOTE: O–rin

AP–13008Nut Sealsto FittingNut Sealsto PortSecondary O–ring SealFitting TORQUENut Ft.–lbs.Wrench Size Thread Size (Nm)11/16’’ 9/16’’ – 18 22 (30)15/16

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONSSpecificationsUse Melroe hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is notavailab

LINEAR Miles Kilometers 1.609MEASUREMENT Yards Meters 0.9144Feet Meters 0.3048Feet Centimeters 30.48Inches Meters 0.0254Inches Centimeters 2.54Inches

–9–18–853, 853H LoaderService Manual853, 853H Service Manual #6720755 – Specifications Section

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–00129 April 1991AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (2–91)SERVIC

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–00210 July 1991AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (2–91)SERVICE

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–00320 September 1991AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (2–91)SE

HYDRAULIC/HYDROSTATIC SYSTEMChecking And Adding FluidUse only recommended fluid in the hydraulic system SeeSPECIFICATIONS, Page 9–1 for the correct fl

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–0046 January 1992AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (2–91)SERVI

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–00510 April 1992AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (2–91)SERVIC

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–00629 June 1992AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (2–91)SERVICE

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–00730 December 1992AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (2–91)SER

TAKE OUT PUT INHYDRAULIC/HYDROSTATIC FLOW CHARTFor Model853H Plus (S/N 75001 & Above)Chart #6722311 (Printed December 1992)HYDRAULIC/HYDROSTATIC S

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–0085 March 1993AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (2–91)SERVICE

Remove the screen (Item 1) [B] and thoroughly clean withclean solvent.Raise the operator cab. (See Page 1–8.)HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)Repl

TAKE OUT PUT INEngine Service Contents (Revised Sept. 91) Engine Service Contents (Revised Mar. 93)7–1, 7–2 7–1, 7–2 (Revised Mar. 93)7–3, 7–4 7–3, 7–

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–0095 January 1994AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (2–91)SERVI

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–01017 February 1994AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (2–91)SER

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–01125 May 1994AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (2–91)SERVICE

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–0122 November 1998AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (2–91)SERV

®DatePARTS MANAGERSERVICE MANAGERSALES MANAGERXRevision Number850–131 June 1999AFFECTING:ModelBOBCAT LOADERProductManual No.8536720755 (6–99)SERVICE M

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)Hydraulic Reservoir Breather CapSee SERVICE SCHEDULE, Page 1–3 for the correctservice interval.Remove the breath

SPARK ARRESTOR MUFFLERCleaning ProcedureSee the SERVICE SCHEDULE, Page 1–3 for serviceinterval for cleaning the spark arrestor muffler.Do not operate

TIRE MAINTENANCEWheel NutsSee the SERVICE SCHEDULE, Page 1–3 for the serviceinterval to check the wheel nuts. The correct torque is105–115 ft.–lbs. (1

FINAL DRIVE TRANSMISSION (CHAINCASE)Checking And Adding OilThe chaincase contains the final drive sprockets andchains and uses the same type of oil as

LUBRICATING THE LOADERProcedureLubricate the loader as specified in the SERVICESCHEDULE, Page 1–3 for the best performance of theloader.Record the ope

LUBRICATING THE LOADER (Cont’d)Procedure (Cont’d)5. Rod End Tilt Cylinder [A].6. Bob–Tach Pivot Pin (Both Sides) [B].7. Bob–Tach Wedge (Both Sides) [B

REMOTE START SWITCHProcedureThe tool listed will be needed to do the followingprocedure:MEL1398 – Remote Start SwitchMEL1416 – Adapter Harness (853 Ba

–1–30–853, 853H LoaderService Manual

HYDRAULICSYSTEM853, 853H Loader–2–1– Service ManualHYDRAULIC SYSTEMBUCKET POSITION VALVE (S/N 5102) & (S/N 5103)Removal And Installation 2–40. . .

–2–2–853, 853H LoaderService ManualHYDRAULIC SYSTEM (Cont’d)SELECT VALVE (JEM) (S/N 512811001 & Above)Checking The Relief Valve 2–30. . . . . . .

HYDRAULIC SYSTEM INFORMATION853, 853H Loader–2–3– Service Manual

HYDRAULIC SYSTEM INFORMATION (Cont’d)–2–4–853, 853H LoaderService Manual

HYDRAULIC SYSTEM INFORMATION (Cont’d)853, 853H Loader–2–5– Service Manual

AIR CLEANER HOUSING 7–1. . . . . . . . . . . . . . . . . . . . . . ALTERNATOR 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE,

–2–6–853, 853H LoaderService Manual

18.0 GPM (68,1 L/min.)at 2750 RPM C apacity . . . 15.5 Qts (14,7 L)DISPLACEMENT CONTROL VALVE Neutral . . . . 310-330 PSI

MC2396U (5-19-99)WORKING CIRCUITSPILOT PRESSUREDRAIN CIRCUITSCOMPONENTSFRONT AUXILIARY VALVE (OPTIONAL)(APITECH)RIGHT DRIVE MOTORBUCKET POSITION VALVE

C apacity . . . 15.5 Qts(14,7 L)DISPLACEMENT CONTROL VALVE Neutral . . . . 310-330 PSI (2137-2275 kPa ) Stroked . . . . 3O0-32

MC2397U (5-19-99)WORKING CIRCUITSPILOT PRESSUREDRAIN CIRCUITSCOMPONENTSRIGHT DRIVE MOTORBUCKET POSITION VALVE (OPTIONAL)HYDRAULICCONTROL VALVEFRONT AU

RADIATOR 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESERVOIR, Hydraulic Fluid 2–1. . . . . . . . . . . . . . . . . . .

2750 RPM at C apacity . . . 15.5 Q ts (14,7 L)DISPLACEMENT CONTROL VALVE Neutral . . . . 310-330 PSI (2137-2275

MC2398U (5-19-99)WORKING CIRCUITSPILOT PRESSUREDRAIN CIRCUITSCOMPONENTS2123234326303033313535322324445171817183636191920202121222589101014141337165671

PUMP CAPACITY: 18.0 GPM (68,1 L/min.)HI FLOW CAPACITY: (Includes ) 24.0 GPM (90,8 L/ min.)at 2750 RPM C apacity . . . 16.0 Q ts (1

MC2399U (5-19-99)WORKING CIRCUITSPILOT PRESSUREDRAIN CIRCUITSCOMPONENTSRIGHT DRIVE MOTORBUCKET POSITION VALVE (OPTIONAL)HYDRAULICCONTROLVALVEFRONT AUX

TROUBLESHOOTINGChartThe following troubleshooting chart is provided forassistance in locating and correcting problems which aremost common. Many of th

When repairing hydrostatic and hydraulicsystems, clean the work area beforedisassembly and keep all parts clean. Alwaysuse caps and plugs on hoses, tu

LIFT CYLINDER(S)Checking The Lift CylinderLower the lift arms. Stop the engine. Raise the seat bar.Check only one cylinder at a time. Disconnect the h

LIFT CYLINDER(S) (Cont’d)Removal And Installation (Cont’d)Remove the retaining bolt and nut (Item 1) [A] from theretaining pin on the base end of the

Disconnect the hose (Item 1) [A] which goes to the baseend of the tilt cylinder.Put a plug in the hose and tighten.Connect a hose between cylinder por

TILT CYLINDER (Cont’d)Removal And Installation (Cont’d)Remove the retainer bolt and nut (Item 1) [A] from thebase end pivot pin.Installation: Tighten

PREVENTIVEMAINTENANCEHYDRAULICSYSTEMHYDROSTATICSYSTEMDRIVESYSTEMMAINFRAMEELECTRICALSYSTEMENGINESERVICESYSTEMSANALYSISSPECIFICATIONS853, 853H Loaderi S

TS–01060HYDRAULIC CYLINDERLift Cylinder Identification 1. Tube 2. O–ring 3. Plug 4. Case 5. O–ring 6. Nut 7. Piston 8. Ring 9. O–rin

TS–01098HYDRAULIC CYLINDER (Cont’d)Tilt Cylinder Identification 1. Case 2. Tube 3. Plug 4. O–ring 5. Clamp 6. Nut 7. Nut 8. Piston 9.

HYDRAULIC CYLINDERS (Cont’d)DisassemblyUse the following tools to disassemble the cylinder:MEL1074 – O–ring Seal HookSpanner WrenchThe lift and tilt c

HYDRAULIC CYLINDERS (Cont’d)Disassembly (Cont’d)Standard Piston: Remove the seal (Item 1) [A], andO–ring (Item 2) [A] from the piston (Item 3) [A].Cus

HYDRAULIC CYLINDERS (Cont’d)AssemblyUse the following tools to assembly the cylinder:MEL1396 – Seal Installation ToolMEL1033 – Rod Seal Installation T

HYDRAULIC CYLINDERS (Cont’d)Assembly (Cont’d)Install the rod seal in the head [A].Install the wiper seal with the wiper toward the outside ofthe head.

HYDRAULIC CYLINDERS (Cont’d)Assembly (Cont’d)Lift Cylinder: Install the head (Item 1) [A], and spacer(Item 2) [A].Lift Cylinder: Install the piston (I

W–2006–0284When the engine is running during service, thesteering levers must be in neutral and theparking brake engaged. Failure to do so cancause in

MAIN RELIEF VALVE (Cont’d)Checking The Main Relief Valve Without AuxiliariesThe tools listed will be needed to do the followingprocedure:MEL10003 – Hy

MAIN RELIEF VALVE (Cont’d)Removal And InstallationRaise the operator cab. (See Page 1–1.)When making repairs on hydrostatic andhydraulic systems, clea

FOREWORDThis manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustmentprocedures for the Bobcat loader and its componen

DUAL PRESSURE MAIN RELIEF VALVE (S/N512811001 & Above) W/ Select Valve (JEM)Checking The Low SettingThe tools listed will be needed to do the foll

DUAL PRESSURE MAIN RELIEF VALVE (S/N512811001 & Above) W/Select Valve (JEM) (Cont’d)Checking The High SettingThe tools listed will be needed to d

W–2006–0284When the engine is running during service, thesteering levers must be in neutral and theparking brake engaged. Failure to do so cancause in

DUAL PRESSURE MAIN RELIEF VALVE (S/N512811001 & Above) W/Select Valve (JEM) (Cont’d)Adjusting The Low SettingNOTE: Adjust the low pressure setting

DUAL PRESSURE MAIN RELIEF VALVE (S/N512811001 & Above) W/Select Valve (JEM) (Cont’d)Adjusting The High SettingNOTE: Adjust the low pressure settin

HYDRAULIC CONTROL VALVERemoval And Installation (Cont’d)Stop the engine. Move the hydraulic controls to releasethe hydraulic pressure. Raise the seat

HYDRAULIC CONTROL VALVE (Cont’d)Removal And Installation (Cont’d)Remove the control valve outlet tubeline (Item1) [A] fromthe control valve.Remove the

SELECT VALVE (S/N 512811001 & Above) W/SelectValve (JEM)Checking The Relief ValveThe tools listed will be needed to do the followingprocedure:MEL1

SELECT VALVE (S/N 512811001 & Above) W/SelectValve (JEM) (Cont’d)Checking The Relief Valve (Cont’d)If the relief pressure is not correct, stop the

SELECT VALVE (S/N 512811001 & Above) W/SelectValve (JEM) (Cont’d)Removal And InstallationRaise the operator cab. (See Page 1–1.)Remove the bolt (I

17. Inspect the air cleaner fordamage or leaks. Check thecondition of the element.18. Check the electrical chargingsystem.19. Check ti

SELECT VALVE (S/N 512811001 & Above) W/SelectValve (JEM) (Cont’d)Removal And Installation (Cont’d)Remove the mounting bolts (Item 1) [A] located o

SELECT VALVE (S/N 512811001 & Above) W/SelectValve (JEM) (Cont’d)Disassembly And Assembly (Cont’d)Remove the 4–way solenoid valve (Item 1) [A].Rem

HYDRAULIC FILTER HOUSINGRemoval And InstallationDisconnect the tubelines from the inlet of the hydraulicfilter [A].Disconnect the hose (Item 1) [B] fr

BP–10949HYDRAULIC PUMPChecking The Output Of The PumpThe tools listed will be needed to do the followingprocedure:MEL10003 – Hydraulic TesterMEL10006

HYDRAULIC PUMP (Cont’d)Removal And InstallationWhen making repairs on hydrostatic andhydraulic systems, clean the work area beforedisassembly and keep

HYDRAULIC FLUID RESERVOIRRemoval And InstallationRaise the operator cab. (See Page 1–1.)Disconnect the motor case drain hose from the case drainfilter

LOCK VALVE (S/N 5103)Removal And InstallationNOTE: The lock valve is optional for the (S/N 5102)& the (S/N 5101) loaders.Disconnect the two tubeli

BUCKET POSITION VALVE (S/N 5102) & (S/N 5103)Removal And InstallationNOTE: The bucket position valve is optional for the(S/N 5101) loader.Remove a

FRONT AUXILIARY CONTROL VALVE (Apitech)Removal And Installation(S/N 508411001 – 15215)(S/N 509711001 & Above)(S/N 510375001 & Above)(S/N 51012

CONTROL PEDALSRemoval And InstallationRemove the bolt and nut (Item 1) [A] from the pedallinkage.Installation: Tighten the bolt and nut to 21–25 ft.–l