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Bobcat 853, 853H HIGH-FLOW Skid-Steer Loader Repair Service Manual - 6724012


(S/N: 512816001 and Above) - (S/N: 508418001 and Above) - (S/N: 509718001 and Above)
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This service manual PDF download for the 853, 853H Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

853, 853H Bobcat Loader
HIGH FLOW
S/N: 512816001 and Above
S/N: 508418001 and Above
S/N: 509718001 and Above


TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
SYSTEM ANALYSIS
SPECIFICATIONS
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6724012 (4–95)
Total Pages : 460


This 853, 853H Bobcat Loader Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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MAINTENANCE SAFETY
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
LOADER SERIAL NUMBER
ENGINE SERIAL NUMBER
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
OPTIONS AND ACCESSORIES
PREVENTIVE MAINTENANCE
SERVICE SCHEDULE
LIFTING AND BLOCKING THE LOADER
Procedure
TRANSPORTING THE LOADER
Procedure
TOWING THE LOADER
Procedure
STOPPING THE BOBCAT LOADER
LIFTING THE LOADER
Four Point Lift
Single Point Lift
LIFT ARM SUPPORT DEVICE
Engaging The Lift Arm Support Device
Disengaging The Lift Arm Support Device
OPERATOR CAB
Description
Raising The Operator Cab
Lowering The Operator Cab
Emergency Exit
SEAT BAR RESTRAINT SYSTEM
Description
Seat Bar Inspection
Seat Bar Maintenance
AIR CLEANER SERVICE
Replacing Filter Element
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Replacing Oil And Filter
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking The Coolant Level
Removing Coolant From The Cooling System
Propylene Glycol
ALTERNATOR BELT
Adjusting The Alternator Belt
USING A BOOSTER BATTERY (Jump Starting)
Procedure
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Replacing Hydraulic/Hydrostatic Filters
Replacing Hydraulic Fluid
Hydraulic Reservoir Breather Cap
SPARK ARRESTOR MUFFLER
Cleaning Procedure
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Tire Mounting
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
Removing Oil From The Chaincase
FAN GEARBOX
Checking And Maintaining
LUBRICATING THE LOADER
Procedure
REMOTE START SWITCH
Procedure
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
TROUBLESHOOTING
HYDRAULIC SYSTEM INFORMATION
Flare Connections
O–ring Face Seal Connection
Straight Thread O–ring Fitting
Tubelines And Hoses
LIFT CYLINDER(S)
Checking The Lift Cylinder
Removal And Installation
TILT CYLINDER
Checking The Tilt Cylinder
Removal And Installation
Rod End Seal
HYDRAULIC CYLINDER
Lift Cylinder Identification
Tilt Cylinder Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Checking The Main Relief Valve
Checking The Main Relief Valve Without Auxiliaries
Removal And Installation
DUAL PRESSURE MAIN RELIEF VALVE – 853H
Checking The Low Setting
Checking The High Setting
Adjusting The Low Setting
Adjusting The High Setting
SELECT VALVE (G.E.M. Block) 853H
Checking The Main Relief Valve
HYDRAULIC CONTROL VALVE
Removal And Installation
Identification Chart
Disassembly And Assembly
Main Relief Valve
Port Relief Valve
Anti–Cavitation Valve
Rubber Boot
Lift Spool And Detent
Tilt Spool And Centering Spring
Auxiliary Spool
Auxiliary Electric Solenoid
H Port – Auxiliary Section
Base End Restrictor
Inspection
Spool Seal Installation
HYDRAULIC PUMP
Checking The Output Of The Pump
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
HYDRAULIC PUMP (Double Gear) 853H
Checking The Output Of The Pump
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
BUCKET POSITION VALVE (Optional)
Removal And Installation
HYDRAULIC FLUID RESERVOIR
Removal And Installation
HYDROSTATIC FILTER HOUSING
Removal And Installation
HYDRAULIC FILTER HOUSING
Removal And Installation
CONTROL PEDALS
Removal And Installation
Pedal Adjustment
PEDAL INTERLOCK LINKAGE
Removal And Installation
Pedal Interlock Linkage Adjustment
HYDROSTATIC SYSTEM
TROUBLESHOOTING
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function
FRONT PANEL
Removal And Installation
STEERING LEVERS
Disassembly And Assembly
Pre–Adjustment Checks
Adjusting Lever Freeplay
Adjusting The Wheel RPM Forward Compared To Reverse Travel
Adjusting The Steering Neutral Setting
Adjusting The Wheel RPM Left Compared To Right Side
HYDROSTATIC MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
Timing The Hydrostatic Motor
HYDROSTATIC PUMP
Removal And Installation
Replenishing/High Pressure Relief Valve
Parts Identification
Hydraulic Pump Removal
Hydrostatic Pump Separation
Charge Pump Disassembly
Disassembly
Inspection
Assembly
Charge Pump Assembly
Hydrostatic Pump Connection
Hydraulic Pump Installation
Hydrostatic Pump Neutral Adjustment
DRIVE BELT SHIELD
Removal And Installation
DRIVE BELT
Adjusting The Drive Belt
Replacing The Drive Belt
DRIVE BELT TENSIONER PULLEY
Removal And Installation
Disassembly
Assembly
Checking Pulley End Play
OIL COOLER
Removal And Installation
DRIVE SYSTEM
PARKING BRAKE PEDAL
Removal And Installation
Disassembly And Assembly
PARKING BRAKE DISC
Removal And Installation
FRONT CHAINCASE COVER
Removal And Installation
REAR CHAINCASE COVER
Removal And Installation
AXLE SEAL
Removal And Installation
AXLE, SPROCKET AND BEARINGS
Removal And Installation
REDUCTION GEARCASE
Reduction Gearcase Seal
Removal And Installation
Checking Reduction Gearcase
Disassembly
Assembly
DRIVE CHAIN
Removal And Installation
CHAINCASE FLUID
Removing The Fluid From The Chaincase
MAIN FRAME
SEAT BAR
Removal And Installation
Assembly
Compressing The Gas Cylinder
OPERATOR CAB GAS CYLINDER
Removal And Installation
Disassembly And Assembly
OPERATOR CAB
Removal And Installation
OPERATOR SEAT
Removal And Installation
BOB–TACH
Removal And Installation
Bob–Tach Lever And Wedge
Bob–Tach Stops
LIFT ARMS
Removal And Installation
REAR GRILL
Removal And Installation
REAR DOOR
Removal And Installation
Hood Removal And Installation
Bumper Removal And Installation
Door Latch Removal And Installation
Door Latch And Catch Adjustment
FUEL TANK
Removal And Installation
Inlet Screen
ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
TROUBLESHOOTING
ELECTRICAL SYSTEM INFORMATION
Description
Fuse Location (Standard & BOSS® Option)
BATTERY
Removal And Installation
ALTERNATOR
Alternator Output Test
Rectifier (Diode) Test
Alternator Regulator Test
Removal And Installation
Disassembly And Inspection
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Rectifier Continuity (Diode) Test
Assembly
STARTER
Removal And Installation
Checking The Starter
Parts Identification
Disassembly And Assembly
Cleaning And Inspection
STANDARD INSTRUMENT PANEL
Removal And Installation
FRONT LIGHTS
Removal And Installation
RELAY SWITCHES
Location
ENGINE SERVICE
TROUBLESHOOTING
ENGINE SPEED CONTROL
Removal And Installation
Disassembly
RADIATOR
Removal And Installation
COOLANT RECOVERY TANK
Removal And Installation
ENGINE MUFFLER
Removal And Installation
AIR CLEANER HOUSING
Removal And Installation
BLOWER HOUSING/FAN GEARBOX
Removal And Installation
FAN DRIVE TENSION PULLEY
Removal And Installation
BLOWER FAN
Removal And Installation
FAN GEARBOX
Parts Identification
Disassembly
Assembly
Checking Backlash
ENGINE
Removal And Installation
Engine Mount Replacement
FLYWHEEL
Removal And Installation
Flywheel Ring Gear
BELT SHIELD
Removal And Installation
VALVE CLEARANCE
Adjustment
ENGINE COMPRESSION
Checking
GLOW PLUGS
Removal And Installation
Checking The Glow Plugs
FUEL INJECTION PUMP
Description
Removal And Installation
Timing The Injection Pump
FUEL INJECTOR NOZZLES
Removal And Installation
Checking
CYLINDER HEAD
Removal And Installation
Cylinder Head Surface Alignment
Exhaust Manifold
VALVES, VALVE SEAT AND GUIDE
Removal
Installation
Reconditioning The Valve And Valve Seats
Valve Seat Insert
Valve Guide
Valve Spring
ROCKER ARM AND SHAFT
Disassembly And Assembly
Checking Rocker Arm And Push Rods
PISTON AND CONNECTING ROD
Removal
Disassembly
Checking
Assembly
Installation
CYLINDER LINERS
Checking The Cylinder Bore
Removal
Installation
MAIN BEARINGS
Description
Removal
Installation
Crankshaft End Play
CRANKSHAFT
Removal And Installation
Checking Tuffriding (Soft Nitriding) Coating
Checking the Crankshaft
CRANKSHAFT GEAR
Removal And Installation
TIMING GEARCASE COVER SEAL
Removal And Installation
TIMING GEARCASE COVER
Removal And Installation
IDLER GEAR AND HUB
Removal
Checking
Installation
FUEL INJECTION PUMP IDLER GEAR
Removal And Installation
Bearing Installation
CAMSHAFT GEAR
Removal And Installation
TIMING GEARCASE
Removal And Installation
CAMSHAFT
Removal And Installation
Checking
Camshaft Bearings
Tappets
Tappet Installation
OIL PAN
Removal
Installation
OIL PUMP
Removal And Installation
Checking
Gear Replacement
Rotor Replacement
Oil Pump Relief Valve
Oil Filter Housing And Block
WATER PUMP
Removal And Installation
Disassembly
Assembly
THERMOSTAT
Removal And Installation
Checking The Thermostat
WATER JACKET TUBE
Removal And Installation
SYSTEMS ANALYSIS
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Inspecting The BICS System Controller (Engine STOPPED – Key ON)
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The Lift Arm By–Pass Control
Maintenance
Troubleshooting Chart
Troubleshooting Guide
BICS SYSTEM CONTROLLER
TRACTION LOCK
SEAT SENSOR
SEAT BAR SENSOR
LIFT LOCK BY–PASS VALVE
BICS™ SYSTEM CONTROLLER
Removal And Installation
Controller Test
SEAT BAR SENSOR
Removal And Installation
Seat Bar Sensor Test
SEAT SENSOR
Removal And Installation
Seat Sensor Test
TRACTION LOCK
Removal And Installation
LIFT LOCK BY–PASS VALVE
Removal And Installation
Disassembly And Assembly
TILT LOCK VALVE
Removal And Installation
Disassembly And Assembly
BOSS® DIAGNOSTIC TOOL
Procedure
SENDER AND SENSOR
Service Checks
Component
RPM SENSOR
Adjustment
MONITOR SERVICE CODES
TROUBLESHOOTING THE BOSS® & LCD DISPLAY
OPERATION SENSING SYSTEM UNIT
Removal And Installation
BOSS® INSTRUMENT PANEL
Removal And Installation
PWM MODULE
Description
PWM TROUBLESHOOTING
Conditions
Chart
PWM CONTROL HANDLE
Handle Testing
PWM ELECTRIC SOLENOID
Solenoid Coil Testing
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
SPECIFICATIONS
LOADER SPECIFICATIONS
LOADER DIMENSIONS
OPERATION & PERFORMANCE
ENGINE
HYDRAULIC SYSTEM
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
VIBRATION DATA
ENGINE SPECIFICATIONS
Cylinder Head
Valve, Valve Guide & Seat Insert
Valve Springs
Rocker Arm
Tappets
Piston, Pin & Rings
Connecting Rod & Bearing
Cylinder Liners
Camshaft
Crankshaft
Idler Gear
Oil Pump
Fuel System
Torque For General Metric Bolts
TORQUE SPECIFICATIONS FOR LOADER
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION
SERVICE MANUAL REVISIONS
850–001
850–002
850–003
850–004
850–005

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