Service manual

ManualsBrandsBobcat ManualsBusiness equipment853H

6720755 (6–99) Printed in U.S.A. © Melroe Company 1999

Service

Manual

(S/N 508411001–508417999)

(S/N 50971

1001–509717999)

(S/N 510250001 & Above)

(S/N 510375001 & Above)

(S/N 512815001–512815999)

(S/N 510125001 & Above)

(S/N 512311001 & Above)

Summary of content (372 pages)

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8 5 3 Service Manual (S/N 508411001–508417999) (S/N 509711001–509717999) (S/N 510250001 & Above) (S/N 510375001 & Above) (S/N 512815001–512815999) (S/N 510125001 & Above) (S/N 512311001 & Above) 8 5 3 H 6720755 (6–99) Printed in U.S.A.
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MAINTENANCE SAFETY WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s 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. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.
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ALPHABETICAL INDEX GEAR, Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 GEAR, Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 GEAR, Fuel Injection Pump Idler . . . . . . . . . . . . . . . . . 7–1 GEAR AND HUB, Idler . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 GEARBOX, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 7–1 GEARCASE, Reduction . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 GEARCASE, Timing . . . . . . . . . .
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ALPHABETICAL INDEX (Cont’d) RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESERVOIR, Hydraulic Fluid . . . . . . . . . . . . . . . . . . . RELAY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOTE START SWITCH . . . . . . . . . . . . . . . . . . . . . ROCKER ARM AND SHAFT . . . . . . . . . . . . . . . . . . . . 7–1 2–1 6–1 1–1 7–1 SEAL, Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAT BAR RESTRAINT SYSTEM . . . . . . . . . .
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CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . .
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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 (Including sidescreens) is in good condition and is not modified. 9.
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17. Inspect the air cleaner for damage or leaks. Check the condition of the element. 18. Check the electrical charging system. 19. Check tires for wear and pressure. 20. Inspect for loose or broken parts or connections. 21. Operate the loader and check all functions. 22. Check for any field modification not completed. 23. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer.
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iv 853, 853H Loader Service Manual
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SAFETY INSTRUCTIONS Instructions are necessary before operating or servicing machine. Read and understand the 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. Untrained operators and failure to follow instructions can cause injury or death.
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SAFETY INSTRUCTIONS (Cont’d) • Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing protection or loader special applications kit are required for some work. See your dealer for Melroe Safety equipment. • Know where fire extinguisher and first aid kit are located and how to use them. • Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.
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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: XXXX P–00369 XXXXX Module 2.
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BOBCAT LOADER IDENTIFICATION FRONT LIGHTS GRAB HANDLES OPERATOR SEAT STEERING LEVER REAR AUXILIARY QUICK COUPLERS SEAT BELT TILT CYLINDER FRONT AUXILIARY QUICK COUPLERS SAFETY TREAD BUCKET BUCKET STEPS OPERATOR CAB (ROPS & FOPS) SEAT BAR LIFT ARM LIFT ARM SUPPORT DEVICE REAR GRILL LIFT CYLINDER TAIL LIGHT REAR LIGHT REAR DOOR REAR TIE DOWN TIRES* B–12555 B–12556 * TIRES – Flotation tires are shown. The Bobcat loader is based–equipped with standard tires.
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PREVENTIVE MAINTENANCE Page Number PREVENTIVE MAINTENANCE AIR CLEANER SERVICE Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 ALTERNATOR BELT Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20 ENGINE COOLING SYSTEM Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . .
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PREVENTIVE MAINTENANCE (Cont’d) Page Number REMOTE START SWITCH Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–29 SEAT BAR RESTRAINT SYSTEM Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .
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SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader. Instructions are necessary before operating or servicing machine. Read and understand the Operation Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manual when making repairs, adjustments or servicing.
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A Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manuals, 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. Untrained operators and failure to follow instructions can cause injury or death. W–2003–0199 Read the Removal & Installation, Disassembly & Assembly, etc.
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TRANSPORTING THE LOADER A Procedure Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury. W–2058–0494 MC–01241 The rear of the transport vehicle must be blocked or supported when loading or un–loading the loader. B A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A].
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LIFTING THE LOADER A Four Point Lift AVOID INJURY OR DEATH • Before lifting, check fasteners on four point lift. • Never allow riders in the cab or bystanders within 15 feet (5 meters) while lifting the machine. MC–01434 W–2046–1290 B The loader can be lifted with the four point lift which is available as a kit from your Bobcat loader dealer. Attach cables or chains to lift eyes as shown [A].
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LIFT ARM SUPPORT DEVICE A 1 Never work on a machine with the lift arms up unless the lift arms are secured by a lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. 2 W–2059–0991 P–02133 Engaging the Lift Arm Support Device Maintenance and service work can be done with the lift arms lowered.
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LIFT ARM SUPPORT DEVICE (Cont’d) A Disengaging The Lift Arm Support Device Remove the pin from the lift arm support device. 1 Connect the spring (Item 1) [A] from the lift arm support device to the bracket below the lift arms. With the operator in the seat, seat belt fastened and seat bar lowered, start the engine. Raise the lift arms a small amount and the spring will lift the support device off the lift cylinder rod. P–01542 Lower the lift arms. Stop the engine.
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OPERATOR CAB A Description The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged. The seat belt must be worn for roll over protection. ROPS/FOPS Roll Over Protective Structure per SAE J104 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level l. Level ll is available.
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OPERATOR CAB (Cont’d) A Lowering The Operator Cab NOTE: Make sure the seat bar is fully raised or lowered when lowering the cab. Pull down on the bottom of the operator cab until it stops at the latching mechanism. Release the latching mechanism (Item 1) [A] and pull the cab all the way down. 1 CD–15124 B Install the plate and nut (Item 1) [B] (both sides). Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque [B].
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SEAT BAR RESTRAINT SYSTEM A Description The seat bar restraint system has a pivoting seat bar with arm rests and has spring loaded interlocks for the lift and tilt control pedals. The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. The interlocks require the operator to lower the seat bar in order to operate the foot pedal.
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AIR CLEANER SERVICE A Replacing Filter Element 1 2 See the SERVICE SCHEDULE, Page 1–3 for the interval to service the air cleaner system. WITH CONDITION INDICATOR: Replace the large (outer) filter element only when the red ring shows in the window of the condition indicator (Item 1) [A]. NOTE: Before replacing the filter element, push the button on the condition indicator (Item 2) [A]. Start the engine. If the red ring does not show, do not replace the filter element.
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AIR CLEANER SERVICE (Cont’d) A Replacing Filter Element (Cont’d) Remove the wing nut (Item 1) [A] at the large air filter element. 1 CD–15119 B Remove the large filter element [B]. NOTE: Make sure all sealing surfaces are free of dirt and debris. Install the new filter element and washer and tighten the wing nut. Check the air intake hose for damage. Check the air cleaner housing for damage. Check to make sure all connections are tight.
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FUEL SYSTEM A Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 1 or Grade No. 2 . The following is one suggested blending guideline which should prevent fuel gelling problems: Temp. F° (C°) No. 2 No.1 +15°(9°) Down to –20° (–29°) Below –20° (29°) 100% 50% 0% 0% 50% 100% 1 We recommend an operator contact their fuel supplier for local recommendations. P–02124 Filling The Fuel Tank B WRONG Stop and cool the engine before adding fuel.
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FUEL SYSTEM (Cont’d) A Removing Air From The Fuel System 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 prior to starting the engine. 1 Loosen the air vent plug (Item 1) [A] at the top of the fuel filter. 2 Operate the priming bulb (Item 2) [A] until fuel flows from the filter vent. Tighten the fuel filter vent plug (Item 1) [A]. CD–15123 B Loosen the air vent plug at the top of the fuel injection pump [B].
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ENGINE LUBRICATION SYSTEM A Checking Engine Oil Check the engine oil level every day. Before starting the engine for the work shift, open the rear door. Remove the dipstick (Item 1) [A]. 1 Keep the oil level between the marks on the dipstick. Use a good quality motor oil that meets API Service Classification of CC, CD or CE. (See Oil Chart below.
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ENGINE LUBRICATION SYSTEM (Cont’d) A Replacing Oil And Filter (Cont’d) Remove the oil filler cap (Item 1) [A]. Put 8 qts. (7,6 L) of oil in the engine. (See Oil Chart, Page 1–16.) Start the engine and let it run for several minutes. Stop the engine. Check for leaks at the oil filter. Add oil as needed if it is not at the top mark on the dipstick. 1 CD–15114 Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.
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ENGINE COOLING SYSTEM A Checking The Coolant Level Check the cooling system every day to prevent over–heating, loss of performance or engine damage. Open the rear door. Check the coolant level in the coolant recovery tank on the right side of the engine [A]. The coolant recovery tank must be 1/3 full. NOTE: The loader is factory filled with propylene glycol coolant. DO NOT mix propylene glycol with ethylene glycol.
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ENGINE COOLING SYSTEM (Cont’d) A Replacing The Coolant 1 Do not remove radiator cap when the engine is hot. You can be seriously burned. W–2070–1285 Open the rear door. Open the rear grill. P–00379 Remove the radiator cap (Item 1) [A]. B Remove the drain plug (Item 1) [B] from the side of the engine block. Drain the coolant into a container. After all the coolant is removed, install and tighten the drain plug.
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ALTERNATOR BELT A Adjusting The Alternator Belt 2 Stop the engine. 1 Raise the operator cab. (See Page 1–8.) Loosen the alternator mounting bolt (Item 1) [A]. Loosen the adjustment bolt (Item 2) [A]. Move the alternator until the belt has 5/16 inch (8,0 mm) movement at the middle of the belt span with 15 lbs. (66 N) of force.
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HYDRAULIC/HYDROSTATIC SYSTEM A Checking And Adding Fluid Use only recommended fluid in the hydraulic system See SPECIFICATIONS, Page 9–1 for the correct fluid. To check the reservoir, use the following procedure: Put the Bobcat loader on a level surface. Lower the lift arms and tilt the Bob–Tach fully back. Stop the engine. Remove the dipstick [A]. CD–15162 The fluid level must be between the marks on the dipstick. B If fluid is needed, remove the fill cap (Item 1) [B].
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HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d) A Replacing The Hydraulic Fluid See the SERVICE SCHEDULE, Page 1–3 for the service interval. The fluid must also be replaced if it becomes contaminated or after major repairs. CD–15135 1 Remove the reservoir fill cap (Item 1) [A]. NOTE: Before installing the fill cap, make sure the rubber gasket is installed on the fill cap (Inset) [A]. Remove the screen (Item 1) [B] and thoroughly clean with clean solvent. CD–15161 Raise the operator cab. (See Page 1–8.
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HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d) A Hydraulic Reservoir Breather Cap See SERVICE SCHEDULE, Page 1–3 for the correct service interval. Remove the breather cap [A]. NOTE: Make sure the rubber gasket is installed on the breather cap (Inset) [A]. CD–15134 Make sure the baffle washer is installed in the hydraulic reservoir [B].
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SPARK ARRESTOR MUFFLER A Cleaning Procedure See the SERVICE SCHEDULE, Page 1–3 for service interval for cleaning the spark arrestor muffler. Do not operate the loader with a defective exhaust system. 1 CD–15172 This loader is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition.
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TIRE MAINTENANCE A Wheel Nuts See the SERVICE SCHEDULE, Page 1–3 for the service interval to check the wheel nuts. The correct torque is 105–115 ft.–lbs. (142–156 Nm) torque [A]. Tire Rotation Check the tires regularly for wear, damage and pressure See SPECIFICATIONS Page 9–1 for the correct tire pressure. Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [B].
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FINAL DRIVE TRANSMISSION (CHAINCASE) A 853,853HServiceManual#6720755–PreventiveMaintenanceSectionPart1of2 Checking And Adding Oil 1 The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic/hydrostatic system See SPECIFICATIONS, Page 9–1. To check the chaincase oil level, use the following procedure: Drive the loader on a level surface. Stop the engine. Remove the plug (Item 1) [A] from the front of the chaincase housing.
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LUBRICATING THE LOADER A Procedure Lubricate the loader as specified in the SERVICE SCHEDULE, Page 1–3 for the best performance of the loader. Record the operating hours each time you lubricate the Bobcat loader. 1 Always use a good quality lithium based multi–purpose grease when you lubricate the loader. Apply the lubricant until extra grease shows. Lubricate the following locations on the loader: CD–15169 1. Rod End Lift Cylinder (Both Sides) [A]. 2. Base End Lift Cylinder (Both Sides) [B].
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LUBRICATING THE LOADER (Cont’d) A Procedure (Cont’d) 5. Rod End Tilt Cylinder [A]. 5 CD–15167 6. Bob–Tach Pivot Pin (Both Sides) [B]. B 7. Bob–Tach Wedge (Both Sides) [B]. 6 7 CD–15166 8. 250 Hours: Steering Lever Shaft and Centering Mechanism [C].
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REMOTE START SWITCH A 853,853HServiceManual#6720755–PreventiveMaintenanceSectionPart2of2 Procedure 1 The tool listed will be needed to do the following procedure: MEL1398 – Remote Start Switch MEL1416 – Adapter Harness (853 Base Only) The remote start switch is required when the service technician is adjusting the steering linkage, checking the hydraulic/hydrostatic system. Lift and block the loader. (See Page 1–4.) CD–11144 Raise the operator cab. (See Page 1–8.
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–1–30– 853, 853H Loader Service Manual
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HYDRAULIC SYSTEM Page Number BUCKET POSITION VALVE (S/N 5102) & (S/N 5103) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–40 CONTROL PEDALS Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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HYDRAULIC SYSTEM (Cont’d) Page Number SELECT VALVE (JEM) (S/N 512811001 & Above) Checking The Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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HYDRAULIC SYSTEM INFORMATION –2–3– 853, 853H Loader Service Manual
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HYDRAULIC SYSTEM INFORMATION (Cont’d) –2–4– 853, 853H Loader Service Manual
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HYDRAULIC SYSTEM INFORMATION (Cont’d) –2–5– 853, 853H Loader Service Manual
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–2–6– 853, 853H Loader Service Manual
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HYDRAULIC/HYDROSTATIC SCHEMATIC 853 (S/N 508411001-15215) (S/N 510125001-26791) (S/N 510250001-50691) (Printed June 1999) MC2396LU LEGEND 1 RESERVOIR: C apacity . . . 15.
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MALE FEMALE FRONT AUXILIARY VALVE (OPTIONAL) (APITECH) FRONT AUXILIARY (OPTIONAL) MALE 30 30 32 FEMALE SECONDARY FRONT AUXILIARY (OPTIONAL) 33 31 LOCK VALVE (OPTIONAL) FEMALE 39 35 35 MALE REAR AUXILIARY (OPTIONAL) RIGHT DRIVE MOTOR HYDRAULIC FILTER 17 18 BUCKET POSITION VALVE (OPTIONAL) D 36 5 11 2 3 4 37 HYDROSTATIC FILTER A 11 HYDROSTATIC PUMPS 28 34 27 24 7 19 2 PORT BLOCK OIL COOLER C 6 B 20 21 29 1 3 23 OUTLET 22 OUTLET 8 HYDRAULIC CONTROL VALVE INLET INLET
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HYDRAULIC/HYDROSTATIC SCHEMATIC 853 (S/N 508415216-17999) (S/N 510126792 AND ABOVE) (S/N 510250692 AND ABOVE) (S/N 512811001-15999) (Printed June 1999) MC2397LU LEGEND 1 RESERVOIR: C apacity . . . 15.
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DIVERTER VALVE (OPTIONAL) FRONT AUXILIARY D2 (S/N 510126792 AND ABOVE) (S/N 510250692 AND ABOVE) MALE D1 FEMALE 29 8 P1 30 P2 31 33 REAR AUXILIARY FEMALE F1 35 MALE F2 32 RIGHT DRIVE MOTOR HYDRAULIC FILTER 17 18 BUCKET POSITION VALVE (OPTIONAL) D 36 5 11 2 3 4 38 HYDROSTATIC FILTER A 11 HYDROSTATIC PUMPS 34 27 24 28 7 19 2 C 6 B 20 21 OIL COOLER 1 3 23 OUTLET 22 OUTLET HYDRAULIC CONTROL VALVE INLET INLET 9 26 10 37 25 10 AUXILIARY SPOOL T1LT CYLINDER 12
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(S/N 512811001-15999 WITH APITECH AUXILIARY VALVE) LEGEND 1 RESERVOIR: C apacity . . . 15.
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30 30 32 33 31 35 17 35 44 18 24 5 11 2 3 36 28 34 4 11 27 2 8 32 19 7 20 9 21 29 6 38 3 1 10 10 22 23 26 12 45 25 14 13 15 21 37 20 14 19 16 36 40 39 42 43 17 Printed in U.S.A.
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HYDRAULIC/HYDROSTATIC SCHEMATIC HI-FLOW MACHINE 853 (S/N 512811001-15999 WITH JEM AUXILIARY VALVE) (Printed June 1999) MC2399LU LEGEND 1 RESERVOIR: C apacity . . . 16.0 Q ts (15,1 L) 2 SPRING LOADED FILTER BYPASS VALVE: 45-55 PSI (311-379 kPa) 3 DIFFERENTIAL PRESSURE SWITCH: 36-44 PSI (248-303 kPa) Standard Loader - Normally Open B.O.S.S.
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FRONT AUXILIARY FEMALE AUXILIARY VALVE (JEM) MALE F2 F1 29 29 32 32 CASE DRAIN FRONT AUXILIARY D1 34 33 31 RIGHT DRIVE MOTOR FEMALE D2 MALE 30 HYDRAULIC FILTER 16 17 BUCKET POSITION VALVE (OPTIONAL) D 36 5 10 2 3 4 38 HYDROSTATIC FILTER A HYDROSTATIC PUMPS 35 28 10 27 24 7 18 2 C 6 19 B 20 PORT BLOCK OIL COOLER 37 1 23 3 22 OUTLET 21 OUTLET HYDRAULIC CONTROL VALVE INLET INLET 8 40 26 9 25 AUXILIARY SPOOL 9 T1LT CYLINDER 11 20 TILT CYLINDER SPOOL 19
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TROUBLESHOOTING Chart The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only. Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death. W–2004–1285 PROBLEM CAUSE The hydraulic system will not operate.
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HYDRAULIC SYSTEM INFORMATION When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I–2003–0888 Tighten Procedures For tightening torques for hydraulic fittings, tubelines etc., See Section 9. – Hydraulic Connection Specifications.
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LIFT CYLINDER(S) A Checking The Lift Cylinder 1 Lower the lift arms. Stop the engine. Raise the seat bar. Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece or 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 from a physician familiar with this injury.
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LIFT CYLINDER(S) (Cont’d) A Removal And Installation (Cont’d) Remove the retaining bolt and nut (Item 1) [A] from the retaining pin on the base end of the cylinder. Installation: Tighten the retainer bolt and nut to 18–20 ft.–lbs. (24–27 Nm) torque. 1 CD–15070 Remove the retaining pin from the base end of the cylinder [B]. B Slide the cylinder forward for clearance to disconnect the hoses. CD–15072 C Mark the hoses for correct installation.
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TILT CYLINDER A Checking The Tilt Cylinder 2 Remove the attachment. Roll the Bob–Tach fully back. Stop the engine. Raise the seat bar. 1 Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece or 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 from a physician familiar with this injury.
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TILT CYLINDER (Cont’d) A Removal And Installation (Cont’d) Remove the retainer bolt and nut (Item 1) [A] from the base end pivot pin. Installation: Tighten the retainer nut and bolt to 18–20 ft.–lbs. (24–27 Nm) torque. 1 CD–15077 Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. B W–2103–1285 Remove the base end pivot pin (Item 1) [B].
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HYDRAULIC CYLINDER Lift Cylinder Identification 1. 2. 3. 4. 5. 6. 7. 8. Tube O–ring Plug Case O–ring Nut Piston Ring 9. 10. 11. 12. 13. 14. 15. 16.
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HYDRAULIC CYLINDER (Cont’d) Tilt Cylinder Identification 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Case Tube Plug O–ring Clamp Nut Nut Piston Seal O–ring 11. 12. 13. 14. 15. 16. 17. 18.
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HYDRAULIC CYLINDERS (Cont’d) A Disassembly Use the following tools to disassemble the cylinder: MEL1074 – O–ring Seal Hook Spanner Wrench The lift and tilt cylinders internal components are similar, the differences are listed below: Tilt rod diameter is larger. Piston relief area is slightly different. No spacer in the tilt cylinder. P–07429 Hold the hydraulic cylinder over a drain pan and move the rod in and out slowly to remove the fluid from the cylinder.
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HYDRAULIC CYLINDERS (Cont’d) A Disassembly (Cont’d) 3 Standard Piston: Remove the seal (Item 1) [A], and O–ring (Item 2) [A] from the piston (Item 3) [A]. 2 1 P–07430 B Cushion Piston: Remove the seal (Item 1) [B], and O–ring (Item 2) [B] from the piston (Item 3) [B]. 3 2 1 P–07439 C Remove the thick O–ring (Item 1) [C], and the back–up washer (Item 2) [C] from the groove in the head. Remove the thin O–ring (Item 3) [C].
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HYDRAULIC CYLINDERS (Cont’d) A Assembly Use the following tools to assembly the cylinder: MEL1396 – Seal Installation Tool MEL1033 – Rod Seal Installation Tool Piston Ring Compressor Spanner Wrench Wash the cylinder parts in solvent and air dry them. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts. P–07424 Always install new O–rings and seals during assembly. Lubricate all O–rings and seals with hydraulic oil during installation.
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HYDRAULIC CYLINDERS (Cont’d) A Assembly (Cont’d) Install the rod seal in the head [A]. Install the wiper seal with the wiper toward the outside of the head. P–07425 B Install the thin O–ring (Item 1) [B]. Install the back–up washer (Item 2) [B] and thick O–ring (Item 3) [B] into the groove on the head. 1 2 3 NOTE: Clean and dry the threads before install the nut. Install the new nut from the kit. P–07422 C Tilt Cylinder: Install the head (Item 1) [C], and the piston (Item 2) [C].
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HYDRAULIC CYLINDERS (Cont’d) A Assembly (Cont’d) 1 3 NOTE: Clean and dry the threads before install the nut. Install the new nut from the kit. 2 4 Lift Cylinder: Install the head (Item 1) [A], and spacer (Item 2) [A]. Lift Cylinder: Install the piston (Item 3) [A], and the nut (Item 4) [A]. Lift Cylinder: Tighten the nut (Item 4) [A] to 600 ft.–lbs. (814 Nm) torque. P–07428 Put the base end of the hydraulic cylinder in a vise. B Tighten the head using a spanner wrench [B] & [C].
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MAIN RELIEF VALVE A Checking The Main Relief Valve The tools listed will be needed to do the following procedure: MEL10003 – Hydraulic Tester MEL10006 – Hydraulic Test Kit Turn the key switch to the OFF position, as the engine stops running, turn the key switch all the way to the left to release the hydraulic pressure at the front auxiliary quick couplers. Lift and block the loader. (See Page 1–1.) P–05061 Connect the IN port of the hydraulic tester to the female quick coupler on the loader [A].
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MAIN RELIEF VALVE (Cont’d) A Checking The Main Relief Valve Without Auxiliaries The tools listed will be needed to do the following procedure: MEL10003 – Hydraulic Tester MEL10006 – Hydraulic Test Kit Stop the engine. 1 Lift and block the loader. (See Page 1–1.) Disconnect the hydraulic hoses (Item 1) [A] at the tilt cylinder. P–01187 Connect the hydraulic tester to the tilt cylinder hoses [B]. B Have a second person in the operator seat, with seat bar in down position.
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MAIN RELIEF VALVE (Cont’d) A Removal And Installation Raise the operator cab. (See Page 1–1.) When making repairs on hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. CD–15094 I–2003–0284 The main relief valve (Item 1) [A] is located at the right rear of the control valve. Clean the area around the control valve.
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DUAL PRESSURE MAIN RELIEF VALVE 512811001 & Above) W/ Select Valve (JEM) (S/N A Checking The Low Setting The tools listed will be needed to do the following procedure: MEL10003 – Hydraulic Tester MEL10006 – Hydraulic Test Kit Turn the key switch to the OFF position. Before the engine stops running, turn the key switch all the way to the left to release the hydraulic pressure at the front auxiliary quick couplers. P–05195 Lift and block the loader. (See Page 1–1.
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DUAL PRESSURE MAIN RELIEF VALVE (S/N 512811001 & Above) W/Select Valve (JEM) (Cont’d) A Checking The High Setting The tools listed will be needed to do the following procedure: MEL10003 – Hydraulic Tester MEL10006 – Hydraulic Test Kit Turn the key switch to the OFF position. Before the engine stops running, turn the key switch all the way to the left to release the hydraulic pressure at the front auxiliary quick couplers. Lift and block the loader. (See Page 1–1.).
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DUAL PRESSURE MAIN RELIEF VALVE (S/N 512811001 & Above) W/Select Valve (JEM) (Cont’d) A Checking The High Setting (Cont’d) Install the hose (Item 1) [A] on the secondary auxiliary quick couplers as shown. NOTE: The hose loop (Item 1) [A] (with .070 inch orifice), provides restriction and pilot pressure necessary to shift the dual stage main relief valve to the high pressure setting.
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DUAL PRESSURE MAIN RELIEF VALVE (S/N 512811001 & Above) W/Select Valve (JEM) (Cont’d) A Select Valve (JEM Block) Adjusting The Low Setting NOTE: Adjust the low pressure setting before adjusting the high pressure setting. Correct pressure for the low setting is 2700–2750 PSI (18617–18961 kPa). (See Page 2–23 for the correct procedure to check the setting.) To adjust the low pressure setting on the main relief valve, (Item 1) [A] disconnect the pilot hose (Item 2) [A] from the adapter fitting (Item 3) [A].
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DUAL PRESSURE MAIN RELIEF VALVE (S/N 512811001 & Above) W/Select Valve (JEM) (Cont’d) A Select Valve (JEM Block) Adjusting The High Setting NOTE: Adjust the low pressure setting before adjusting the high pressure setting. Correct pressure for the high setting is 3000 PSI (20685 kPa). (See Page 2–24 for the correct procedure to check the setting.) To adjust the high pressure setting on the main relief valve (Item 1) [A] disconnect the pilot hose (Item 2) [A] from the adapter fitting (Item 3) [A].
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HYDRAULIC CONTROL VALVE A Removal And Installation (Cont’d) Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 1 CD–10937 B 1 Stop the engine. Move the hydraulic controls to release the hydraulic pressure. Raise the seat bar. 2 Lift and block the loader. (See Page 1–1.
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HYDRAULIC CONTROL VALVE (Cont’d) A Removal And Installation (Cont’d) 1 Remove the control valve outlet tubeline (Item1) [A] from the control valve. CD–10941 Remove the power beyond tubeline which goes to the auxiliary control valve inlet [B]. B Disconnect the control valve inlet hose (Item 1) [B] which comes from the outlet of the hydraulic pump. 1 CD–10942 C Disconnect the two connectors from the solenoids on the auxiliary section of the control valve [C].
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SELECT VALVE (S/N 512811001 & Above) W/Select Valve (JEM) A Checking The Relief Valve The tools listed will be needed to do the following procedure: 2 MEL10003 – Hydraulic Tester MEL10006 – Hydraulic Test Kit Lift and block the loader. (See Page 1–1.) Connect the IN port of the hydraulic tester to the female quick couplers (Item 1) [A] on the loader. 1 Connect the OUT port of the hydraulic tester to the male quick coupler (Item 2) [A] on the loader.
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SELECT VALVE (S/N 512811001 & Above) W/Select Valve (JEM) (Cont’d) A Checking The Relief Valve (Cont’d) 1 If the relief pressure is not correct, stop the engine. Adjust the relief valve in the select valve (Item 1) [A]. The select valve is located at the left side under the control panel. P–05201 Remove the cap from the relief valve (Item 1) [B]. Loosen the locking nut (Item 2) [B]. Turn the adjusting screw (Item 3) [B] in or out until the correct pressure is reached.
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SELECT VALVE (S/N 512811001 & Above) W/Select Valve (JEM) (Cont’d) A 1 Removal And Installation Raise the operator cab. (See Page 1–1.) 4 Remove the bolt (Item 1) [A]. 3 Disconnect the controls harness at the left side steering lever connectors (Item 2) [A]. 2 If so equipped disconnect the attachment harness from the controls harness and the left side steering lever connectors. Put the relay assembly (Item 3) [A] and attachment harness aside.
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SELECT VALVE (S/N 512811001 & Above) W/Select Valve (JEM) (Cont’d) A Removal And Installation (Cont’d) Remove the mounting bolts (Item 1) [A] located on the outside left frame. Remove the select valve. 1 P–09190 Disassembly And Assembly B Clean the select valve to remove dirt before disassembly. 2 1 When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out.
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SELECT VALVE (S/N 512811001 & Above) W/Select Valve (JEM) (Cont’d) A Disassembly And Assembly (Cont’d) Remove the 4–way solenoid valve (Item 1) [A]. 1 Remove the check valve (Item 2) [A]. Remove the pilot piston (Item 3) [A] located between the check valves (Item 2) [A] & [B]. Remove the 2–way solenoid valves (Item 4) [A]. Inspect the solenoid valves for contamination or damage. Wash all parts in clean solvent. Use air pressure to dry them. Install new O–rings and back–up washers.
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HYDRAULIC FILTER HOUSING A Removal And Installation Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 CD–10945 B 1 Disconnect the tubelines from the inlet of the hydraulic filter [A]. Disconnect the hose (Item 1) [B] from the outlet of the filter.
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HYDRAULIC PUMP A 853,853HServiceManual#6720755–HydraulicSystemSectionPart1of2 Checking The Output Of The Pump The tools listed will be needed to do the following procedure: MEL10003 – Hydraulic Tester MEL10006 – Hydraulic Test Kit NOTE: Make sure all the air is removed from the hydraulic system before beginning the test. Air in the system can give an inaccurate test. *Relief pressure must be per specification before the test is done. CD–11093 Lift and block the loader. (See Page 1–1.
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HYDRAULIC PUMP (Cont’d) A Removal And Installation NOTE: The hydraulic pump is shown being removed with the hydrostatic pump/engine assembly out of the loader for photo clarity. It can be removed in the loader. 1 When making repairs on hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
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HYDRAULIC FLUID RESERVOIR A Removal And Installation 1 Raise the operator cab. (See Page 1–1.) Disconnect the motor case drain hose from the case drain filter (Item 1) [A]. Cap and plug the filter and hose. Remove the case drain filter (Item 1) [A] (if so equipped) and drain the fluid into a container. P–00971 Loosen and disconnect the reservoir outlet hose [B]. B CD–10954 Remove the bolt and plate (Item 1) [C] from the mounting strap. C Installation: Tighten the bolt to 16–20 ft.–lbs.
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LOCK VALVE (S/N 5103) A Removal And Installation NOTE: The lock valve is optional for the (S/N 5102) & the (S/N 5101) loaders. Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 CD–10957 B Disconnect the two tubelines on the lock valve [A].
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BUCKET POSITION VALVE (S/N 5102) & (S/N 5103) A Removal And Installation NOTE: The bucket position valve is optional for the (S/N 5101) loader. Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 CD–10960 B Remove all the tubelines connected to the valve [A].
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FRONT AUXILIARY CONTROL VALVE (Apitech) A Removal And Installation (S/N 508411001 – 15215) (S/N 509711001 & Above) (S/N 510375001 & Above) (S/N 510125001 – 16791) (W/Front Aux. Opt.) (S/N 510250001 – 50691) (S/N 512811001 & Above) (Ww/Apitech) CD–10962 Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
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CONTROL PEDALS A Removal And Installation Remove the bolt and nut (Item 1) [A] from the pedal linkage. 1 Installation: Tighten the bolt and nut to 21–25 ft.–lbs. (28–34 Nm) torque. Check the rubber bushing in the pedal for wear and replace as needed. P–04771 Remove the two mounting bolts (Item 1) [B]. B Remove the pedal assembly from the loader.
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PEDAL INTERLOCK LINKAGE A Removal And Installation Raise the lift arms and install an approved lift arm support device. (See Page 1–1.) Raise the operator cab. (See Page 1–1.) 1 Remove the interlock shield mounting nuts (Item 1) [A]. 2 Installation: Tighten the shield mounting nuts to 25–28 ft.–lbs. (34–38 Nm) torque. Remove the interlock shield (Item 2) [A]. P–01216 B Remove the interlock mounting nuts and plastic washers from behind the nuts [B].
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PEDAL INTERLOCK LINKAGE (Cont’d) A Removal And Installation (Cont’d) Remove the panel from the loader frame [A]. P–01215 Install the mounting bolts (Item 1) [B] through the back of the panel as shown. B 1 P–01212 Pedal Interlock Linkage Adjustment C Check the pedal interlock linkage so it is free and locks both pedals. Check that the tab (Item 1) [C] on the linkage, slides into the slot on the interlock and holds the pedal in locked position.
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HYDROSTATIC SYSTEM Page Number COLD OIL BY–PASS VALVE Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21 DRIVE BELT Replacing The Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27 DRIVE BELT SHIELD Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26 FIXED TENSIONER PULLEY Adjusting The Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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–3–2– 853, 853H Loader Service Manual
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TROUBLESHOOTING Chart The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only. Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can cause injury or death. W–2004–1285 PROBLEM CAUSE No drive on one side, in one direction. 1, 2 No drive on one side in both directions.
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HYDROSTATIC SYSTEM INFORMATION A When making repairs on hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. CHARGE OIL FUNCTION 1 Valve Moves for Charge Oil Replacement I–2003–0284 Replenishing Valve Function The functions of the replenishing valves are: 1. To give replacement fluid to the low pressure side of the hydrostatic circuit.
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FRONT PANEL A Removal And Installation 1 Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W–2017–0286 P–09926 B Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.
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FRONT PANEL (Cont’d) A Removal And Installation (Cont’d) Remove the steering cable U–bolt (Item 1) [A]. Disconnect the steering cable ball joint (Item 2) [A]. Remove the steering panel brace (Item 3) [A]. 2 1 3 P–09928 B Remove the top mounting bolts (Item 1) [B] (both sides). Remove the shock absorber mounting bolt (Item 2) [B]. 1 3 Disconnect the shock absorber panel brace bolt (Item 3) [B]. Remove panel brace and shock.
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STEERING LEVERS A Disassembly And Assembly Remove the front panel/steering lever assembly. (See Page 3–5.) Remove the steering shaft centering mechanism bolt and nut (Item 1) [A] and spring. 1 P–05033 B Disconnect the steering shock (Item 1) [B]. Loosen both U–bolts (Item 2) [B] at the steering lever. Remove the steering lever. 1 3 2 P–05034 C Loosen both U–bolts (Item 1) [C] at the steering lever. 1 Remove the steering lever.
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STEERING LEVERS (Cont’d) A Disassembly And Assembly (Cont’d) Check the nylon bushing (Item 1) [A] and replace as needed. 3 2 Assembly: Make sure the wave washer (Item 2) [A] is between the nylon bushings. Check and replace the cams (Item 3) [A] if worn or damaged. 1 NOTE: The cams must not rotate on the mounting bolts. P–05040 Remove the bolts (Item 1) [B] to remove the steering shaft mounting bracket (Item 1) [C] and the steering lever stop plate (Item 2) [C].
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STEERING LEVERS (Cont’d) A Neutral Pre–Adjustment Checks Read this adjustment completely to become familiar with the procedure before beginning the adjustment. The loader should not creep (slow wheel movement) when the steering levers are at rest in the neutral position. The following special tool will be needed to do the following procedure: MEL1429A – Remote Start Switch Lift and block the loader. (See Page 1–1.) P–02865 Raise the operator cab. (See Page 1–1.) B Connect the remote start switch.
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STEERING LEVERS (Cont’d) A Adjusting Lever Freeplay Read this adjustment completely to become familiar with the procedure before beginning the adjustment. 1 Use the following procedure to adjust the steering linkage so both steering levers have no free play against the cam. To remove the free play, move the right cam to match the left cam so there is no free play between the two cams in the pocket of the detent bracket [C]. Use the following procedure to adjust the the cam free play. 3 1.
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STEERING LEVERS (Cont’d) A Adjusting The Wheel RPM Forward Compared To Reverse Travel 1 Read this adjustment completely to become familiar with the procedure before beginning the adjustment. NOTE: This procedure adjusts the position of the steering levers in the panel when in neutral. Levers centered in steering panel give equal travel forward compared to reverse. 1. Disconnect the two bolts of the pintle links (both sides) (Item 1) [A]. P–07927 2.
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STEERING LEVERS (Cont’d) A Adjusting The Wheel RPM Forward Compared To Reverse Travel (Cont’d) NEUTRAL 5. Move the lever to the neutral position. Measure the distance from the U–bolt to the lock nut [A]. Neutral must be adjusted to 3.21 inch (82 mm) per example. EXAMPLE: Forward Reverse 3.66 inch (93,0 mm) – 2.76 inch (70,0 mm) 0.90 inch (23,0 mm) Total Travel* 3.21 “ (82,0 mm) Divided by Two =0.45 inch (11,0 mm) Half the Travel +2.76 inch (70,0 mm) Reverse Travel 3.
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STEERING LEVERS (Cont’d) A Adjusting The Steering Neutral Setting Read this adjustment completely to become familiar with the procedure before beginning the adjustment. NOTE: This procedure adjusts the creep (wheel movement in neutral) and dead–band (lever travel before wheels start to turn). Adjusting steering cable length will match lever neutral and pump neutral.
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STEERING LEVERS (Cont’d) A Adjusting The Wheel RPM Left Compared To Right Side NOTE: This procedure is for MINOR adjustment in full forward travel only. Steering neutral setting must be correctly adjusted before this procedure. Early S/N loaders do not have this adjustment. 1. Loosen the bolts at the stop (Item 1) [A] and lower the lever stops (both sides). 1 2. Start the engine. P–02875 B Put jackstands under the front axles and rear corners of the frame before running the engine for service.
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STEERING LEVERS (Cont’d) A Hydrostatic Pump Neutral Adjustment When working on the left side of the hydrostatic pump, Be Careful to keep your fingers and tools clear of the cooling fan belt. W–2185–0395 P–02866 After the hydrostatic pump has been rebuilt, the neutral for the servo valve spool will have to be adjusted. Use the following procedure: B NOTE: The hydrostatic pump must be installed in the loader for this procedure.
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STEERING LEVERS (Cont’d) A Hydrostatic Pump Neutral Adjustment (Cont’d) 3. Clamp the control lever to the neutral adjustment bracket with a small locking pliers [A]. P–07929 B 4. Start the engine. With the engine running at full RPM, move the control lever forward until the wheels just begin to move. Mark the position on the bracket (felt tip pen) [B]. 5. Move the control lever in reverse until the wheels just begin to move. Mark this position. 6. Stop the engine. P–07930 7.
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HYDROSTATIC MOTOR A Removal And Installation 1 When making repairs on hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. P–04804 I–2003–0284 B 2 1 Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device.
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HYDROSTATIC MOTOR (Cont’d) A Removal And Installation (Cont’d) 1 Remove the hydrostatic motor from the gearcase. Installation: Replace the large O–ring (Item 1) [A] and face seals on the motor fittings before installing the motor Inspect and clean or replace case drain filters (Item 1) [B] & [C] during motor repair or replacement. NOTE: The case drain filters were added at (S/N 510125001 & Above), (S/N 510250001 & Above) and (S/N 510370001 & Above) on the loaders.
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HYDROSTATIC CHARGE OIL FILTER A Removal And Installation Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 CD–10993 B Disconnect the temperature switch wire from the hydrostatic filter [A]. Disconnect the differential pressure switch wire from the filter [B].
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HYDROSTATIC CHARGE OIL FILTER (Cont’d) A Removal And Installation (Cont’d) Remove the four mounting bolts [A]. Installation: Tighten the mounting bolts to 25 ft.–lbs. (34 Nm) torque. CD–10997 Remove the hydrostatic filter and housing [B].
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COLD OIL BY–PASS VALVE A Removal And Installation Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 CD–10999 B Remove the cold oil by–pass valve plug, spring and poppet to check for damage [A]. Replace the plug, spring and poppet if necessary.
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COLD OIL BY–PASS VALVE (Cont’d) A Removal And Installation (Cont’d) Disconnect the oil cooler outlet tubeline (shown) and the front auxiliary valve charge hose (not shown) from by–pass valve [A]. NOTE: The auxiliary valve charge hose is next to the oil cooler outlet tubeline on the by–pass valve. The (S/N 5101) loader without front auxiliary hydraulics does not have the auxiliary valve charge hose. CD–11003 Remove the by–pass valve mounting bolt and remove the valve [B].
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HYDROSTATIC PUMP A Removal And Installation 1 Remove the hydrostatic pump/engine assembly from the loader. (See Page 7–1.) Remove the belt shield clips (Item 1) [A] and belt shield (Item 2) [A]. 2 1 1 P–04924 B Loosen the tensioner pulley nut (Item 1) [B]. 2 1 Remove the drive belt (Item 2) [B]. Installation: Tighten the drive belt to the correct specifications. (See Page 3–32 or 3–41.) P–04926 C Remove the washer and nut (Item 1) [C] from the hydrostatic pump drive shaft.
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HYDROSTATIC PUMP (Cont’d) A Removal And Installation (Cont’d) 1 2 1 Remove the two mounting bolts (Item 1) [A] and nuts (Item 1) [B]. Installation: Tighten the mounting bolts and nuts to 65–70 ft.–lbs. (88–95 Nm) torque. Make sure the key (Item 2) [A] is installed. P–04933 B 1 P–04935 Remove the mounting bolt (Item 1) [C] at the hydraulic pump end of the pump. C Remove the hydrostatic pump from the mounting bracket and drive belt housing.
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HYDROSTATIC PUMP (Cont’d) A Replenishing/High Pressure Relief Valve There are four replenishing/high pressure relief valves (Item 1) [A] in the hydrostatic pump. Two are located at the front of the pump and two at the rear of the pump. See Page 3–4 for valve function. 1 P–04936 Remove the plug spring and high pressure relief valve from the pump [B]. B 2 1 Check for damage and replace as needed. 3 Ref. Description 1. 2. 3. 4.
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DRIVE BELT SHIELD A Removal And Installation Stop the engine. Open the rear door. Remove the three belt shield holddown clips (Item 1) [A]. 1 1 P–05041 Remove the belt shield (Item 1) [B] from the drive belt housing.
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DRIVE BELT A Replacing The Drive Belt 2 3 Raise the operator cab. (See Page 1–1.) Remove the belt shield. (See Page 3–26.) Loosen the bolt (Item 1) [A] on the idler pulley tensioner mounting bracket. Loosen the jam nut (Item 2) [A] and turn the nut (Item 3) [A] to release the belt tension. 1 P–04926 Remove the drive belt from the hydrostatic pump pulley and flywheel pulley. B Remove the drive belt [B]. Installation: Install the new drive belt and adjust. (See Page 3–32 or 3–41.
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SPRING LOADED TENSIONER PULLEY Parts Identification 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Cover Bolt Washer Pins Washer Spring Snap Ring Snap Ring Bearing Dust Shield Pulley Bushing Hub Washer Seal Arrow Indicator Plate Locating Pin Spring Shaft Bracket 1 2 11 3 12 4 5 NOTE: Drive idler parts are not available individually. Consult parts catalog for available sub–assemblies. 13 6 14 5 15 7 8 16 17 9 18 10 19 20 E–02296 Revised Feb.
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SPRING LOADED TENSIONER PULLEY (Cont’d) A Disassembly 1 Remove the grease cover (Item 1) [A]. P–08858 Remove the bolt (Item 1) [B], the flat washer (Item 2) [B], the retainer washer (Item 3) [B], the spring washer (Item 4) [B] and the second retainer washer (Item 3) [B] from the pulley assembly (Item 5) [B]. B 5 2 3 4 1 P–08859 Remove the two pins (Item 1) [C] from the hub assembly (Item 2) [C] only if they have been damaged.
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SPRING LOADED TENSIONER PULLEY (Cont’d) A Assembly Install the spring (Item 1) [A] on the pulley (Item 2) [A] as shown. 1 2 P–08871 Install the shaft from the bracket assembly (Item 1) [B] into the pulley assembly (Item 2) [B] and align the spring (Item 3) [B] over the alignment pin on the bracket. B 1 2 3 P–08872 Turn the pulley assembly over and install the two pins (Item 1) [C] into the hub. C 1 P–08873 Install a punch as shown and turn clockwise while applying down pressure on the pulley.
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SPRING LOADED DRIVE BELT TENSIONER PULLEY (Cont’d) A Assembly (Cont’d) Install the first retainer washer (Item 1) [A] and spring washer (Item 2) [A] over the roll pins. 2 1 P–08875 Install the second retainer washer (Item 1) [B], the washer (Item 2) [B] and the bolt (Item 3) [B]. Tighten the bolt to 28–32 ft.–lbs. (38–45 Nm) torque. B 3 Fill the grease cap 1/4 full (approximately 1/2–3/4 oz.) of grease. 2 1 P–08876 C Press the grease cap (Item 1) [C] onto the pulley assembly (Item 2) [C].
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SPRING LOADED TENSIONER PULLEY (Cont’d) A Adjusting The Drive Belt 2 When adjusted correctly the spring loaded idler assembly will increase the service life of the drive belt. To adjust the spring loaded tensioner pulley, use the following procedure: Loosen the mounting bolt (Item 1) [A] on the idler bracket. The pointer (Item 1) [B] will be at the seven o’clock position when the belt tensioner is not under spring pressure.
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FIXED TENSIONER PULLEY A Removal And Installation 1 Remove the three belt shield holddown clips (Item 1) [A]. Remove the belt shield. 1 1 P–04924 Loosen the tensioner pulley mounting bolt (Item 1) [B]. B Loosen the jam nut and lock nut (Item 2) [B]. 2 Remove the drive belt. Installation: Tighten the drive belt to the correct specifications. (See Page 3–41.) 1 P–04926 Remove the jam nut and lock nut (Item 1) [C]. C Remove the mounting bolt (Item 2) [C].
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FIXED TENSIONER PULLEY (Cont’d) A Disassembly NOTE: Be careful, the pulley hub is full of oil. Remove the cap [A]. CD–12634 Remove the bolt and washer [B]. B CD–12635 Install a long bolt into the shaft [C]. C CD–12636 Remove the idler pulley and bearing from the shaft using a press [D].
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FIXED TENSIONER PULLEY (Cont’d) A Disassembly (Cont’d) Install a bearing puller behind the seal and wear sleeve [A]. CD–12638 PHOTO CLARITY ONLY: If the bearing puller is installed behind the bearing, seal and wear sleeve, the wear sleeve will also be removed [B]. B CD–12639 Remove the bearing, seal and wear sleeve using the press [C].
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FIXED TENSIONER PULLEY (Cont’d) A Assembly NOTE: The bearings, cups and spacers are a matched set and must be replaced as a unit. If the spacer is replaced, compress the new spacer and install into the pulley [A]. CD–12641 Use a driver tool (1–5/16’’ diameter) and push the spacer into the machined groove [B]. B CD–12642 Install the bearing cup using the driver tool (both sides) [C]. C NOTE: The seal side of the pulley hub has the larger I.D. diameter.
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FIXED TENSIONER PULLEY (Cont’d) A Assembly (Cont’d) Put sealant (P/N 6633538) around the diameter of the shaft where the wear sleeve is installed [A]. CD–12645 Put grease (P/N 6599719) on the seal lips (Item 1) [B]. Make sure the grease is between the outside and inside lips and all the way around the seal. B 1 MC–01648 Press the seal into the pulley hub larger diameter using a press [C]. C NOTE: The wear sleeve and the seal must be replaced as a unit.
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FIXED TENSIONER PULLEY (Cont’d) A Assembly (Cont’d) Install the small bearing spacer [A]. CD–12648 Install the taper roller bearing pushing on the I.D. of the bearing [B]. B CD–12649 Put LOCTITE (P/N 6540410) on the bolt threads [C]. C CD–12650 Install the bolt and washer into the shaft [D].
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FIXED TENSIONER PULLEY (Cont’d) A Assembly (Cont’d) Tighten the bolt to 25–28 ft.–lbs. (43–38 Nm) torque [A]. CD–12652 Use only 15W/50 synthetic oil (Example: Mobil One) for the bearings. Use the cap and add oil until it is at the 0.50’’ (12,7 mm) mark on the scale, which should be 0.75 oz. (20 C.C.) of oil [B]. B Measure Oil Level in the Center of the Cap 0.75 oz. (20 C.C.) Capacity 0.
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FIXED TENSIONER PULLEY (Cont’d) A Checking Pulley End Play Install the pulley/mounting bracket assembly in to vise. Install a dial indicator on the pulley hub [A]. CD–12655 B Move the pulley by hand, back and forth. The correct end play is 0.005–0.013 inch (0,13–0,33 mm) [B]. If the end play is not correct, there is no adjustment. Replace the hub, pulley and/or bearings.
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FIXED TENSIONER PULLEY (Cont’d) A 853,853HServiceManual#6720755–HydrostaticSystemSectionPart1of2 Adjusting The Drive Belt 1 5 6 See the SERVICE SCHEDULE Page 1–1 for the service interval. To adjust the drive belt between the engine flywheel and the hydrostatic pump pulley, use the following procedure: Raise the operator cab. (See Page 1–1.) Remove the belt shield. (See Page 3–26.) 4 Use the following tools to check the belt tension: P–04927 MEL1404 – Bar MEL1406 – Spring Scale 1.
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OIL COOLER A Removal And Installation Disconnect the tubeline (Item 1) [A] from the oil cooler. 1 P–04884 B Disconnect the tubeline (Item 1) [B] from the oil cooler. 1 P–04885 C Install caps and plugs on open connections. Remove the oil cooler [C].
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DRIVE SYSTEM Page Number AXLE SEAL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9 AXLE, SPROCKET AND BEARINGS Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11 CHAINCASE FLUID Removing The Fluid From The Chaincase . . . . . . . . . . . . . . . . . . . . . . . . 4–27 DRIVE CHAIN Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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–4–2– 853, 853H Loader Service Manual
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PARKING BRAKE PEDAL A Adjustment When the parking brake is in good condition and adjusted correctly, it will keep the loader from moving when the steering levers are moved. 1 Raise the operator cab. (See Page 1–1.) Loosen the lock nut and turn the nut (Item 1) [A] to adjust the parking brake linkage. With the brake released, lift the pedal to remove linkage end play. CD–11014 Lift release pedal to remove linkage end play B Adjust the pedal so there is 2.
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PARKING BRAKE A Removal And Installation Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 CD–10989 Raise the operator cab. (See Page 1–1.) B Remove the bolt and nut from the lift pedal linkage [A]. Disconnect the lift linkage from the control valve spool [B].
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PARKING BRAKE (Cont’d) A Removal And Installation (Cont’d) Remove the nuts from the brake linkage rod [A]. CD–11014 Disconnect the brake lever spring and remove the spring (Item 1) [B], retainer plate (Item 2) [B] and bolt (Item 3) [B]. B Installation: Tighten the brake lever bolt to 65–70 ft.–lbs. (88–95 Nm) torque. 3 Remove the cover bolts [B]. 2 1 CD–11018 Remove the cover/brake block assembly [C]. C Installation: Clean and dry the cover.
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PARKING BRAKE (Cont’d) A Brake Block And Pads Remove the brake lever [A]. CD–11020 Loosen the brake pad bolts and remove the bolts [B]. B Installation: Tighten the bolts to 65–70 ft.–lbs. (88–95 Nm) torque. CD–11021 Remove the guide and pads [C]. C Check the pads for wear and replace them as needed. CD–11022 Remove the bolts which fasten the brake block to the cover [D]. D Installation: Tighten the bolts to 65–70 ft.–lbs. (88–95 Nm) torque.
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PARKING BRAKE (Cont’d) A Brake Block And Pads (Cont’d) Remove the brake block [A]. Installation: Clean and dry the brake block. Put a bead of R.T.V. sealant on the brake block. CD–11024 Remove the shaft from the brake block [B]. B Installation: Always install a new O–ring (Item 1) [B] when the shaft is installed. Make sure the shaft rotates in the cover. Check the parts for wear or damage and replace as needed.
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FRONT CHAINCASE COVER A Removal And Installation Disconnect the brake pedal/linkage rod assembly [A]. CD–08824 Remove the front cover mounting bolts [B]. B Remove the front cover plate from the chaincase. Installation: Clean and dry the cover. Clean the surface on the chaincase. Install a new gasket on the front cover. CD–11027 REAR CHAINCASE COVER C Removal And Installation Remove the rear cover mounting bolts and remove the rear cover plate from the chaincase [C].
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AXLE SEAL A Removal And Installation 2 Lift and block the loader. (See Page 1–1.) Remove the tire/wheel assembly. Installation: Tighten the wheel nuts to 105–115 ft.–lbs. (142–155 Nm) torque. Remove the bolts (Item 1) [A] and plate. 1 Installation: Tighten the bolts to 175–190 ft.–lbs. (240–260 Nm) torque. 2 P–04850 Remove the two wheel studs (Item 2) [A] across from each other. B Install puller (Item 1) [B] on the wheel hub. NEVER STAND IN–LINE OF THE HUB WHEN REMOVING A HUB FROM AN AXLE.
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AXLE SEAL (Cont’d) A Removal And Installation (Cont’d) Install a slide hammer (Item 1) [A] with a screw tip end into the axle seal. Remove the axle seal. The tool listed will be needed to do the following procedure: MEL1407 – Seal Installation Tool 1 If the axle is damaged or worn, an axle repair sleeve kit is available from Melroe Parts Sales in Chicago. P–04817 NOTE: If a new wear ring is being installed with new seal, put LOCTITE sealant on the inside diameter of the wear ring.
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AXLE, SPROCKET AND BEARINGS A Removal And Installation The tools listed will be needed to do the following procedure: MEL1242 – Port–a–Power MEL1202B – Axle Bearing Service Set NOTE: The procedure shown for removal and installation of the axle, sprocket and bearings is for a front axle. This procedure will be the same for the rear axle also (See Page 4–8 for rear chaincase cover removal).
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AXLE, BEARINGS AND SPROCKET (Cont’d) A Removal And Installation (Cont’d) Push the axle out until the ram 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. 2 Remove the drive chain from the sprocket. Remove the sprocket (Item 1) [A] and inner bearing (Item 2) [A]. Installation: Pack the inner and outer bearing with grease before installing them.
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AXLE, BEARINGS AND SPROCKET (Cont’d) A Removal And Installation (Cont’d) Use the tools provided in the (MEL1202B) Axle Bearing Service Set for bearing cup removal and installation. A slide hammer is also needed. Use the long rod and bearing cup tool to remove the inner bearing cup [A]. P–04812 B To remove the outer bearing cup, install a bearing cup tool on the slide hammer. Leave the bearing cup tool loose until the tool is installed inside the tube [B].
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AXLE, BEARING AND SPROCKET (Cont’d) A Removal And Installation (Cont’d) 1 Use the bearing cup installation tools (Item 1) [A] & (Item 1) [B]. Put the inner cup (Item 2) [A] in the axle tube. Install the long treaded rod (Item 2) [B] into the axle tube and through the installation tool (Item 1) [A]. 3 Install the nut (Item 3) [A]. 2 P–04807 Install the installation tool (Item 1) [B] on the threaded rod. Install the nut.
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REDUCTION GEARCASE A Reduction Gearcase Seal The tool listed will be needed to do the following procedure: MEL1047 – Seal Installation Tool Lift and block the loader. (See Page 1–1.) Remove the hydrostatic motor. (See Page 3–1.) Drill a hole into the reduction gearcase seal [A]. P–04795 Install a slide hammer with a screw tip end into the seal [B]. B Remove the reduction gearcase seal. P–04798 Install the new quad ring on the installation tool. C Install the backup washer.
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REDUCTION GEARCASE (Cont’d) A Removal And Installation 1 1 Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 P–04805 B Lift and block the loader. (See Page 1–1.) Raise the operator cab. (See Page 1–1.) Remove the front panel/steering levers assembly. (See Page 3–1.
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REDUCTION GEARCASE (Cont’d) A Checking Reduction Gearcase Before disassembly of the gearcase do the following checks: Install a dial indicator on the input shaft [A]. The end play must be between 0.00–0.010 inch (0,0254 mm.) If not, the following parts may need replacing: Bearing, bearing cups, gear or gearcase housing. B–13458 B Install the dial indicator on the output shaft [B]. The end play must be between 0.00–0.010 inch (0,0254 mm.
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REDUCTION GEARCASE (Cont’d) A Disassembly (Cont’d) Remove the end plate [A]. B–08704 B Remove the dust cap [B]. B–08728 C Loosen the bolt from the output shaft [C]. B–08721 D Remove the bolt and washer [D].
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REDUCTION GEARCASE (Cont’d) A Disassembly (Cont’d) Remove the bolt from the disc hub [A]. B–08751 B Remove the bolt and washer [B]. B–08752 C Remove the disc hub and key [C]. B–08750 Put the gearcase housing in the press and remove the output shaft [D].
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REDUCTION GEARCASE (Cont’d) A Disassembly (Cont’d) Remove the bearing [A]. B–08707 B Remove the spacer [B]. B–08706 C Remove the output shaft [C]. B–08749 Remove the large gear [D].
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REDUCTION GEARCASE (Cont’d) A Disassembly (Cont’d) Remove the bearing at the input shaft [A]. B–08745 B Use a press and remove the input shaft [B]. B–08679 C Remove the input shaft assembly from the housing [C]. B–08744 Use a punch and hammer and remove the bearing cups as needed [D].
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REDUCTION GEARCASE (Cont’d) A Assembly Using a press and bearing cup tool, install the bearing cup in the housing. Install the input shaft [A]. B–08744 B Install the bearing on the input shaft [B]. B–08745 C Install the large gear into the housing [C]. B–08722 Install the output shaft into the housing and large gear [D].
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REDUCTION GEARCASE (Cont’d) A Assembly (Cont’d) Install the spacer [A]. B–08706 B Install the bearing [B]. B–08707 C Put LOCTITE on the bolt. Install the bolt and washer [C]. B–08727 Tighten the bolt to 210–235 ft.–lbs. (285–305 Nm) torque [D]. D Put Boretite sealant on the edge of the dust cup and install the dust cup into the housing.
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REDUCTION GEARCASE (Cont’d) A Assembly (Cont’d) Install the key and hub on the input shaft [A]. B–08750 B Put LOCTITE #242 adhesive on the bolt threads. Install the bolt and washer [B]. B–08752 C Tighten the bolt to 210–235 ft.–lbs. (285–305 Nm) torque [C]. B–08751 Instal the end plate on the housing [D].
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REDUCTION GEARCASE (Cont’d) A 853,853HServiceManual#6720755–DriveSystemSectionPart1of2 Assembly (Cont’d) Install the end plate bolts and tighten to 13–14 ft.–lbs. (Nm) torque [A]. B–08705 B Install a new quad ring. Install the backup washer [B]. B–08675 C Install the new seal using the seal installation tool [C].
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DRIVE CHAIN A Removal And Installation Front Drive Chain Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 Rear Drive Chain P–04805 Lift and block the loader. (See Page 1–1.) Raise the operator cab. (See Page 1–1.) Removing the front panel/steering lever assembly. (See Page 3–1.
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CHAINCASE FLUID A Removing The Fluid From The Chaincase To drain the oil from the chaincase, remove the cover (Item 1) [A] which is installed over the drain plug at the rear of the chaincase. 1 P–1616 B Remove the drain plug (Item 1) [B] and drain the oil into a container. Check the drain plug and replace if necessary.
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MAIN FRAME Page Number BOB–TACH Bob–Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9 Bob–Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 FUEL TANK Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16 Inlet Screen . . . . . . . . .
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OPERATOR CAB GAS CYLINDER A Removal And Installation 1 Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 CD–15014 B Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death. W–2113–0288 Remove the operator cab stop (Item 1) [A] (both sides).
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OPERATOR CAB GAS CYLINDER (Cont’d) A Disassembly And Assembly 2 1 Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death. W–2113–0288 P–01008 Remove the clevis (Item 1) [A] and washer (Item 2) [A] from the end of the gas cylinder. B Remove the gas cylinder from the outer housing. Assembly: Install a replacement cylinder inside the cylinder housing. Apply a small amount of LOCTITE #242 adhesive on the threads of the cylinder rod [B].
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OPERATOR CAB A Removal And Installation Remove the cab nut and holddown plate (Item 1) [A] (both sides). Installation: Tighten the nut to 40–50 ft.–lbs. (54–68 Nm) torque. Remove both gas cylinders (Page 5–7). 1 CD–15125 B Disconnect the wiring harness connectors (Item 1) [B]. Disconnect the ground wire (Item 2) [B]. 1 1 2 P–00883 Connect a chain hoist to the operator cab grab handles and lower the operator cab when the gas cylinders are disconnected [C].
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OPERATOR CAB (Cont’d) A Removal And Installation (Cont’d) Remove the nut (Item 1) [A] from the pivot bolt (both sides). Installation: Tighten the pivot bolt and nut to 25–35 ft.–lbs. (34–47 Nm) torque. Remove the pivot bolt (both sides). 1 P–05048 B Move the operator cab forward a small amount for clearance at the pivot mounting brackets [B]. Install the pivot bolt, washer (one on each side) and nut (Item 1) [B] (both sides). Install the sling under the pivot bolt and pivot of the operator cab [B].
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BOB–TACH A Removal And Installation Tilt the Bob–Tach forward, so it is parallel to the floor. Put blocks approximately 3 inches thick under each side of the Bob–Tach (Item 1) [A]. Lower the Bob–Tach onto the blocks [A]. 1 CD–15075 Remove the retainer bolt (Item 1) [B] from the pivot pin. B Installation: Tighten the retainer bolt to 18–20 ft.–lbs. (24–27 Nm) torque. 1 P–04601 Remove the grease fitting from the pivot pin (Item 1) [C]. C Remove the rod end pivot pin (Item 1) [C].
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BOB–TACH (Cont’d) A Removal And Installation (Cont’d) Installation: Use two pieces of shim stock (light cardboard) to protect the seals during installation. Install the rod end of the tilt cylinder into the Bob–Tach [A]. Be careful not to damage the seals during installation. NOTE: Removal procedure is shown for the right side. Left side procedure is the same. P–03910 Remove the grease fitting (Item 1) [B] from the Bob–Tach frame for the pivot pin (both sides) [C].
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BOB–TACH (Cont’d) A Removal And Installation (Cont’d) Install the Bob–Tach mounting bolt (Item 1) [A] into the pivot pin (Item 2) [A]. Remove the pivot pin from the Bob–Tach frame. Check for wear and damage. Replace the pivot pins as needed. 3 Installation: Push the pivot pin (Item 2) [A] into the Bob–Tach frame. Position the end of the pin flush with the end of the Bob–Tach bushing (Item 3) [A]. 1 2 Reverse the removal procedure to install the Bob–Tach.
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BOB–TACH (Cont’d) A 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 and clevis assembly. 1 P–03925 B Remove the spring, bolt and clevis assembly (Item 1) [B]. Remove the wedge (Item 2) [B] from the Bob–Tach frame. 2 Always replace bent or broken wedges. 1 P–03926 C If the bolt (Item 1) [C], handle pivot (Item 2) [C], spring (Item 3) [C] or clevis (Item 4) [C] are damaged, put the assembly in the vise.
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LIFT ARMS A Removal And Installation Roll the Bob–Tach (Item 1) [A] fully forward. Stop the engine. Remove the Bob–Tach (Item 1) [A] from the lift arms (Page 5–7). 2 Install the slings (Item 2) [A] on the lift arms. Connect a chain hoist to the slings [A]. 2 1 P–05052 B Remove the retainer bolt and nut (Item 1) [B] from the rod end lift cylinder pivot pin (both sides). Installation: Tighten the retainer bolt and nut to 18–20 ft.–lbs. (24–27 Nm) torque.
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REAR GRILL A Removal And Installation 1 Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death. W–2113–0288 Raise the rear grill. P–04881 Support the rear grill. B Remove the nut (Item 1) [A] to disconnect the gas cylinder from the rear grill. Lower the rear grill. Remove the cotter pin (Item 1) [B] from the pivot pin (both sides). 1 P–04882 Remove the pivot pin (Item 1) [C] (both sides).
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REAR DOOR A Removal And Installation Open the rear door, disconnect the wiring harness connector (Item 1) [A]. Remove the nuts (Item 2) [A] from the pivot bolts. Installation: Tighten the bolts and nuts to 25–28 ft.–lbs. (34–38 Nm) torque. 1 P–05041 B Connect a 1/4 inch chain to the rear door using two bolts (Item 1) [B]. Inside the rear door, secure the chain with washers and nuts. Connect a chain hoist to the chain. 2 Remove the rear door pivot bolts.
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REAR DOOR (Cont’d) A Hood Removal And Installation Remove the rear lights harness from the rear door hood if so equipped. 1 Remove the mounting bolts from the rear door hood (Item 1) [A]. Installation: Tighten the hood mounting bolts to 25–28 ft.–lbs. (34–38 Nm) torque. Remove the hood from the rear door. P–05043 Bumper Removal And Installation B Remove the rear bumper mounting bolts (Item 1) [B] with a 7/32 inch allen wrench. Installation: Tighten the mounting bolts to 180–200 in.–lbs.
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FUEL TANK A Removal And Installation Remove the cover (Item 1) [A] which is installed over the drain plug. 1 P–01616 B Remove the drain plug (Item 1) [B]. Drain the fuel into a container. Check the drain plug and replace if necessary. Remove the engine/hydrostatic pump assembly from the loader (Page 7–1). 1 P–01619 C Disconnect the fuel fill hose (Item 1) [C]. 2 Disconnect the tank vent hose (Item 2) [C]. 1 P–04855 Remove the bolts (Item 1) [D] from the battery holddown plate.
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FUEL TANK (Cont’d) A Removal And Installation (Cont’d) Remove the mounting plate (Item 1) [A] for the battery holddown plate. 1 P–04960 B Lift the fuel tank and remove it from the loader frame [B]. Fuel Level Sender Loosen the fuel level sender (Item 1) [B]. 1 P–04961 C Remove the fuel level sender from the fuel tank [C]. P–07922 Inlet Screen D The inlet screen (Item 1) [D] is located at fuel tank fill neck. Disconnect the fuel fill hose. 1 Remove the inlet screen (Item 1) [D].
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ELECTRICAL SYSTEM Page Number ALTERNATOR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rectifier (Diode) Test . . . . . . .
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–6–3– 853, 853H Loader Service Manual
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–6–4– 853, 853H Loader Service Manual
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B A A B DGN RNG BLK LBL/RED BLK DGN/WHT A B C402 CONTROLS HARNESS 6576297 YEL B A B A DGN/RED DGN/LGN FRONT AUX.
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B A DGN RNG DETENT C404 CONTROLS HARNESS - CONTROLS HARNESS 6576323 6702634 RIGHT HANDLE (IF EQUIPPED) B A DIODE BLK B A BLK B A B A YEL DGN DIODE RNG A B DGN/RED DGN/LGN FRONT AUX.
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B A BLK YEL/WHT B A BLK RED BLK RED DIODE B A C420 DIODE HARNESS - 6703898 CONTROLS HARNESS 6703005 S/N 508411354-11714 S/N 509711001-11094 (Printed June 1999) MC2566 C410 853 BOSS - WIRING SCHEMATIC B A REAR AUXILIARY ROD SOLENOID RNG/DBL A B C404 RNG/WHT B A C403 RIGHT HANDLE (IF EQUIPPED) A B C DGN RNG RNG DGN/RED BLK DGN/LGN DGN/WHT BLK LEFT HANDLE (IF EQUIPPED) RNG/DBL A B C402 RNG/WHT A B RNG C401 DGN/RED B C A DGN BRN YEL A B C RNG FRONT AUXILIARY ROD SOLENOI
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RNG/DBL A B C404 RNG/WHT S/N 508411715-12360 S/N 509711095-11308 (Printed June 1999) MC2572 B C A C403 853 BOSS - WIRING SCHEMATIC A B B A B A C414 BLK DGN/LGN RIGHT HANDLE (IF EQUIPPED) B A FRONT AUXILIARY ROD SOLENOID C415 CONTROLS HARNESS - 6703878 B A FRONT AUXILIARY BASE SOLENOID RNG A B DGN YEL A C DGN/LGN BLK B DGN/RED DGN/RED A B RNG B C A YEL RNG LEFT HANDLE (IF EQUIPPED) RNG/DBL B A BLK YEL HORN YEL/WHT K A DGN/YEL LGN/DBL RNG LGN/RED J E F B B G
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BLK DGN/LGN C404 A B C403 RNG/DBL A C B RNG C402 A B RNG/WHT A B RNG C401 RIGHT HANDLE (IF EQUIPPED) B C A YEL B A B A C414 S/N 508412361-12460 S/N 509711309-11334 (Printed June 1999) MC2567 B A FRONT AUXILIARY ROD SOLENOID C415 CONTROLS HARNESS - 6703878 853 BOSS - WIRING SCHEMATIC B A FRONT AUXILIARY BASE SOLENOID RNG DGN DGN BRN YEL FRONT AUX.
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853 BOSS - WIRING SCHEMATIC S/N 508412461-15055 S/N 509711335-15096 S/N 510250001-50161 S/N 510375001-75092 (Printed June 1999) MC2563 C404 A B RNG/WHT RNG/DBL B A B A C414 BLK DGN/LGN RIGHT HANDLE (IF EQUIPPED) B A FRONT AUXILIARY ROD SOLENOID C415 CONTROLS HARNESS - 6703878 B A FRONT AUXILIARY BASE SOLENOID RNG A B DGN A C DGN/LGN BLK B DGN/RED DGN/RED A B RNG B C A YEL B C A A B LEFT HANDLE (IF EQUIPPED) RNG/DBL B A BLK YEL HORN BLK YEL/WHT YEL/WHT A B G J K H C D E F
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B A BLK A B RNG/WHT RNG/DBL C404 S/N 508415056-15187 S/N 509715097-15221 S/N 510250162-50448 S/N 510375093-75213 (Printed June 1999) MC2564 DGN/LGN RNG A B DGN A C DGN/LGN BLK B DGN/RED DGN/RED C414 CONTROLS HARNESS - 6703878 RIGHT HANDLE (IF EQUIPPED) 853 BOSS - WIRING SCHEMATIC B A FRONT AUXILIARY ROD SOLENOID BRN YEL RNG B A C415 B C A DGN FRONT AUX. C403 DETENT B A B A BLK C402 A B RNG B C A YEL YEL HORN B C A DGN BRN YEL REAR AUX.
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WITHOUT FRONT AUXILIARY VALVE CONTROLS HARNESS - 6702999 DGN/RED DGN A B DGN A B RNG B A BLK A B YEL RNG RNG/DBL C441 REAR AUXILIARY BASE SOLENOID HERE OR TO ATTACHMENT B C A B A YEL B A BLK YEL/WHT YEL/WHT RNG B A SKI CONTROL RNG/WHT DBL WHT RNG/DBL A B HORN B A C DGN YEL/LGN BRN YEL/RED YEL B A RNG TURN SIGNAL C B A LBL/RED RNG/DBL B C A YEL YEL/WHT RNG REAR AUX.
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DGN/RED B A BLK DGN/LGN DGN/LGN DGN/RED RNG/WHT DETENT DGN A B FRONT AUXILIARY ROD SOLENOID TO ATTACHMENT RNG A B DGN A B RNG B A BLK A B YEL RNG RNG/DBL B A REAR AUXILIARY BASE SOLENOID HERE OR TO ATTACHMENT B C A C441 DGN B YEL B A BLK YEL/WHT YEL/WHT RNG B A WATER KIT B A SKI CONTROL DBL RNG/WHT WHT RNG/DBL A B HORN B A C DGN YEL/LGN BRN YEL B A B A BLK TO ATTACHMENT YEL/RED RNG TURN SIGNAL C B A LBL/RED RNG/DBL B C A B A HIGH PRESSURE RELIEF SOLENO
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853 WITHOUT BOSS - WIRING SCHEMATIC S/N 510125001-25239 (Printed June 1999) MC2568 A B C404 RNG/DBL B C A C403 RNG/WHT A B B A B A C414 BLK DGN/LGN RIGHT HANDLE (IF EQUIPPED) B A FRONT AUXILIARY ROD SOLENOID C415 CONTROLS HARNESS - 6703878 B A FRONT AUXILIARY BASE SOLENOID RNG A B DGN A C RNG DGN/LGN BLK B DGN/RED DGN/RED A B RNG B C A YEL LEFT HANDLE (IF EQUIPPED) B A BLK YEL HORN B A BLK YEL/WHT YEL/WHT REAR AUXILIARY BASE SOLENOID A B G J K H C D E F B A REAR AU
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853 WITHOUT BOSS - WIRING SCHEMATIC S/N 510125240-26110 (Printed June 1999) MC2569 RNG/DBL A B C404 RNG/WHT A B A B A C414 BLK DGN/LGN RIGHT HANDLE (IF EQUIPPED) B A FRONT AUXILIARY ROD SOLENOID C415 CONTROLS HARNESS - 6703878 B A FRONT AUXILIARY BASE SOLENOID RNG B DGN RNG RNG YEL LEFT HANDLE (IF EQUIPPED) B A BLK YEL RNG/DBL HORN YEL/WHT LGN/PNK LGN/DBL RNG RNG D H G J K A DGN/YEL LGN/RED C E F D H E B LGN/DBL F K CAB HARNESS (WITHOUT BOSS) - 6704494 AUXILI
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WITHOUT FRONT AUXILIARY VALVE CONTROLS HARNESS - 6702999 DGN/LGN DGN/RED C415 FRONT AUXILIARY ROD SOLENOID WATER KIT YEL/WHT YEL/WHT RNG C441 B A A B RNG/WHT WHT RNG/DBL DGN C B A YEL/LGN BRN YEL/RED YEL B A DGN A B RNG RNG TURN SIGNAL LBL/RED RNG/DBL HIGH PRESSURE RELIEF SOLENOID HERE OR TO ATTACHMENT B C A YEL YEL/WHT RNG REAR AUX.
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853 - WIRING SCHEMATIC ATTACHMENT CONTROLS HARNESS - 6705901 TO OPTIONS BLK RED RNG/DBL BRN LBL DIODE MODULE RNG/WHT C509 DBL K E D C B A F H G J K E D C B A F H G J LBL DGN YEL YEL DGN DGN YEL/WHT RNG B J N P A L D C E F G H M K C506 ATTACHMENT CONTROL OPTION S/N 508415001-17999 S/N 509715001-17999 S/N 510125001 AND ABOVE S/N 510250001 AND ABOVE S/N 510375001 AND ABOVE S/N 512811001-15999 (Printed June 1999) MC2574 DBL RNG/WHT BRN WHT BRN/YEL B C A YEL/LGN RNG 85 A LGN/WHT LGN/WHT
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DBL RED YEL RNG BRN BLK DBL RED YEL GRADER HARNESS 6707303 BRN J E F G H L K BLK DBL RED YEL REAR WIPER SWITCH 2 1 4 RNG/BLK PUR DBL YEL DBL/BLK 6 RED WHT 3 5 C202 RNG/BLK DGN OLD TO NEW ADAPTER HARNESS 6706392 NEW TO OLD ADAPTER HARNESS 6706391 RNG S LT TM CENTER GD RT TO CAB C211 BLK S LT TM CENTER GD RT V M TO CAB RED/WHT BRN C506 S LT TM CENTER GD RT TO ATTACHMENT C627 WHT TO OLDER MODEL ATTACHMENTS REAR WIPER MOTOR B D N P M C A C628 B J N P M C D A E F G H L K
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DGN/RED FRONT AUXILIARY ROD SOLENOID WATER KIT LGN DETENT YEL B A BLK YEL/WHT YEL/WHT RNG C441 B A B A FRONT AUXILIARY ROD SOLENOID TO ATTACHMENT RNG A B DGN A B RNG B A BLK SKI CONTROL DBL A B RNG/WHT WHT B A C C460 DGN/LGN DGN/RED RNG/DBL DGN YEL/RED YEL TURN SIGNAL B A C B A YEL/LGN BRN RNG LBL/RED B A RNG/DBL HIGH PRESSURE RELIEF SOLENOID HERE OR TO ATTACHMENT B C A YEL YEL/WHT RNG REAR AUX.
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TROUBLESHOOTING Chart The following troubleshooting chart is provided for assistance in locating and correcting problems. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only. Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manuals, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing.
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ELECTRICAL SYSTEM INFORMATION A Description 1 The loader has a 12 volt, negative ground alternator charging system. The electrical system is protected by fuses. The fuses will protect the electrical system when there is an electrical overload. The reason for the overload must be found before starting the engine again.
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BATTERY A Removal And Installation Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body. 1 In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. CD–15008 B If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.
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BATTERY (Cont’d) A Removal And Installation (Cont’d) Always clean the terminals and cable ends when installing a new battery [A] and [B]. When installing the battery in the loader, do not touch any metal parts with the battery terminal posts. Connect and tighten the battery cables. Connect the negative (–) cable last to prevent sparks. P–09589 B Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.
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BATTERY (Cont’d) A Using A Booster Battery (Jump Starting) 2 4 Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body. CD–15010 In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. If electrolyte is taken internally drink large quantities of water or milk. DO NOT induce vomiting. Get prompt medical attention.
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ALTERNATOR A Alternator Output Test 1 Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W–2017–0286 P–4944 Lift and block the loader (See Page 1–1). B Disconnect the negative (–) cable from the battery. Output Terminal Disconnect the red wire (Item 1) [A] from the alternator. Connect the wire to the negative (–) side of the ammeter.
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ALTERNATOR (Cont’d) A Alternator Regulator Test 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. P–05054 W–2050–1285 B Connect the positive (+) voltmeter lead to the positive (+) battery terminal [A]. Connect the negative (–) voltmeter lead to the negative (–) battery terminal [A].
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ALTERNATOR A Removal And Installation NOTE: The engine/hydrostatic pump assembly is shown removed for photo clarity purpose only. 1 2 Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 P–04944 B 1 Damage to the alternator can occur if: • Engine is operated with battery cables 2 disconnected.
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ALTERNATOR (Cont’d) A Disassembly 1 (Motorola or Prestolite 30 Amp., Enclosed) 2 Disassemble the alternator as shown in Fig. [A]. 7 Remove the regulator cover and regulator. 4 5 3 6 9 16 6 8 Remove the four bolts holding halves together. Pry the halves apart. Use a soft jaw vise to hold rotor while removing pulley nut. Remove front case half from the rotor using a plastic hammer. Unsolder the stator leads from the rectifier. Remove the stator. 10 11 12 13 15 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
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ALTERNATOR (Cont’d) A Rotor Continuity Test Touch the probes to the slip rings [A]. The ohmmeter should read between 3.0–33.0 ohms. If there is no continuity replace the rotor. P–01365 Rotor Ground Test B Touch one probe to one of the slip rings and the other probe to the rotor shaft [B]. There should be no continuity. Replace the rotor if there is continuity. P–01378 Rectifier Continuity (Diode) Test C NOTE: In the diode tests there should be continuity in one direction only.
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ALTERNATOR (Cont’d) A Assembly Reverse the order of disassembly. Place the rotor in soft jaws when tightening the shaft nut. Tighten to 50 ft.–lbs. (68 Nm) torque [A]. Install the rear case half and the remaining parts.
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STARTER A Checking The Starter Jumper Wire Bat S M The key switch must be in the OFF position. The battery must be at full charge. The cable connections on the battery must be clean and tight. Cranking Motor Connect a jumper wire between S terminal and BAT terminal [A]. If the starter turns but does not turn the engine, the starter drive has a defect. A–01992 B Connect a jumper wire between the M terminal and the BAT terminal [B].
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STARTER (Cont’d) A Removal And Installation Disconnect the negative (–) cable from the battery. Disconnect the positive (+) cable (Item 1) [A] and starter wires from the starter solenoid. 1 CD–15138 B Remove the starter mounting bolt (Item 1) [B] and engine harness ground wires from the starter. 1 CD–15140 C Remove the other two mounting bolts (Item 1) [C]. Remove the starter from the engine.
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STARTER (Cont’d) Parts Identification 1 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 3 2 4 1 5 6 7 9 8 41 10 13 12 19 14 17 16 15 18 20 11 21 26 22 25 24 Screw Solenoid Bolt Lever Washer Nut Plug Washer Housing Drive Washer Bushing Ring Stop Drive Drive Support Support Drive Shaft Washer Washer Washer Screw Brush Frame Assy.
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STARTER (Cont’d) A Disassembly And Assembly Remove the starter thru–bolts [A]. CD–08924 Remove the screws for the brush holders [B]. B CD–08925 Remove the starter end cap [C]. C CD–08926 Remove the starter housing/armature assembly from the reduction gear drive [D].
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STARTER (Cont’d) A Disassembly And Assembly (Cont’d) Remove the armature and brushes from the starter housing [A]. CD–08928 Remove the bolts from the reduction gear housing [B]. B CD–08929 Remove the reduction gear housing [C].
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STARTER (Cont’d) A Cleaning And Inspection Use a brush and air pressure to clean the drive, field coils, armature and starter housing. NOTE: DO NOT use solvent to clean the drive assembly. The solvent will remove the lubricant and the drive will slip.
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STANDARD INSTRUMENT PANEL A Removal And Installation Pry the rubber light mount loose from the operator cab (both sides) [A]. P–03995 Lower the light from the operator cab and locate the three instrument panel mounting bolts (Item 1) [B] (both sides). B Remove the three mounting bolts (Item 1) [B]. 1 Installation: Be careful not to overtighten the instrument panel mounting bolts to prevent stripping the threaded holes in the panels.
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FRONT LIGHTS A 963ServiceManual#6724545–ElectricalSystemSectionPart2of2 Removal And Installation The front lights are mounted in the upper corners of the operator cab [A]. P–03956 B Pry the rubber light mount free from the operator cab [B]. P–03995 C Pull the light down and remove the three mounting bolts (Item 1) [C] from the instrument panel. 1 Disconnect the front light connector from the instrument panel. Remove the front light from the operator cab.
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STEERING LEVER CONTROL HANDLE (Early Series) A Disassembly And Assembly EARLY MODELS Remove all the screws and nuts from the control handle [A]. B–10577 Remove one side of the control handle [B]. B Disconnect the wires and remove the other half of the handle with the switch plate. EARLY MODELS Assembly: When connecting the electrical wires to the switches, see AUXILIARY WIRING DIAGRAM for correct installation.
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ENGINE SERVICE Page Number AIR CLEANER HOUSING Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 BELT SHIELD Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38 CAMSHAFT Camshaft Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ENGINE SERVICE (Cont’d) Page Number FAN GEARBOX/BLOWER HOUSING Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13 FAN DRIVE TENSION PULLEY Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12 FAN GEARBOX Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ENGINE SERVICE (Cont’d) Page Number OIL PUMP Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter Housing And Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . .
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–7–4– 853, 853H Loader Service Manual
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TROUBLESHOOTING Chart The following troubleshooting chart is provided for 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 Slow cranking speed. Engine will not start. Difficult to start. No power for engine. Engine is mis–firing. Too much fuel consumption. Black exhaust. Blue/white exhaust. Low oil pressure. Engine knocking. Engine running rough. Vibration. High oil pressure warning.
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ENGINE SPEED CONTROL A Removal And Installation Raise the operator cab. (See Page 1–1.) Remove the two mounting bolts (Item 1) [A] and nuts from the speed control mounting bracket. 1 1 Installation: Tighten the bolts (Item 2) [A] evenly until the speed control lever moves back and forth at a comfortable tension. 2 P–09326 Pull the speed control away from the loader frame and disconnect the speed control rod (Item 1) [B] from the control.
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ENGINE MUFFLER A Removal And Installation Open the rear door. Raise the rear grill. Remove the air cleaner. (See Page 7–8.) Loosen the exhaust pipe clamp (Item 1) [A]. 1 Disconnect the exhaust pipe from the muffler. P–04892 Remove the mounting bolt (Item 1) [B] from the muffler (both sides). B Remove the muffler from the loader.
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AIR CLEANER HOUSING A Removal And Installation Loosen the hose clamp (Item 1) [A]. Disconnect the hose from the intake manifold. 1 P–04889 Loosen the hose clamp (Item 1) [B]. B Disconnect the intake hose from the air cleaner housing. 1 P–04890 NOTE: The manual indicator (Item 1) [C] is equipped on the 853 standard loader only. C 1 Remove the two mounting bolts (Item 2) [C] (at the top) and one mounting bolt at the bottom of the housing. Remove the air cleaner housing.
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COOLANT RECOVERY TANK A Removal And Installation 1 Open the rear door. Raise the rear grill. Lift the coolant recovery tank from the bracket [A]. P–09369 B Disconnect the overflow hose (Item 1) [B]. 1 P–04898 C Remove the two mounting bolts (Item 1) [C] from the recovery tank mounting bracket. Remove the mounting bracket.
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RADIATOR A Removal And Installation 1 Open the rear door. Remove the rear grill. (See Page 5–1.) Remove the oil cooler. (See Page 3–1.) Remove the engine muffler. (See Page 7–7.) Loosen the radiator cap. Connect a hose to the engine block drain (Item 1) [A]. P–04896 Open the block drain (Item 1) [A] and drain coolant into a container. B NOTE: Early S/N Loaders use a hex plug in this location for the drain. 1 Disconnect the hose (Item 1) [B]. P–04894 Disconnect the hose (Item 1) [C].
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RADIATOR (Cont’d) A Removal And Installation (Cont’d) 2 Disconnect the over–fill hose (Item 1) [A]. 1 P–04904 B If so equipped, disconnect the wires from the water level sensor (Item 1) [B]. BOSS® Remove the radiator from the loader. 1 P–05191 C Installation: Be sure the rubber bumpers (Item 2) [A] are located at each side (Item 1) [C] before installing the radiator tabs into the loader frame.
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FAN DRIVE TENSION PULLEY A Removal And Installation Remove the fan drive belt. Remove the idler pulley bolt (Item 1) [A]. 1 P–04954 B Remove the spacers, bolt and washers from the arm [B]. 1 Installation: Put a small amount of grease around the outside edge on the grease rings (Item 1) [B] between ring and bearing. P–00581 P–04956 C Remove the bolt (Item 1) [C], spring and arm. Check all parts for damage or wear. Replace the parts as needed.
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FAN GEARBOX/BLOWER HOUSING A Removal And Installation Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 1 CD–15015 Raise the operator cab. (See Page 1–1.) B Remove the mounting bolts (Item 1) [A] from the gas cylinder mounting bracket. 1 Installation: Tighten the mounting bolts to 80–90 in.–lbs.
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FAN GEARBOX/BLOWER HOUSING (Cont’d) A Removal And Installation (Cont’d) Installation: Use R.T.V. sealant to reseal the blower housing to the loader frame [A]. P–4877 B Remove the four mounting bolts (Item 1) [B] and spacer tubes (two outside housing and two inside housing). NOTE: Remove the two rear mounting bolts first. 1 Installation: Use sealant on each end of the inside spacer tubes to prevent the tubes from falling out of the housing during installation.
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FAN GEARBOX/BLOWER HOUSING (Cont’d) A Removal And Installation (Cont’d) Remove the lock nut and spacer [A]. Installation: Tighten the nut to 45–55 ft.–lbs. (61–75 Nm) torque. CD–09952 Use the following procedure to remove the fan from the shaft: B 2 AVOID INJURY OR DEATH Wear safety goggles to prevent eye injury when drilling or grinding. 1 W–2108–1186 Install the nut (Item 1) [B] on the tapered shaft to protect the shaft and threads. P–03006 C Install the puller on the fan as shown [B].
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FAN GEARBOX/BLOWER HOUSING (Cont’d) A Removal And Installation (Cont’d) Drive Shaft Early S/N Loaders: Use the following procedure to remove the fan from the shaft: Use a center punch to mark the aluminum bushing in the fan as shown in [A]. 0.562–0.570 “ (14,3–14,5 mm) B To insure straight drilling and tapping of the holes, a drill press is recommended. Drill the two holes (Item 1) [B] 1.0 inch (25,4 mm) deep using a 13/64 inch drill bit.
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FAN GEARBOX Parts Identification 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. *16. 17. 18. 19. 20. 21. 22. Seal Snap Ring (Small) Shims (1.0 inch O.D.) Bearing Shaft (Long) Shims (2.0 inch O.D.) Long Key Shaft (Short) Short Key Long Housing Nut Gear Washer Screw 1 Square Shim Short Housing Bolt Snap Ring (Large) Cap Long Housing Assy. Short Housing Assy.
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FAN GEARBOX (Cont’d) A Disassembly 3 NOTE: When repairing the gearbox order the following as needed: 1. 2. 3. 4. Complete Assembly Long Housing Assembly Long Housing Short Housing Assembly (See Note Below) 5. Internal Parts 1 2 NOTE: The short housing is only available as an assembly. See the Parts Identification Page 7–17 for reference. (Order parts from Melroe Parts Sales.) P–03005 NOTE: Be sure to count the number and thickness of shims during disassembly.
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FAN GEARBOX (Cont’d) A Disassembly (Cont’d) Remove the small shims [A]. P–02963 Remove the screw and washer from the shaft [B]. B P–02966 Support the lower flange and press the shaft from the bearing [C]. C NOTE: The gear and the other bearing (pulley end) will be removed with the shaft. P–03004 Support the bearing and press the shaft from the bearing [D].
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FAN GEARBOX (Cont’d) A Disassembly (Cont’d) Short Housing Remove the end cap [A]. Use care not to damage the housing. P–02997 AVOID INJURY OR DEATH Wear safety goggles to prevent eye injury when drilling or grinding. B W–2108–1186 Drill an 1/8 inch (3 mm) hole in the seal. Use a slide hammer tool to remove the seal [B]. P–02996 C Remove the large snap ring from the flange end of the housing [C]. P–02970 Remove the large shims from the housing [D].
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FAN GEARBOX (Cont’d) A Disassembly (Cont’d) Remove the screw and washer (Item 1) [A] from the shaft. 1 P–02978 B Remove the snap ring from the cap end of the housing [B]. P–02973 C Press the shaft from the housing [C]. NOTE: Both bearings may come out of the housing with the shaft. If one bearing remains in the housing, use a non metal object to tap the bearing from the housing. P–02998 Press the bearing from the tapered end of the shaft [D].
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FAN GEARBOX (Cont’d) A Disassembly (Cont’d) Press the bearing, shims and gear from the shaft [A]. P–03001 B Remove the key (Item 1) [B] from the shaft. 1 P–02972 Assembly C Long Housing Press a bearing on the short keyed end of the long shaft [C]. Install the long housing on the shaft [D]. Be sure the bearing is seated in the bore at the lower end of the housing. Install a bearing on the long keyed end of the shaft [C].
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FAN GEARBOX (Cont’d) A Assembly (Cont’d) Install the small snap ring in the groove above the shims [A]. P–02964 Install the gear key in the flange end of the shaft [B]. B P–02965 Align the key and gear. While supporting the bearing on the other end, press the gear on the shaft until it seats against the bearing [C]. C P–02967 Install the washer [D]. D Put LOCTITE #242 adhesive on the screw threads. Install and tighten the screw [D].
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FAN GEARBOX (Cont’d) A Assembly (Cont’d) Short Housing Install a bearing in the flanged end of the housing [A]. P–02968 B Install the large shims on the bearing (flanged end) [B]. P–02969 C Install the large snap ring in the groove above the shims [C]. P–02970 Install the short key (Item 1) [D]. D Align and press the gear on the shaft (teeth toward the tapered end of the shaft) [D].
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FAN GEARBOX (Cont’d) A Assembly (Cont’d) After the gear is seated, drive the key down inside the gear key way [A]. NOTE: This will prevent damage to the shims when the bearing is installed later. P–02975 Install the shaft in the housing, tapered end in the bearing at the round flange end of the housing [B]. B P–02976 Install on the shaft, the same number and size shims that were removed during disassembly [C]. C P–02977 D Install a bearing on the gear end of the shaft [D].
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FAN GEARBOX (Cont’d) A 853,853HServiceManual#6720755–EngineServiceSectionPart1of4 Assembly (Cont’d) Install the snap ring in the groove above the bearing [A]. P–02973 Install the washer (Item 1) [B] on the shaft. Put liquid adhesive (LOCTITE #242) on the screw threads and install the screw [B].
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FAN GEARBOX (Cont’d) A Checking Backlash NOTE: For procedures requiring the use of LOCTITE adhesive, thoroughly clean and dry affected parts before the application of LOCTITE. The backlash tolerance between the gears should be 0.005–0.008 inch (0,127–0,203 mm). To check the gear backlash use the following procedure: Put the short housing in a vise, square flange facing up as shown [A]. P–02987 Install the same size and number of square shims (if present during disassembly) between the two housings [B].
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FAN GEARBOX (Cont’d) A 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 support the handle against the long housing [A]. 1 P–02982 Using a magnetic based dial indicator mounted on a bench vise, touch the dial stem on the bolt (Item 1) [B]. B Hold the locking pliers against the long housing and rotate the pulley back and forth to read the dial gauge [B]. 1 If the backlash is GREATER than 0.
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FAN GEARBOX (Cont’d) A Checking Backlash (Cont’d) When the backlash is correct, install the seals, cap and gear oil as follows: Remove the bolts from the flanges and separate the two housings. Put liquid adhesive (LOCTITE #242) on the outside diameter of the seal(s) [A]. P–03089 Install the seal(s) flush with the housing surface [B] & [C]. B Clean any oil from the flange surface. LONG HOUSING Install the long housing on the short housing flange. Install the four bolts and part number tag.
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ENGINE A Removal And Installation 2 1 Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W–2059–0598 P–04856 B 1 Raise the operator cab. (See Page 1–1.) 2 Disconnect the case drain hose (Item 1) [A] and drain the hydraulic fluid into a container.
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ENGINE (Cont’d) A Removal And Installation (Cont’d) 1 Disconnect the wires (Item 1 & 2) [A] at the filter. 2 CD–10993 Disconnect the electrical harness connectors (Item 1) [B]. B Disconnect the ground wire and harness clamp (Item 2) [B]. 1 NOTE: The electrical harness will be removed with the engine. 1 2 P–00883 Disconnect the hose (Item 1) [C] from the oil cooler. C Disconnect the hose (Items 2 & 3) [C] from the hydrostatic pump.
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ENGINE (Cont’d) A Removal And Installation (Cont’d) 1 2 Disconnect the steering cables (Item 1) [A]. Installation: See Page 3–1 for transmission neutral adjustment. Mark the high pressure hoses for correct installation. Disconnect the four high pressure hoses (Item 2) [A] from the pump. 2 B Disconnect the high pressure hose (Item 1) [B] from the hydraulic pump. P–04878 1 2 P–04870 C Disconnect the case drain filter hose (Item 1) [C] from the pump.
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ENGINE (Cont’d) A Removal And Installation (Cont’d) Remove the battery. (See Page 6–1.) Remove the air cleaner housing. (See Page 7–8.) After the air cleaner hose is disconnected, remove the air horn (Item 1) [A] from the intake manifold. 1 Plug the intake manifold to prevent material from falling into manifold. Remove the rear grill. (See Page 5–1.) P–04889 Remove the muffler. (See Page 7–7.) Loosen the radiator cap. B 1 Connect a hose to the engine block drain (Item 1) [B].
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ENGINE (Cont’d) A Removal And Installation (Cont’d) Disconnect the electrical connector (Item 1) [A]. Remove the coolant recovery tank and bracket (Page 7–9). 1 P–05042 Disconnect the throttle linkage (Item 1) [B] from the bellcrank. B 1 P–04900 Disconnect the ground cable (Item 1) [C] from the loader frame. C 2 Disconnect the fuel hose (Item 2) [C] from the fuel filter. 1 P–04901 Disconnect the fuel return hose (Item 1) [D] from the injection pump.
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ENGINE (Cont’d) A Removal And Installation (Cont’d) Remove the left rear engine mount bolt and nut [A]. P–04903 Remove the right rear engine mount bolt (Item 1) [B]. B Installation: Tighten the bolts and nuts to 65–70 ft.–lbs. (88–95 Nm) torque. 1 Use the dimensions from Figure [C] to make the engine Removal And Installation brackets. C P–04902 13.0 (330) 0.50 (12,7) 2.5 (64) INCHES (MM) 3/8 Dia. (3) 1–1/2’’ I.S. Dia. 2–1/2’’ O.S. Dia. 0.75 (19,05) 2–1/2 x 2–1/2 x 6 1/4’’ Angle Iron 2.
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ENGINE (Cont’d) A Removal And Installation (Cont’d) 3 The engine lift eye bracket (Item 1) [A] has been turned down for clearance at the exhaust pipe. Turn the lift eye bracket and install the bolt. The valve cover (Item 2) [A] will have to be removed for clearance for the engine lift brackets. Install the engine lift brackets on the engine as shown in Figure [A]. Connect a chain hoist to the ring (Item 3) [A] on the lift bracket.
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FLYWHEEL A Removal And Installation Remove the drive belt. (See Page 3–1.) Remove the bolts (Item 1) [A] from the flywheel. 1 Installation: Put LOCTITE on the flywheel bolts. Tighten the bolts to 83–90 ft.–lbs. (113–122 Nm) torque. P–04928 Remove the flywheel from the engine crankshaft [B]. B 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 to remove it evenly.
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BELT SHIELD A Removal And Installation Remove the mounting bolt (Item 1) [A] from the thermostat housing. 1 2 Remove the mounting bolt (Item 2) [A] from the cylinder head. Remove the mounting bolt (Item 3) [A]. 3 P–04947 B Remove the mounting bolt (Item 1) [B] from the alternator mounting bracket. Remove the belt shield from the engine.
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ENGINE MOUNTS A Removal And Installation 1 2 3 There is a kit available to replace the existing engine mounts in older model 853 loaders. 4 Use the following procedure to install new engine mounts: Remove the existing mount from the engine. Refer to engine Removal And Installation for engine mount locations. 5 6 Replace all four engine mounts (2 front and 2 rear). 7 Use the parts shown to install the new engine mounts [A].
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GLOW PLUGS A Removal And Installation Disconnect the negative (–) cable from the battery. Remove the electrical bar holddown nuts at the glow plugs [A]. B–08957 B Remove the electrical connector bar [B]. B–08919 C Remove the glow plug from the cylinder head [C]. B–08923 Checking The Glow Plugs D Connect the voltmeter to the terminal end of the glow plug. Touch the other lead from the voltmeter to the heating end of the glow plug [D]. The reading must be approximately 1.5 ohms.
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VALVE CLEARANCE A Adjustment 0.016 inch (0,41 mm) Cold Make the valve clearance adjustment with engine stopped and cold. The correct clearance is 0.016 inch (0,41 mm) with the engine cold [A]. B–04123 Put the correct size feeler gauge between the rocker arm and the valve stem. Turn the adjustment bolt until the clearance is correct [B]. B Use the following sequence to set the valve clearance: Front Cylinder No. Rear 1 2 Valve arrangement I E Piston in No.
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FUEL INJECTION PUMP A Description The injection pump contains parts which have a very close tolerance and its operation has a direct effect on the performance of the engine. Do not attempt to maintain or adjust unless you are trained and have the correct equipment. B–08976 I–2028–0289 B Removal And Installation Disconnect the throttle linkage. Disconnect the shut–off wire [A]. Remove the valve cover. Rotate the engine until No. 1 piston is at TDC. Both valves at No.
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FUEL INJECTION PUMP (Cont’d) A Removal And Installation (Cont’d) 1 Use the parting line (off–set) (Item 2) [A] or (Item 1) [B] of the timing case cover to make alignment of the TDC mark. P–04949 B 1 Early S/N Loader: P–04952 Disregard the pointer (Item 1) [C] in the belt shield for timing reference. C 1 Align the mark on the injection pump gear with the pointer in the window [D].
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FUEL INJECTION PUMP (Cont’d) A Removal And Installation (Cont’d) Do not bend the high pressure fuel injection tubes when removing or installing them. I–2029–0289 Disconnect the high pressure fuel lines at the injection pump [A]. B–08975 B Disconnect the fuel lines at the injectors [B]. Installation: Tighten the fittings on the high pressure fuel lines to 14–29 ft.–lbs. (19–39 Nm) torque. B–08917 C Remove the high pressure fuel lines from the engine [C].
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FUEL INJECTION PUMP (Cont’d) A Removal And Installation (Cont’d) Remove the fuel injection pump [A]. Installation: After the injection pump is installed, the air must be removed from the fuel system. (See Page 1–1.) Also the injection pump timing must be set. (See Page 7–46.
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FUEL INJECTION PUMP (Cont’d) A Timing The Injection Pump The tools listed will be needed to do the following procedure: MEL1201 – Timing Tool Remove the valve cover. Rotate the engine until No. 1 piston is at TDC. Both valves at No. 1 cylinder are not moving and have clearance [A]. B–08935 12 o’clock Position B The TDC mark (Item 1) [B] is located on the engine pulley v–belt groove. There are two sets of timing marks on the engine pulley one at 12 o’clock and the other at the 3 o’clock position.
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FUEL INJECTION PUMP (Cont’d) A Timing The Injection Pump (Cont’d) Install the timing tool and dial indicator [A]. Rotate the engine counterclockwise so the front pulley mark goes 30° to 40° before TDC. B–08977 B Set the dial indicator to zero [B]. Rotate the engine back to 17° BTDC mark on the front pulley. The dial indicator must read approximately 0.020 inch (0,50 mm) [B]. B–08977 C If not, loosen the bolts at the injection pump flange [C]. Move the injection pump to obtain the 0.020–0.
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FUEL INJECTOR NOZZLES A Removal And Installation 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. B–08975 W–2074–1285 B Some problems caused by faulty injector nozzles: The engine is hard to start or will not start. Rough engine operation and idle.
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FUEL INJECTOR NOZZLES (Cont’d) A 853,853HServiceManual#6720755–EngineSystemSectionPart2of4 Removal And Installation (Cont’d) Remove the nut at the fuel injector holddown clamp [A]. Installation: Tighten the nuts to 23–32 ft.–lbs. (31–43 Nm) torque. B–08914 B Use a screwdriver and pry the injector from the cylinder head [B]. B–08924 C Remove the injector nozzle from the head [C]. Checking Do not disassemble or test the fuel injector nozzles unless you have the correct service and testing tools.
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FUEL INJECTOR NOZZLES (Cont’d) A Checking (Cont’d) If the pressure is not correct, do the following: Disassemble the injector nozzle and clean. 6 Replace the shim (Item 6) [A]. 5 Check the pressure again. 4 3 7 2 Keep away from fuel under pressure in injector system. It may not be visible. Wear safety goggles. Fuel under pressure can penetrate skin or eyes causing serious injury. If fluid enters skin or eyes, get immediate medical attention.
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CYLINDER HEAD 2 A Removal And Installation 3 1 The tools listed will be needed to do the following procedure: MEL1267 – 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 7–48.) B–08186 Remove the valve cover nuts in the correct sequence [A]. B Installation: Tighten the nuts to 6–13 ft.–lbs. (8–17 Nm) torque in the correct sequence [A].
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CYLINDER HEAD (Cont’d) A Cylinder Head Surface Alignment Check the surface of the head with the straight edge [A]. B–08198 B Check the head at six different directions [B]. The standard distortion is 0.002 inch (0,05 mm) and the maximum limit is 0.008 inch (0,20 mm). When the head distortion exceeds the maximum limit, regrind the head with a maximum limit of 0.012 inch (0,30 mm).
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VALVES, VALVE SEAT AND GUIDE A Removal 1 The tools listed will be needed to do the following procedure: 1. 2. 3. 4. 5. MEL1266 – Valve Stem Seal Installer Mark the valves and parts so they are returned to their original position when assembling. Spring Seat Springs Valve Oil Seal Spring Seat 2 4 Remove the valve spring locks [A], using a spring compressor [B]. Remove the valve springs, spring seats, oil seal and valve [A]. 5 Before reassembly, check the valves, valve seats and guides.
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VALVES, VALVE SEAT AND GUIDE (Cont’d) A Reconditioning The Valve And Valve Seats (Cont’d) Check the valve head depth in the cylinder head after grinding the valves and seat. The correct specifications are as follows[A]: Intake – Standard Limit Exhaust – Standard Limit Contact Width 0.029 inch (0,74 mm) 0.05 inch (1,27 mm) 0.028 inch (0,71 mm) 0.047 inch (1,20 mm Depression Check the valve seat contact width [A]: Intake – Standard Limit Exhaust – Standard Limit 0.067 inch (1,70 mm) 0.
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VALVES, VALVE SEAT AND GUIDE (Cont’d) A Valve Guide (Cont’d) Remove the guide [A]. B–08206 B Install the new guide [B]. The height of the valve guide top edge to the cylinder is 0.51 inch. (13,0 mm). B–08207 C Valve Spring Inclination Std. Limit Inner 1.783 inch (45,3 mm) 1.748 inch (44,4 mm) Outer 1.957 inch (49,7 mm) 1.898 inch (48,2 mm) Inner ––– 0.118 inch (3,0 mm) Outer ––– 0.126 inch (3,2 mm) Free Length Check the free length and inclination [C].
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ROCKER ARM AND SHAFT A Disassembly And Assembly Mark the rocker arms and support brackets for correct assembly. Remove the snap ring (Item 1) [A] from each end of the shaft (Item 5) [A]. 5 Remove the rocker arms (Items 2 & 4) and support brackets (Item 3) [A]. 2 Assembly: The support bracket with the oil hole is toward the front of the engine. 1 4 3 B–08191 Inspect all the parts for wear or damage. B Check the rocker arm O.D. [B]. Standard – 0.7478–0.7486 inch (18,98–19,0 mm) Limit – 0.
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PISTON AND CONNECTING ROD A Removal Remove the cylinder head. (See Page 7–51.) Remove the oil pan. (See Page 7–81.) Remove the ridge and carbon deposits at the top of the cylinder bore with a ridge reamer. F 1 F 2 F 3 F 4 Make sure the pistons have identification marks [A]. Rotate the crankshaft until a pair of connecting rods are at the bottom dead center. Make sure the connecting rod caps and the rods have identification marks. B–03248 B Remove the nuts and remove the bearing caps [B].
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PISTON AND CONNECTING ROD (Cont’d) A Disassembly (Cont’d) Remove the piston pin snap ring [A]. B–08195 B Drive out the piston pin using a brass rod [B]. P–08196 C Checking Clean all the parts in clean solvent. Check the clearance of the new rings in the piston grooves [C]. Standard Limit 1st Compression 0.0035–0.0049 inch (0,09–0,125 mm) 0.006 inch (0,15 mm) 2nd Compression 0.002–0.0033 inch (0,05–0,085 mm) 0.006 inch (0,15 mm) Oil 0.001–0.003 inch (0,03–0,07 mm) 0.
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PISTON AND CONNECTING ROD (Cont’d) A Checking (Cont’d) Check the ring gap in the cylinder bore [A]. Standard Limit Compression 0.008–0.016 inch (0,20–0,40 mm) 0.059 inch (1,50 mm) Oil 0.004–0.012 inch (0,10–0,30 mm) 0.059 inch (1,50 mm) B–08229 B Check the piston pin diameter [B]. Standard – 1.220 inch (31,0 mm) Limit – 1.219 inch (30,97 mm) P–08230 Check the clearance between piston pin and piston pin bore [C]. C Clearance – 0.00008–0.
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PISTON AND CONNECTING ROD (Cont’d) A Checking (Cont’d) Check the connecting rod small end bushing [A]. Standard – 1.2208–1.2211 inch (31,008–31,015 mm) B–08233 B Check the clearance between the piston pin and connecting rod [B]. Standard – 0.0003–0.00079 inch (0,008–0,02 mm) Limit – 0.0002 inch (0,5 mm) P–08230 C Replace the small end bushing if not within specifications using a hydraulic press [C].
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PISTON AND CONNECTING ROD (Cont’d) A Assembly Heat the piston to about 140°F (60°C) [A]. B–08251 B Assemble the piston and connecting rod [B]. C–02936 C Install the piston to the connecting rod. The piston head front mark (Item 1) [C] and the connecting rod ‘‘ISUZU’’ casting mark (Item 2) [C] must be facing the same direction. 1 2 B–08252 Install the piston pin. Install the snap rings [D].
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PISTON AND CONNECTING ROD (Cont’d) A Assembly (Cont’d) Marked Side Up Install the rings on the piston [A]. 1st Comp. The face with the mark NPR or TOP must be turned up for the 1st and 2nd compression rings. 2nd Comp. Oil B–08253 B 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 [B]. B–03337 C Put oil on the bearings. Install the bearing cap [C].
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CYLINDER LINERS A Checking The Cylinder Bore The tools listed will be needed to do the following procedure: MEL1180 – Puller Set MEL1261 – Cylinder Liner Remover Ankle Check the cylinder bore with an inside micrometer. The checks must be made at parallel and right angles to the center line of the bore [A]. 0.75 ” (20 mm) Measuring point is done approximately 0.75 inch (20 mm) below the top of the cylinder bore. B–08223 Standard – 3.6622–3.6638 inch (93,021–93,060 mm Limit – 3.
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MAIN BEARINGS A Description The crankshaft has five main bearings. The end play is controlled by a thrust washer on both sides of the center main bearing. FRONT Each main bearing cap has an identification mark in relation to the engine block [A]. The position of each cap can not be changed from the original location. B–08256 B Removal Remove the oil pan. (See Page 7–81.) Remove the oil pump. (See Page 7–84.) Remove the bolts from the main bearing caps.
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MAIN BEARINGS (Cont’d) A Installation Check the bearing spread as listed [A]. Limit – 2.93 inch (74,5 mm) B–08241 B Check to see if the bearing has enough tension, so that finger pressure is needed to fit the bearing into the cap [B]. B–08242 C Check the crankshaft journals before installing the main bearings. (See Page 7–68.) Make sure to position the bearing halves in their correct locations [C]. With Oil Hole and Groove (Upper Side) Fit Correctly Lubricate the new bearings.
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MAIN BEARINGS (Cont’d) A Installation (Cont’d) Tighten the crankshaft bearing cap bolts in the correct sequence [A]. 6 10 2 7 3 Torque – 116–130 ft.–lbs. (157–176 Nm). 9 5 1 4 8 B–08257 B Crankshaft End Play The end play can be checked by either a feeler gauge [B] or dial indicator [C]. Standard End Play . . . . . . . . . . . . 0.004 inch (0,10 mm) Limit . . . . . . . . . . . . . . . . . . . . . . . . 0.
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CRANKSHAFT The portion to be tested shall be held horizontally so as not to let the test No testing solution solution flow. near the oil hole. The sliding surface of the pin or journal A Removal And Installation Remove the oil pan. (See Page 7–81.) Remove the oil pump. (See Page 7–82.) Remove the crankshaft pulley, timing gearcase cover and timing gears. (See Page 7–71.) Approximately 0.393 inch (10 mm) Remove the flywheel. Remove the connecting rod cap. (See Page 7–57.) Remove the main bearing cap.
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CRANKSHAFT (Cont’d) A Checking The Crankshaft (Cont’d) Check the crankshaft main bearing journals [A]. Standard – 2.7526–2.7532 inch (69,917–69,932 mm) Limit – 2.7524 inch (69,910) B–08246 B Check the clearance between connecting rod bearing and crankshaft journal [B]. 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 inch (53,0 mm) Clearance between journal and bearing: Standard – 0.0011–0.
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CRANKSHAFT GEAR A Removal And Installation The tools listed will be needed to do the following procedure: MEL1263 – Crankshaft Gear Installer MEL1264 – Crankshaft Rear Oil Seal Use a puller to remove the gear [A]. B–08249 B Use the correct size driver tool to install the gear [B]. Clean the crankshaft and check that all the oil passages are clean and open. Clean the engine block, lubricate and install the upper halves of the main bearings. Put the crankshaft carefully in position.
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TIMING GEARCASE COVER SEAL A Removal And Installation The tool listed will be needed to do the following procedure: MEL1265 – Crankshaft Front Oil Seal Installer Remove the alternator and belt. (See Page 6–1.) Remove the bolt at the crankshaft pulley [A]. Installation: Tighten the bolt to 123–152 ft.–lbs. (167–206 Nm) torque. B–08945 B Install a standard puller and remove the crankshaft pulley [B]. B–08983 B–08943 C Use a screwdriver and pry the front seal out of the timing case cover [C].
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TIMING GEARCASE COVER A Removal And Installation Remove the alternator and belt. (See Page 6–1.) Remove the bolt at the crankshaft pulley [A]. Installation: Tighten the bolt to 123–152 ft.–lbs. (167–206 Nm) torque. B–08945 B Use a puller to remove the crankshaft pulley [B]. B–08943 C Remove the bolts which fasten the noise dampening shield to the timing case cover [C]. B–08947 Remove the noise dampening shield [D].
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TIMING GEARCASE COVER (Cont’d) A Removal And Installation (Cont’d) Remove the bolts from the timing gearcase cover [A]. Installation: Tighten the bolts to 10 ft.–lbs. (14 Nm) torque. B–08940 B Use an allen wrench to remove the allen head bolt from the cover [B]. Installation: Tighten the bolt to 11–17 ft.–lbs. (15–23 Nm) torque. B–08941 C Remove the timing gearcase cover [C].
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IDLER GEAR AND HUB A Removal Remove the timing gearcase cover. (See Page 7–71.) Remove the bolts at the tube for gear lubrication [A]. B–08929 B Remove the tube [B]. B–08928 C Remove the bolts at the idler gear [C]. Installation: Tighten the bolts to 10–12 ft.–lbs. (14–16 Nm) torque. B–08926 Remove the idler gear and hub [D]. D Checking Check the idler gear hub. Standard – 1.7695–1.7707 inch (44,945–44,975 mm) Limit – 1.7656 inch (44,845 mm) Check the clearance between the idler gear and hub.
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IDLER GEAR AND HUB (Cont’d) A 853,853HServiceManual#6720755–EngineServiceSectionPart3of4 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 [A]. Check the backlash between the gears. The correct backlash is 0.003 inch (0,076 mm).
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FUEL INJECTION PUMP IDLER GEAR A Removal And Installation Remove the timing gearcase cover. (See Page 7–71.) Remove the idler gear. (See Page 7–73.) Remove the bolt at the fuel injection pump idler gear [A]. Installation: Tighten the bolt to 72–87 ft.–lbs. (98–118 Nm) torque. B–08930 B Remove the idler gear and bearing [B]. B–08927 C If the bearing needs replacement, remove the snap ring at the bearing [C]. Use a press to remove and install the new bearing.
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CAMSHAFT GEAR A Removal And Installation Remove the timing gearcase cover. (See Page 7–71.) Remove the idler gear. (See Page 7–73.) Remove the bolt at the camshaft gear [A]. Installation: Tighten the bolt to 72–87 ft.–lbs. (98–118 Nm) torque. B–08931 B Install the puller and remove the gear [B]. B–08932 C Remove the bolts at the retainer plate [C]. Installation: Tighten the bolts to 11–17 ft.–lbs. (15–23 Nm) torque. B–08980 Remove the retainer plate [D].
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TIMING GEARCASE A Removal And Installation Remove the timing gearcase cover. (See Page 7–71.) Remove the idler gear. (See Page 7–73.) Remove the fuel injection pump. (See Page 7–42.) Remove the fuel injection pump idler gear. (See Page 7–75.) Remove the camshaft gear. (See Page 7–76.) Remove the water pump. (See Page 7–85.) B–08925 Remove the oil pan. (See Page 7–81.) B Remove the bolts at the timing case [A]. Installation: Tighten the bolts to 11–17 ft.–lbs. (15–23 Nm) torque.
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CAMSHAFT A Removal And Installation Remove the rocker arm cover, rocker arm assembly and the push rods. (See Page 7–56.) Remove the timing gearcase cover. (See Page 7–71.) Remove the camshaft gear. (See Page 7–76.) Remove the oil pan and oil pump. (See Pages 7–81 & 7–82.) Remove the camshaft from the engine. B–08217 Checking Check the camshaft journals [A]. B Standard – 1.9662–1.9675 inch (49,945–49,975 mm) Limit – 1.9528 inch (49,60 mm) Check the bearing inside diameter [B]. Standard – 1.9685–1.
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CAMSHAFT (Cont’d) A Camshaft Bearings The tools listed will be needed to do the following procedure: MEL1260 – Camshaft Bearing Remover/Installer Use the correct tool to remove the bearings [A]. B–08219 B When installing the new bearings, make sure to align the oil hole in the bearing with the hole in the engine block (Item 1) [B]. 1 B–08220 C Tappets Remove the tappets from the engine block. Mark the cylinder number on each tappet after removal [C].
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CAMSHAFT (Cont’d) A 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) B–08211 B Clearance between tappet and engine block bore as listed [B]. Standard – 0.0012 inch (0,03 mm) Limit – 0.0039 inch (0,09 mm) B–08212 C Tappet Installation Lubricate the tappets before installation. Lubricate the camshaft bearings and journals. Install the camshaft, carefully not to damage the bearings. Install the camshaft gear.
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OIL PAN A Removal Remove the oil drain plug and remove the oil. Remove the fastening bolts and nuts from the oil pan [A]. B–08953 B Installation Clean the surface on the oil pan and engine block. Put Three Bond (TB–1207B) at the front and rear main bearing caps (Item 1) [B] & [C]. 1 Put liquid gasket on the oil pan surface area of the engine block. 1 B–08418 C 1 B–08911 Install the oil pan. Install and tighten the bolts in the sequence shown [D]. D Tighten the bolts and nuts to 13–18 ft.–lbs.
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OIL PUMP A Removal And Installation Remove the oil pan. (See Page 7–81.) Remove the bolts at the oil pump [A]. Installation: Tighten the bolts to 10–17 ft.–lbs. (14–23 Nm) torque. B–08912 B Remove the oil pump assembly from the engine block [B]. B–08982 Checking C Disassemble the oil pump as illustrated [C]. 1. 2. 3. 4.
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OIL PUMP (Cont’d) A 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 (0,15 mm) B–08421 B Check the clearance between the rotor and vane [B]. Standard – 0.0055 inch (0,14 mm) or less. Check the clearance between the vane and pump body [B]. Standard – 0.0079–0.0105 inch (0,20–0,27 mm) Check clearance between rotor shaft and pump body. Standard – 0.0016 inch (0,04 mm) Limit – 0.
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OIL PUMP (Cont’d) A Rotor Replacement Remove the pin at the rotor using a punch and hammer [A]. 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 [A]. After the oil pump is assembled, put oil into the pump and turn the shaft to prime the pump. B–08426 B–08427 B Oil Pump Relief Valve Remove the relief valve from the oil filter housing [B]. Check the relief valve and clean. Replace as needed.
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WATER PUMP A Removal And Installation Remove the alternator belt. Remove the water pump pulley [A]. B–08951 B Remove the water pump bolts [B]. Installation: Tighten the bolts to 11–18 ft.–lbs. (15–24 Nm) torque. B–08950 C Remove the water pump from the engine block [C]. B–08972 Disassembly D Remove the hub for the pulley using a press [D].
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WATER PUMP (Cont’d) A Disassembly (Cont’d) Disassemble the water pump [A]. B–08428 B Check the bearing for abnormal noise, binding or wear [B]. Replace the parts as needed. B–08430 C Assembly Apply a thin coat of liquid gasket cement to the outer surface of the seal unit before assembly [C]. B–08432 Press the bearing assembly into position by aligning the set screw hole in the bearing with that in the pump body [D].
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WATER PUMP (Cont’d) A Assembly (Cont’d) After installation, check that the rear face of the impeller has the correct height [A]. Height – 0.98 inch (24,8 mm) 0.98 ” (24,8 mm) B–08433 B Check the distance between the pulley hub and pump body [B]. Distance – 3.12–3.14 inch (79,2–79,8 mm) 3.12–3.
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THERMOSTAT A Removal And Installation Remove the bolts from the thermostat housing [A]. Installation: Tighten the bolts to 10–17 ft.–lbs. (14–23 Nm) torque. Remove the thermostat. B–08954 B Checking The Thermostat Check the thermostat opening temperature [B]. Standard – 176–183°F (80–84°C) Check the thermostat valve lift. Standard – Approximately 0.3 inch (7,6 mm) @ 203°F (95°C) B–08435 C If the thermostat housing assembly is removed, tighten the bolts to 10–17 ft.–lbs. (14–34 Nm) torque [C].
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WATER JACKET TUBE A 853,853HServiceManual#6720755–EngineServiceSectionPart4of4 Removal And Installation Remove the timing gearcase cover. (See Page 7–71.) Remove the idler gear and hub. (See Page 7–73.) Remove the fuel injection pump. (See Page 7–42.) Remove the fuel injection pump idler gear. (See Page 7–75.) Remove the camshaft gear. (See Page 7–76.) Remove the timing case. (See Page 7–77.) B–08981 Remove the water pump. (See Page 7–85.) B Grip the edge of the water jacket tube with a vise grip.
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–7–90– 853, 853H Loader Service Manual
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SYSTEM ANALYSIS Page Number BOSS® DIAGNOSTIC TOOL Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 BOSS® INSTRUMENT PANEL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9 MONITOR SERVICE CODE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 BOSS® UNIT Removal And Installation . . . . . . . . . . . . . . . . . .
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–8–2– 853, 853H Loader Service Manual
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BOSS® DIAGNOSTIC TOOL A Procedure 1 The tool listed will be needed to do the following procedure: MEL1400 – Diagnostic Tool Stop the engine. Lift and block the loader. (See Page 1–1.) Remove the dust cap from the diagnostic connector plug. Connect the diagnostic tool plug (Item 1) [A] into the loader connector. P–03871 NOTE: Early S/N loaders have the diagnostic plug located at rear window as shown in Fig. [B].
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RPM SENSOR A Adjustment Continuity Resistance of 3000–3500 ohms. 1 Disconnect the connector [A] from the engine harness. Loosen the jam nut (Item 1) [A] on the RPM sensor. P–05193 Turn the RPM sensor (Item 1) [B] in until it makes contact with the engine flywheel. B Turn the jam nut until it contacts the flywheel housing. The jam nut should not be tightened, it needs to turn with the RPM sensor when the sensor is turned back out for adjustment.
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SERVICE CODES Chart The following list references the defect codes that are transmitted to the instrument panel display which can occur. Some service procedures for correcting the problems can be found in this manual and other procedures must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine.
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SUBJECT DISPLAY READS CONDITION Hydrostatic Charge Filter Condition HF1–2 HF1–6 Hydrostatic Fluid HP 1 HP 2 HP 3 HP 4 SHUTDOWN, Pressure WARNING, Pressure Wiring Not Connected Wiring Shorted HP 5 HP 7 HC 1 High Sensor Voltage Sensor Out Of Range SHUTDOWN, Temperature HC 2 HC 3 HC 4 HC 5 WARNING, Temperature Wiring Not Connected Wiring Shorted High Sensor Voltage HC 7 Sensor Out Of Range Hydrostatic Fluid Temperature WARNING, High Restriction Sensor No Signal –8–6– 853, 853H Loader Service M
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TROUBLESHOOTING THE BOSS® & LCD DISPLAY Chart SUBJECT BOSS SYMPTOM INDICATES Temperature related 12 volt supply and 1. *2. shutdown codes BOSS failure. when no heating occurs. * NOTE: You may have some or all of the codes listed. You will have high temps, high press, low voltage and low fuel. Check stored defects with the BOSS tool. If defect list has EC1, HC1, EC2.1, HC2. EP3, EP7, HP7, B2.2, low fuel, Fuel 7 and last occurrence hr.
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BOSS® UNIT A Removal And Installation 1 Raise the loader operator cab. (See Page 1–1.) 1 Loosen the nuts (Item 1) [A] from the sensing system unit (Item 2) [A]. Slide the unit forward in the mounting slots and remove it from the operator cab. 2 P–04043 Remove the two connectors (Item 1) [B] from the sensing system unit (Item 2) [B]. B Installation: Put the heads of the mounting bolts into the slots of the operator cab and slide the unit back into place.
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BOSS® INSTRUMENT PANEL A 853,853HServiceManual#6720755–BICSSystemSection Removal And Installation Pry the rubber light mount from the operator cab (both sides) [A]. P–03995 Lower the light from the operator cab and remove the three panel mounting bolts (Item 1) [B] (both sides.) B 1 1 P–03955 Pull the left panel (Item 1) [C] down from the operator cab. C Installation: Do not overtighten the panel mounting bolts to prevent stripping the threaded holes of the panels.
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–8–10– 853, 853H Loader Service Manual
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SPECIFICATIONS Page Number DECIMAL & MILLIMETER EQUIVALENTS Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17 ENGINE SPECIFICATIONS Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rod & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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–9–2– 853, 853H Loader Service Manual
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• LOADER SPECIFICATIONS Dimensions are given for loader equipped with standard tires and dirt bucket. Dimensions may vary with other types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. • Where applicable, specifications conform to SAE/ISO standards and are subject to change without notice. Loader Dimensions 153.5 (3899) 95o 119.6 (3038) 63.3 (1608) 76.7 (1948) 40o 48.4 (1229) 23.4 (594) 93.07 (2364) 45o 80.9 (2055) 61.
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LOADER SPECIFICATIONS (Cont’d) Hydraulic System Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Capacity . . . . . . . . . . . . . . . . . . . . . System Main Relief . . . . . . . . . . . . . . . . . . Filters (charge & implement) . . . . . . . . . . Engine driven gear type 18.0 GPM (68,1 L/min.) @ 2750 RPM @ 1150 PSI (7929 kPa) 2550–2600 PSI (17580–17924 kPa) @ Quick Couplers Full flow replaceable 4 micron synthetic medial element Hydraulic Cylinders . . . . . . . . . . . . . . . .
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ENGINE SPECIFICATIONS All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Cylinder Head Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.002 (0,05) Limit 0.008 (0,20) Re–Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ENGINE SPECIFICATIONS (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Piston, Pin & Rings Piston O.D. Piston Grade A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.661–3.662 (92,99–93,015) Piston Grade C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.662–3.
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ENGINE SPECIFICATIONS (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. NOTE: Crankshaft is Tuffride coated and cannot be re–ground. Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.004 (0,10) Limit 0.012 (0,31) Connecting Rod Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TORQUE SPECIFICATIONS FOR LOADER Specifications Item Ft.–Lbs. Nm Air Cleaner Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Hub Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Sprocket Bolt . . . . . . . . .
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TORQUE SPECIFICATIONS FOR LOADER (Cont’d) Specifications (Cont’d) Item (Cont’d) Ft.–Lbs. Nm Thermostat Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Case Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Case Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TORQUE SPECIFICATIONS FOR BOLTS Torque For General SAE Bolts The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from Melroe that have zinc phosphate coating are specified by the letter ‘‘H’’ following the part number. INCH. LBS. (Nm) FOOT LBS. (Nm) THREAD SIZE SAE GRADE 5 SAE GRADE 8 .250 80–90 (9,0–10,2) 110–120 (12,4–13,6) .3125 180–200 (20,3–22,6) 215–240 (24,2–27,1) .375 25–28 (34–38) 35–40 (47–54) .
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TORQUE SPECIFICATIONS FOR BOLTS (Cont’d) Torque For General Metric Bolts Material Thread Size (Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10 M 5 x 0.8 3–4 ft.–lbs. (4–5 Nm) M 6 x 1.0 6–7 ft.–lbs. (8–9 Nm) 6–9 ft.–lbs. (8–12 Nm) M 8 x 1.25 6–9 ft.–lbs. (8–12 Nm) 11–16 ft.–lbs. (15–22 Nm) 18–25 ft.–lbs. (24–34 Nm) M 10 x 1.25 13–18 ft.–lbs. (18–24 Nm) 22–30 ft.–lbs. (30–41 Nm) 36–50 ft.–lbs. (49–68 Nm) M 12 x 1.25 22–30 ft.–lbs. (30–41 Nm) 40–54 ft.–lbs. (54–73 Nm) 69–87 ft.–lbs.
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HYDRAULIC CONNECTION SPECIFICATIONS A When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system. I–2003–0888 B–07575 O–ring Face Seal Connection When the fitting is tightened, you can feel when the fitting is tight to eliminate leakage caused by under or over torqued fittings.
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HYDRAULIC CONNECTION SPECIFICATIONS (CONT’D) O–ring Flare Fitting A O–ring Flare Primary Seal The flare is the primary seal, the O–ring is the secondary seal and helps absorb vibration and pressure pulses at the connection [A]. If necessary, the O–ring–flare fitting can be used without an O–ring. Secondary Seal P–13009 Use the following procedure to tighten the O–ring flare fitting. Tighten the nut until it contacts with the seat.
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HYDRAULIC CONNECTION SPECIFICATIONS (CONT’D) O–ring Flare Fitting (Cont’d) A Copper Bonnet Orifice NOTE: O–ring flare fittings are not recommended in all applications. Use the standard flare fittings in these applications. Do not use a O–ring flare fitting when a copper bonnet orifice is used. When tightened the connection at the bonnet may distort the flare face and prevent it from sealing. 1 Use a standard flare fitting (Item 1) [A] as shown.
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HYDRAULIC CONNECTION SPECIFICATIONS (CONT’D) Port Seal Fitting A The nut is the primary seal, the O–ring is the secondary seal and helps absorb vibration and pressure pulses at the connection [A]. The hex portion of the nut does not contact the surface of the component when the nut is tight. Use the following procedure to tighten the port seal fitting: Port seal and nut, washer and O–ring (O–ring Boss) fittings use the same tightening torque valve chart.
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HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 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. Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. Fluid leaks under pressure may not be visible.
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DECIMAL AND MILLIMETER EQUIVALENTS FRACTIONS 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 DECIMALS MM 0.015625 0.03125 0.046875 0.0625 0.078125 0.09375 0.109375 0.1250 0.140625 0.15625 0.171875 0.1876 0.203125 0.21875 0.234375 0.2500 0.265625 0.28125 0.296875 0.3125 0.328125 0.34375 0.359375 0.3750 0.390625 0.40625 0.421875 0.4375 0.453125 0.46875 0.484375 0.5000 0.397 0.794 1.
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853,853HServiceManual#6720755–SpecificationsSection –9–18– 853, 853H Loader Service Manual
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850–001 ® Revision Number 29 April 1991 SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model 853 Date ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER Manual No. 6720755 (2–91) Revise your Service Manual with the enclosed page(s) as shown below. TAKE OUT PUT IN 1–21, 1–22 1–21, 1–22 (Revised Apr.
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850–002 ® Revision Number 10 July 1991 SERVICE MANUAL REVISION Date ROUTE TO ATTENTION AFFECTING: Product BOBCAT LOADER Model PARTS MANAGER SERVICE MANAGER SALES MANAGER 853 X Manual No. 6720755 (2–91) Revise your Service Manual with the enclosed page(s) as shown below.
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850–003 ® Revision Number 20 September 1991 SERVICE MANUAL REVISION Date ROUTE TO ATTENTION AFFECTING: Product BOBCAT LOADER Model PARTS MANAGER SERVICE MANAGER SALES MANAGER 853 X Manual No. 6720755 (2–91) Revise your Service Manual with the enclosed page(s) as shown below.
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850–004 ® Revision Number 6 January 1992 SERVICE MANUAL REVISION Date ROUTE TO ATTENTION AFFECTING: Product BOBCAT LOADER Model PARTS MANAGER SERVICE MANAGER SALES MANAGER 853 X Manual No. 6720755 (2–91) Revise your Service Manual with the enclosed pages as shown below. TAKE OUT PUT IN MAINTENANCE SAFETY MAINTENANCE SAFETY (Cont’d) MAINTENANCE SAFETY (Revised Jan. 92) MAINTENANCE SAFETY (Cont’d) PREVENTIVE MAINTENANCE–TAB PAGE PREVENTIVE MAINTENANCE–TAB PAGE (Revised Jan.
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850–005 ® Revision Number 10 April 1992 SERVICE MANUAL REVISION Date ROUTE TO ATTENTION AFFECTING: Product BOBCAT LOADER Model PARTS MANAGER SERVICE MANAGER SALES MANAGER 853 X Manual No. 6720755 (2–91) Revise your Service Manual with the enclosed pages as shown below. TAKE OUT PUT IN PREVENTIVE MAINTENANCE – TAB PAGE (Revised Jan.
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850–006 ® Revision Number 29 June 1992 SERVICE MANUAL REVISION Date ROUTE TO ATTENTION AFFECTING: Product BOBCAT LOADER Model PARTS MANAGER SERVICE MANAGER SALES MANAGER 853 X Manual No. 6720755 (2–91) Revise your Service Manual with the enclosed pages as shown below. TAKE OUT PUT IN 6–11, 6–12 6–11 (Revised June 92), 6–12 7–23 (Revised Sept. 92), 7–24 (Revised Sept. 91) 7–27, 7–28 7–23 (Revised Sept.
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850–007 ® Revision Number 30 December 1992 SERVICE MANUAL REVISION Date ROUTE TO ATTENTION AFFECTING: Product BOBCAT LOADER Model PARTS MANAGER SERVICE MANAGER SALES MANAGER 853 X Manual No. 6720755 (2–91) Revise your Service Manual with the enclosed pages as shown below.
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TAKE OUT PUT IN HYDRAULIC/HYDROSTATIC FLOW CHART For Model 853H Plus (S/N 75001 & Above) Chart #6722311 (Printed December 1992) HYDRAULIC/HYDROSTATIC SYSTEM OPERATION To Be Used With HYDRAULIC/HYDROSTATIC FLOW CHART For Model 853 Plus (S/N 50001 & Above) & 853 Base (S/N 25001 & Above) Chart #6722310 (Printed December 1992)
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850–008 ® Revision Number 5 March 1993 SERVICE MANUAL REVISION Date ROUTE TO ATTENTION AFFECTING: Product BOBCAT LOADER Model PARTS MANAGER SERVICE MANAGER SALES MANAGER 853 X Manual No. 6720755 (2–91) Revise your Service Manual with the enclosed pages as shown below. TAKE OUT PUT IN Foreword Page Foreword Page Contents Page Contents Page (Revised Mar. 93) Page i, Page ii Page iii Page i, Page ii (Revised Mar. 93) Page iii (Revised Mar. 93), Page iv (Added Mar. 93) Page v (Added Mar.
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TAKE OUT PUT IN Engine Service Contents (Revised Sept. 91) 7–1, 7–2 7–3, 7–4 7–5, 7–6 7–7, 7–8 7–9, 7–10 7–11, 7–12 7–13, 7–14 7–15, 7–16 7–17, 7–18 7–19, 7–20 7–21, 7–22 Engine Service Contents (Revised Mar. 93) 7–1, 7–2 (Revised Mar. 93) 7–3, 7–4 (Revised Mar. 93) 7–5 (Revised Mar. 93), 7–6 7–7, 7–8 (Revised Mar. 93) 7–9 (Revised Mar. 93), 7–10 (Revised Mar. 93) 7–11 (Revised Mar. 93), 7–12 (Revised Mar. 93) 7–13 (Revised Mar. 93), 7–14 (Revised Mar. 93) 7–15 (Revised Mar. 93), 7–16 (Revised Mar.
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850–009 ® Revision Number 5 January 1994 SERVICE MANUAL REVISION Date ROUTE TO ATTENTION AFFECTING: Product BOBCAT LOADER Model PARTS MANAGER SERVICE MANAGER SALES MANAGER 853 X Manual No. 6720755 (2–91) NOTICE Insert This Sheet With The Above Listed Manual For Future Reference. The following pages are a revision to the 853 Service Manual P/N 6720755 (2–91).
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850–010 ® Revision Number 17 February 1994 SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model Date ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER 853 X Manual No. 6720755 (2–91) NOTICE Insert This Sheet With The Above Listed Manual For Future Reference. The following pages are a revision to the 853 Service Manual P/N 6720755 (2–91).
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850–011 ® Revision Number 25 May 1994 SERVICE MANUAL REVISION Date ROUTE TO ATTENTION AFFECTING: Product BOBCAT LOADER Model PARTS MANAGER SERVICE MANAGER SALES MANAGER 853 X Manual No. 6720755 (2–91) NOTICE Insert This Sheet With The Above Listed Manual For Future Reference. The following pages are a revision to the 853 Service Manual P/N 6720755 (2–91). Take out the pages shown and put in the revised pages as follows: TAKE OUT PUT IN 3–7, 3–8 (Revised Mar. 93) 3–9 (Revised Mar.
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850–012 ® Revision Number 2 November 1998 SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model 853 Date ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER X Manual No. 6720755 (2–91) NOTICE Insert This Sheet With The Above Listed Manual For Future Reference. The following pages are a revision to the above Service Manual.
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850–13 ® Revision Number 1 June 1999 SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model 853 Date ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER X Manual No. 6720755 (6–99) NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
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