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SYSTEMS ANALYSIS Page Number BICS SYSTEM CONTROLLER Controller Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10 BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Inspecting the BICS System Controller (Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 Inspecting the Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 Inspecting the Seat and Seat Bar Sensors (Engine RUNNING) . . . . . . 8–3 Inspecting the Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . 8–3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 BOSS® DIAGNOSTIC TOOL Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–21 BOSS® INSTRUMENT PANEL Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–27 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE Controls Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–32 LIFT LOCK BY–PASS CONTROL VALVE Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–18 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17 MONITOR SERVICE CODES Alphabetic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–22 Numeric Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–22 Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–23 OPERATION SENSING SYSTEM UNIT Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–26 PWM CONTROL HANDLE Handle Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–31 PWM ELECTRIC SOLENOID Solenoid Coil Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–31 PWM MODULE Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–28 PWM TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–30 Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–29 RPM SENSOR Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–21 SEAT BAR SENSOR Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–12 Seat Bar Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–13 SEAT SENSOR Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14 Seat Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–15 Revised Mar. 03 Continued On Next Page SYSTEMS ANALYSIS 853,853H BICS Loader –8–1– Service Manual
SYSTEMS ANALYSIS (Cont’d) Page Number SENDER AND SENSOR Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–21 Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–21 TILT LOCK VALVE Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–20 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–19 TRACTION LOCK Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16 TROUBLESHOOTING THE BOSS® & L.C.D. DISPLAY . . . . . . . . . . . . . 8–25 Revised June 97 –8–2– 853, 853H BICS Loader Service Manual
Page 1:
EQUIPPED WITH BOBCAT INTERLOCK CONT
Page 5 and 6:
FOREWORD . . . . . . . . . . . . .
Page 7 and 8:
17. Inspect the air cleaner for dam
Page 9 and 10:
SAFETY INSTRUCTIONS Instructions ar
Page 11 and 12:
SERIAL NUMBER LOCATIONS Always use
Page 13 and 14:
All 853 & 853H Bobcat loaders are e
Page 15 and 16:
PREVENTIVE MAINTENANCE Page Number
Page 17 and 18:
SERVICE SCHEDULE Maintenance work m
Page 19 and 20:
TRANSPORTING THE LOADER Procedure A
Page 21 and 22:
LIFT ARM SUPPORT DEVICE Never work
Page 23 and 24:
OPERATOR CAB (Cont’d) Lowering th
Page 25 and 26:
AIR CLEANER SERVICE Replacing Filte
Page 27 and 28:
FUEL SYSTEM Fuel Specifications Use
Page 29 and 30:
ENGINE LUBRICATION SYSTEM Checking
Page 31 and 32:
ENGINE COOLING SYSTEM Cleaning the
Page 33 and 34:
USING A BOOSTER BATTERY (Jump Start
Page 35 and 36:
HYDRAULIC/HYDROSTATIC SYSTEM (Cont
Page 37 and 38:
SPARK ARRESTOR MUFFLER Cleaning Pro
Page 39 and 40:
FINAL DRIVE TRANSMISSION (CHAINCASE
Page 41 and 42:
LUBRICATING THE LOADER (Cont’d) P
Page 43 and 44:
REMOTE START SWITCH (Cont’d) Proc
Page 45 and 46:
HYDRAULIC SYSTEM Page Number BUCKET
Page 47 and 48:
1 FLUID RESERVOIR: Cap . . . . 15.5
Page 49 and 50:
HYDRAULIC/HYDROSTATIC SCHEMATIC 853
Page 51 and 52:
HYDRAULIC SYSTEM TROUBLESHOOTING Ch
Page 53 and 54:
LIFT CYLINDER(S) Checking the Lift
Page 55 and 56:
TILT CYLINDER Checking the Tilt Cyl
Page 57 and 58:
HYDRAULIC CYLINDER Lift Cylinder Id
Page 59 and 60:
HYDRAULIC CYLINDER (Cont’d) Disas
Page 61 and 62:
HYDRAULIC CYLINDER (Cont’d) Disas
Page 63 and 64:
HYDRAULIC CYLINDER (Cont’d) Assem
Page 65 and 66:
HYDRAULIC CYLINDER (Cont’d) Assem
Page 67 and 68:
MAIN RELIEF VALVE Checking the Main
Page 69 and 70:
MAIN RELIEF VALVE (Cont’d) Remova
Page 71 and 72:
DUAL PRESSURE MAIN RELIEF VALVE - 8
Page 73 and 74:
DUAL PRESSURE MAIN RELIEF VALVE - 8
Page 75 and 76:
SELECT VALVE (G.E.M. Block) 853H Ch
Page 77 and 78:
HYDRAULIC CONTROL VALVE (Cont’d)
Page 79 and 80:
Page 81 and 82:
Page 83 and 84:
Page 85 and 86:
Page 87 and 88:
Page 89 and 90:
Page 91 and 92:
Page 93 and 94:
HYDRAULIC PUMP Checking the Output
Page 95 and 96:
HYDRAULIC PUMP (Cont’d) Parts Ide
Page 97 and 98:
HYDRAULIC PUMP (Cont’d) Disassemb
Page 99 and 100:
HYDRAULIC PUMP (Cont’d) Assembly
Page 101 and 102:
HYDRAULIC PUMP (Double Gear) 853H C
Page 103 and 104:
HYDRAULIC PUMP (Double Gear) 853H (
Page 105 and 106:
Page 107 and 108:
Page 109 and 110:
Page 111 and 112:
Page 113 and 114:
HYDRAULIC FLUID RESERVOIR Removal a
Page 115 and 116:
HYDRAULIC FILTER HOUSING Removal an
Page 117 and 118:
PEDAL INTERLOCK LINKAGE Removal and
Page 119 and 120:
Revised June 96 HYDROSTATIC SYSTEM
Page 121 and 122:
TROUBLESHOOTING Chart The following
Page 123 and 124:
FRONT PANEL Removal and Installatio
Page 125 and 126:
STEERING LEVERS Disassembly and Ass
Page 127 and 128:
STEERING LEVERS (Cont’d) Pre-Adju
Page 129 and 130:
STEERING LEVERS (Cont’d) Adjustin
Page 131 and 132:
STEERING LEVERS (Cont’d) Adjustin
Page 133 and 134:
HYDROSTATIC MOTOR Removal and Insta
Page 135 and 136:
HYDROSTATIC MOTOR (Cont’d) Disass
Page 137 and 138:
Page 139 and 140:
Page 141 and 142:
HYDROSTATIC MOTOR (Cont’d) Assemb
Page 143 and 144:
HYDROSTATIC MOTOR (Cont’d) 853, 8
Page 145 and 146:
HYDROSTATIC PUMP Removal and Instal
Page 147 and 148:
HYDROSTATIC PUMP (Cont’d) Repleni
Page 149 and 150:
HYDROSTATIC PUMP (Cont’d) Parts I
Page 151 and 152:
HYDROSTATIC PUMP (Cont’d) Parts I
Page 153 and 154:
HYDROSTATIC PUMP (Cont’d) Hydraul
Page 155 and 156:
HYDROSTATIC PUMP (Cont’d) Charge
Page 157 and 158:
HYDROSTATIC PUMP (Cont’d) Disasse
Page 159 and 160:
Page 161 and 162:
Page 163 and 164:
Page 165 and 166:
HYDROSTATIC PUMP (Cont’d) Inspect
Page 167 and 168:
HYDROSTATIC PUMP (Cont’d) Assembl
Page 169 and 170:
Page 171 and 172:
Page 173 and 174:
Page 175 and 176:
Page 177 and 178:
HYDROSTATIC PUMP (Cont’d) Hydraul
Page 179 and 180:
HYDROSTATIC PUMP (Cont’d) Hydrost
Page 181 and 182:
DRIVE BELT Adjusting the Drive Belt
Page 183 and 184:
DRIVE BELT TENSIONER PULLEY Removal
Page 185 and 186:
DRIVE BELT TENSIONER PULLEY (Cont
Page 187 and 188:
Page 189 and 190:
Page 191 and 192:
OIL COOLER Removal and Installation
Page 193 and 194:
DRIVE SYSTEM Page Number AXLE SEAL
Page 195 and 196:
DRIVE SYSTEM PARKING BRAKE PEDAL Re
Page 197 and 198:
PARKING BRAKE DISC Removal and Inst
Page 199 and 200:
FRONT CHAINCASE COVER Removal and I
Page 201 and 202:
AXLE SEAL (Cont’d) Removal and In
Page 203 and 204:
AXLE, BEARINGS AND SPROCKET (Cont
Page 205 and 206:
AXLE, BEARING AND SPROCKET (Cont’
Page 207 and 208:
REDUCTION GEARCASE (Cont’d) Remov
Page 209 and 210:
REDUCTION GEARCASE (Cont’d) Disas
Page 211 and 212:
REDUCTION GEARCASE (Cont’d) Disas
Page 213 and 214:
REDUCTION GEARCASE (Cont’d) Assem
Page 215 and 216:
REDUCTION GEARCASE (Cont’d) Assem
Page 217 and 218:
DRIVE CHAIN 853, 853H BICS Service
Page 219 and 220:
MAIN FRAME Page Number BOB-TACH Bob
Page 221 and 222:
MAIN FRAME SEAT BAR Removal and Ins
Page 223 and 224:
SEAT BAR (Cont’d) Removal and Ins
Page 225 and 226:
OPERATOR CAB GAS CYLINDER Removal a
Page 227 and 228:
OPERATOR CAB Removal and Installati
Page 229 and 230:
OPERATOR SEAT Removal and Installat
Page 231 and 232:
BOB-TACH (Cont’d) Removal and Ins
Page 233 and 234:
BOB-TACH (Cont’d) Bob-Tach Lever
Page 235 and 236:
REAR GRILL Removal and Installation
Page 237 and 238:
REAR DOOR (Cont’d) Hood Removal a
Page 239 and 240:
FUEL TANK (Cont’d) Removal and In
Page 241 and 242:
ELECTRICAL SYSTEM Page Number ALTER
Page 274 and 275:
WIRE LEGEND NO.'s COLOR GAUGE PARTS
Page 276 and 277:
WIRE LEGEND NO.'s COLOR GAUGE 12 Or
Page 278 and 279:
ELECTRICAL SYSTEM TROUBLESHOOTING C
Page 280 and 281:
BATTERY Removal and Installation Ba
Page 282 and 283:
ALTERNATOR (Cont’d) Alternator Re
Page 284 and 285:
ALTERNATOR (Cont’d) Disassembly a
Page 286 and 287:
ALTERNATOR (Cont’d) Assembly Reve
Page 288 and 289:
STARTER (Cont’d) Checking the Sta
Page 290 and 291:
STARTER (Cont’d) Disassembly and
Page 292 and 293:
STARTER (Cont’d) Cleaning and Ins
Page 294 and 295:
FRONT LIGHTS Removal and Installati
Page 296 and 297:
ENGINE SERVICE Page Number AIR CLEA
Page 298 and 299:
ENGINE SERVICE TROUBLESHOOTING Char
Page 300 and 301:
RADIATOR Removal and Installation O
Page 302 and 303:
COOLANT RECOVERY TANK Removal and I
Page 304 and 305:
AIR CLEANER HOUSING Removal and Ins
Page 306 and 307:
BLOWER HOUSING/FAN GEARBOX (Cont’
Page 308 and 309:
BLOWER FAN Removal and Installation
Page 310 and 311:
FAN GEARBOX (Cont’d) Disassembly
Page 312 and 313:
Page 314 and 315:
Page 316 and 317:
FAN GEARBOX (Cont’d) Assembly (Co
Page 318 and 319:
FAN GEARBOX (Cont’d) Assembly (Co
Page 320 and 321:
FAN GEARBOX (Cont’d) 853, 853H BI
Page 322 and 323:
FAN GEARBOX (Cont’d) Checking Bac
Page 324 and 325:
ENGINE (Cont’d) Removal and Insta
Page 326 and 327:
Page 328 and 329:
Page 330 and 331:
ENGINE (Cont’d) Engine Mount Repl
Page 332 and 333:
BELT SHIELD Removal and Installatio
Page 334 and 335: GLOW PLUGS Removal and Installation
Page 336 and 337: FUEL INJECTION PUMP (Cont’d) Remo
Page 338 and 339: FUEL INJECTION PUMP (Cont’d) Remo
Page 340 and 341: FUEL INJECTION PUMP (Cont’d) Timi
Page 342 and 343: FUEL INJECTOR NOZZLES (Cont’d) Re
Page 344 and 345: CYLINDER HEAD Removal and Installat
Page 346 and 347: VALVES, VALVE SEAT AND GUIDE Remova
Page 348 and 349: VALVES, VALVE SEAT AND GUIDE (Cont
Page 350 and 351: PISTON AND CONNECTING ROD Removal R
Page 352 and 353: PISTON AND CONNECTING ROD (Cont’d
Page 354 and 355: PISTON AND CONNECTING ROD (Cont’d
Page 356 and 357: CYLINDER LINERS Checking the Cylind
Page 358 and 359: MAIN BEARINGS (Cont’d) Installati
Page 360 and 361: CRANKSHAFT Removal and Installation
Page 362 and 363: CRANKSHAFT GEAR Removal and Install
Page 364 and 365: TIMING GEARCASE COVER Removal and I
Page 366 and 367: IDLER GEAR AND HUB Removal Remove t
Page 368 and 369: FUEL INJECTION PUMP IDLER GEAR Remo
Page 370 and 371: TIMING GEARCASE 853, 853H BICS Serv
Page 372 and 373: CAMSHAFT (Cont’d) Camshaft Bearin
Page 374 and 375: OIL PAN Removal Remove the oil drai
Page 376 and 377: OIL PUMP (Cont’d) Checking (Cont
Page 378 and 379: WATER PUMP Removal and Installation
Page 380 and 381: WATER PUMP (Cont’d) Assembly (Con
Page 382 and 383: WATER JACKET TUBE Removal and Insta
Page 386 and 387: BOBCAT INTERLOCK CONTROL SYSTEM (BI
Page 394 and 395: BICS SYSTEM CONTROLLER (Cont’d) C
Page 396 and 397: SEAT BAR SENSOR (Cont’d) Seat Bar
Page 398 and 399: SEAT SENSOR (Cont’d) Seat Sensor
Page 400 and 401: LIFT LOCK BY-PASS VALVE Removal and
Page 402 and 403: TILT LOCK VALVE Removal and Install
Page 404 and 405: BOSS® DIAGNOSTIC TOOL Procedure Th
Page 406 and 407: SERVICE CODES (Cont’d) The follow
Page 408 and 409: TROUBLESHOOTING THE BOSS® & LCD DI
Page 410 and 411: BOSS® INSTRUMENT PANEL Removal and
Page 412 and 413: PWM MODULE (Cont’d) Description (
Page 414 and 415: PWM CONTROL HANDLE Handle Testing T
Page 416 and 417: SPECIFICATIONS Page Number DECIMAL
Page 418 and 419: LOADER SPECIFICATIONS LOADER DIMENS
Page 420 and 421: ENGINE SPECIFICATIONS All dimension
Page 422 and 423: ENGINE SPECIFICATIONS (Cont’d) Al
Page 424 and 425: TORQUE SPECIFICATIONS FOR LOADER Sp
Page 426 and 427: HYDRAULIC/HYDROSTATIC FLUID SPECIFI
Page 428 and 429: DECIMAL AND MILLIMETER EQUIVALENTS
Page 430: AFFECTING: Product BOBCAT LOADER Mo
Page 434:
AFFECTING: Product BOBCAT LOADER Mo
Page 437 and 438:
TAKE OUT PUT IN 853 BICS - OPERATOR
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