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SERVICE CODES (Cont’d) 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. SUBJECT DISPLAY READS Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death. W–2003–1289 CONDITION Engine Coolant Level ECL 1 SHUTDOWN, No Coolant Engine Coolant Temp. EC–1.1 SHUTDOWN, Engine Temperature EC–2.1 WARNING, Engine Temperature EC 3 Wiring Not Connected EC 4 Wiring Shorted EC 5 High Sensor Voltage EC 7 Sensor Out Of Range Engine Oil Pressure EP 1 SHUTDOWN, Pressure EP 2 WARNING, Pressure EP 3 Wiring Not Connected EP 4 Wiring Shorted EP 5 High Sensor Voltage EP 7 Sensor Out Of Range Engine Speed ES 1 SHUTDOWN, Engine Speed Too High ES–2.1 WARNING, Engine Speed Slightly High ES–6 Sensor No Signal ES–7 Sensor Out Of Range Air Filter AF 2 WARNING, Restriction Too High AF 6 Sensor No Signal Battery b–2.1 WARNING, Bad Battery b–2.2 WARNING, Battery Voltage Fuel Level FUEL2 WARNING, Low Level FUEL3 Wiring Not Connected FUEL4 Wiring Shorted FUEL5 High Sensor Voltage FUEL7 Sensor Out Of Range 853,853H BICS Loader –8–23– Service Manual
SUBJECT DISPLAY READS CONDITION Hydrostatic Charge HF1–2 WARNING, High Restriction Filter Condition HF1–6 Sensor No Signal Hydrostatic Fluid HP 1 SHUTDOWN, Pressure HP 2 WARNING, Pressure HP 3 Wiring Not Connected HP 4 Wiring Shorted HP 5 High Sensor Voltage HP 7 Sensor Out Of Range Hydrostatic Fluid HC 1 SHUTDOWN, Temperature Temperature HC 2 WARNING, Temperature HC 3 Wiring Not Connected HC 4 Wiring Shorted HC 5 High Sensor Voltage HC 7 Sensor Out Of Range –8–24– 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
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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
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1 FLUID RESERVOIR: Cap . . . . 15.5
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HYDRAULIC/HYDROSTATIC SCHEMATIC 853
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HYDRAULIC SYSTEM TROUBLESHOOTING Ch
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LIFT CYLINDER(S) Checking the Lift
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TILT CYLINDER Checking the Tilt Cyl
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HYDRAULIC CYLINDER Lift Cylinder Id
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HYDRAULIC CYLINDER (Cont’d) Disas
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HYDRAULIC CYLINDER (Cont’d) Disas
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HYDRAULIC CYLINDER (Cont’d) Assem
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HYDRAULIC CYLINDER (Cont’d) Assem
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MAIN RELIEF VALVE Checking the Main
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MAIN RELIEF VALVE (Cont’d) Remova
Page 71 and 72:
DUAL PRESSURE MAIN RELIEF VALVE - 8
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DUAL PRESSURE MAIN RELIEF VALVE - 8
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SELECT VALVE (G.E.M. Block) 853H Ch
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HYDRAULIC CONTROL VALVE (Cont’d)
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HYDRAULIC PUMP Checking the Output
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HYDRAULIC PUMP (Cont’d) Parts Ide
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HYDRAULIC PUMP (Cont’d) Disassemb
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HYDRAULIC PUMP (Cont’d) Assembly
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HYDRAULIC PUMP (Double Gear) 853H C
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HYDRAULIC PUMP (Double Gear) 853H (
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HYDRAULIC FLUID RESERVOIR Removal a
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HYDRAULIC FILTER HOUSING Removal an
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PEDAL INTERLOCK LINKAGE Removal and
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Revised June 96 HYDROSTATIC SYSTEM
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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
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STEERING LEVERS (Cont’d) Adjustin
Page 133 and 134:
HYDROSTATIC MOTOR Removal and Insta
Page 135 and 136:
HYDROSTATIC MOTOR (Cont’d) Disass
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Page 141 and 142:
HYDROSTATIC MOTOR (Cont’d) Assemb
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HYDROSTATIC MOTOR (Cont’d) 853, 8
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HYDROSTATIC PUMP Removal and Instal
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HYDROSTATIC PUMP (Cont’d) Repleni
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HYDROSTATIC PUMP (Cont’d) Parts I
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HYDROSTATIC PUMP (Cont’d) Parts I
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HYDROSTATIC PUMP (Cont’d) Hydraul
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HYDROSTATIC PUMP (Cont’d) Charge
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HYDROSTATIC PUMP (Cont’d) Disasse
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HYDROSTATIC PUMP (Cont’d) Inspect
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HYDROSTATIC PUMP (Cont’d) Assembl
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HYDROSTATIC PUMP (Cont’d) Hydraul
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HYDROSTATIC PUMP (Cont’d) Hydrost
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DRIVE BELT Adjusting the Drive Belt
Page 183 and 184:
DRIVE BELT TENSIONER PULLEY Removal
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DRIVE BELT TENSIONER PULLEY (Cont
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Page 189 and 190:
Page 191 and 192:
OIL COOLER Removal and Installation
Page 193 and 194:
DRIVE SYSTEM Page Number AXLE SEAL
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DRIVE SYSTEM PARKING BRAKE PEDAL Re
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PARKING BRAKE DISC Removal and Inst
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FRONT CHAINCASE COVER Removal and I
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AXLE SEAL (Cont’d) Removal and In
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AXLE, BEARINGS AND SPROCKET (Cont
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AXLE, BEARING AND SPROCKET (Cont’
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REDUCTION GEARCASE (Cont’d) Remov
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REDUCTION GEARCASE (Cont’d) Disas
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REDUCTION GEARCASE (Cont’d) Disas
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REDUCTION GEARCASE (Cont’d) Assem
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REDUCTION GEARCASE (Cont’d) Assem
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DRIVE CHAIN 853, 853H BICS Service
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MAIN FRAME Page Number BOB-TACH Bob
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MAIN FRAME SEAT BAR Removal and Ins
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SEAT BAR (Cont’d) Removal and Ins
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OPERATOR CAB GAS CYLINDER Removal a
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OPERATOR CAB Removal and Installati
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OPERATOR SEAT Removal and Installat
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BOB-TACH (Cont’d) Removal and Ins
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BOB-TACH (Cont’d) Bob-Tach Lever
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REAR GRILL Removal and Installation
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REAR DOOR (Cont’d) Hood Removal a
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FUEL TANK (Cont’d) Removal and In
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ELECTRICAL SYSTEM Page Number ALTER
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WIRE LEGEND NO.'s COLOR GAUGE PARTS
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WIRE LEGEND NO.'s COLOR GAUGE 12 Or
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ELECTRICAL SYSTEM TROUBLESHOOTING C
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BATTERY Removal and Installation Ba
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ALTERNATOR (Cont’d) Alternator Re
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ALTERNATOR (Cont’d) Disassembly a
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ALTERNATOR (Cont’d) Assembly Reve
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STARTER (Cont’d) Checking the Sta
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STARTER (Cont’d) Disassembly and
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STARTER (Cont’d) Cleaning and Ins
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FRONT LIGHTS Removal and Installati
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ENGINE SERVICE Page Number AIR CLEA
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ENGINE SERVICE TROUBLESHOOTING Char
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RADIATOR Removal and Installation O
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COOLANT RECOVERY TANK Removal and I
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AIR CLEANER HOUSING Removal and Ins
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BLOWER HOUSING/FAN GEARBOX (Cont’
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BLOWER FAN Removal and Installation
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FAN GEARBOX (Cont’d) Disassembly
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FAN GEARBOX (Cont’d) Assembly (Co
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FAN GEARBOX (Cont’d) Assembly (Co
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FAN GEARBOX (Cont’d) 853, 853H BI
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FAN GEARBOX (Cont’d) Checking Bac
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ENGINE (Cont’d) Removal and Insta
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ENGINE (Cont’d) Engine Mount Repl
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BELT SHIELD Removal and Installatio
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GLOW PLUGS Removal and Installation
Page 336 and 337:
FUEL INJECTION PUMP (Cont’d) Remo
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FUEL INJECTION PUMP (Cont’d) Remo
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FUEL INJECTION PUMP (Cont’d) Timi
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FUEL INJECTOR NOZZLES (Cont’d) Re
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CYLINDER HEAD Removal and Installat
Page 346 and 347:
VALVES, VALVE SEAT AND GUIDE Remova
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VALVES, VALVE SEAT AND GUIDE (Cont
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PISTON AND CONNECTING ROD Removal R
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PISTON AND CONNECTING ROD (Cont’d
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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 384 and 385: SYSTEMS ANALYSIS Page Number BICS S
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 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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