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HYDRAULIC CYLINDER (Cont’d) Tilt Cylinder Identification 1. Case 2. Tube 3. Plug 4. O–ring 5. Nut 6. Clamp 7. Nut 8. Piston 9. Seal 10. O–ring 11. O–ring 12. Washer 13. O–ring 14. Head 15. Seal 16. Seal 17. Rod 18. Bushing MC–1688 * Tighten to 600 ft.–lbs. (813 Nm) torque. 6 7 Revised June 97 –2–10– *5 1 4 3 8 9 2 10 11 12 13 18 14 15 16 MC–01688 17 TS–01098 853, 853H BICS Loader Service Manual
HYDRAULIC CYLINDER (Cont’d) Disassembly Tools necessary for the disassembly/assembly procedures: MEL1074 – O–ring Seal Hook MEL1075 – Adjustable Gland Nut Wrench MEL1396 – Seal Installation Tool MEL1033 – Rod Seal Installation Tool Piston Ring Compressor NOTE: The drawings may not show the cylinder exactly as it appears, but the procedure is correct for all cylinders. Put the base end of the hydraulic cylinder in a drain pan. Move the rod in and out to remove the fluid from the cylinder. Move the rod slowly so the fluid will go directly into the drain pan. Put the base end of the cylinder in a vise. Use the adjustable gland nut wrench to loosen the head [A]. Remove the rod assembly from the cylinder case [B]. Remove the cylinder case from the vise. Put the rod end in the vise. Remove the nut from the piston end of the rod [C]. Pull the piston off the rod (Item 1) [D]. Pull the head (Item 2) [D] off the rod. A B C D 1 2 B–07000 B–07001 B–07002 B–07003 853, 853H BICS Loader –2–11– 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: HYDRAULIC CYLINDER Lift Cylinder Id
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 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 109 and 110:
HYDRAULIC PUMP (Double Gear) 853H (
Page 111 and 112:
HYDRAULIC PUMP (Double Gear) 853H (
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
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Page 139 and 140:
Page 141 and 142:
HYDROSTATIC MOTOR (Cont’d) Assemb
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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
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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
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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
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
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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 384 and 385:
SYSTEMS ANALYSIS Page Number BICS S
Page 386 and 387:
BOBCAT INTERLOCK CONTROL SYSTEM (BI
Page 388 and 389:
Page 390 and 391:
Page 392 and 393:
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
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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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