Bobcat 853H Skid Steer Loader OEM Service & Repair Manual

6720755 (6–99) Printed in U.S.A. © Melroe Company 1999 Service Manual 8 5 3 8 5 3 H (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)

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 instructions can cause injury or death. W-2003-0903 Never service the Bobcat Skid- Steer Loader without instructions. Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed. Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame. Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged. Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the loader. Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company. Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention. Use the correct procedure to lift or lower operator cab. Cleaning and maintenance are required daily. Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. MSW01-0805 WRONG B-6590 WRONG B-16102 B-6580 WRONG B-16102 B-6589 WRONG B-15280 WRONG B-15231 WRONG B-11799 B-10731a CORRECT B-12365 CORRECT B-7469 CORRECT Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

AIR CLEANER HOUSING 7–1 . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR 6–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE, BEARINGS AND SPROCKET 4–1 . . . . . . . . . . . . BATTERY 6–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELT, Alternator 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELT, Drive 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOB–TACH 5–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOSS UNIT 8–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE, Parking 4–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAINS, Drive 4–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAINCASE FLUID 4–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . CODES, Monitor Service 8–1 . . . . . . . . . . . . . . . . . . . . . . . CONTROL, Engine Speed 7–1 . . . . . . . . . . . . . . . . . . . . . . COVER, Front Chaincase 4–1 . . . . . . . . . . . . . . . . . . . . . . COVER, Rear Chaincase 4–1 . . . . . . . . . . . . . . . . . . . . . . . COVER, Timing Gearcase 7–1 . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER, Hydraulic 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER(S), Lift 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER, Tilt 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER, Operator Cab Gas 5–1 . . . . . . . . . . . . . . . . . . CYLINDER HEAD 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DECIMAL & MILLIMETER EQUIVALENTS 9–1 . . . . . . . DOOR, Rear 5–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE COOLING SYSTEM 1–1 . . . . . . . . . . . . . . . . . . . ENGINE LUBRICATION SYSTEM 1–1 . . . . . . . . . . . . . . . FAN, Blower 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FILTER,Hydrostatic Charge Oil 3–1 . . . . . . . . . . . . . . . . . . FILTER HOUSING, Hydraulic 2–1 . . . . . . . . . . . . . . . . . . . FINAL DRIVE TRANSMISSION (CHAINCASE) 1–1 . . . FLYWHEEL 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOSS–BOBCAT OPERATION SENSING SYSTEM 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 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . GLOW PLUGS 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GRILL, Rear 5–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE, Steering Lever Control (Early Series) 6–1 . . . . HOUSING, Fan Gearbox/Blower 7–1 . . . . . . . . . . . . . . . . . HYDRAULIC/HYDROSTATIC SYSTEM 1–1 . . . . . . . . . . . INFORMATION, Electrical System 6–1 . . . . . . . . . . . . . . . . INFORMATION, Hydraulic System 2–1 . . . . . . . . . . . . . . . INFORMATION, Hydrostatic System 3–1 . . . . . . . . . . . . . . LIFT ARMS 5–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIFT ARM SUPPORT DEVICE 1–1 . . . . . . . . . . . . . . . . . . . LIFTING AND BLOCKING THE LOADER 1–1 . . . . . . . . . LIFTING THE LOADER 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . LIGHTS, Front 6–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINERS, Cylinder 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINKAGE, Pedal Interlock 2–1 . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE LOADER 1–1 . . . . . . . . . . . . . . . . . . . LUBRICATION SYSTEM 7–1 . . . . . . . . . . . . . . . . . . . . . . . . MOTOR, Hydrostatic 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . MOUNTS, Engine 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUFFLER, Engine 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MUFFLER, Spark Arrestor 1–1 . . . . . . . . . . . . . . . . . . . . . . . NOZZLE, Fuel Injector 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . OIL COOLER 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATOR CAB 1–1 & 5–1 . . . . . . . . . . . . . . . . . . . . . . . . PANEL, BOSS Instrument 8–1 . . . . . . . . . . . . . . . . . . . . . . . PANEL, Front 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, Standard Instrument 6–1 . . . . . . . . . . . . . . . . . . . . PEDAL, Parking Brake 4–1 . . . . . . . . . . . . . . . . . . . . . . . . . . PEDALS, Control 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PISTONS AND CONNECTING ROD 7–1 . . . . . . . . . . . . . PUMP, Hydraulic 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP, Hydrostatic 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP, Fuel Injection 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP, Oil 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PUMP, Water 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PULLEY, Fixed Tensioner 3–1 . . . . . . . . . . . . . . . . . . . . . . . PULLEY, Spring Loaded Tensioner 3–1 . . . . . . . . . . . . . . . PULLEY, Fan Drive Tension 7–1 . . . . . . . . . . . . . . . . . . . . . Cont’d On Next Page 1

RADIATOR 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESERVOIR, Hydraulic Fluid 2–1 . . . . . . . . . . . . . . . . . . . RELAY SWITCHES 6–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOTE START SWITCH 1–1 . . . . . . . . . . . . . . . . . . . . . ROCKER ARM AND SHAFT 7–1 . . . . . . . . . . . . . . . . . . . . SEAL, Axle 4–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAT BAR RESTRAINT SYSTEM 1–1 . . . . . . . . . . . . . . . SENDER AND SENSOR 8–1 . . . . . . . . . . . . . . . . . . . . . . . SENSOR, RPM 8–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE, Air Cleaner 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE SCHEDULE 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . SHIELD, Drive Belt 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIELD, Belt 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS, Engine 9–1 . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS, Hyd./Hydr. Fluid 9–1 . . . . . . . . . . . . . SPECIFICATIONS, Hydraulic Connection 9–1 . . . . . . . . SPECIFICATIONS, Loader 9–1 . . . . . . . . . . . . . . . . . . . . . STARTER 6–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING LEVERS 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . TANK, Coolant Recovery 7–1 . . . . . . . . . . . . . . . . . . . . . . . TANK, Fuel 5–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIRE MAINTENANCE 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 2–1, 3–1, 6–1, 7–1, 8–1 . . . . . . . TOOL, BOSS Diagnostic 8–1 . . . . . . . . . . . . . . . . . . . . . . . TORQUE, Loader 9–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE, Specifications For Bolts 9–1 . . . . . . . . . . . . . . . TOWING THE LOADER 1–1 . . . . . . . . . . . . . . . . . . . . . . . TRANSPORTING THE LOADER 1–1 . . . . . . . . . . . . . . . . U.S. TO METRIC CONVERSION 9–1 . . . . . . . . . . . . . . . . VALVE, Bucket Position 2–1 . . . . . . . . . . . . . . . . . . . . . . . . VALVE CLEARANCE 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE, Cold Oil By–Pass 3–1 . . . . . . . . . . . . . . . . . . . . . . VALVE, Dual Pressure Main Relief 2–1 . . . . . . . . . . . . . . . VALVE, Front Auxiliary Control (Apitech) 2–1 . . . . . . . . . . VALVE, Hydraulic Control 2–1 . . . . . . . . . . . . . . . . . . . . . . . VALVE, Lock 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE, Main Relief 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE, Select (JEM) 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . VALVES, VALVE SEAT AND GUIDE 7–1 . . . . . . . . . . . . . WATER JACKET TUBE 7–1 . . . . . . . . . . . . . . . . . . . . . . . . ALPHABETICAL INDEX (Cont’d) 2

PREVENTIVE MAINTENANCE HYDRAULIC SYSTEM HYDROSTATIC SYSTEM DRIVE SYSTEM MAIN FRAME ELECTRICAL SYSTEM ENGINE SERVICE SYSTEMS ANALYSIS SPECIFICATIONS 853, 853H Loader i Service Manual FOREWORD ii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY INSTRUCTIONS v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERIAL NUMBER LOCATIONS vii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DELIVERY REPORT vii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOBCAT LOADER IDENTIFICATION viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREVENTIVE MAINTENANCE 1–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEM 2–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDROSTATIC SYSTEM 3–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SYSTEM 4–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAIN FRAME 5–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 6–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SERVICE 7–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SYSTEM ANALYSIS 8–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 9–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTENTS Component Repair Manual A Component Repair Manual is available for this model Bobcat loader. A component Repair Manual gives complete teardown procedures for service and repair of all major components such as control valves, hydrostatic pumps and motors, hydraulic pumps, etc. See your Bobcat dealer about availability of this important addition to your service library. CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

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. 2. Check that ROPS mounting hardware is tightened and is Melroe approved. 3. The seat belt must be correctly installed, functional and in good condition. 4. The seat bar and pedal interlocks must be correctly adjusted, clean and lubricated. 5. Machine signs must be legible and in the correct location. 6. Steering levers and foot pedals must return to neutral. 7. Check for correct function of the work lights. 8. The parking brake must function correctly. 9. Enclosure door latches must open and close freely. 10. Bob–Tach wedges and linkages must function correctly and be in good condition. 11. Safety treads must in good condition. 12. Check for correct function of indicator lamps (Optional on some models). 13. Check hydraulic fluid level, engine oil level and fuel supply. 14. Inspect for fuel, oil or hydraulic fluid leaks. 15. Lubricate the loader. 16. Check the condition of the battery and cables. ii 853, 853H Loader Service Manual

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. Recommend to the owner that all necessary corrections be made before the machine is returned to service. 23. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer. 853, 853H Loader iii Service Manual

iv 853, 853H Loader Service Manual

Bobcat 853H Skid Steer Loader OEM Service & Repair Manual

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