Bobcat 853 H loader Service Manual
Below you will find brief information for loader 853 853H. This manual provides instructions for servicing and adjusting the Bobcat loader and its component parts. It is essential for maintaining the proper operation and safety of your loader. Proper maintenance ensures your loader functions efficiently and safely for years to come.
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3
H
8
5
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)
6720755 (6–99) Printed in U.S.A.
©
Melroe Company 1999
WARNING
MAINTENANCE SAFETY
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
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT
CORRECT CORRECT
B-10731a
Never service the Bobcat Skid-
Steer Loader without instructions.
WRONG
B-12365
Use the correct procedure to lift or lower operator cab.
WRONG
B-7469
Cleaning and maintenance are required daily.
WRONG
B-11799
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.
WRONG
B-15231
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.
WRONG
B-15280
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.
WRONG
B-6590
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.
B-6580
B-16102
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.
B-6589
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.
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
ALPHABETICAL INDEX
AIR CLEANER HOUSING
ALTERNATOR
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AXLE, BEARINGS AND SPROCKET . . . . . . . . . . . .
7–1
6–1
4–1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BELT, Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BELT, Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BOB–TACH
BOSS UNIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE, Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6–1
1–1
3–1
5–1
8–1
4–1
GEAR, Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR, Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEAR, Fuel Injection Pump Idler
GEAR AND HUB, Idler
. . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
7–1
7–1
7–1
7–1
GEARBOX, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARCASE, Reduction
GEARCASE, Timing
1–1, 7–1
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4–1
7–1
GLOW PLUGS
GRILL, Rear
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–1
5–1
HANDLE, Steering Lever Control (Early Series)
HOUSING, Fan Gearbox/Blower
. . . .
. . . . . . . . . . . . . . . . .
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . .
6–1
7–1
1–1
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAINS, Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAINCASE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . .
CODES, Monitor Service . . . . . . . . . . . . . . . . . . . . . . .
CONTROL, Engine Speed . . . . . . . . . . . . . . . . . . . . . .
COVER, Front Chaincase
COVER, Rear Chaincase
COVER, Timing Gearcase
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER, Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER(S), Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER, Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER, Operator Cab Gas . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–1
4–1
4–1
8–1
7–1
4–1
4–1
7–1
7–1
2–1
2–1
2–1
5–1
7–1
INFORMATION, Electrical System
INFORMATION, Hydraulic System
INFORMATION, Hydrostatic System
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
6–1
2–1
3–1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFT ARM SUPPORT DEVICE
LIFTING AND BLOCKING THE LOADER
LIFTING THE LOADER
. . . . . . . . . . . . . . . . . . .
. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
LIGHTS, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LINERS, Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5–1
1–1
1–1
1–1
6–1
7–1
LINKAGE, Pedal Interlock
LUBRICATING THE LOADER
LUBRICATION SYSTEM
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
2–1
1–1
7–1
DECIMAL & MILLIMETER EQUIVALENTS
DOOR, Rear
. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9–1
5–1
MOTOR, Hydrostatic . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOUNTS, Engine
MUFFLER, Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MUFFLER, Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . .
3–1
7–1
7–1
1–1
NOZZLE, Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . .
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . .
7–1
1–1
1–1
FAN, Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FILTER,Hydrostatic Charge Oil . . . . . . . . . . . . . . . . . .
FILTER HOUSING, Hydraulic . . . . . . . . . . . . . . . . . . .
FINAL DRIVE TRANSMISSION (CHAINCASE)
FLYWHEEL
. . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–1
3–1
2–1
1–1
7–1
1–1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . .
7–1
1–1 & 5–1
BOSS–BOBCAT OPERATION SENSING SYSTEM
PANEL, BOSS Instrument
PANEL, Front
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, Standard Instrument
PEDAL, Parking Brake
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
PEDALS, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PISTONS AND CONNECTING ROD . . . . . . . . . . . . .
PUMP, Hydraulic
PUMP, Hydrostatic
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP, Fuel Injection
PUMP, Oil
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUMP, Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PULLEY, Fixed Tensioner . . . . . . . . . . . . . . . . . . . . . . .
PULLEY, Spring Loaded Tensioner
PULLEY, Fan Drive Tension
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
7–1
7–1
7–1
3–1
3–1
7–1
8–1
3–1
6–1
4–1
2–1
7–1
2–1
3–1
Cont’d On Next Page
1
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
SENDER AND SENSOR
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
SENSOR, RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE, Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SCHEDULE
SHIELD, Drive Belt
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIELD, Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS, Engine . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS, Hyd./Hydr. Fluid . . . . . . . . . . . . .
SPECIFICATIONS, Hydraulic Connection . . . . . . . .
SPECIFICATIONS, Loader
STARTER
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . .
4–1
1–1
8–1
8–1
1–1
1–1
3–1
7–1
9–1
9–1
9–1
9–1
6–1
3–1
TANK, Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . .
TANK, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–1
5–1
1–1
7–1
TROUBLESHOOTING . . . . . . .
TOOL, BOSS Diagnostic
2–1, 3–1, 6–1, 7–1, 8–1
. . . . . . . . . . . . . . . . . . . . . . . 8–1
TORQUE, Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
TORQUE, Specifications For Bolts
TOWING THE LOADER
. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
TRANSPORTING THE LOADER . . . . . . . . . . . . . . . .
9–1
1–1
1–1
U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . 9–1
VALVE, Bucket Position
VALVE CLEARANCE
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE, Cold Oil By–Pass . . . . . . . . . . . . . . . . . . . . . .
VALVE, Dual Pressure Main Relief . . . . . . . . . . . . . . .
VALVE, Front Auxiliary Control (Apitech) . . . . . . . . . .
VALVE, Hydraulic Control
VALVE, Lock
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE, Main Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE, Select (JEM) . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVES, VALVE SEAT AND GUIDE . . . . . . . . . . . . .
2–1
7–1
3–1
2–1
2–1
2–1
2–1
2–1
2–1
7–1
WATER JACKET TUBE . . . . . . . . . . . . . . . . . . . . . . . . 7–1
2
CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii vii ii v
BOBCAT LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
1–1
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDROSTATIC SYSTEM
DRIVE SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–1
3–1
4–1
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5–1
6–1
ENGINE SERVICE
SYSTEM ANALYSIS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
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.
PREVENTIVE
MAINTENANCE
HYDRAULIC
SYSTEM
HYDROSTATIC
SYSTEM
DRIVE
SYSTEM
MAIN
FRAME
ELECTRICAL
SYSTEM
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.
ENGINE
SERVICE
SYSTEMS
ANALYSIS
SPECIFICATIONS i
853, 853H Loader
Service Manual
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. Enclosure door latches must open and close freely.
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.
10. Bob–Tach wedges and linkages must function correctly and be in good condition.
11. Safety treads must 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.
12. Check for correct function of indicator lamps (Optional on some models).
13. Check hydraulic fluid level, engine oil level and fuel supply.
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.
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.
23. Check for correct function of the Bobcat Interlock Control
System (BICS
™
) before the machine is returned to the customer.
Recommend to the owner that all necessary corrections be made before the machine is returned to service.
iii
853, 853H Loader
Service Manual
iv
853, 853H Loader
Service Manual
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.
W–2003–0299
The following publications provide information on the safe use and maintenance of the loader and attachments:
•
The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
•
The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
•
The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
•
The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your
Bobcat dealer for more information on translated versions.
•
The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
•
The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and repair work.
•
The Skid–Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.
•
The Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and correct service procedures for Bobcat Skid–Steer loaders.
•
The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.
Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.
W–2044–1285
This notice identifies procedures which must be followed to avoid damage to the machine.
I–2019–0284
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.
v
SI05–0299
853, 853H Loader
Service Manual
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.
•
The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating.
•
Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.
•
Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.
•
Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti–freeze.
•
Do not use ether or starting fluids on engines which have glow plugs. These starting aids can cause explosion and injure you or bystanders.
•
Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.
•
Stop the engine and let it cool before adding fuel. No smoking!
•
Use the procedure in the Operation & Maintenance or Service Manuals for connecting the battery.
A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].
SI06–0398
A vi
P–3705
853, 853H Loader
Service Manual
SERIAL NUMBER LOCATIONS
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 XXXXX
Module 2. – Production
Sequence (Series)
Module 1. – Model/Engine
Version
The four digit Model/Engine Combination module number identifies the model number and engine combination.
This number (in parenthesis beside the model number) is used in the Service Manual to more easily identify the standard, optional and field accessory equipment included or available for each specific model.
The five digit Production Sequence Number identifies the order which the loader is produced.
ENGINE SERIAL NUMBER
The serial number is located above the starter on the engine block [B].
A
B
DELIVERY REPORT
The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [C].
C vii
853, 853H Loader
Service Manual
P–00369
P–00370
BOBCAT LOADER IDENTIFICATION
FRONT LIGHTS
GRAB HANDLES
STEERING LEVER
TILT CYLINDER
SEAT BELT
OPERATOR SEAT
REAR AUXILIARY
QUICK COUPLERS
BUCKET
SEAT BAR
BUCKET STEPS
FRONT AUXILIARY
QUICK COUPLERS
SAFETY TREAD
OPERATOR CAB
(ROPS & FOPS)
LIFT ARM
LIFT ARM
SUPPORT DEVICE
LIFT CYLINDER
REAR GRILL
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.
BUCKET – Several different buckets and other attachments are available for the Bobcat loader.
ROPS, FOPS – Roll Over Protective Structure, per SAE J1040 and ISO 3471 and Falling Object Protective
Structure per SAE J1043 and ISO 3449 Level I. Level ll FOPS is available for protection from heavy falling objects. The Bobcat loader is base–equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level).
viii
853, 853H Loader
Service Manual
PREVENTIVE MAINTENANCE
Page
Number
AIR CLEANER SERVICE
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
ALTERNATOR BELT
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking The Coolant Level
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Coolant From The Cooling System . . . . . . . . . . . . . . . . . . . . .
1–18
1–18
1–19
ENGINE LUBRICATION SYSTEM
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–16
1–16
FAN GEARBOX
Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26
FUEL SYSTEM
Filling The Fuel Tank
Fuel Filter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–14
1–14
1–14
1–15
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Hydraulic/Hydrostatic Filters
Hydraulic Reservoir Breather Cap
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–21
1–21
1–23
1–22
LIFT ARM SUPPORT DEVICE
Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disengaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . .
1–7
1–8
LIFTING AND BLOCKING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
LIFTING THE LOADER
Four Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–6
1–6
LUBRICATING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27
OPERATOR CAB
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raising The Operator Cab
Emergency Exit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–9
1–10
1–9
1–10
PREVENTIVE
MAINTENANCE
–1–1–
853, 853H Loader
Service Manual
PREVENTIVE MAINTENANCE (Cont’d)
Page
Number
REMOTE START SWITCH
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–29
SEAT BAR RESTRAINT SYSTEM
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–11
1–11
1–11
SERVICE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
SPARK ARRESTOR MUFFLER
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24
TIRE MAINTENANCE
Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire Rotation
Wheel Nuts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–25
1–25
1–25
TOWING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
TRANSPORTING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
–1–2–
853, 853H Loader
Service Manual
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. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.
W–2003–0199
ITEM SERVICE REQUIRED
Engine Oil
Air Cleaner
Engine Cooling System
Check the oil level and add oil as needed.
Check condition indicator or display panel. Service only when required.
Clean debris from oil cooler, radiator and grill. Check coolant level cold in recovery tank. See Page 1–18 for correct coolant mixture.
Lubricate with multi–purpose lithium based grease (12 places).
Lift Arms, Cyl., Bob–Tach
Pivot Pins & Wedges
Engine Air System
Tires Check for damaged tires and correct air pressure.
Seat Belt, Seat Bar & Pedal Check the condition of seat belt. Check the seat bar and pedal
Interlocks interlocks for correct operation. Clean dirt and debris from moving parts.
Safety Signs & Safety
Tread
Operator Cab
Check for damaged signs (decals) and safety tread. Replace any signs or safety treads that are damaged or worn.
Check the fastening bolts, washers and nuts. Check the condition
Fuel Filter
Hydraulic Fluid, Hoses
& Tubelines
Final Drive Transmission
(Chaincase)
Battery
Check for leaks and damaged components.
of cab.
Remove the trapped water.
Check fluid level and add as needed. Check for damage and leaks.
Repair and replace as needed.
Check oil level.
Check cables and electrolyte level.
Control Pedals & Steering
Wheel Nuts
Parking Brake
Alternator Belt
Engine Oil & Filter
Spark Arrestor Muffler
Engine/Hydro. Drive Belt
Fuel Filter
Seat Bar
Steering Shaft
Hyd./Hydro. Filter
Hydraulic Reservoir
Breather Cap
Fan Drive Gearbox
Final Drive Transmission
Hydraulic Reservoir
Hydraulic Motors
*
Check for correct operation. Repair or adjust as needed.
Check for loose wheel nuts and tighten to 105–115 ft.–lbs. (142–156
Nm) torque.
Check operation.
Check tension and adjust as needed.
Replace oil and filter.
Clean the spark chamber.
Check for wear or damage. Adjust as needed.
Replace filter element.
Grease pivots as needed.
Grease three fittings.
Replace the filter element.
Replace the reservoir breather cap.
Check gear lube level.
Replace the oil in the chaincase.
Replace the fluid.
Replace the two case drain filters.
8–10 50 100 250 1000
Check wheel nut torque every 8 hours for the first 24 hours.
Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON.
Or every 12 months.
* Inspect the new belt after first 50 hours.
Clean or replace case drain filters in the event of any major hydraulic or hydrostatic repair.
–1–3–
853, 853H Loader
Service Manual
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. completely to become familiar with the procedure before beginning [A].
LIFTING AND BLOCKING THE LOADER
Procedure
Always park the loader on a level surface.
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
Put floor jack under the rear of the loader [B].
Lift the rear of the loader and install jackstands [B].
B
Put the floor jack under the front the loader [C].
Lift the front of the loader and put jackstands under the axle tubes [C].
NOTE: Make sure the jackstands do not touch the tires.
C
–1–4–
B–07023
CD–11160
CD–11159
853, 853H Loader
Service Manual
TRANSPORTING THE LOADER
Procedure
A
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
The rear of the transport vehicle must be blocked or supported when loading or un–loading the loader.
A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A].
Be sure the transport and towing vehicles are of adequate size and capacity.
Use the following procedure to fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up or down slopes [B].
Lower the bucket or attachment to the floor. Stop the engine. Engage the parking brake. Install chains at the front and rear loader tie down positions (Inset) [B]. Fasten each end of the chain to the transport vehicle and tighten the chain with a chain tightener.
TOWING THE LOADER
Procedure
To prevent damage to the loaders hydrostatic system, the loader must be towed only a short distance at slow speed.
(Example: Moving the loader onto a transport vehicle.)
The towing chain (or cable) must be rated at 1–1/2 times the weight of the loader. (See Specification Page 9–1.)
•
Disengage the parking brake.
•
Tow the Bobcat at 2 MPH (3,2 km/hr.) or less for not more than 25 feet (7,6 meters).
B
P–05090
6707867
MC–01241
P–05077
MC–01242
–1–5–
853, 853H Loader
Service Manual
LIFTING THE LOADER
Four Point Lift
A
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.
W–2046–1290
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].
Single Point Lift
B
AVOID INJURY OR DEATH
•
Before lifting, check fasteners on single point lift and operator cab.
•
Assemble front cab fasteners as shown in manual.
•
Never allow riders in the cab or bystanders within 15 feet (5 meters) while lifting the machine.
W–2007–1285
The loader can also be lifted with the single point lift which is available as a kit from your Bobcat loader dealer.
Install the kit and lift as shown [B].
The single point lift, supplied by Melroe Company is designed to lift and support the Bobcat loader without affecting roll over and falling object protection features of the operator cab.
MC–01434
MC–01664
–1–6–
853, 853H Loader
Service Manual
LIFT ARM SUPPORT DEVICE
A
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.
W–2059–0991
Engaging the Lift Arm Support Device
Maintenance and service work can be done with the lift arms lowered.
If the lift arms must be raised for service, use the following procedure:
Put jackstands under the rear corners of the loader.
Disconnect the spring (Item 1) [A] from the lift arm support device retaining pin (Item 2) [A]. Hold onto the lift arm support device and remove the retaining pin.
Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring (Item 1) [B] to the lift arm support device so there will be no interference with the support device engagement.
With the operator in the seat, seat belt fastened and seat bar lowered, start the engine.
Raise the lift arms, until the lift arm support device drops onto the lift cylinder rod [C].
Lower the lift arms slowly until the support device is held between the lift arm and the lift cylinder. Stop the engine.
Raise the seat and move pedals until both pedals lock.
Install pin (Item 1) [C] into the rear of the lift arm support device below the cylinder rod.
B
C
Service lift arm support device if damaged or if parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death.
W–2271–1197
–1–7–
1
2
P–02133
1
P–02118
1
P–00095
853, 853H Loader
Service Manual
LIFT ARM SUPPORT DEVICE (Cont’d)
Disengaging The Lift Arm Support Device
Remove the pin from the lift arm support device.
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.
Lower the lift arms. Stop the engine.
Raise the seat bar and move pedals until both pedals lock.
Disconnect the spring from the bracket.
Raise the support device into storage position and insert pin through lift arm support device and bracket [B].
Connect spring to pin.
A
B
1
P–01542
P–02133
–1–8–
853, 853H Loader
Service Manual
OPERATOR CAB
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.
Level l – Protection from falling bricks, small concrete blocks and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services.
Level ll – Protection from falling trees, rocks; for machines involved in site clearing, overhead demolition or forestry.
A
B
1
Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Melroe Company.
Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.
W–2069–1285
Raising The Operator Cab
Stop the loader on a level surface. Lower the lift arms. If the lift arms must be up while raising the operator cab, install the lift arm support device. (See Page 1–7.)
Loosen the nut (Item 1) [A] (both sides) at the front corner of the operator cab.
Remove the nut and plate (both sides) [B].
Lift on the grab handle and bottom of the operator cab slowly until the cab latching mechanism engages and the cab is all the way up [C].
C
CD–15126
CD–15125
P–00380
–1–9–
Before the cab or the lift arms are raised for service, jackstands must be put under the rear corners of the frame. Failure to use jackstands may allow the machine to tip backward causing injury or death.
W–2014–1285
853, 853H Loader
Service Manual
OPERATOR CAB (Cont’d)
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.
A
Install the plate and nut (Item 1) [B] (both sides).
Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque [B].
B
1
Emergency Exit
The front opening on the operator cab and rear window provide exits.
To exit through the rear window, use the following procedure:
Pull on the tag on the top of the rear window to remove the rubber cord [C].
C
Push the rear window out of the rear of the operator cab.
Exit through the rear of the operator cab [D].
D
1
CD–15124
CD–15126
P–00660
–1–10–
P–00383
853, 853H Loader
Service Manual
SEAT BAR RESTRAINT SYSTEM
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.
When the seat bar is up, the lift and tilt pedals are locked when returned to the NEUTRAL POSITION.
A
B
AVOID INJURY OR DEATH
The seat bar system must lock the lift and tilt control pedals in neutral when the seat bar is up. Service the system if pedals do not lock correctly.
W–2105–1285
Inspecting The Seat Bar
Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Operate each foot pedal to check both the lift and tilt functions. Raise the lift arms until the bucket is about
2 feet (600 mm) off the ground.
Raise the seat bar. Try to move each foot pedal. Pedals must be firmly locked in neutral position. There must be no motion of the lift arms or tilt (bucket) when the pedals are pushed.
Pull the seat bar down, lower the lift arms. Operate the lift pedals. While the lift arms are going up, raise the seat bar and the lift arms should stop.
Lower the seat bar, lower the lift arms and place the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the foot pedals to be sure that the pedals are firmly locked in the neutral position. Unbuckle the seat belt.
Maintaining The Seat Bar
See the SERVICE SCHEDULE, Page 1–3 for correct service interval.
Clean any debris or dirt from the moving parts [A] & [B].
Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).
Use a general purpose grease to lubricate the seat bar pivot points at each side of the cab [A].
If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust pedal control linkage.
Replace parts that are worn or damaged. Use only genuine Melroe replacement parts.
Clean
–1–11–
Clean &
Lubricate
P–00384
Pedal Lock
Shield
P–01223
853, 853H Loader
Service Manual
AIR CLEANER SERVICE
Replacing Filter Element
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.
Replace the inner filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter has been replaced.
WITH BOSS
®
OPTION: It is important to change the air filter element only when the service codes (on the
BOSS
®
option instrument panel) shows the symbols
[AF.2] [B].
A
B
2
1
Service the air cleaner as follows:
Remove the dust cover wing nut (Item 1) [C].
Remove the dust cover.
C
1
CD–15118
MC–02042
CD–15117
–1–12–
853, 853H Loader
Service Manual
AIR CLEANER SERVICE (Cont’d)
Replacing Filter Element (Cont’d)
Remove the wing nut (Item 1) [A] at the large air filter element.
A
1
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.
B
Inner Filter Element:
Only replace the inner filter element under the following conditions:
1. Replace the inner filter element every third time the outer filter is replaced.
2. If the service codes show symbols, Page 8–1, during full engine speed, replace the inner filter element only after the outer filter element has been changed.
Remove the inner filter wing nut (Item 1) [C] to remove the filter element.
C
1
CD–15119
CD–15120
CD–15121
–1–13–
853, 853H Loader
Service Manual
FUEL SYSTEM
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
°
)
+15
°
(9
°
)
Down to –20
°
(–29
°
)
Below –20
°
(29
°
)
No. 2
100%
50%
0%
No.1
0%
50%
100%
We recommend an operator contact their fuel supplier for local recommendations.
Filling The Fuel Tank
A
B
Stop and cool the engine before adding fuel.
NO SMOKING! Failure to obey warnings can cause an explosion or fire.
W–2063–0887
Remove the fuel fill cap (Item 1) [A].
Use a clean, approved safety container to add fuel of the correct specifications. Add fuel only in an area that has free movement of air and no open flames or sparks. NO
SMOKING! [B].
Install and tighten the fuel fill cap [A].
Fuel Filter
C
1
2
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.
W–2103–1285
See the SERVICE SCHEDULE, Page 1–3 for the service interval when to remove the water from the fuel filter.
Loosen the drain (Item 1) [C] at the bottom of the filter element to drain any water from the filter.
See the SERVICE SCHEDULE, Page 1–3 for the service interval when to replace the fuel filter.
To replace the fuel filter element (Item 2) [C], use a filter wrench to remove the filter element.
Clean the area around the filter housing. Put oil on the seal of the new filter element. Install the fuel filter, and hand tighten. Remove the air from the fuel system. ( See
Page 1–15.)
–1–14–
P–02124
WRONG
B–13456
1
CD–15123
853, 853H Loader
Service Manual
FUEL SYSTEM (Cont’d)
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.
Loosen the air vent plug (Item 1) [A] at the top of the fuel filter.
Operate the priming bulb (Item 2) [A] until fuel flows from the filter vent. Tighten the fuel filter vent plug (Item 1) [A].
A
Loosen the air vent plug at the top of the fuel injection pump [B].
Again operate the priming bulb (Item 2) [A] until fuel flows from the air vent plug with no air bubbles showing.
Tighten the air vent plug at the fuel injection pump [B].
B
1
2
CD–15123
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.
W–2103–1285
CD–10847
–1–15–
853, 853H Loader
Service Manual
ENGINE LUBRICATION SYSTEM
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].
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.)
C
°
–40
RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
–34 –29 –23 –18 –13 –7 –1 +4 +10 +15 +21 +27 +32 +38 +43 +49
SAE 40W or 20W–50
SAE 10W–30
SAE 15W–40
SAE 30W
*
SAE 5W–30
SAE 10W
SAE 20W–20
SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.
–40
F
°
–30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120
TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CD, CF4, CG4 )
*
Can be used ONLY when available with appropriate diesel rating.
Replacing Oil And Filter
See the SERVICE SCHEDULE, Page 1–3 for the service interval for replacing the engine oil and filter.
Run the engine until it is at operating temperature. Stop the engine.
Open the rear door. Remove the drain plug (Item 1) [B].
Drain the oil into a container.
Remove the oil filter (Item 1) [C].
Clean the filter housing surface. Put clean oil on the new oil filter gasket. Install the filter and hand tighten only.
Install and tighten the drain plug.
A
B
C
1
1
1
CD–15112
CD–15113
CD–15122
–1–16–
853, 853H Loader
Service Manual
ENGINE LUBRICATION SYSTEM (Cont’d)
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.
A
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.
W–2103–1285
1
CD–15114
–1–17–
853, 853H Loader
Service Manual
ENGINE COOLING SYSTEM
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.
Propylene Glycol
Add premixed coolant, 47% water and 53% propylene glycol to the recovery tank if the coolant level is low.
One gallon and one pint of propylene glycol mixed with one gallon of water is the correct mixture of coolant to provide a –34
°
F (–37
°
C) freeze protection.
Use a refractometer to check the condition of propylene glycol in your cooling system.
Ethylene Glycol
Add premixed coolant, 50% water and 50% ethylene glycol to the recovery tank if the coolant level is low.
Cleaning The Cooling System
Raise the rear grill.
Use air pressure or water pressure to clean the top of the oil cooler [B].
Raise the oil cooler and clean the top of the radiator [C].
Check cooling system for leaks.
A
B
C
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.
Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.
I–2124–0497
–1–18–
CD–10853
P–00378
P–00381
853, 853H Loader
Service Manual
ENGINE COOLING SYSTEM (Cont’d)
Replacing The Coolant
A
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.
Remove the radiator cap (Item 1) [A].
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.
Propylene Glycol
Add premixed coolant; 47% water and 53% propylene glycol to the recovery tank if the coolant level is low.
One gallon and one pint of propylene glycol mixed with one gallon of water is the correct mixture of coolant to provide a –34
°
F (–37
°
C) freeze protection.
Mix the coolant in a separate container See
SPECIFICATIONS, Page 9–1 for correct capacity.
Fill the radiator and engine block with the premixed coolant.
Install the radiator cap.
Fill the coolant recovery tank 1/3 full.
Run the engine until it is at operating temperature. Stop the engine. Check the coolant level in the recovery tank when cool. Add coolant to the recovery tank as needed.
B
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.
Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.
I–2124–0497
–1–19–
1
1
P–00379
CD–10854
853, 853H Loader
Service Manual
ALTERNATOR BELT
Adjusting The Alternator Belt
Stop the engine.
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.
A
2
1
CD–09339
–1–20–
853, 853H Loader
Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM
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].
The fluid level must be between the marks on the dipstick.
If fluid is needed, remove the fill cap (Item 1) [B].
NOTE: Before installing the fill cap, make sure the rubber gasket is installed on the fill cap (Inset
[B].
A
B
1
Add the fluid as needed to bring the level to the top mark on the dipstick [A].
Replacing Hydraulic/Hydrostatic Filters
See the SERVICE SCHEDULE, Page 1–3 for the correct service interval.
Raise the operator cab. (See Page 1–8.)
Use a filter wrench and remove the filter elements (Item
1 & 2) [C].
Clean the surface of the filter housing where the element seal contacts the housing. Put clean oil on the rubber seal of the filter element.
Install and hand tighten the filter elements.
C
1
CD–15162
CD–15135
CD–15161
1
CD–10855
–1–21–
853, 853H Loader
Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)
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.
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.
Raise the operator cab. (See Page 1–8.)
NOTE: Case drain filters are added to later model loaders listed below:
S/N 510125001 & Above
S/N 510250001 & Above
S/N 510374001 & Above
Remove the two case drain filters (Item 1) [C] &[D] (one for each hydrostatic motor) and clean thoroughly or replace filters.
When all the fluid is removed from the reservoir, connect and tighten the filters and case drain hoses.
Add the correct fluid to the reservoir until the fluid level is between the marks on the dipstick. DO NOT fill above the top mark on the dipstick.
Lower the operator cab. Start the engine and operate the loader hydraulic controls.
Lower the lift arms. Stop the engine. Check for leaks.
Check the fluid level in the reservoir and add as needed.
A
B
C
1
1
1
CD–15135
CD–15161
CD–15163
P–00971
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.
W–2103–1285
D
1
–1–22–
P–00969
853, 853H Loader
Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)
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].
A
Make sure the baffle washer is installed in the hydraulic reservoir [B].
B
CD–15134 CD–15132
CD–15133
–1–23–
853, 853H Loader
Service Manual
SPARK ARRESTOR MUFFLER
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.
A
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. The spark arrestor muffler must be serviced by dumping the spark chamber every
100 hours of operation.
If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of
California State Law, Section 4442 PRC.
Make reference to local laws and regulations for spark arrestor requirements.
I–2022–0595
Stop the engine. Open the rear door and rear grill.
Remove the plug (Item 1) [A] from the bottom of the muffler.
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.
W–2050–1285
Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety glasses or goggles. Failure to obey can cause serious injury.
W–2011–1285
Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.
W–2068–1285
When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death.
W–2006–0284
Start the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler.
Stop the engine. Put anti–seize coating on plug. Install and tighten the plug. Lower the rear grill and close the rear door.
–1–24–
853, 853H Loader
Service Manual
TIRE MAINTENANCE
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].
It is important to keep the same size tires on each side of the loader. If different sizes are used, each tire will be turning at a different rate and cause excessive wear. The tread bars of all the tires must face the same direction.
Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for the correct pressure before operating the loader.
Tire Mounting
Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire, avoid excessive pressure which can rupture the tire and cause serious injury or death. During inflation of the tire, check the tire pressure frequently to avoid over inflation.
A
B
Do not inflate tires above specified pressure.
Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.
W–2078–1285
Inflate tires to the MAXIMUM pressure shown on the sidewall of the tire. DO NOT mix brands of tires used on the same loader.
I–2057–0794
–1–25–
CD–15165
B–09976
853, 853H Loader
Service Manual
FINAL DRIVE TRANSMISSION (CHAINCASE)
853, 853H Service Manual #6720755 – Preventive Maintenance Section Part 1 of 2
Checking And Adding Oil
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.
If oil can be reached with the tip of the your finger through the hole the oil level is correct.
If the level is low, add oil through the check plug hole until the oil flows from the hole. Install and tighten the plug.
FAN GEARBOX
Checking And Maintaining
See the SERVICE SCHEDULE, Page 1–3 for the correct service interval.
Raise the operator cab. (See Page 1–8.)
Remove the plug (Item 1) [B] to check the lubricant level.
If the level is low, add SAE 90W gear lube through the check plug hole until the lubricant flows from the hole.
Install and tighten the plug.
A
B
1
1
P–01551
CD–15164
–1–26–
853, 853H Loader
Service Manual
LUBRICATING THE LOADER
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.
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:
1. Rod End Lift Cylinder (Both Sides) [A].
2. Base End Lift Cylinder (Both Sides) [B].
A
B
1
CD–15169
3. Lift Arm Pivot Pin (Both Sides) [C].
4. Base End Tilt Cylinder [D].
–1–27–
C
D
2
CD–15171
4
3
CD–15170
CD–15168
853, 853H Loader
Service Manual
LUBRICATING THE LOADER (Cont’d)
Procedure (Cont’d)
5. Rod End Tilt Cylinder [A].
A
6. Bob–Tach Pivot Pin (Both Sides) [B].
7. Bob–Tach Wedge (Both Sides) [B].
B
5
CD–15167
6
7
CD–15166
8. 250 Hours: Steering Lever Shaft and Centering
Mechanism [C].
C
8
P–07609
–1–28–
853, 853H Loader
Service Manual
REMOTE START SWITCH
853, 853H Service Manual #6720755 – Preventive Maintenance Section Part 2 of 2
Procedure
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.)
Raise the operator cab. (See Page 1–8.)
Disconnect the operator cab wire harness from the engine wire harness.
Connect the remote start switch to the engine harness connectors (Item 1) [A].
853 Base Only: Use MEL1416 adapter harness (Item 1)
[B]. Connect the adapter harness to the remote start switch.
Disconnect the operator cab wire harness from the engine wire harness.
A
B
1
Connect the adapter harness (Item 1) [C] to the engine harness connectors.
C
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
1
1
CD–11144
P–01190
P–01191
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
–1–29–
853, 853H Loader
Service Manual
–1–30–
853, 853H Loader
Service Manual
HYDRAULIC SYSTEM
Page
Number
BUCKET POSITION VALVE (S/N 5102) & (S/N 5103)
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–40
CONTROL PEDALS
Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–42
2–42
DUAL PRESSURE MAIN RELIEF VALVE (S/N 512811001 & Above)
W/Select Valve(JEM)
Adjusting The Low Setting
Adjusting The High Setting
Checking The Low Setting
Checking The High Setting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–26
2–27
2–23
2–24
FRONT AUXILIARY CONTROL VALVE (Apitech)
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–41
HYDRAULIC CONTROL VALVE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–28
HYDRAULIC CYLINDER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lift Cylinder Identification
Tilt Cylinder Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–17
2–15
2–13
2–14
HYDRAULIC FLUID RESERVOIR
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–38
HYDRAULIC PUMP
Checking The Output Of The Pump
Removal And Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–36
2–37
HYDRAULIC SYSTEM INFORMATION
Tighten Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
HYDRAULIC FILTER HOUSING
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–35
LIFT CYLINDER(S)
Checking The Lift Cylinder
Removal And Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–9
2–9
LOCK VALVE (S/N 5103)
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39
MAIN RELIEF VALVE
Checking The Main Relief Valve
Checking The Main Relief Valve Without Auxiliaries
Removal And Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–20
2–21
2–22
PEDAL INTERLOCK LINKAGE
Pedal Interlock Linkage Adjustment
Removal And Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–44
2–43
HYDRAULIC
SYSTEM
–2–1–
853, 853H Loader
Service Manual
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
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–30
2–33
2–32
2–34
TILT CYLINDER
Checking The Tilt Cylinder
Removal And Installation
Rod End Seal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–11
2–11
2–12
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
–2–2–
853, 853H Loader
Service Manual
HYDRAULIC SYSTEM INFORMATION
–2–3–
853, 853H Loader
Service Manual
HYDRAULIC SYSTEM INFORMATION (Cont’d)
–2–4–
853, 853H Loader
Service Manual
HYDRAULIC SYSTEM INFORMATION (Cont’d)
–2–5–
853, 853H Loader
Service Manual
–2–6–
853, 853H Loader
Service Manual
1
2
3
RESERVOIR:
C apacity . . . 15.5 Qts (14,7 L)
SPRING LOADED FILTER BYPASS
VALVE: 45-55 PSI (311-379 kPa)
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
853 PLUS - Normally Closed
853 BASE - Normally Closed
CHECK VALVE - FILTER 4
5 FLOW DIVIDER ADJUSTMENT VALVE
6
7
8
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
CONTROL VALVE POWER-BEYOND
OUTLET
9 RELIEF VALVE - PORT: (OPTIONAL)
3100 PSI (21371 kPa)
10 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
11
(OPTIONAL)
CHECK VALVE - BUCKET POSITION
VALVE
12 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END) (OPTIONAL):
2500 PSI (17238 kPa)
13
14
15
16
17
18
19
20
21
22
23
HYDRAULIC/HYDROSTATIC SCHEMATIC
853 (S/N 508411001-15215)
(S/N 510125001-26791)
(S/N 510250001-50691)
(Printed June 1999)
MC2396LU
LEGEND
RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
LOAD CHECK VALVE
ONE WAY RESTRICTOR VALVE
RELIEF VALVE - MAIN:
2550-2600 PSI (17582-17927 kPa) at Front Quick Couplers
SHUTTLE RELIEF VALVE:
225-290 PSI (1551-2000 kPa)
DRIVE MOTOR SHUTTLE VALVE
TOW VALVE
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
STANDARD . 4350 PSI (29990 kPa)
OPTIONAL . 5000 PSI (34475 kPa )
DISPLACEMENT CONTROL VALVE
CHARGE PUMP . . . . 11.0 GPM
(41,6 L./M in.) at 2850 RPM
HYDRAULIC PUMP
18.0 GPM (68,1 L/min.) at 2750 RPM
24
FILTER
25 RELIEF VALVE - CHARGE:
140°F. (60°C.) Fluid at Full RPM
Neutral . . . . 310-330 PSI
(2137-2275 kPa)
Stroked . . . . 3O0-320 PSI
(2069-2206 kPa)
26 MUFFLER (If Equipped )
27 CHARGE PRESSURE SENSOR
28 FLUID TEMPERATURE SENSOR
29 BYPASS VALVE - COLD OIL
85 PSI (596 kPa)
30 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FRONT
AUXILIARY (OPTIONAL ON 853 BASE)
31 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
32 FILTER
33 RELIEF VALVE - FRONT AUXILIARY
2400-2600 PSI (16548-17927 kPa)
34 FILTER - HYDROSTATIC (CANISTER)
35 RESTRICTION
36 FILTER - HYDRAULIC (CANISTER)
37 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
38 ANTICAVITATION VALVE
39 PILOT TO OPEN CHECK VALVE
40 FILTER
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A.
MC2396LU (5-19-99)
RIGHT DRIVE MOTOR
17
21
LEFT DRIVE MOTOR
37
19
20
18
OIL
COOLER
PORT
BLOCK
29
28
HYDROSTATIC
FILTER
34
2
27
3
26
37
HYDROSTATIC PUMPS
19
20
21
OUTLET
OUTLET
23
22
25
Printed in U.S.A.
17
18
FRONT AUXILIARY VALVE (OPTIONAL)
(APITECH)
30
32
31
35
INLET
INLET
40
33
35
HYDRAULIC
FILTER
36
2
4
24
3
1
30
FEMALE
MALE
REAR AUXILIARY (OPTIONAL)
MALE
FEMALE
FRONT AUXILIARY (OPTIONAL)
MALE
FEMALE
SECONDARY FRONT AUXILIARY (OPTIONAL)
LOCK VALVE (OPTIONAL)
39
A
BUCKET POSITION VALVE (OPTIONAL)
5
11
11
6
D
C
7
B
HYDRAULIC
CONTROL VALVE
8
9
10
10
AUXILIARY
SPOOL
12
13
TILT CYLINDER
SPOOL
14
15
T1LT CYLINDER
LIFT CYLINDER
38
16
LIFT CYLINDER SPOOL
14
WORKING CIRCUITS
PILOT PRESSURE
DRAIN CIRCUITS
COMPONENTS
MC2396U (5-19-99)
1
2
3
RESERVOIR:
C apacity . . . 15.5 Qts (14,7 L)
SPRING LOADED FILTER BYPASS
VALVE: 45-55 PSI (311-379 kPa)
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
853 PLUS - Normally Closed
853 BASE - Normally Closed
CHECK VALVE - FILTER
FLOW DIVIDER ADJUSTMENT VALVE
4
5
6
7
8
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D2")
9 RELIEF VALVE - PORT: (OPTIONAL)
3100 PSI (21371 kPa)
10 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
(OPTIONAL)
11 CHECK VALVE - BUCKET POSITION
VALVE
12 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END):
2500 PSI (17238 kPa)
13
14
15
16
17
18
19
20
21
22
23
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
RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
LOAD CHECK VALVE
ONE WAY RESTRICTOR VALVE
RELIEF VALVE - MAIN:
2550-2600 PSI (17582-17927 kPa) at Front Quick Couplers
SHUTTLE RELIEF VALVE:
225-290 PSI (1551-2000 kPa )
DRIVE MOTOR SHUTTLE VALVE
TOW VALVE
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
STANDARD . 4350 PSI (29990 kPa)
OPTIONAL . 5000 PSI (34475 kPa)
DISPLACEMENT CONTROL VALVE
CHARGE PUMP . . . . 11.0 GPM
(41,6 L./M in .) at 2850 RPM
HYDRAULIC PUMP
18.0 GPM (68,1 L/min.) at 2750 RPM
24 FILTER
25
RELIEF VALVE - CHARGE:
140°F. (60°C.) Fluid at Full
Neutral . . . . 310-330 PSI
(2137-2275 kPa )
Stroked . . . . 3O0-320 PSI
(2069-2206 kPa)
RPM
26 MUFFLER (If Equipped)
27 CHARGE PRESSURE SENSOR
28 FLUID TEMPERATURE SENSOR
29 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY OPEN
("D1")
30
31
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FRONT
AUXILIARY (OPTIONAL ON 853 BASE)
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P1" and "F1")
32 FILTER
33 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE
34 FILTER - HYDROSTATIC (CANISTER)
35 PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FOR REAR
AUXILIARY - NORMALLY CLOSED
("P2" and "F2")
36 FILTER - HYDRAULIC (CANISTER)
37 FILTER
38
39
FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
ANTICAVITATION VALVE
NOTE: Unless otherwise specified,
springs have NO significant
pressure value.
Printed in U.S.A.
(S/N 510126792 AND ABOVE)
(S/N 510250692 AND ABOVE)
28
OIL
COOLER
HYDROSTATIC
FILTER
34
2
27
3
26
DIVERTER VALVE (OPTIONAL)
8
32
33
30
RIGHT DRIVE MOTOR
17
18
35
29
31
D2
FRONT AUXILIARY
MALE
D1
FEMALE
P1
P2
F1
REAR AUXILIARY
FEMALE
F2
MALE
HYDRAULIC
FILTER
36
2
4
24
3
38
HYDROSTATIC PUMPS
19
20
21
OUTLET
OUTLET
23
22
25
INLET
INLET
37
1
HYDRAULIC
CONTROL VALVE
10
9
AUXILIARY
SPOOL
10
12
21
13
TILT CYLINDER
SPOOL
14
15
19
20
LEFT DRIVE MOTOR
38
39
16
LIFT CYLINDER SPOOL
14
17
18
Printed in U.S.A.
A
BUCKET POSITION VALVE (OPTIONAL)
5
11
11
6
D
C
7
B
WORKING CIRCUITS
PILOT PRESSURE
DRAIN CIRCUITS
COMPONENTS
MC2397U (5-19-99)
T1LT CYLINDER
LIFT CYLINDER
(S/N 512811001-15999 WITH APITECH AUXILIARY VALVE)
1
2
3
4
RESERVOIR:
C apacity . . . 15.5 Qts (14,7 L)
SPRING LOADED FILTER BYPASS
VALVE: 45-55 PSI (311-379 kPa )
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
853 PLUS - Normally Closed
853 BASE - Normally Closed
CHECK VALVE - FILTER
5 FLOW DIVIDER ADJUSTMENT VALVE
6
7
8
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - UNLOADING
SPOOL
CONTROL VALVE POWER-BEYOND
OUTLET
9 RELIEF VALVE - PORT: (OPTIONAL)
3100 PSI (21371 kPa)
10 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - REAR
11
AUXILIARY (OPTIONAL)
CHECK VALVE - BUCKET POSITION
VALVE
12 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END) (OPTIONAL)
2500 PSI (17238 kPa)
LEGEND
13
14
15
16
17
18
19
20
21
22
23
RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
LOAD CHECK VALVE
ONE WAY RESTRICTOR VALVE
RELIEF VALVE - MAIN:
3300 PSI (22750 kPa ) at 18 GPM (68,1 L/ min.)
SHUTTLE RELIEF VALVE:
225-290 PSI (1551-2000 kPa)
DRIVE MOTOR SHUTTLE VALVE
TOW VALVE
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
STANDARD . 4350 PSI (29990 kPa)
OPTIONAL . 5000 PSI (34475 kPa)
DISPLACEMENT CONTROL VALVE
CHARGE PUMP . . . . 11.0 GPM
(41,6 L./M in.) at 2850 RPM
HYDRAULIC PUMP
18.0 GPM (68,1 L/ min.)
2750 RPM at
1150 PSI (7929 kPa)
24 FILTER - HYDRAULIC (CANISTER)
25
RELIEF VALVE - CHARGE:
140°F. (60°C.) F luid at Full RPM
Neutral . . . . 310-330 PSI
(2137-2275 kPa)
Stroked . . . . 3O0-320 PSI
(2069-2206 kPa)
26 MUFFLER (I f Equipped)
27 CHARGE PRESSURE SENSOR
28 FLUID TEMPERATURE SENSOR
29 BYPASS VALVE - COLD OIL
85 PSI (596 kPa)
30 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FRONT
AUXILIARY (OPTIONAL ON 853 BASE)
31 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
32
FILTER
33 RELIEF VALVE - FRONT AUXILIARY
(OPTIONAL) . 2500 PSI (17235 kPa)
34 FILTER - HYDROSTATIC (CANISTER)
35
RESTRICTION
36 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
37 ANTICAVITATION VALVE
38 HYDRAULIC PUMP
6.0 GPM (22,7 L/ min.)
2750 RPM at
1150 PSI (7929 kPa)
39 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW
SELECTIVE VALVE
40 CHECK VALVE - FLOW SELECTIVE
VALVE
41 RELIEF VALVE
3200-3400 PSI (22061-23439 kPa)
42 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - RELIEF
SELECTIVE VALVE
43 RELIEF VALVE
44 PILOT TO OPEN CHECK VALVE
45 FILTER
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A.
MC2398LU (5-19-99)
Printed in U.S.A.
29
28
3
2
34
27
26
36
17
17
18
36
21
19
20
38
23
22
25
32
30
31
35
33
35
30
24
2
4
3
32
1
45
21
19
20
44
13
37
16
43
42
10
9
8
12
14
15
14
10
41
18
5
11
6
11
7
40
39
WORKING CIRCUITS
PILOT PRESSURE
DRAIN CIRCUITS
COMPONENTS
MC2398U (5-19-99)
1
2
3
4
RESERVOIR:
C apacity . . . 16.0 Qts (15,1 L)
SPRING LOADED FILTER BYPASS
VALVE: 45-55 PSI (311-379 kPa)
DIFFERENTIAL PRESSURE SWITCH:
36-44 PSI (248-303 kPa)
Standard Loader - Normally Open
B.O.S.S. L oader - Normally Closed
CHECK VALVE - FILTER
5 FLOW DIVIDER ADJUSTMENT VALVE
6
7
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - FLOW CONTROL
SPOOL
PILOT ACTIVATED DIRECTIONAL
8 RELIEF VALVE - PORT: (OPTIONAL)
2500 PSI (17238 kPa)
9
CONTROL VALVE - UNLOADING
SPOOL
10
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - AUXILIARY
CHECK VALVE - BUCKET POSITION
VALVE
11 RELIEF/ANTICAVITATION VALVE -
PORT (TILT BASE END) (OPTIONAL)
2500 PSI (17238 kPa)
HYDRAULIC/HYDROSTATIC SCHEMATIC
HI-FLOW MACHINE
853 (S/N 512811001-15999 WITH JEM AUXILIARY VALVE)
(Printed June 1999)
MC2399LU
LEGEND
12
13
20
RELIEF VALVE - PORT:
3500 PSI (24132 kPa)
LOAD CHECK VALVE
14 ONE WAY RESTRICTOR VALVE
15 RELIEF VALVE - MAIN: at Front Quick Couplers
SYSTEM MAIN RELIEF:
2800 PSI (19306 kPa)
16
HI FLOW MAIN RELIEF:
3300 PSI (22754 kPa)
SHUTTLE RELIEF VALVE:
17
290 PSI (2000 kPa)
DRIVE MOTOR SHUTTLE VALVE
18
19
TOW VALVE
RELIEF/REPLENISHING VALVE - HIGH
PRESSURE:
STANDARD . 4350 PSI (29990 kPa)
OPTIONAL . 5000 PSI (34475 kPa)
DISPLACEMENT CONTROL VALVE
21 AUXILIARY HYDRAULIC PUMP:
6.0 GPM (22,7 L/ min.) at 2750 RPM at 1150 PSI (7929 kPa)
22
PUMP CAPACITY:
18.0 GPM (68,1 L/min.)
HI FLOW CAPACITY: (Includes )
24.0 GPM (90,8 L/ min.)
23 at 2750 RPM at 1150 PSI (7929 kPa)
23 CHARGE PUMP . 14.0-15.0 GPM
24
(52,9-56,7 L/ min.) at 2700 RPM
FILTER
25 RELIEF VALVE - CHARGE:
140°F. (60°C.) Fluid at Full RPM
N eutral . . . . 310-330 PSI
(2137-2275 kPa)
Stroked . . . . 3O0-320 PSI
(2069-2206 kPa)
26 MUFFLER (If Equipped)
27 CHARGE PRESSURE SENSOR
28 FLUID TEMPERATURE SENSOR
29 PILOT TO OPEN CHECK VALVE
30
31
SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - FRONT
AUXILIARY
RELIEF VALVE - MAIN HIGH FLOW
3000 PSI (20685 kPa)
32 RESTRICTION
33 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE
34 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE (TWO COIL)
35 FILTER - HYDROSTATIC (CANISTER)
36 FILTER - HYDRAULIC (CANISTER)
37 COLD OIL BYPASS VALVE
38 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
MOTOR
39 ANTICAVITATION VALVE
40 FILTER
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A.
MC2399LU (5-19-99)
OIL
COOLER
PORT
BLOCK
37
28
HYDROSTATIC
FILTER
35
2
27
3
26
Printed in U.S.A.
AUXILIARY VALVE (JEM)
29
32
F1
34
31
30
F2
29
32
33
RIGHT DRIVE MOTOR
16
17
38
HYDROSTATIC PUMPS
18
19
20
OUTLET
OUTLET
23
22
21
25
HYDRAULIC
FILTER
36
2
4
24
3
1
INLET
INLET
40
FRONT AUXILIARY
FEMALE
MALE
20
19
LEFT DRIVE MOTOR
38
16
17
CASE DRAIN
D1
FRONT AUXILIARY
FEMALE
D2
MALE
HYDRAULIC
CONTROL
VALVE
12
9
8
AUXILIARY
SPOOL
9
11
TILT CYLINDER
SPOOL
13
14
39
LIFT CYLINDER SPOOL
13
15
A
BUCKET POSITION VALVE (OPTIONAL)
5
10
10
6
D
C
7
B
T1LT CYLINDER
LIFT CYLINDER
MC2399U (5-19-99)
WORKING CIRCUITS
PILOT PRESSURE
DRAIN CIRCUITS
COMPONENTS
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
The hydraulic system will not operate.
The transmission warning light comes ON when hydraulics are
operating. (853 Base)
Slow hydraulic system action.
Hydraulic action is not smooth.
Lift arms go up slowly at full engine RPM.
The lift arms or Bob–Tach will move the pedal in neutral position.
The lift arms come down with the pedal in the neutral position.
CAUSE
1, 2, 3, 5
1, 3
1, 3, 4, 5, 6, 8
1, 4, 5, 6, 7
1, 3, 4, 5, 6, 7, 8, 9
4
4, 9, 10, 11
KEY TO CORRECT THE CAUSE
1.
The fluid level is not correct.
2.
The pedal linkage is disconnected.
3.
The hydraulic pump has damage.
4.
The pedal linkage is not adjusted correctly.
5.
Relief valve is not at the correct pressure.
6.
Suction leak on the inlet side of the hydraulic pump.
7.
Fluid is cold. Wrong viscosity fluid. (See Section 9.)
8.
Using the loader for more than its rated capacity.
9.
Internal leak in the lift cylinder(s).
10.
External leak from the lift cylinder(s).
11.
Damaged lift spool.
–2–7–
853, 853H Loader
Service Manual
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.
Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately.
W–2145–0290
–2–8–
853, 853H Loader
Service Manual
LIFT CYLINDER(S)
Checking The Lift Cylinder
Lower the lift arms. Stop the engine. Raise the seat bar.
A
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.
W–2072–0496
Check only one cylinder at a time. Disconnect the hose
(Item 1) [A] which goes to the base end of the lift cylinder.
Install a plug (Item1) [B] in the hose and tighten.
Engage the parking brake. Lower the seat bar. Start the engine and push the top (toe) of the lift pedal.
If there is any leakage from the open port, remove the lift cylinder for repair. Repeat the procedure to check the other lift cylinder.
Removal And Installation
Engage the parking brake.
Raise the lift arms so the rod end retaining pin will clear the loader frame for removal.
Have a second person put jackstands under the
Bob–Tach to support the lift arms [C]. Stop the engine.
Raise the operator cab. (See Page 1–1.)
B
C
1
Remove the retaining bolt and nut (Item 1) [D] from the retaining pin on the rod end of the cylinder.
Installation: Tighten the retainer bolt and nut to 18–20 ft.–lbs. (24–27 Nm) torque.
Remove the retaining pin from the rod end of the cylinder.
D
1
–2–9–
CD–15067
CD–15068
CD–15066
CD–15069
853, 853H Loader
Service Manual
LIFT CYLINDER(S) (Cont’d)
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.
A
Remove the retaining pin from the base end of the cylinder [B].
Slide the cylinder forward for clearance to disconnect the hoses.
B
1
CD–15070
Mark the hoses for correct installation.
Disconnect the two hoses (Item 1) [C] from the lift cylinder.
Remove the lift cylinder.
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.
W–2103–1285
C
1
CD–15072
CD–15073
–2–10–
853, 853H Loader
Service Manual
TILT CYLINDER
Checking The Tilt Cylinder
Remove the attachment. Roll the Bob–Tach fully back.
Stop the engine. Raise the seat bar.
A
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.
W–2072–0496
Disconnect the hose (Item 1) [A] which goes to the base end of the tilt cylinder.
Put a plug in the hose and tighten.
Connect a hose between cylinder port and into a drain pan.
Engage the parking brake. Lower the seat bar. Start the engine and push the bottom (heel) of the tilt pedal. If there is leakage from the open port, remove the tilt cylinder for repair.
Removal And Installation
Remove the attachment. Roll the Bob–Tach fully forward
[B].
Stop the engine. Raise the seat bar.
Disconnect both hydraulic hoses (Items 1 & 2) [A].
Remove the retainer bolt and nut (Item 1) [C] from the rod end pivot pin.
Installation: Tighten the retainer nut to 18–20 ft.–lbs.
(24–27 Nm) torque.
Remove the grease fitting from the rod end pivot pin.
Remove the rod end pivot pin (Item 1) [D].
B
C
D
1
1
1
2
CD–15074
CD–15075
CD–15076
–2–11–
P–03904
853, 853H Loader
Service Manual
TILT CYLINDER (Cont’d)
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.
A
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.
W–2103–1285
Remove the base end pivot pin (Item 1) [B].
Remove the tilt cylinder from the loader.
Rod End Seal
Remove the old seal (both sides) from the rod end of the tilt cylinder.
Install the new seals with the lip facing out [C].
B
C
1
1
CD–15077
CD–15078
P–03911
Use two pieces of shim stock to protect the new seals during installation.
Install the rod end of the tilt cylinder into the Bob–Tach
[D].
Be careful not to damage the new seals during installation.
D
–2–12–
P–03910
853, 853H Loader
Service Manual
HYDRAULIC CYLINDER
Lift Cylinder Identification
1. Tube
2. O–ring
3. Plug
4. Case
5. O–ring
6. Nut
7. Piston
8. Ring
9. O–ring
10. Spacer
11. O–ring
12. Washer
13. Head
14. Seal
15. Seal
16. Rod
1
2
3
3
2
4
8
9
10
7
6
11
12
5
13
14
15
16
–2–13–
TS–01060
853, 853H Loader
Service Manual
HYDRAULIC CYLINDER (Cont’d)
Tilt Cylinder Identification
1. Case
2. Tube
3. Plug
4. O–ring
5. Clamp
6. Nut
7. Nut
8. Piston
9. Seal
10. O–ring
11. Seal
12. Washer
13. O–ring
14. Head
15. Seal
16. Seal
17. Rod
18. Bushing
MC–01688
1
2
5
6
7
4
3
8
9
10
11
12
13
MC–01688
–2–14–
18
14
15
16
17
TS–01098
853, 853H Loader
Service Manual
HYDRAULIC CYLINDERS (Cont’d)
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.
Hold the hydraulic cylinder over a drain pan and move the rod in and out slowly to remove the fluid from the cylinder.
Put the base end of the cylinder in a vise.
Use a spanner wrench to loosen the head [A] & [B].
A
B
P–07429
Lift Cylinder: Remove the head and the rod assembly from the cylinder [C]. Put the rod end in a vise.
Lift Cylinder: Remove the nut (Item 1) [C], piston (Item 2)
[C], spacer (Item 3) [C] (if so equipped) and head (Item
4) [C].
C
1
2
3
4
P–07435
Tilt Cylinder: Remove the head and rod assembly from the cylinder [D]. Put the rod end in a vise.
Tilt Cylinder: Remove the nut (Item 1) [D], piston (Item 2)
[D] and head (Item 3) [D].
D
1
2
3
P–07428
–2–15–
P–07434
853, 853H Loader
Service Manual
HYDRAULIC CYLINDERS (Cont’d)
Disassembly (Cont’d)
Standard Piston: Remove the seal (Item 1) [A], and
O–ring (Item 2) [A] from the piston (Item 3) [A].
A
1
2
3
P–07430
Cushion Piston: Remove the seal (Item 1) [B], and O–ring
(Item 2) [B] from the piston (Item 3) [B].
B
1
2
3
P–07439
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].
C
1
2
3
Remove the wiper seat (Item 1) [D], and rod seal (Item 2)
[D].
Remove the O–ring (Item 3) [D] from the rod seal.
D
3
–2–16–
P–07422
2
1
P–07426
853, 853H Loader
Service Manual
HYDRAULIC CYLINDERS (Cont’d)
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.
Always install new O–rings and seals during assembly.
Lubricate all O–rings and seals with hydraulic oil during installation.
Install the new seal on the tool and slowly stretch it until it fits the piston [A].
Allow the seal to stretch for 30 seconds before installing it on the piston.
Standard Piston: Install the seal (Item 1) [B] and O–ring
(Item 2) [B] on the piston (Item 3) [B].
A
B
1
2
3
Cushion Piston: Install the seal and O–ring on the piston
(Item 1) [C].
Use a ring compressor to compress the seal to the correct size. Leave the piston in the compressor for about three minutes.
C
1
P–07424
P–07430
P–07438
Install the rod seal on the rod seal tool [D].
NOTE: During installation the O–ring side of the seal must be toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [D].
D
–2–17–
P–07427
853, 853H Loader
Service Manual
HYDRAULIC CYLINDERS (Cont’d)
Assembly (Cont’d)
Install the rod seal in the head [A].
Install the wiper seal with the wiper toward the outside of the head.
A
P–07425
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.
B
3
2
1
NOTE: Clean and dry the threads before install the nut. Install the new nut from the kit.
Tilt Cylinder: Install the head (Item 1) [C], and the piston
(Item 2) [C]. The small diameter of the piston goes into the cylinder tube first.
Tilt Cylinder: Grease the piston where the nut contacts the piston. Do not get grease on the threads.
Tilt Cylinder: Install the nut (Item 3) [C].
Tilt Cylinder: Tighten the nut to 100 ft.–lbs. (136 Nm) torque.
C
3
2
1
P–07422
P–07434
Tilt Cylinder: Mark the end of the shaft and nut [D].
Tighten the nut an additional 135 degrees or 2–1/4 flats
[D].
D
–2–18–
P–10450 P–10456
853, 853H Loader
Service Manual
HYDRAULIC CYLINDERS (Cont’d)
Assembly (Cont’d)
NOTE: Clean and dry the threads before install the nut. Install the new nut from the kit.
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.
Put the base end of the hydraulic cylinder in a vise.
Tighten the head using a spanner wrench [B] & [C].
A
B
4
3
2
1
P–07428
P–07429
C
P–07435
–2–19–
853, 853H Loader
Service Manual
MAIN RELIEF VALVE
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.)
Connect the IN port of the hydraulic tester to the female quick coupler on the loader [A].
Connect the OUT port of the hydraulic tester to the male quick coupler on the loader [A].
A
B
P–05061
1
The hydraulic tester must be in the fully open position before you start the engine.
I–2024–0284
2
B–13443
C
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
Start the engine and run at low engine idle RPM. Push the mode switch (Item 1) [B] two times (on the instrument panel) to engage the front auxiliary hydraulics, the light
(Item 2) [B] will come ON.
Push the button (Item 1) [C] for fluid pressure to the quick couplers.
Watch the flow meter on the hydraulic tester to make sure the flow is correct. Increase the engine speed to full RPM.
There should be 18.0 GPM (68 L/min.) free flow. Turn the restrictor control, on the tester, until the main relief valve opens. The correct pressure for the main relief is
2700–2750 PSI (18617–18961 kPa).
If the relief pressure is not correct, stop the engine.
Replace or adjust the main relief valve. (See Page 2–15.)
Left
Steering
Lever
Control
P–00391
1
Right
Steering
Lever
Control
P–00387
When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death.
W–2006–0284
–2–20–
853, 853H Loader
Service Manual
MAIN RELIEF VALVE (Cont’d)
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.
Lift and block the loader. (See Page 1–1.)
Disconnect the hydraulic hoses (Item 1) [A] at the tilt cylinder.
Connect the hydraulic tester to the tilt cylinder hoses [B].
Have a second person in the operator seat, with seat bar in down position.
A
B
1
The hydraulic tester must be in the fully open position before you start the engine.
I–2024–0284
Start the engine and run at idle RPM.
Push the tilt pedal at the top (toe) or bottom (heel) until the hydraulic tester shows the correct fluid flow through the flow meter.
Increase the engine RPM to maximum.
There should be 18.0 GPM (68,1 L/min.) free flow.
Turn the restrictor control, at the tester, to increase the pressure until the main relief valve opens.
The correct pressure is 2700–2750 PSI (18617–18961 kPa).
If not, stop the engine.
Replace or adjust the main relief valve. (See Page 2–15.)
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.
W–2050–1285
–2–21–
P–01187
P–01193
853, 853H Loader
Service Manual
MAIN RELIEF VALVE (Cont’d)
Removal And Installation
Raise the operator cab. (See Page 1–1.)
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.
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.
CD–15094
1
CD–11193
Loosen and remove the main relief valve [B].
Installation: Tighten the main relief valve to 35–40 ft.–lbs. (47–54 Nm) torque.
B
Remove the O–rings and back–up washers.
Clean the main relief valve in clean solvent. Use air pressure to dry the valve.
Install new O–rings and backup washers. Install the main relief valve and tighten [A]. Check the pressure again.
(See Page 2–20.)
If the pressure is not correct, adjust the main relief valve.
Remove the end cap (Item 1) [C].
Loosen the locking nut (Item 2) [C].
Turn the adjusting screw in or out until the pressure is correct.
Tighten the locking nut (Item 2) [C].
Reinstall the end cap (Item 1) [C].
NOTE: If the correct pressure can not be reached, replace the main relief valve. Check the pressure setting of the new relief valve.
–2–22–
C
2
CD–15091
1
CD–15093
853, 853H Loader
Service Manual
DUAL PRESSURE MAIN RELIEF VALVE (S/N
512811001 & Above) W/ Select Valve (JEM)
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.
Lift and block the loader. (See Page 1–1.)
Connect the IN port of the hydraulic tester to the female quick coupler on the loader [A].
Connect the OUT port of the hydraulic tester to the male quick coupler on the loader [A].
NOTE: Flow will be out from the female coupler on the loader.
A
B
P–05195
The hydraulic tester must be in the fully open position before you start the engine.
I–2024–0284
Start the engine and run at low idle RPM. Push the mode switch (Item 1) [B] twice (on the instrument panel) to engage the front auxiliary hydraulics detent, both lights
(Items 2 & 3) [B] will come ON.
NOTE: High horsepower switch should be in the
OFF position.
Push the button (Item 1) [C] for fluid flow to the quick couplers.
Watch the flow meter on the hydraulic tester to make sure the flow is correct. Increase the engine speed to full RPM.
There should be approximately 18.0 GPM (68,1 L/min.) free flow. Turn the restrictor control, on the tester, until the main relief valve opens. The correct pressure for the main relief is 2700–2750 PSI (18617–18961 kPa).
Push the button (Item 1) [C] to disengage the detent flow to the front quick couplers.
If the relief pressure is not correct, stop the engine. Adjust or replace the main relief valve. (See Page 2–26.)
C
Left
Steering
Lever
Control
2
3
1
P–00391
Right
Steering
Lever
Control
1
P–00998
P–00387
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
–2–23–
853, 853H Loader
Service Manual
DUAL PRESSURE MAIN RELIEF VALVE (S/N
512811001 & Above) W/Select Valve (JEM) (Cont’d)
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.).
Connect the hydraulic tester to the auxiliary quick coupler
[A].
The IN port on the tester connects to the female coupler on the loader.
The OUT port from the tester connects to the male coupler on the loader.
A
B
2
The hydraulic tester must be in the fully open position before you start the engine.
I–2024–0284
C
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
Obtain a 3/8 inch (9,5 mm) I.D. hose (Item 1) [B] with a
3000 PSI (20685 kPa) rating or greater.
The hose loop (Item 1) [B] should be approximately of 28 inches (711 mm) in length (including quick couplers).
A small male coupler (Item 2) [B] is needed for one end of the hose, and a small female coupler (Item 3) [B] is needed for the other end of the hose.
Use the correct fittings and O–rings to connect the couplers to the hose.
Drill orifice (Item 1) [C] size to 0.070 inch (1,8 mm). Install the threaded orifice (Item 1) [C] in the male coupler (Item
2) [C] and install the coupler on the fitting.
1
1
3
2
P–05195
P–04717
P–04757
–2–24–
853, 853H Loader
Service Manual
DUAL PRESSURE MAIN RELIEF VALVE (S/N
512811001 & Above) W/Select Valve (JEM) (Cont’d)
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.
A
1
P–05196
B
When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death.
W–2006–0284
Start the engine and run at low idle RPM. Increase the engine speed to full RPM. Push the mode switch (Item 1)
[B] twice (on the instrument panel) to engage the front auxiliary hydraulics detent, the lights (Items 2 & 3) [B] will come ON.
NOTE: The High Horsepower switch should be in the
OFF position.
Push the button (Item 1) [C] to engage the detent position to the front auxiliary quick couplers.
Push and hold the button (Item 2) [C] for fluid flow through the secondary auxiliary couplers and hose loop.
Watch the flow meter on the hydraulic tester to be sure the flow is correct.
There should be approximately 18.0 GPM (68,1 L/min.) free flow. Turn the restrictor control on the tester, until the main relief valve opens. The correct pressure for the main relief is 3000 PSI (20685 kPa).
Release the button (Item 2) [C] and push the button (Item
1) [C] to disengage the detent position to the front auxiliary quick couplers.
If the relief pressure is not correct, stop the engine.
Replace or adjust the main relief valve. (See Page 2–27.)
C
2
Left
Steering
Lever
Control
2
3
1
1
P–00998
P–00391
Right
Steering
Lever
Control
P–00389
–2–25–
853, 853H Loader
Service Manual
DUAL PRESSURE MAIN RELIEF VALVE (S/N
512811001 & Above) W/Select Valve (JEM) (Cont’d)
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].
Remove the adapter fitting (Item 3) [A].
A
2
3
Remove the high pressure adjustment housing (Item 1)
[B] from the main relief valve.
B
Select Valve
(JEM Block)
Control Valve
1
E–02232
1
Use a 1/4’’ allen wrench (Item 1) [C] to turn the adjusting screw (Item 2) [C] in to increase pressure or out to decrease pressure.
One turn is equal to approximately 490 PSI (3379 kPa).
Reinstall the high pressure adjustment housing and adapter.
Reconnect the pilot hose.
Start the engine and increase the engine speed to full
RPM. Check for the correct pressure setting.
Repeat the procedure until the pressure setting is approximately 2700–2750 PSI (18617–18961 kPa).
When the correct pressure setting is reached, the next step is to set the high pressure adjustment on the main relief valve. (See Page 2–24 for the correct procedure.)
Stop the engine.
–2–26–
C
1
2
MC–01654
MC–01654
853, 853H BICS Loader
Service Manual
DUAL PRESSURE MAIN RELIEF VALVE (S/N
512811001 & Above) W/Select Valve (JEM) (Cont’d)
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].
Remove the adapter fitting (Item 3) [A].
A
2
3
Use a 1/4’’ allen wrench (Item 1) [B] to press the push pin
(Item 2) [B] in until it bottoms out.
Turn the adjusting guide (Item 3) [B] in to increase pressure or out to decrease pressure.
One turn is equal to approximately 390 PSI (2689 kPa).
Reinstall the adapter fitting and pilot hose.
Check for the high pressure setting.
Reconfirm the correct adjustment.
Repeat the adjustment procedure if necessary.
B
2
1
Select Valve
(JEM Block)
Control Valve
1
E–02232
3
–2–27–
MC–01654
853, 853H BICS Loader
Service Manual
HYDRAULIC CONTROL VALVE
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
A
B
1
1
CD–10937
Stop the engine. Move the hydraulic controls to release the hydraulic pressure. Raise the seat bar.
Lift and block the loader. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Clean the area around the control valve.
Remove both cotter pins from the clevis pins connecting the linkages to the valve spools [A].
Remove the clevis pins (Item 1) [A] from the linkages.
Remove the two tubelines (Item 1) [B] from the auxiliary section of the control valve.
Disconnect the front auxiliary control valve return hose
(Item 2) [B].
Remove the two tubelines (Item 1) [C] from the tilt section on the control valve.
Remove the three tubelines (Item 1) [D] from the lift section on the control valve.
C
D
2
1
CD–10938
CD–10939
1
–2–28–
CD–10940
853, 853H BICS Loader
Service Manual
HYDRAULIC CONTROL VALVE (Cont’d)
Removal And Installation (Cont’d)
Remove the control valve outlet tubeline (Item1) [A] from the control valve.
Remove the power beyond tubeline which goes to the auxiliary control valve inlet [B].
Disconnect the control valve inlet hose (Item 1) [B] which comes from the outlet of the hydraulic pump.
A
B
Disconnect the two connectors from the solenoids on the auxiliary section of the control valve [C].
C
Remove the two mounting bolts and remove the control valve [D].
Installation: Tighten the mounting bolts to 25 ft.–lbs. (34
Nm) torque.
SEE THE COMPONENT REPAIR MANUAL FOR THE
HYDRAULIC CONTROL VALVE FOR THE
DISASSEMBLY AND ASSEMBLY PROCEDURE.
D
–2–29–
CD–10943
CD–10944
853, 853H BICS Loader
Service Manual
1
1
CD–10941
CD–10942
SELECT VALVE (S/N 512811001 & Above) W/Select
Valve (JEM)
Checking The Relief Valve
The tools listed will be needed to do the following procedure:
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.
Connect the OUT port of the hydraulic tester to the male quick coupler (Item 2) [A] on the loader.
A
The hydraulic tester must be in the fully open position before you start the engine.
I–2024–0284
B
3
Left
Steering
Lever
Control
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
Start the engine and run at low idle RPM. Push the mode switch (Item 1) [B] once (on the instrument panel) to engage the front auxiliary hydraulics momentary, the light
(Item 2) [B] will come ON.
Push the rocker switch (Item 3) [B] for fluid pressure to the secondary quick couplers.
Watch the flow meter on the hydraulic tester to make sure the flow is correct. Increase the engine speed to full RPM.
The free flow should be approximately 8.0 GPM (30,3
L/min.). Turn the restrictor control, on the tester, until the main relief valve opens. The correct pressure for the main relief is approximately 3000 PSI (20685 kPa).
Release the rocker switch (Item 3) [B] to disengage the flow to the secondary quick couplers.
P–02130
2
2
1
P–04761
1
P–00998
–2–30–
853, 853H BICS Loader
Service Manual
SELECT VALVE (S/N 512811001 & Above) W/Select
Valve (JEM) (Cont’d)
Checking The Relief Valve (Cont’d)
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.
A
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.
If the correct pressure is not reached remove the relief valve and inspect the O–rings and back–up rings (Item 4)
[B]. Replace the relief valve if required.
B
1
1
P–05201
3
2
4
P–09199
P–05200
–2–31–
853, 853H BICS Loader
Service Manual
SELECT VALVE (S/N 512811001 & Above) W/Select
Valve (JEM) (Cont’d)
Removal And Installation
Raise the operator cab. (See Page 1–1.)
Remove the bolt (Item 1) [A].
Disconnect the controls harness at the left side steering lever connectors (Item 2) [A].
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.
Remove the front mount nut and steering panel brace
(Item 4) [A].
Disconnect the controls harness from the select valve connectors (Item 1) [B].
Remove the rear bolt (Item 2) [B] on the left side pedal link
(Item 3) [B].
Remove the link front bolt and push the link (Item 3) [B] forward.
A
B
3
2
1
2
1
Disconnect and remove the tubeline (Item 1) [C].
Disconnect and lower the tubeline (Item 2) [C].
Disconnect the tubeline (Item 3) [C].
Disconnect the hose (Item 4) [C].
C
2
1
3
4
2
P–09185
1
P–09189
3
4
P–09187
Disconnect the tubelines (Item 1) [D] at the select valve.
Install caps and plugs on open connections.
Remove the select valve.
Installation: Connect controls harness to select valve solenoids. Refer to the Electrical Wiring Diagram for the correct controls harness wire colors.
D
1
–2–32–
P–09186
853, 853H BICS Loader
Service Manual
SELECT VALVE (S/N 512811001 & Above) W/Select
Valve (JEM) (Cont’d)
Removal And Installation (Cont’d)
Remove the mounting bolts (Item 1) [A] located on the outside left frame.
Remove the select valve.
A
1
P–09190
Disassembly And Assembly
Clean the select valve to remove dirt before disassembly.
B
1
2
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
Remove the solenoid valve coils in Fig. [B].
NOTE: The controls wiring harness colors are listed below for identification during select valve assembly installation.
Second aux. male coupler (Item 1) [B] Yellow/Brown
Second aux. female coupler (Item 2) [B] Yellow/Lt. Green
High Flow (Item 3) [B] Lt. Blue/Red
Second aux. diverter (Item 4) [B] Yellow
Assembly: The coils largest opening (Item 1) [C] must position on the valve shoulder (Item 2) [C]. Install the washer (Item 1) [D] between the double coils. Install the coils and tighten the nuts (Item 2) [D] to 5 ft.–lbs. (6,7 Nm) torque.
C
D
1
4
3
P–09184
2
P–09177
–2–33–
2
1
2
2
P–09194
853, 853H BICS Loader
Service Manual
SELECT VALVE (S/N 512811001 & Above) W/Select
Valve (JEM) (Cont’d)
Disassembly And Assembly (Cont’d)
Remove the 4–way solenoid valve (Item 1) [A].
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.
Remove the fitting (Item 1) [B]. Remove the check valve
(Item 2) [B].
Remove the relief valve (Item 3) [B].
Inspect the relief valve, check valves, pilot piston, and fitting for contamination or damage. Wash all parts in clean solvent. Use air pressure to dry them. Install new
O–rings and back–up washers.
The fitting (Item 1) [B] and fig. [C] has a poppet valve. The poppet valve allows flow out of the select valve only.
Inspect the poppet (Item 1) [C] for smooth opening and closing.
Assembly: Put oil on O–rings and back–up washers.
Install and tighten the solenoid valves (Items 1 & 4) [A] to
25 ft.–lbs. (33,9 Nm) torque. Install the pilot piston (Item
3) [A] in the port between the check valves (Item 2) [A]
& [B]. Install the check valves and tighten to 20 ft.–lbs.
(27,1 Nm) torque.
Install the fitting (Item 1) [B] and tighten to 20 ft.–lbs. (27
Nm) torque. Install the relief valve (Item 3) [B] and tighten to 25 ft.–lbs. (33,9 Nm) torque.
A
B
C
1
2
3
4
2
1
P–09197
3
P–09196
1
P–09195
Solenoid Testing
Use a test meter to measure coil resistance [D]. Coil wires do not have polarity. Correct resistance for the coils is 5–8 ohms.
Replace the test meter with 12 volt power. You can see and hear the spool shift.
D
–2–34–
P–09175
853, 853H BICS Loader
Service Manual
HYDRAULIC FILTER HOUSING
Removal And Installation
A
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
B
Disconnect the tubelines from the inlet of the hydraulic filter [A].
Disconnect the hose (Item 1) [B] from the outlet of the filter.
Remove the two mounting bolts and remove the hydraulic filter and housing [C].
Installation: Tighten the mounting bolts to 25 ft.–lbs. (34
Nm) torque.
C
1
CD–10945
CD–10946
CD–10947
–2–35–
853, 853H BICS Loader
Service Manual
HYDRAULIC PUMP
853, 853H Service Manual #6720755 – Hydraulic System Section Part 1 of 2
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.
Lift and block the loader. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Connect the remote start switch. (See Page 1–1.)
Disconnect the OUTLET hose from the pump [A].
Connect the INLET hose from the tester to the OUTLET of the pump. Connect the OUTLET hose from the tester to the hose which was disconnected from the pump [B].
A
B
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
Start the engine and run at low idle RPM. Make sure the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected wrong. With the hoses connected correctly, increase the engine speed to full
RPM.
Warm the fluid to 140
°
F. (60
°
C.) by turning the restrictor control on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure. Open the restrictor control and record the free flow (GPM) at full RPM.
Push the mode switch (on the remote start switch) to engage the front auxiliary hydraulics, the light will come
ON. Push the button (on the right steering lever) for fluid pressure to the quick coupler (fluid pressure will go over main relief). Record the highest pressure (PSI) and flow
(GPM). The high pressure flow must be at least 80% of free flow.
% =
HIGH PRESSURE FLOW (GPM)
FREE FLOW (GPM)
A low percentage may indicate a pump problem.
X 100
–2–36–
CD–11093
P–10949
853, 853H BICS Loader
Service Manual
HYDRAULIC PUMP (Cont’d)
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.
A
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.
I–2003–0284
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.
W–2059–0598
Raise the operator cab. (See Page 1–1.)
Drain the hydraulic reservoir. (See Page 1–1.)
Disconnect the hose (Item 1) [A] from the pump outlet.
Install a cap on the fitting.
Disconnect the tubeline from the inlet of the pump [A].
Remove the mump mounting bolts [B].
Remove the hydraulic pump [C].
C
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.
W–2103–1285
–2–37–
CD–10950
CD–10951
P–04857
853, 853H BICS Loader
Service Manual
HYDRAULIC FLUID RESERVOIR
Removal And Installation
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.
A
Loosen and disconnect the reservoir outlet hose [B].
B
1
P–00971
CD–10954
Remove the bolt and plate (Item 1) [C] from the mounting strap.
Installation: Tighten the bolt to 16–20 ft.–lbs. (21–27
Nm) torque.
Remove the hydraulic reservoir from the loader.
C
1
P–04858
–2–38–
853, 853H BICS Loader
Service Manual
LOCK VALVE (S/N 5103)
Removal And Installation
NOTE: The lock valve is optional for the (S/N 5102)
& the (S/N 5101) loaders.
A
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
B
CD–10957
Disconnect the two tubelines on the lock valve [A].
Remove the two (right) rear auxiliary hoses from the valve
[B].
Remove the two (left) rear auxiliary hoses from the lock valve [C].
Remove the mounting bolt (Item 1) [C] and remove the lock valve.
Installation: Tighten the mounting bolt to 25 ft.–lbs. (34
Nm) torque.
C
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.
W–2103–1285
–2–39–
CD–10958
1
CD–10959
853, 853H BICS Loader
Service Manual
BUCKET POSITION VALVE (S/N 5102) & (S/N 5103)
Removal And Installation
NOTE: The bucket position valve is optional for the
(S/N 5101) loader.
A
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
B
Remove all the tubelines connected to the valve [A].
Remove the two mounting bolts and remove the valve
[B].
Installation: Tighten the mounting bolts to 15–16 ft.–lbs.
(20–22 Nm) torque.
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.
W–2103–1285
–2–40–
CD–10960
CD–10961
853, 853H BICS Loader
Service Manual
FRONT AUXILIARY CONTROL VALVE (Apitech)
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)
A
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
B
CD–10962
CD–10963
Disconnect the outlet tubeline which returns to the hydraulic filter [B].
Disconnect the two auxiliary tubelines [B].
Disconnect the solenoid connector [C].
C
Remove the two mounting bolts and remove the auxiliary control valve [D].
Installation: Tighten the mounting bolts to 64–70 ft.–lbs.
(88–95 Nm) torque.
D
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.
W–2103–1285
–2–41–
N–10964
CD–10965
853, 853H BICS Loader
Service Manual
CONTROL PEDALS
Removal And Installation
Remove the bolt and nut (Item 1) [A] from the pedal linkage.
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.
A
Remove the two mounting bolts (Item 1) [B].
Remove the pedal assembly from the loader.
Pedal Adjustment
After installing the pedal, adjust the pedal so that there is clearance under the rear of the pedal and the valve spool must travel full stroke without hitting the floor panel.
B
AVOID INJURY OR DEATH
Adjust locking tabs on pedal control linkage so that lift and tilt control pedals are locked in neutral when the seat bar is up.
W–2104–1285
NOTE: See Page 2–44 for correct procedure to adjust the pedal interlock linkage.
1
P–04771
1
P–04770
–2–42–
853, 853H BICS Loader
Service Manual
PEDAL INTERLOCK LINKAGE
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.)
Remove the interlock shield mounting nuts (Item 1) [A].
Installation: Tighten the shield mounting nuts to 25–28 ft.–lbs. (34–38 Nm) torque.
Remove the interlock shield (Item 2) [A].
Remove the interlock mounting nuts and plastic washers from behind the nuts [B].
Remove the interlock (Item 1) [B] and plastic washers from behind the interlock.
A
B
2
1
P–01216
1
P–01210
Installation: Hold the inside plastic washer up with an
O–ring pick or a small screwdriver so the plastic washer does not become wedged between the side panel and the interlock nut [C].
Installation: Tighten the interlock mounting nuts to
84–95 in.–lbs. (9,5–10,8 Nm) torque.
C
P–01219
To install new interlock mounting bolts, remove the top bolt from the front panel and loosen the two bolts at the bottom of the panel [D].
D
–2–43–
P–01213
853, 853H BICS Loader
Service Manual
PEDAL INTERLOCK LINKAGE (Cont’d)
Removal And Installation (Cont’d)
Remove the panel from the loader frame [A].
A
Install the mounting bolts (Item 1) [B] through the back of the panel as shown.
B
Pedal Interlock Linkage Adjustment
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.
If not, loosen the bolts and adjust the tab for correct engagement.
Tighten the bolts to 25–28 ft.–lbs. (34–38 Nm) torque.
C
AVOID INJURY OR DEATH
Adjust locking tabs on pedal control linkage so that lift and tilt control pedals are locked in neutral when the seat bar is up.
W–2104–1285
The locking tab should fit into the slot of the interlock as shown in figure [D], when adjusted correctly.
D
–2–44–
P–01215
1
P–01212
1
P–01214
P–04051
853, 853H BICS Loader
Service Manual
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
Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Pulley End Play
Disassembly
Removal And Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3–41
3–36
3–40
3–34
3–33
FRONT PANEL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5
HYDROSTATIC CHARGE OIL FILTER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–19
HYDROSTATIC MOTOR
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17
HYDROSTATIC PUMP
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . .
3–23
3–25
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function
Tow Valves
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3–4
3–4
OIL COOLER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–42
SPRING LOADED TENSIONER PULLEY
Adjusting The Drive Belt
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Idenification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3–32
3–30
3–29
3–28
STEERING LEVERS
Adjusting Lever Freeplay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting The Steering Neutral Setting . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting The Wheel RPM Forward Compared To Reverse Travel . . .
. . . . . . . . . . . Adjusting The Wheel RPM Left Compared To Right Side
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Neutral Pre–Adjustment Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Pump Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3–10
3–13
3–11
3–14
3–7
3–9
3–15
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
HYDROSTATIC
SYSTEM
–3–1–
853, 853H Loader
Service Manual
–3–2–
853, 853H Loader
Service Manual
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
No drive on one side, in one direction.
No drive on one side in both directions.
The loader does not move in a straight line.
The hydrostatic system is overheating.
Service code HP 2 appears (Warnings, low charge pressure) or the
warning light comes ON (853 Base).
KEY TO CORRECT THE CAUSE
1.
The hydrostatic pump replenishing valves not seating.
2.
The steering linkage needs adjustment.
3.
The hydrostatic pump has damage.
4.
The final drive chains are broken.
5.
The hydrostatic motor has damage.
6.
The tires do not have the correct tire pressure.
7.
The tires are not the same size.
8.
The hydrostatic fluid is not at the correct level.
9.
The oil cooler has a restriction.
10.
The temperature sending switch is not operating correctly.
11.
The loader is not being operated at the correct RPM.
12.
The sender is defective.
13.
Pump is defective or worn hydrostatics.
14.
Hydraulic filter is plugged.
CAUSE
1, 2
2, 3, 4, 5
2, 3, 5, 6, 7
8, 9, 10, 11
8, 11, 12, 13, 14
–3–3–
853, 853H Loader
Service Manual
HYDROSTATIC SYSTEM INFORMATION
A
CHARGE OIL
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.
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. Replacement fluid is needed because of normal internal leakage and the controlled flow to the oil cooler for cooling; Function
1 [A].
2. To keep high pressure fluid out of the low pressure side of the hydrostatic circuitry; Function 2 [A].
FUNCTION 2
Valve Stays on Seat to
Hold High Pressure for Drive
B–02804
B
Tow Valves
The loader can be moved for a short distance when the tow valves are open.
Turn the two valves open one half turn before moving the loader [B] [C].
NOTE: After moving the loader with the tow valves open, make sure the two valves are completely closed and tight because they have a direct effect on the operation of the loader drive system.
FUNCTION 1
Valve Moves for Charge
Oil Replacement
CD–11194
C
–3–4–
CD–11195
853, 853H Loader
Service Manual
FRONT PANEL
Removal And Installation
A
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
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.
W–2059–0598
Raise the operator cab. (See Page 1–1.)
Remove the mounting bolts (Item 1) [A] from the throttle lever.
Disconnect the linkage rod (Item 1) [B] from the throttle lever.
Disconnect the wire harness connectors (Item 1) [C]from the steering lever wire harness.
NOTE: The 853 without front auxiliary hydraulics does not have electric control handle.
1
C
2
1
Remove the right side steering shock (Item 2) [D].
NOTE: Early S/N loaders do not have steering panel braces (Item 3) [C]. The right side steering shock is mounted inside the steering panel.
Remove the steering panel brace bolts (Item 1) [D].
NOTE: Bolts have a nut on rear side holding panel brace.
D
1
1
3
P–09926
P–09927
P–04737
–3–5–
P–09329
853, 853H Loader
Service Manual
FRONT PANEL (Cont’d)
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].
A
2
1
3
P–09928
Remove the top mounting bolts (Item 1) [B] (both sides).
Remove the shock absorber mounting bolt (Item 2) [B].
Disconnect the shock absorber panel brace bolt (Item 3)
[B]. Remove panel brace and shock.
Installation: Connect the bottom panel brace (both sides) prior to connecting shock absorber/panel brace bolt (Item 3) [B]. Lift upward on rear edge of panel to align panel and brace.
Remove the steering cable U–bolt (Item 4) [B].
Disconnect the steering cable ball joint (Item 5) [B].
Remove the two mounting bolts (Item 1) [C] at the side of the front panel (both sides).
Remove the mounting bolt (Item 2) [C] on the bottom of the front panel.
Remove the front panel.
Installation: Align pedal link grommets in steering panel and lower cover slots (Item 3) [C].
B
C
3
3
2
4
1
2
1
5
P–04743
3
P–09330
–3–6–
853, 853H Loader
Service Manual
STEERING LEVERS
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.
A
1
P–05033
Disconnect the steering shock (Item 1) [B].
Loosen both U–bolts (Item 2) [B] at the steering lever.
Remove the steering lever.
B
Loosen both U–bolts (Item 1) [C] at the steering lever.
Remove the steering lever.
Assembly: The steering levers must be mounted flush with the back of the mounting plate (Item 3) [B].
Remove the steering shaft assembly bolts (Item 2) [C]
(both sides).
Remove the steering shaft.
C
Disassemble the right and left steering shaft from the cross shaft [D].
Install new nylon bushings (Item 1) [D] as needed at the ends of the steering shaft.
D
1
3
2
1
1
P–05034
2
P–05035
1
–3–7–
P–05039
853, 853H Loader
Service Manual
STEERING LEVERS (Cont’d)
Disassembly And Assembly (Cont’d)
Check the nylon bushing (Item 1) [A] and replace as needed.
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.
NOTE: The cams must not rotate on the mounting bolts.
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].
NOTE: Early S/N loaders do no have thr stop plate
(Item 2) [C].
A
B
3
2
1
1
P–05040
1
C
1
P–05037
2
P–05036
To remove the centering mechanism bracket from the front panel, remove the two nuts and bolts (Item 1) [D].
D
1
–3–8–
P–05038
853, 853H Loader
Service Manual
STEERING LEVERS (Cont’d)
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.)
Raise the operator cab. (See Page 1–1.)
Connect the remote start switch. (See Page 1–1.)
A
B
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–2184–0395
Check the following items (Steps 1, 2 & 3) before making any adjustments on the steering linkage:
1. Always check tire pressure and tire size before making any adjustments. Inflate tires to maximum pressure shown on the sidewall of the tire. Be sure the tires do not vary more than 1 inch (25,4 mm) in circumference [A] which could cause different rate of travel and the loader drifting to one side with both steering levers at equal travel.
2. To be sure the hydrostatic pump is in neutral, block the neutral spring bracket out with a deep socket
(approximately 7/16 inch) so you can no longer feel the linkage neutral setting [B] & [C].
3. Start the engine. Move the levers while observing the neutral position on the pump servo spool valve.
You can feel and see the spring (Item 1) [D] of the pump neutral adjustment. If the wheels do not move when the pump is in the neutral position, then the pump is correctly adjusted. Only linkage adjustment will be necessary for neutral position. If the wheels move when the pump levers are in neutral position, see Page 3–15 for the pump neutral adjustment.
4. Stop the engine. Remove the socket [B].
C
D
Detent
Bracket
1
–3–9–
P–02865
P–02866
Socket
MC–01944
P–07927
853, 853H Loader
Service Manual
STEERING LEVERS (Cont’d)
Adjusting Lever Freeplay
Read this adjustment completely to become familiar with the procedure before beginning the adjustment.
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.
1. Only the right side cam is adjustable in slotted hole in bellcrank (Item 1) [B]. The left side cam is fixed and will not require adjustment. The cam should not rotate on the mounting bolt. If cam rotates, tighten the jam nut (Item 1) [A] against the cam while holding cam mounting bolt (Item 3) [A].
2. Loose the cam mounting bolt nut (Item 2) [A] and move the cam to the rear to get free play in the left hand lever.
3. Tighten the cam bolt. Use a punch and hammer, hit the cam nut (cam mounting bolt is still tight) until the
free play is removed from the left hand lever [B].
The cam must be centered in the detent bracket pocket [C].
4. Recheck the torque at the cam bolt to be sure it is still tight. Check again to be sure there is no free play in the cams. If there is any free play the neutral
setting can not be obtained.
A
B
C
Detent
Bracket
2
1
3
P–02867
1
P–02868
Cam
MC–01944
–3–10–
853, 853H Loader
Service Manual
STEERING LEVERS (Cont’d)
Adjusting The Wheel RPM Forward Compared To
Reverse Travel
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].
2. Fully lower steering lever stop and tighten (both sides) (Item 1) [B].
NOTE: Before measuring, move the steering lever a small amount to be sure the cam is in the detent pocket with no freeplay.
A
B
1
P–07927
FORWARD
1
P–02875
3. Move the lever to full forward, measure the distance from the U–bolt to the lock nut. Record this measurement [C].
EXAMPLE ONLY: 3.66 inch (82,0 mm)
C
4. Move the lever to full reverse, measure the distance from the U–bolt to the lock nut. Make a record of this measurement [D].
EXAMPLE ONLY: 2.76 inch (70,0 mm)
D
3.66 “
(93,0 mm)
REVERSE
MC–01944
2.76 “
(70,0 mm)
–3–11–
MC–01943
853, 853H Loader
Service Manual
STEERING LEVERS (Cont’d)
Adjusting The Wheel RPM Forward Compared To
Reverse Travel (Cont’d)
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*
Divided by Two =0.45 inch (11,0 mm) Half the Travel
+2.76 inch (70,0 mm) Reverse Travel
3.21 inch (82,0 mm) Is Neutral
If adjustment is required, loosen the mounting bolts (Item
1) [B].
Moving the neutral spring bracket up will allow more forward stroke and more forward wheel RPM. Moving it down will allow more rearward stroke and more reverse wheel RPM.
A
B
3.21 “
(82,0 mm)
NEUTRAL
1
Use a screwdriver to move the neutral spring bracket
(Item 1) [C] down or a large pliers to move it up in its slotted holes.
NOTE: Keep the bracket vertical to be sure that the cams make full contact in the pocket of the detent bracket.
Tighten the mounting bolts on the spring bracket (Item 1)
[B].
Neutral to forward cable travel must be within 0.010 inch
(0,25 mm) left compared to right side.
C
1
1
Install pintle link bolts (Item 1) [D] (both sides).
D
N–00301
1
MC–01943
CD–11204
P–02875
N–00302
–3–12–
P–07927
853, 853H Loader
Service Manual
STEERING LEVERS (Cont’d)
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.
NOTE: The following adjustments (Steps a, b, c & d) are not necessary if the thread engagement in the ball joint is equal on both ends of the
cable (Item 1) [A] & [B]. a.
Disconnect the cable ball joint from the steering lever shaft (Item 2) [A].
b.
Loosen the jam nut and turn the ball joint all the way to the end of the threads (toward cable housing).
c.
At the pumps, loosen the jam nut and turn the inner cable until the ball joint is all the way to the end of the threads (toward the cable housing).
d.
Connect the steering cable ball joint.
1. Start the engine. WHEN THE ENGINE IS
RUNNING, THE WHEELS WILL BE TURNING.
A
B
C
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
2. The steering cable ends have right and left hand threads. By turning the inner cable, it will shorten or lengthen the cable. Turn the inner cable until the wheels stop turning [C].
NOTE: Before measuring, move the steering lever a small amount to be sure the cam is in the detent pocket with no freeplay.
3. Use a straight edge for a measuring reference point positioned against the pedal lock links (Item 1) [D].
Put a ruler between reference and steering lever to measure lever travel from neutral until wheel starts to travel forward. Then measure from neutral until wheel starts to travel reverse [D].
4. Adjust cable length by turning the inner cable until the two measurements are equal [C]. Tighten the jam nut (both ends).
5. Repeat the procedure for the other side of the loader.
–3–13–
D
1
1
2
P–07721
P–07723
P–02869
1
P–07724
853, 853H Loader
Service Manual
STEERING LEVERS (Cont’d)
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).
2. Start the engine.
A
B
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
3. Check wheel RPM left and right side [B]. They should be the same. If not, the stop (Item 1) [A] can be used for MINOR adjustment. Bring the stop up on the faster side until RPM is equal. (Tighten stop before re–checking) tighten remaining side in down position.
1
P–02875
P–07959
–3–14–
853, 853H Loader
Service Manual
STEERING LEVERS (Cont’d)
Hydrostatic Pump Neutral Adjustment
A
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
After the hydrostatic pump has been rebuilt, the neutral for the servo valve spool will have to be adjusted. Use the following procedure:
NOTE: The hydrostatic pump must be installed in the loader for this procedure.
B
P–02866
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
The following tool will be needed to do the following procedure:
MEL1429A – Remote Start Switch
Lift and block the loader. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Connect the remote start switch. (See Page 1–1.)
1. Block the neutral spring bracket out with a large socket (1–1/8 inch) so you can feel and see the linkage neutral setting [A] & [B].
The pump neutral adjustment bracket (Item 1) [C] controls the position of the spool lever arm (Item 2) [C] with a centering spring (Item 1) [D].
Inspect centering spring ends for damage or wear.
Replace the spring if there is excessive freeplay between spool lever arm (Item 2) [C] and spring ends (Item 1) [D].
2. Loosen the bolt (Item 2) [D] for the neutral adjustment bracket.
C
D
2
1
1
1
–3–15–
Socket
Cam
MC–01944
P–07927
2
P–07928
853, 853H Loader
Service Manual
STEERING LEVERS (Cont’d)
Hydrostatic Pump Neutral Adjustment (Cont’d)
3. Clamp the control lever to the neutral adjustment bracket with a small locking pliers [A].
A
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.
B
7. Position the neutral adjustment bracket between the two marks and tighten the holddown bolt [C].
Remove the locking pliers. Start the engine and check in both directions to be sure the pump will return to neutral.
C
8. Remove the socket from blocking the neutral spring bracket [D].
9. Adjust the steering neutral setting. (See Page
3–12.)
D
–3–16–
P–07929
P–07930
P–07931
P–02866
853, 853H Loader
Service Manual
HYDROSTATIC MOTOR
Removal And Installation
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.
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. 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
Lift and block the loader. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Remove the front tire/wheel assembly.
Remove the four mounting bolts for the motor cover (Item
1) [A].
Remove the motor cover.
Mark the hoses for correct installation.
Disconnect the case drain hose (Item 1) [B].
Disconnect the high pressure hoses (Item 2) [B].
Remove the four mounting bolts (Item 1) [C] from the motor.
Installation: Tighten the bolts to 65–70 ft.–lbs. (88–95
Nm) torque.
C
1
1
P–04804
P–04801
1
P–04802
–3–17–
853, 853H Loader
Service Manual
HYDROSTATIC MOTOR (Cont’d)
Removal And Installation (Cont’d)
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.
A
B
C
SEE THE COMPONENT REPAIR MANUAL FOR
HYDROSTATIC MOTORS FOR DISASSEMBLY AND
ASSEMBLY PROCEDURE.
1
1
1
P–04799
P–00972
P–00969
–3–18–
853, 853H Loader
Service Manual
HYDROSTATIC CHARGE OIL FILTER
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
A
B
Disconnect the temperature switch wire from the hydrostatic filter [A].
Disconnect the differential pressure switch wire from the filter [B].
Remove the inlet tubeline from the hydrostatic filter [C].
C
Disconnect the charge pump inlet hose from the filter [D].
D
–3–19–
CD–10993
CD–10994
CD–10995
CD–10996
853, 853H Loader
Service Manual
HYDROSTATIC CHARGE OIL FILTER (Cont’d)
Removal And Installation (Cont’d)
Remove the four mounting bolts [A].
Installation: Tighten the mounting bolts to 25 ft.–lbs. (34
Nm) torque.
A
Remove the hydrostatic filter and housing [B].
B
CD–10997
Cd–10998
–3–20–
853, 853H Loader
Service Manual
COLD OIL BY–PASS VALVE
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
A
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.
Disconnect the cold oil by–pass valve outlet tubeline [B].
Disconnect the charge pump outlet hose from the tee on the by–pass valve [C].
C
Disconnect the oil cooler inlet tubeline from the tee fitting
[D].
D
–3–21–
CD–10999
CD–11000
CD–11001
CD–11002
853, 853H Loader
Service Manual
COLD OIL BY–PASS VALVE (Cont’d)
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.
Remove the by–pass valve mounting bolt and remove the valve [B].
A
B
CD–11003
CD–11004
–3–22–
853, 853H Loader
Service Manual
HYDROSTATIC PUMP
Removal And Installation
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].
A
1
Loosen the tensioner pulley nut (Item 1) [B].
Remove the drive belt (Item 2) [B].
Installation: Tighten the drive belt to the correct specifications. (See Page 3–32 or 3–41.)
2
1
B
2
1
P–04924
1
Remove the washer and nut (Item 1) [C] from the hydrostatic pump drive shaft.
Installation: Tighten the nut to 175–200 ft.–lbs.
(237–271 Nm) torque.
Install the nut on the end of the pump drive shaft (without washer).
Use a puller (Item 1) [D] to remove the pulley from the pump drive shaft.
–3–23–
C
D
P–04926
1
P–04931
1
P–04932
853, 853H Loader
Service Manual
HYDROSTATIC PUMP (Cont’d)
Removal And Installation (Cont’d)
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.
A
1
2
1
P–04933
B
1
P–04935
Remove the mounting bolt (Item 1) [C] at the hydraulic pump end of the pump.
Remove the hydrostatic pump from the mounting bracket and drive belt housing.
SEE THE COMPONENT REPAIR MANUAL FOR
HYDROSTATIC PUMPS FOR DISASSEMBLY AND
ASSEMBLY PROCEDURE.
C
1
P–04946
–3–24–
853, 853H Loader
Service Manual
HYDROSTATIC PUMP (Cont’d)
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.
A
1
Remove the plug spring and high pressure relief valve from the pump [B].
Check for damage and replace as needed.
Ref.
1.
2.
3.
4.
Description
PLUG
O–RING
SPRING
HIGH PRESSURE RELIEF
B
4
3
2
1
P–04936
P–04938
–3–25–
853, 853H Loader
Service Manual
DRIVE BELT SHIELD
Removal And Installation
Stop the engine.
Open the rear door.
Remove the three belt shield holddown clips (Item 1) [A].
A
1
Remove the belt shield (Item 1) [B] from the drive belt housing.
B
1
1
P–05041
P–05096
–3–26–
853, 853H Loader
Service Manual
DRIVE BELT
Replacing The Drive Belt
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.
A
Remove the drive belt from the hydrostatic pump pulley and flywheel pulley.
Remove the drive belt [B].
Installation: Install the new drive belt and adjust. (See
Page 3–32 or 3–41.)
B
2
3
1
P–04926
B–05095
–3–27–
853, 853H Loader
Service Manual
SPRING LOADED TENSIONER PULLEY
Parts Identification
1. Cover
2. Bolt
3. Washer
4. Pins
5. Washer
6. Spring
7. Snap Ring
8. Snap Ring
9. Bearing
10. Dust Shield
11. Pulley
12. Bushing
13. Hub
14. Washer
15. Seal
16. Arrow Indicator Plate
17. Locating Pin
18. Spring
19. Shaft
20. Bracket
NOTE: Drive idler parts are not available individually. Consult parts catalog for available sub–assemblies.
6
5
3
1
4
2
5
7
8
9
10
17
12
11
14
15
16
13
18
19
Revised Feb. 99
–3–28–
20
E–02296
853, 853H Loader
Service Manual
SPRING LOADED TENSIONER PULLEY (Cont’d)
Disassembly
Remove the grease cover (Item 1) [A].
A
1
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
2
3
P–08858
5
1
Remove the two pins (Item 1) [C] from the hub assembly
(Item 2) [C] only if they have been damaged.
Remove the bracket assembly (Item 3) [C] by tapping on the shaft (Item 4) [C] with a plastic hammer.
C
4
2
3
4
1
P–08859
P–08861
Remove the spring (Item 1) [D] from the bracket (Item 2)
[D].
D
2
1
–3–29–
P–08862
853, 853H Loader
Service Manual
SPRING LOADED TENSIONER PULLEY (Cont’d)
Assembly
Install the spring (Item 1) [A] on the pulley (Item 2) [A] as shown.
A
1
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
Turn the pulley assembly over and install the two pins
(Item 1) [C] into the hub.
C
3
2
P–08871
1
2
P–08872
1
P–08873
Install a punch as shown and turn clockwise while applying down pressure on the pulley.
Turn until the pulley snaps down into place; this procedure winds the spring and retains the end of the spring in proper location [D].
D
–3–30–
P–08874
853, 853H Loader
Service Manual
SPRING LOADED DRIVE BELT TENSIONER PULLEY
(Cont’d)
Assembly (Cont’d)
Install the first retainer washer (Item 1) [A] and spring washer (Item 2) [A] over the roll pins.
A
2
1
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.
Fill the grease cap 1/4 full (approximately 1/2–3/4 oz.) of grease.
B
1
3
2
P–08875
P–08876
Press the grease cap (Item 1) [C] onto the pulley assembly (Item 2) [C]. Press on the outer formed edge of the grease cap.
NOTE: When pressing the grease cap onto the pulley assembly, do not press down on the arrow indicator plate. Support the hub assembly so that it contacts only the hub and not the arrow indicator plate.
C
1
2
P–08877
–3–31–
853, 853H Loader
Service Manual
SPRING LOADED TENSIONER PULLEY (Cont’d)
Adjusting The Drive Belt
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.
Pull the idler pulley against the drive belt, with the adjusting nut (Item 2) [A], until the pointer is at the nine o’clock position (Item 2) [B], lower the idler assembly a small amount so that the idler is operating on spring tension.
Tighten the mounting bolt (Item 1) [A] to 25–28 ft.–lbs.
(34–38 Nm) torque.
Run the engine for a few minutes. Stop the engine and check the pointer position.
Adjust the idler assembly as needed.
After the spring loaded tensioner pulley has been in service, readjust when the pointer reaches the seven o’clock position.
A
2
B
2
1
1
C–03519
P–07019
–3–32–
853, 853H Loader
Service Manual
FIXED TENSIONER PULLEY
Removal And Installation
Remove the three belt shield holddown clips (Item 1) [A].
Remove the belt shield.
A
1
Loosen the tensioner pulley mounting bolt (Item 1) [B].
Loosen the jam nut and lock nut (Item 2) [B].
Remove the drive belt.
Installation: Tighten the drive belt to the correct specifications. (See Page 3–41.)
B
1
Remove the jam nut and lock nut (Item 1) [C].
Remove the mounting bolt (Item 2) [C].
Remove the tensioner pulley assembly.
C
1
P–04924
2
1
1
P–04926
2
P–04929
–3–33–
853, 853H Loader
Service Manual
FIXED TENSIONER PULLEY (Cont’d)
Disassembly
NOTE: Be careful, the pulley hub is full of oil.
Remove the cap [A].
A
Remove the bolt and washer [B].
B
Install a long bolt into the shaft [C].
C
Remove the idler pulley and bearing from the shaft using a press [D].
D
–3–34–
CD–12634
CD–12635
CD–12636
CD–12637
853, 853H Loader
Service Manual
FIXED TENSIONER PULLEY (Cont’d)
Disassembly (Cont’d)
Install a bearing puller behind the seal and wear sleeve
[A].
A
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
Remove the bearing, seal and wear sleeve using the press [C].
C
CD–12638
CD–12639
CD–12640
–3–35–
853, 853H Loader
Service Manual
FIXED TENSIONER PULLEY (Cont’d)
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].
A
Use a driver tool (1–5/16’’ diameter) and push the spacer into the machined groove [B].
B
Install the bearing cup using the driver tool (both sides)
[C].
NOTE: The seal side of the pulley hub has the larger
I.D. diameter.
C
Install the taper roller bearing to the pulley (seal side) [D].
D
–3–36–
CD–12641
CD–12642
CD–12643
CD–12644
853, 853H Loader
Service Manual
FIXED TENSIONER PULLEY (Cont’d)
Assembly (Cont’d)
Put sealant (P/N 6633538) around the diameter of the shaft where the wear sleeve is installed [A].
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
Press the seal into the pulley hub larger diameter using a press [C].
NOTE: The wear sleeve and the seal must be replaced as a unit.
DO NOT damage the seal lips with the sharp edge of the wear sleeve. Install the wear sleeve into the seal.
C
Use a spacer tube which goes over the shaft and pushes on the inside diameter of the taper bearing, install the pulley, seal and wear sleeve onto the shaft [D].
D
1
MC–01648
CD–12646
–3–37–
CD–12647
853, 853H Loader
Service Manual
FIXED TENSIONER PULLEY (Cont’d)
Assembly (Cont’d)
Install the small bearing spacer [A].
A
Install the taper roller bearing pushing on the I.D. of the bearing [B].
B
Put LOCTITE (P/N 6540410) on the bolt threads [C].
C
Install the bolt and washer into the shaft [D].
D
–3–38–
CD–12648
CD–12649
CD–12650
CD–12651
853, 853H Loader
Service Manual
FIXED TENSIONER PULLEY (Cont’d)
Assembly (Cont’d)
Tighten the bolt to 25–28 ft.–lbs. (43–38 Nm) torque [A].
A
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
0.50’’ (12,7)
CD–12652
Add the oil slowly, at one location of the bearing which will allow the trapped air to escape from the other side [C].
NOTE: Oil capacity is very critical, do not add any more and/or any less oil to the idler pulley.
C
OIL LEVEL
MC–01648
MC–01648
Check the cap sealing edge to make sure it is not damaged. Replace the cap as needed.
Make sure the sealing edge on the hub bore and cap sealing edge is clean and free of oil, put a bead of sealant
(P/N 6633538) on the cap [D].
Install the cap.
D
–3–39–
CD–12653
853, 853H Loader
Service Manual
FIXED TENSIONER PULLEY (Cont’d)
Checking Pulley End Play
Install the pulley/mounting bracket assembly in to vise.
Install a dial indicator on the pulley hub [A].
A
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.
B
CD–12655
CD–12656
–3–40–
853, 853H Loader
Service Manual
FIXED TENSIONER PULLEY (Cont’d)
853, 853H Service Manual #6720755 – Hydrostatic System Section Part 1 of 2
Adjusting The Drive Belt
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.)
Use the following tools to check the belt tension:
MEL1404 – Bar
MEL1406 – Spring Scale
1. Install the tool on the drive belt. The pin (Item 1) [A] must be pulled tight against the engine drive pulley.
2. Make a mark (Item 2) [A] on the cast flange just above the tool handle.
3. Install the spring scale on the tool handle. The line of pull (Item 3) [A] on the spring scale must be at approximately 90
°
from the tool handle.
4. Loosen bolt (Item 4) [A] and jam nut (Item 5) [A].
5. Tighten adjustment nut (Item 6) [A] to increase belt tension; loosen to decrease belt tension.
6. Tighten bolt (Item 4) [A] and jam nut (Item 5) [A].
NEW BELT: (less than .5 hours use): With 14 lbs. (62 N) for force, the tool should move 1.25 inches (32,0 mm) (the width of the tool handle). Run the engine approximately
5 minutes and readjust the tension.
USED BELT: (more than .5 hours use): With 12 lbs. (52
N) of force, the tool should move 1.25 inches (32,0 mm)
(the width of the tool handle).
Always readjust if a tension check results in a reading of less than 10 lbs. (44N) of force.
A
1
1.25 ” (32,0 mm)
3
90 o
2
5
6
4
P–04927
B–13459
–3–41–
853, 853H Loader
Service Manual
OIL COOLER
Removal And Installation
Disconnect the tubeline (Item 1) [A] from the oil cooler.
A
1
Disconnect the tubeline (Item 1) [B] from the oil cooler.
B
P–04884
1
P–04885
Install caps and plugs on open connections.
Remove the oil cooler [C].
C
P–04887
–3–42–
853, 853H Loader
Service Manual
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–26
FRONT CHAINCASE COVER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
PARKING BRAKE
Brake Block And Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4–6
4–7
4–4
PARKING BRAKE PEDAL
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
REAR CHAINCASE COVER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
REDUCTION GEARCASE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Reduction Gearcase
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reduction Gearcase Seal
Removal And Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4–22
4–17
4–17
4–15
4–15
DRIVE
SYSTEM
–4–1–
853, 853H Loader
Service Manual
–4–2–
853, 853H Loader
Service Manual
PARKING BRAKE PEDAL
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.
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.
Adjust the pedal so there is 2.0 inch (51 mm) from the top of the pedal to the top of the chaincase cover [B].
Tighten the lock nut against the adjustment nut when the adjustment is correct.
NOTE: If the correct brake adjustment can not be obtained by turning the nut, the brake lever must be adjusted using the following procedure.
Loosen the nut (Item 1) [A].
Disconnect the spring (Item 1) [C] from the brake lever.
Loosen the bolt (Item 2) [C] on the brake lever. Do not remove the bolt.
A
B
C
2.0 “
(51 mm)
1
CD–11014
Lift release pedal to remove linkage end play
B–13820
1
2
CD–11015
Use a pry bar and hammer, pry up on the lever and hit the bolt with a hammer until the brake lever is loose [D].
Remove the bolt and brake lever.
Turn the brake block shaft counterclockwise until the brake pads make contact with the brake discs.
Install the brake lever. Install the bolt and tighten to 65–70 ft.–lbs. (88–95 Nm) torque.
Re–adjust the parking brake.
D
–4–3–
CD–11016
853, 853H Loader
Service Manual
PARKING BRAKE
Removal And Installation
A
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
Raise the operator cab. (See Page 1–1.)
Remove the bolt and nut from the lift pedal linkage [A].
Disconnect the lift linkage from the control valve spool
[B].
B
CD–10989
CD–10937
Remove the pivot bolt from the lift linkage cross–member and remove the cross–member linkage (Item 1) [C].
C
1
Remove the nylon washer (Item 1) [D].
Installation: Check the nylon washer and bushing (Item
2) [D] for wear and replace as needed.
D
–4–4–
CD–10988
2
1
CD–11017
853, 853H Loader
Service Manual
PARKING BRAKE (Cont’d)
Removal And Installation (Cont’d)
Remove the nuts from the brake linkage rod [A].
A
Disconnect the brake lever spring and remove the spring
(Item 1) [B], retainer plate (Item 2) [B] and bolt (Item 3)
[B].
Installation: Tighten the brake lever bolt to 65–70 ft.–lbs.
(88–95 Nm) torque.
Remove the cover bolts [B].
B
Remove the cover/brake block assembly [C].
Installation: Clean and dry the cover. Clean the surface on the chaincase where the cover sets.
Install a new gasket on the cover/brake block assembly.
C
CD–11014
3
2
1
CD–11018
CD–11019
–4–5–
853, 853H Loader
Service Manual
PARKING BRAKE (Cont’d)
Brake Block And Pads
Remove the brake lever [A].
A
Loosen the brake pad bolts and remove the bolts [B].
Installation: Tighten the bolts to 65–70 ft.–lbs. (88–95
Nm) torque.
B
Remove the guide and pads [C].
Check the pads for wear and replace them as needed.
C
CD–11020
CD–11021
CD–11022
Remove the bolts which fasten the brake block to the cover [D].
Installation: Tighten the bolts to 65–70 ft.–lbs. (88–95
Nm) torque.
D
–4–6–
CD–11023
853, 853H Loader
Service Manual
PARKING BRAKE (Cont’d)
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.
A
CD–11024
Remove the shaft from the brake block [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.
Brake Discs
To remove the parking brake discs [C], use the following procedure:
MEL1242 – Port–a–Power tool is needed for the removal procedure.
B
C
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
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.)
Remove the parking brake/cover assembly. (See Page
4–4.)
Remove the front and rear covers. (See Page 4–8.)
Remove the fluid from the chaincase. (See page 4–27.)
Remove the hydrostatic motor. (See Page 3–1.)
Remove the rear and front axles. (See Page 4–11.)
Disconnect the rear and front drive chains.
Move the gearcase away from the chaincase to slide the brake discs off.
–4–7–
1
CD–11025
CD–11026
853, 853H Loader
Service Manual
FRONT CHAINCASE COVER
Removal And Installation
Disconnect the brake pedal/linkage rod assembly [A].
A
Remove the front cover mounting bolts [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.
B
REAR CHAINCASE COVER
Removal And Installation
Remove the rear cover mounting bolts and remove the rear cover plate from the chaincase [C].
Installation: Clean and dry the cover. Clean the surface on the chaincase. Install a new gasket on the rear cover.
C
CD–08824
CD–11027
N–11029
–4–8–
853, 853H Loader
Service Manual
AXLE SEAL
Removal And Installation
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.
Installation: Tighten the bolts to 175–190 ft.–lbs.
(240–260 Nm) torque.
Remove the two wheel studs (Item 2) [A] across from each other.
Install puller (Item 1) [B] on the wheel hub.
B
A
2
1
NEVER STAND IN–LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a tapered fit on the axle end and can come off the axle with great force and cause serious injury.
W–2186–0395
Remove the hub from the axle.
Remove the key (Item 1) [C] from the axle.
C
1
1
2
P–04850
P–04849
P–04848
D
Drill a hole into the axle seal [D].
–4–9–
P–04815
853, 853H Loader
Service Manual
AXLE SEAL (Cont’d)
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
If the axle is damaged or worn, an axle repair sleeve kit is available from Melroe Parts Sales in Chicago.
NOTE: If a new wear ring is being installed with new seal, put LOCTITE sealant on the inside diameter of the wear ring.
Place the taper on the wear ring so it faces the outside [B].
Place the seal with the lip facing in [B].
A
B
1
Taper
P–04817
B–13493
Use a hammer, install the new axle seal until the tool is flush with the edge of the axle tube [C].
C
P–04814
–4–10–
853, 853H Loader
Service Manual
AXLE, SPROCKET AND BEARINGS
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).
A
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
Lift and block the loader. (See Page 1–1)
Remove the front panel/steering lever assembly. (See
Page 3–1.)
Remove the front cover. (See Page 4–8.)
Remove the fluid from the chaincase. (See Page 4–27.)
Loosen the axle sprocket bolt (Item 1) [A].
Installation: Tighten the axle sprocket bolt to 475–525 ft.–lbs. (644–710 Nm) torque.
Remove the bolts (Item 1) [B] and plate.
Installation: Tighten the bolts to 175–190 ft.–lbs.
(240–260 Nm) torque.
Remove the two wheel studs (Item 2) [B] across from each other.
Install a puller (Item 1) [C] on the wheel hub.
C
NEVER STAND IN–LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a tapered fit on the axle end and can come off the axle with great force and cause serious injury.
W–2186–0395
Remove the hub from the axle.
Install a Port–a–Power ram between the two sprockets
[D].
–4–11–
D
B
2
1
1
1
2
P–04810
P–04850
P–04849
P–04809
853, 853H Loader
Service Manual
AXLE, BEARINGS AND SPROCKET (Cont’d)
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.
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.
A bearing puller (Item 1) [B] is needed to do the following procedure:
Be sure the bearing puller makes good contact with the inner race and press the bearing off the mounting surface of the axle [B].
NOTE: Hold onto the axle during removal as it will slide freely after the bearing is removed from the mounting surface.
A
B
1
Press the splined end of the axle free from the bearing
[C].
C
2
1
P–04808
P–04170
Installation: Put the spline end of the axle shaft into the bearing and press the bearing onto the axle.
NOTE: Hold onto the axle during installation as it will slide freely after the bearing is pressed over the splined end of the shaft.
Put a piece of tubing (Item 1) [D] that contacts inner race of the bearing only.
Press the bearing onto the mounting surface until the bearing is fully seated [D].
–4–12–
D
P–04171
1
P–04175
853, 853H Loader
Service Manual
AXLE, BEARINGS AND SPROCKET (Cont’d)
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].
A
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].
Pull the tool against the bearing cup and tighten the nut.
B
Use the slide hammer and remove the bearing cup from the axle tube [C].
C
P–04812
P–04818
P–04816
–4–13–
853, 853H Loader
Service Manual
AXLE, BEARING AND SPROCKET (Cont’d)
Removal And Installation (Cont’d)
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].
Install the nut (Item 3) [A].
A
Install the installation tool (Item 1) [B] on the threaded rod. Install the nut.
Hold the inside nut (Item 3) [A] with a wrench and tighten the outside nut [B].
Tighten the nut until the bearing cup is installed inside the axle tube.
Remove the installation tools and threaded rod.
B
2
3
1
1
To install the outer bearing cup, install the bearing cup tool on the driver handle.
Install the bearing cup into the axle tube, and put the tool into the bearing cup.
Hit the driver handle with a hammer until the bearing cup is installed inside the axle tube [C].
C
2
P–04807
P–04811
P–04813
–4–14–
853, 853H Loader
Service Manual
REDUCTION GEARCASE
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].
Install a slide hammer with a screw tip end into the seal
[B].
Remove the reduction gearcase seal.
A
B
Install the new quad ring on the installation tool.
Install the backup washer.
Use a hammer, hit the installation tool until the quad ring is fully seated [C].
C
P–04795
P–04798
P–04806
–4–15–
853, 853H Loader
Service Manual
REDUCTION GEARCASE (Cont’d)
Removal And Installation
A
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
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.)
Remove the hydraulic control valve if the right side reduction gearcase is removed. (See Page 2–1.)
Remove the center cover. (See Page 4–4.)
Remove the front cover. (See Page 4–7.)
Remove the fluid from the chaincase. (See Page 4–27.)
Remove the hydrostatic motor. (See Page 3–1.)
Remove the front axle. (See Page 4–11.)
Remove the reduction gearcase mounting bolts (Item 1)
[A].
Installation: Tighten the mounting bolts to the following torque:
3/4 inch Bolt – 220–245 ft.–lbs. (300–330 Nm)
1/2 inch Bolt – 65–70 ft.–lbs. (88–95 Nm)
Remove the front and the rear drive chains from the cluster sprocket.
Connect a chain hoist as shown in figure [B].
Remove the reduction gearcase from the chaincase [B].
Installation: Make sure the large ring (Item 1) [C] and the
O–ring (Item 2) [C] are in position before tightening the bolts.
B
C
–4–16–
1
2
1
P–04805
P–04819
P–04797
853, 853H Loader
Service Manual
REDUCTION GEARCASE (Cont’d)
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.
A
Install the dial indicator on the output shaft [B]. 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.
Remove the seal (See Page 4–15.)
B
Install a feeler gauge between the teeth of the gears [C].
The back lash must be between 0.003–0.009 inch
(0,076–0,228 mm.) If not, the following parts may need replacing: Large gear or the shaft.
Measure the bore diameter for the seal. Correct diameter is 3.750
±
0.001 inch (95,25
±
0,025 mm.) Install a dial indicator on the input shaft. Set the indicator so the stylus is against the pilot bore for the drive motor. Rotate the shaft 360 degrees. Maximum run–out should not exceed
0.009 inch (0,23 mm.) If either check (Bore I.D. &
Run–Out) is not within these specifications, replace the gearbox.
Disassembly
The tool listed will be needed to do the following procedure:
MEL1047 – Seal Installation Tool
Remove the bolts from the end plate [D].
C
D
–4–17–
B–13458
B–13457
B–08673
B–08705
853, 853H Loader
Service Manual
REDUCTION GEARCASE (Cont’d)
Disassembly (Cont’d)
Remove the end plate [A].
A
Remove the dust cap [B].
B
B–08704
B–08728
Loosen the bolt from the output shaft [C].
C
Remove the bolt and washer [D].
D
–4–18–
B–08721
B–08727
853, 853H Loader
Service Manual
REDUCTION GEARCASE (Cont’d)
Disassembly (Cont’d)
Remove the bolt from the disc hub [A].
A
Remove the bolt and washer [B].
B
B–08751
B–08752
Remove the disc hub and key [C].
C
B–08750
Put the gearcase housing in the press and remove the output shaft [D].
D
–4–19–
B–08682
853, 853H Loader
Service Manual
REDUCTION GEARCASE (Cont’d)
Disassembly (Cont’d)
Remove the bearing [A].
A
Remove the spacer [B].
B
Remove the output shaft [C].
C
Remove the large gear [D].
D
–4–20–
B–08707
B–08706
B–08749
B–08722
853, 853H Loader
Service Manual
REDUCTION GEARCASE (Cont’d)
Disassembly (Cont’d)
Remove the bearing at the input shaft [A].
A
Use a press and remove the input shaft [B].
B
B–08745
B–08679
Remove the input shaft assembly from the housing [C].
C
B–08744
Use a punch and hammer and remove the bearing cups as needed [D].
D
–4–21–
B–08678
853, 853H Loader
Service Manual
REDUCTION GEARCASE (Cont’d)
Assembly
Using a press and bearing cup tool, install the bearing cup in the housing.
Install the input shaft [A].
A
Install the bearing on the input shaft [B].
B
Install the large gear into the housing [C].
C
Install the output shaft into the housing and large gear [D].
D
–4–22–
B–08744
B–08745
B–08722
B–08749
853, 853H Loader
Service Manual
REDUCTION GEARCASE (Cont’d)
Assembly (Cont’d)
Install the spacer [A].
A
Install the bearing [B].
B
B–08706
B–08707
Put LOCTITE on the bolt.
Install the bolt and washer [C].
C
B–08727
Tighten the bolt to 210–235 ft.–lbs. (285–305 Nm) torque
[D].
Put Boretite sealant on the edge of the dust cup and install the dust cup into the housing.
D
–4–23–
B–08721
853, 853H Loader
Service Manual
REDUCTION GEARCASE (Cont’d)
Assembly (Cont’d)
Install the key and hub on the input shaft [A].
A
Put LOCTITE #242 adhesive on the bolt threads.
Install the bolt and washer [B].
B
Tighten the bolt to 210–235 ft.–lbs. (285–305 Nm) torque
[C].
C
Instal the end plate on the housing [D].
D
–4–24–
B–08750
B–08752
B–08751
B–08704
853, 853H Loader
Service Manual
REDUCTION GEARCASE (Cont’d)
853, 853H Service Manual #6720755 – Drive System Section Part 1 of 2
Assembly (Cont’d)
Install the end plate bolts and tighten to 13–14 ft.–lbs.
(Nm) torque [A].
A
Install a new quad ring. Install the backup washer [B].
B
Install the new seal using the seal installation tool [C].
C
B–08705
B–08675
B–08734
–4–25–
853, 853H Loader
Service Manual
DRIVE CHAIN
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
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.)
Remove the center chaincase cover. (See Page 4–5.)
Remove the front and rear chaincase cover. (See Page
4–8.)
Remove the fluid from the chaincase. (See Page 4–27.)
Remove the rear axle. (See Page 4–11.)
NOTE: It is necessary to remove the rear axle and drive chain [A]. If the front chain has to be removed.
A
Front Drive
Chain
Rear Drive
Chain
P–04805
–4–26–
853, 853H Loader
Service Manual
CHAINCASE FLUID
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.
A
Remove the drain plug (Item 1) [B] and drain the oil into a container.
Check the drain plug and replace if necessary.
B
1
1
P–1616
P–1619
–4–27–
853, 853H Loader
Service Manual
–4–28–
853, 853H Loader
Service Manual
MAIN FRAME
Page
Number
BOB–TACH
Bob–Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9
Bob–Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation
5–10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
FUEL TANK
Fuel Level Sender
Inlet Screen
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5–16
5–16
5–15
LIFT ARMS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11
OPERATOR CAB
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
OPERATOR CAB GAS CYLINDER
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5–4
5–3
REAR DOOR
Bumper Removal And Installation
Door Latch And Catch Adjustment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hood Removal And Installation
Removal And Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5–14
5–14
5–14
5–14
5–13
REAR GRILL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12
MAIN
FRAME
–5–1–
853, 853H Loader
Service Manual
–5–2–
853, 853H Loader
Service Manual
OPERATOR CAB GAS CYLINDER
Removal And Installation
A
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
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).
NOTE: Be careful not to break the rear window when the cab is raised after the cab stops are removed.
Raise the operator cab (See Page 1–1).
Remove the nuts (Item 1) [B] from the gas cylinder mounting bracket.
Move the mounting bracket to relieve any remaining tension on the gas cylinder [C].
C
1
1
CD–15014
CD–15015
Remove the cotter pin (Item 1) [D] from the top pivot pin.
Remove the pivot pin and bushing from the gas cylinder.
Remove the gas cylinder.
D
CD–15016
1
–5–3–
CD–15173
853, 853H Loader
Service Manual
OPERATOR CAB GAS CYLINDER (Cont’d)
Disassembly And Assembly
A
Cylinder contains high pressure gas. Do not open. Opening cylinder can release rod and cause injury or death.
W–2113–0288
Remove the clevis (Item 1) [A] and washer (Item 2) [A] from the end of the gas cylinder.
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].
Reinstall the washer and clevis on the cylinder rod.
B
1
2
P–01008
P–01006
–5–4–
853, 853H Loader
Service Manual
OPERATOR CAB
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).
A
Disconnect the wiring harness connectors (Item 1) [B].
Disconnect the ground wire (Item 2) [B].
B
1
1
CD–15125
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].
C
Revised June 97
–5–5–
P–05051
853, 853H Loader
Service Manual
OPERATOR CAB (Cont’d)
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).
A
1
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].
B
1
Connect the slings to a chain hoist and remove the operator cab from the loader [C].
C
P–05048
P–05049
–5–6–
P–05050
853, 853H Loader
Service Manual
BOB–TACH
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].
A
Remove the retainer bolt (Item 1) [B] from the pivot pin.
Installation: Tighten the retainer bolt to 18–20 ft.–lbs.
(24–27 Nm) torque.
B
1
CD–15075
1
P–04601
Remove the grease fitting from the pivot pin (Item 1) [C].
Remove the rod end pivot pin (Item 1) [C].
C
1
P–03915
Remove the tilt cylinder rod end.
Remove the seals (Item 1) [D].
D
–5–7–
1
P–03911
853, 853H Loader
Service Manual
BOB–TACH (Cont’d)
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.
A
NOTE: Removal procedure is shown for the right side. Left side procedure is the same.
Remove the grease fitting (Item 1) [B] from the Bob–Tach frame for the pivot pin (both sides) [C].
NOTE: The grease fitting must be removed to prevent the pivot pin from being hydraulic locked in the Bob–Tach frame.
Loosen the bolt (Item 2) [B] at the Bob–Tach pivot pin.
Installation: Tighten the bolt to 250–260 ft.–lbs.
(339–353 Nm) torque.
Strike the head of the bolt (Item 2) [B] to push the pivot pin into the Bob–Tach frame.
Remove the bolt (Item 2) [B].
Use a punch to push the pivot pin all the way into the
Bob–Tach frame.
Installation: A longer bolt is necessary to install through lift arms into the pivot pin, to pull the pivot pin into the lift arms.
NOTE: Use tapered reamer MEL1233 to clean the tapered hole in the lift arms. The tapered hole must be clean and free of debris to provide a good contact surface for the pivot pin.
Remove the Bob–Tach frame from the lift arms [C].
Remove the seal dust cup (Item 1) [C].
Remove the rubber seal [D].
B
C
D
2
1
1
P–03910
P–03913
P–03908
–5–8–
P–03909
853, 853H Loader
Service Manual
BOB–TACH (Cont’d)
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.
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].
Reverse the removal procedure to install the Bob–Tach.
Bob–Tach Lever And Wedge
Use the following procedure to remove and install the
Bob–Tach lever (Item 1) [B], spring and wedge:
A
B
1
2
3
P–03912
Remove the lever mounting bolt and nut (Item 1) [C], washer (Item 2) [C] and spring (Item 3) [C].
Installation: Tighten the nut to 25–28 ft.–lbs. (34–38 Nm) torque.
C
Remove the Bob–Tach lever (Item 1) [D].
D
1
2
3
1
P–03930
P–03928
–5–9–
1
P–03924
853, 853H Loader
Service Manual
BOB–TACH (Cont’d)
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.
A
1
P–03925
Remove the spring, bolt and clevis assembly (Item 1) [B].
Remove the wedge (Item 2) [B] from the Bob–Tach frame.
Always replace bent or broken wedges.
B
2
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. Loosen and remove the bolt (Item
1) [C] with a 5/16 inch allen wrench.
Replace the worn or damaged parts as needed.
Reverse the removal procedure to install the Bob–Tach
Lever and Wedge.
C
D
4
3
Bob–Tach Stops
Remove and replace the Bob–Tach stop (Item 1) [D]
(both sides) if worn or damaged.
NOTE: The Bob–Tach stop (Item 1) [D] must contact the lift arm at the same time the tilt cylinder reaches full extension. Use available shims to adjust the Bob–Tach stop and tilt cylinder sequence as closely as possible.
1
–5–10–
P–03926
2
1
P–03929
1
P–03914
853, 853H Loader
Service Manual
LIFT ARMS
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).
Install the slings (Item 2) [A] on the lift arms.
Connect a chain hoist to the slings [A].
A
2
2
1
P–05052
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.
Raise the lift arms with the chain hoist so there is enough clearance to remove the rod end pivot pin.
Remove the lift cylinder rod end pivot pin (both sides).
Lower the lift arms.
B
1
CD–15169
Disconnect the auxiliary hydraulic tubelines and hoses
(Item 1) [C] if so equipped (both sides).
Remove the retainer bolt and nut (Item 2) [C] from the lift arm pivot pin.
Installation: Tighten the retainer bolt and nut to 18–20 ft.–lbs. (24–27 Nm) torque.
Remove the lift arm pivot pin.
Raise the lift arms with the chain hoist and remove from the loader frame.
C
–5–11–
1
2
P–05053
853, 853H Loader
Service Manual
REAR GRILL
Removal And Installation
A
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.
Support the rear grill.
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).
B
Remove the pivot pin (Item 1) [C] (both sides).
C
1
Remove the rear grill from the loader [D].
D
1
P–04881
1
P–04882
P–04883
–5–12–
P–04886
853, 853H Loader
Service Manual
REAR DOOR
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.
A
1
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.
Remove the rear door pivot bolts.
Lift the rear door away from the loader frame and put the door flat on the floor.
B
2
1
2
P–05041
–5–13–
P–05042
853, 853H Loader
Service Manual
REAR DOOR (Cont’d)
Hood Removal And Installation
Remove the rear lights harness from the rear door hood if so equipped.
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.
Bumper Removal And Installation
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. (21–23 Nm) torque.
Remove the bumper (Item 2) [B] from the rear door.
A
B
2
1
P–05043
1
P–04281
Door Latch Removal And Installation
Remove the door latch mounting bolts (Item 1) [C] from the door latch mechanism.
Installation: Tighten the mounting bolts to 80–90 in.–lbs.
(9–10 Nm) torque.
Remove the latch and handle mechanisms from the rear door.
Door Latch And Catch Adjustment
C
AVOID INJURY
Never service or adjust the machine when the engine is running unless instructed to do so in the manual.
W–2012–0290
The door catch (Item 1) [D] can be adjusted side to side for alignment with the door latch.
The door latch mechanism (Item 1) [C] can be adjusted forward or backward for alignment with the door catch.
D
1
–5–14–
1
P–05044
P–05045
853, 853H Loader
Service Manual
FUEL TANK
Removal And Installation
Remove the cover (Item 1) [A] which is installed over the drain plug.
A
1
P–01616
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).
B
1
C
Disconnect the fuel fill hose (Item 1) [C].
Disconnect the tank vent hose (Item 2) [C].
Remove the bolts (Item 1) [D] from the battery holddown plate.
Remove the battery holddown plate from the loader.
D
1
1
2
P–01619
P–04855
–5–15–
P–04959
853, 853H Loader
Service Manual
FUEL TANK (Cont’d)
Removal And Installation (Cont’d)
Remove the mounting plate (Item 1) [A] for the battery holddown plate.
A
1
Lift the fuel tank and remove it from the loader frame [B].
Fuel Level Sender
Loosen the fuel level sender (Item 1) [B].
B
1
P–04960
P–04961
Remove the fuel level sender from the fuel tank [C].
C
Inlet Screen
The inlet screen (Item 1) [D] is located at fuel tank fill neck.
Disconnect the fuel fill hose.
Remove the inlet screen (Item 1) [D].
Wash the screen in clean solvent.
Dry the screen and check for damage. Replace as needed.
–5–16–
D
P–07922
1
P–05007
853, 853H Loader
Service Manual
ELECTRICAL SYSTEM
Page
Number
ALTERNATOR
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Regulator Test
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation
Rotor Continuity Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6–15
6–10
6–11
6–13
6–10
6–14
6–12
6–14
6–14
6–13
6–13
BATTERY
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . .
6–7
6–8
6–9
ELECTRICAL SYSTEM INFORMATION
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6–6
6–6
FRONT LIGHTS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–23
STANDARD INSTRUMENT PANEL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–22
STARTER
Checking The Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly And Assembly
Parts Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6–16
6–21
6–19
6–18
6–17
STEERING LEVER CONTROL HANDLE (Early Series)
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
ELECTRICAL
SYSTEM
–6–1–
853, 853H Loader
Service Manual
–6–2–
853, 853H Loader
Service Manual
–6–3–
853, 853H Loader
Service Manual
–6–4–
853, 853H Loader
Service Manual
853 BOSS - WIRING SCHEMATIC
S/N 508411001-11010
(Printed June 1999)
MC2561
RIGHT HANDLE
(IF EQUIPPED)
DETENT
FRONT AUX.
CONTROLS HARNESS -
6576323
DGN
RNG
B
A
B
A
CONTROLS HARNESS - 6579881
DGN
RNG
DGN/RED
DGN/LGN
A
B
A
B
DGN/RED
DGN/LGN
CONTROLS HARNESS -
6576297
RNG
YEL
A
B
A
B
RNG
YEL/LGN
LEFT HANDLE
(IF EQUIPPED)
HORN
REAR AUX.
TO OPTIONS
RED/WHT
TO OPTIONS
RNG
BACKUP
ALARM
RIGHT
WORK
LIGHT
WORK
LIGHT
RNG
RNG/DGN
PNK
DBL/WHT
BLK
A
B
C
A
C
B
PNK
BLK
DBL/WHT
AUXILIARY
HOURMETER AND
HARNESS (IF EQUIPPED)
BLK h
RNG
B A
C121
B A
REAR LIGHT HARNESS - 6577648
LGN/WHT
LGN
A B
C118
A B
RED
PUR
EXC
S
G
B
ALTERNATOR
RED
RED
HYDRAULIC
OIL
PRESSURE
HYDRAULIC
OIL
TEMPERATURE
HYDRAULIC
CHARGE
PRESSURE
RESISTOR
5 OHM
HORN
RNG/DBL
E D F
E D
B A K J H G C
F
C408
B A K J H G C
B A D F E C
C407
B A D F E C
CONTROLS MODULE
C110
*
PIN NUMBER = 30 PIN CONNECTOR
* * * * * * * * * * # # # # #
BOSS
# # # # * * * * * * * *
C119
#
PIN NUMBER = 18 PIN CONNECTOR
* * * * * * * * * * # # # #
FUEL SHUTOFF
SOLENOID
C K J G H F A D B E
C120
C A B G J F K D H E
C122
COOLANT
LEVEL
FUEL
LEVEL
ENGINE OIL
PRESSURE
AIR
FILTER
ENGINE
COOLANT
BLK
RNG
SHUTDOWN RELAY
86
30
85
87
87A
WHT/BLK
RED
B
A
E
F
D
C
D
C
LGN/RED
RNG
B
A
E
F
LGN/DBL
LGN/PNK
DGN/YEL
RED
RNG
BLK
RNG
WHT
LBL/BLK
RED
WHT
BLK
RED
RNG
RNG
STARTER RELAY
86
WHT
85
87
87A
30
BLK
RED
WHT/LGN
S
STARTER
M
B
RED
RED
RED
RED
RED
BLK
RED
GLOW PLUG RELAY
86
30
85
87
87A
LBL/BLK
LBL/RNG
ENGINE HARNESS (BOSS) - 6579653
BATTERY
GLOW
PLUGS
HR
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
SOME CONNECTOR
FOR DRAWING CLARITY
RNG
PUR/RED
PUR/WHT
PNK
BLK
DBL/WHT
RED/WHT
RNG
PNK
DBL/WHT
RED/WHT
BLK
PUR/WHT
PUR/RED
1
2
DIAGNOSTIC PORT
RED
3
4
PUR/RED
PUR/WHT
BLK
LCD DISPLAY MONITOR
BOSS DISPLAY
B
C
A
PUR/RED
PUR/WHT
RNG
E
D
RNG
BLK
DGN/WHT
DGN/WHT
BLK
YEL/WHT
YEL
BLK
B
A
B
A
B
A
B
A
REAR AUXILIARY
ROD SOLENOID
REAR AUXILIARY
BASE SOLENOID
BLK
LBL/RED
B
A
FOR FUTURE USE
BLK
DGN/WHT
B
A
B
A
FRONT AUXILIARY
ROD SOLENOID
BLK
DGN/RED
B
A
B
A
CAB HARNESS (BOSS) - 6576352
AUXILIARY HYDRAULIC SWITCH
(IF EQUIPPED)
MODE LIGHT
DETENT LIGHT
ACC
OFF
RUN
START
SO
ST
I
IGNITION SWITCH
B
RED/WHT
LIGHT SWITCH
(IF EQUIPPED)
B1
WARNING
B2
HEADLIGHT
TAIL
REAR WORK
FUSE
RED
RED
IGNITION FUSE HOLDER
RED/WHT
RED/WHT
FUSE
ACCESSORY FUSE HOLDER
RED/WHT
BLK 2
1
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
BLK
LEFT
HEADLIGHT
(IF
EQUIPPED)
RIGHT
HEADLIGHT
(IF
EQUIPPED)
FLASHER
MC2561 (5-25-99)
BRN
853 BOSS - WIRING SCHEMATIC
S/N 508411011-11353
(Printed June 1999)
MC2562
RIGHT HANDLE
(IF EQUIPPED)
DETENT
FRONT AUX.
CONTROLS HARNESS -
6576323
DGN
RNG
B
A
CONTROLS HARNESS -
6702634
B
A
DGN
RNG
DGN/RED
DGN/LGN
A
B
CONTROLS HARNESS -
6702633
RNG A
B
A
B
A
B
DGN/RED
DGN/LGN
RNG
YEL
YEL/WHT
A
B
A
B
YEL
YEL/WHT
DIODE
DIODE
DIODE
DIODE
DIODE
DIODE
DIODE
DIODE
BLK
YEL/WHT
B
A
B
A
YEL
BLK
B
A
B
A
BLK
DGN/WHT
B
A
B
A
BLK
DGN/RED
B
A
B
A
REAR AUXILIARY
BASE SOLENOID
FRONT AUXILIARY
ROD SOLENOID
HORN
REAR AUX.
BACKUP
ALARM
RNG
RNG/DGN
PNK
DBL/WHT
BLK
A
B
C
A
C
B
PNK
BLK
DBL/WHT
TO OPTIONS
RED/WHT
RED/WHT
TO OPTIONS
RNG
RIGHT
TAILLIGHT RIGHT
WORK
LIGHT
WORK
LIGHT
REAR LIGHT HARNESS - 6577648
AUXILIARY
HOURMETER AND
HARNESS (IF EQUIPPED)
BLK h
RNG
B A
C121
B A
A B
C118
A B
LGN/WHT
LGN
RED
PUR
EXC
S
G
B
ALTERNATOR
RED
RED
HORN
RNG/DBL
RETURN FILTER
PRESSURE
PRE-FILTER
PRESSURE
HYDRAULIC
OIL
PRESSURE
HYDRAULIC
OIL
TEMPERATURE
CHARGE
PRESSURE
RESISTOR
5 OHM
C110
*
PIN NUMBER = 30 PIN CONNECTOR
* * * * * * * * * * # # # # #
BOSS
# # # # * * * * * * * *
E D F B A K J H G C
E D F
C408
B A K J H G C
B A D F E C
C407
B A D F E C
CONTROLS MODULE
C119
#
PIN NUMBER = 18 PIN CONNECTOR
* * * * * * * * * # # # #
C122
ENGINE RPM
(MAGNETIC PICKUP)
COOLANT
LEVEL
FUEL
LEVEL
AIR
FILTER
FUEL SHUTOFF
SOLENOID
DIODE
BLK
SHUTDOWN RELAY
86
RNG
30
85
87
87A
WHT/BLK
C K J G H F A
C120
D B E
C A B G J F K D H E
BLK
RNG
RNG
WHT
LBL/BLK
RED/WHT
RED
B
A
E
F
D
C
D
C
LGN/RED
RNG
B
A
E
F
LGN/DBL
LGN/PNK
DGN/YEL
RED
WHT
BLK
RED/WHT
RNG
RNG
CAB HARNESS (BOSS) - 6702610
AUXILIARY HYDRAULIC SWITCH
(IF EQUIPPED)
MODE LIGHT
DETENT LIGHT
ACC
OFF
RUN
START
SO
ST
I
IGNITION SWITCH
B
RED/WHT
RNG
PUR/RED
PUR/WHT
PNK
BLK
DBL/WHT
RED/WHT
RNG
PNK
DBL/WHT
RED/WHT
BLK
PUR/WHT
PUR/RED
WARNING
HEADLIGHT
TAIL
REAR WORK
B1
RED/WHT
B2
RED/WHT
BLK
TO OPTIONS
(FRONT WIPER)
2
1
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
STARTER RELAY
86
WHT
WHT/LGN
85
87
87A
30
BLK
RED
WHT/LGN
BLK
RED
GLOW PLUG RELAY
86
30
85
87
87A
LBL/BLK
LBL/RNG
GLOW
PLUGS
HR
S
M
B
RED
RED
RED
RED
RED
BATTERY
STARTER
ENGINE HARNESS (BOSS) - 6702898
WIRES CONNECT BY
CONNECTORS
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
BODIES NOT SHOWN
FOR DRAWING CLARITY
DIAGNOSTIC PORT
2
1
3
4
RED
PUR/RED
PUR/WHT
BLK
LCD DISPLAY MONITOR
BOSS DISPLAY
B
C
A
PUR/RED
PUR/WHT
RNG
E
D
RNG
BLK
DGN/WHT
DGN/WHT
BLK
LEFT
HEADLIGHT
(IF
EQUIPPED)
RIGHT
HEADLIGHT
(IF
EQUIPPED)
MC2562 (5-25-99)
BRN
FLASHER
853 BOSS - WIRING SCHEMATIC
S/N 508411354-11714
S/N 509711001-11094
(Printed June 1999)
MC2566
CONTROLS HARNESS -
6703005
BLK
YEL/WHT
B
A
DIODE HARNESS - 6703898
B
A
BLK
RED
B
A
DIODE
BLK
RED
B
A
REAR AUXILIARY
ROD SOLENOID
RIGHT HANDLE
(IF EQUIPPED)
DETENT
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
FRONT
AUX.
A
B
C
B
A
DGN
RNG
RNG
DGN/RED
DGN/LGN
LEFT HANDLE
(IF EQUIPPED)
HORN
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
REAR
AUX.
A
B
C
A
B
RNG
RNG/DBL
RNG
YEL/WHT
YEL
BLK
DGN/WHT
B
A A
B
BLK
DGN/RED
B
A A
B
FRONT AUXILIARY
BASE SOLENOID
YEL
BLK
DIODE HARNESS - 6703898
B
A
A
B
BLK
RED BLK
RED
B
A
DIODE
B
A
REAR AUXILIARY
BASE SOLENOID
RNG
RNG/DGN
PNK
DBL/WHT
BLK
A
B
C
A
C
B
PNK
BLK
DBL/WHT
TO OPTIONS
RED/WHT
RED/WHT
TO OPTIONS
RNG
LEFT
TAILLIGHT
RIGHT
TAILLIGHT RIGHT
WORK
LIGHT
LEFT
WORK
LIGHT
REAR LIGHT HARNESS - 6577648
HOURMETER AND
HARNESS (IF EQUIPPED)
BLK h
RNG
B A
C121
B A
A B
C118
A B
LGN/WHT
LGN
RED
PUR
EXC
S
G
B
ALTERNATOR
RED
RED
HORN
E D F
E D
K A B J H G C
F
C408
K A B J H G C
B A D F E C
C407
B A D F E C
CONTROLS MODULE
C110
*
PIN NUMBER = 30 PIN CONNECTOR
* * * * * * * * * *
# # # # #
BOSS
# # # #
* * * * * * * *
C119
#
PIN NUMBER = 18 PIN CONNECTOR
* * * * * * * * *
# # # #
RETURN FILTER
PRESSURE
PRE-FILTER
PRESSURE
OIL
PRESSURE
HYDRAULIC
OIL
TEMPERATURE
HYDRAULIC
CHARGE
PRESSURE
RESISTOR
5 OHM
C122
ENGINE RPM
(MAGNETIC PICKUP)
ENGINE OIL
PRESSURE
ENGINE
COOLANT
FUEL SHUTOFF
SOLENOID
DIODE
BLK
SHUTDOWN RELAY
86
RNG
30
85
87
87A
WHT/BLK
C K J G H F A
C120
D B E
C A B G J F K D H E
BLK
RNG
RNG
WHT
LBL/BLK
RED/WHT
RED
E
F
B
A
D
C
D
C
LGN/RED
RNG
E
F
B
A
LGN/DBL
LGN/PNK
DGN/YEL
RED
WHT
BLK
RED/WHT
RNG
RNG
CAB HARNESS (BOSS) - 6702610
AUXILIARY HYDRAULIC SWITCH
(IF EQUIPPED)
MODE LIGHT
DETENT LIGHT
ACC
OFF
RUN
START
SO
ST
I
IGNITION SWITCH
B
RED/WHT
RNG
PUR/RED
PUR/WHT
PNK
BLK
DBL/WHT
RED/WHT
RNG
PNK
DBL/WHT
RED/WHT
BLK
PUR/WHT
PUR/RED
LIGHT SWITCH
(IF EQUIPPED)
WARNING
B1
RED/WHT
B2
HEADLIGHT
TAIL
REAR WORK
RED/WHT
BLK
2
1
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
STARTER RELAY
86
WHT
WHT/LGN
85
87
87A
30
BLK
RED
WHT/LGN
BLK
RED
GLOW PLUG RELAY
86
30
85
87
87A
LBL/BLK
LBL/RNG
S
M
B
RED
RED
RED
RED
RED
BATTERY
STARTER
ENGINE HARNESS (BOSS) - 6702898
HR
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
SOME CONNECTOR
FOR DRAWING CLARITY
DIAGNOSTIC PORT
2
1 RED
PUR/RED
3
4
PUR/WHT
BLK
LCD DISPLAY MONITOR
BOSS DISPLAY
B
C
PUR/RED
PUR/WHT
A
E
RNG
RNG
D BLK
DGN/WHT
DGN/WHT
BLK
LEFT
HEADLIGHT
(IF
EQUIPPED)
RIGHT
HEADLIGHT
(IF
EQUIPPED)
BRN
MC2566 (5-25-99)
FLASHER
853 BOSS - WIRING SCHEMATIC
S/N 508411715-12360
S/N 509711095-11308
(Printed June 1999)
MC2572
BACKUP
ALARM
RNG
RNG/DGN
PNK
DBL/WHT
BLK
A
B
C
A
C
B
PNK
BLK
DBL/WHT
RIGHT
WORK
LIGHT
WORK
LIGHT
REAR LIGHT HARNESS - 6577648
TO OPTIONS
RED/WHT
RED/WHT
TO OPTIONS
RNG
HOURMETER AND
HARNESS (IF EQUIPPED)
BLK h
RNG
B A
C121
B A
A B
C118
A B
LGN/WHT
LGN
RED
PUR
EXC
S
G
B
ALTERNATOR
RED
RED
CONTROLS HARNESS - 6703878
RIGHT HANDLE
(IF EQUIPPED)
DETENT
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
FRONT
AUX.
A
C
B
A
B
RNG
DGN
RNG
DGN/LGN
DGN/RED
LEFT HANDLE
(IF EQUIPPED)
HORN
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
REAR
AUX.
B
C
A
A
B
RNG
RNG/DBL
YEL
YEL/WHT
RNG
HORN
A B G J K H C D E F
C408
A B G J K H C D E F
A C E F B D
C407
A C E F B D
CONTROLS MODULE
C110
*
PIN NUMBER = 30 PIN CONNECTOR
* * * * * * * * * * # # # # #
BOSS
# # # # * * * * * * * *
C119
#
PIN NUMBER = 18 PIN CONNECTOR
* * * * * * * * * # # # #
FUEL SHUTOFF
SOLENOID
C D H G J K A
C120
E F B
C A B G J F K D H E
PRE-FILTER
PRESSURE
HYDRAULIC
OIL
PRESSURE
HYDRAULIC
OIL
TEMPERATURE
CHARGE
PRESSURE
RESISTOR
5 OHM
C122
COOLANT
LEVEL
FUEL
LEVEL
ENGINE OIL
PRESSURE
AIR
FILTER
ENGINE
COOLANT
DIODE
BLK
SHUTDOWN RELAY
86
RNG
30
85
87
87A
WHT/BLK
BLK
RNG
RNG
WHT
LBL/BLK
RED/WHT
BLK
DGN/LGN
B
A
B
A
BLK
DGN/RED
B
A
B
A
RED
B
A
E
F
D
C
D
C
LGN/RED
RNG
B
A
E
F
LGN/DBL
LGN/PNK
DGN/YEL
RED
YEL
BLK
B
A
B
A
BLK
YEL/WHT
B
A
B
A
WHT
BLK
RED/WHT
RNG
RNG
FRONT AUXILIARY
ROD SOLENOID
FRONT AUXILIARY
BASE SOLENOID
REAR AUXILIARY
BASE SOLENOID
REAR AUXILIARY
ROD SOLENOID
CAB HARNESS (BOSS) - 6702610
AUXILIARY HYDRAULIC SWITCH
(IF EQUIPPED)
MODE LIGHT
DETENT LIGHT
ACC
OFF
RUN
START
SO
ST
I
IGNITION SWITCH
B
RED/WHT
RNG
PUR/RED
PUR/WHT
PNK
BLK
DBL/WHT
RED/WHT
RNG
PNK
DBL/WHT
RED/WHT
BLK
PUR/WHT
PUR/RED
WARNING
HEADLIGHT
TAIL
REAR WORK
B1
RED/WHT
B2
RED/WHT
BLK
TO OPTIONS
(FRONT WIPER)
2
1
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
STARTER RELAY
86
WHT
WHT/LGN
85
87
87A
30
BLK
RED
BLK
RED
GLOW PLUG RELAY
86
30
85
87
87A
LBL/BLK
LBL/RNG
GLOW
PLUGS
HR
DIAGNOSTIC PORT
2
3
4
1 RED
PUR/RED
PUR/WHT
BLK
LCD DISPLAY MONITOR
BOSS DISPLAY
B
C
PUR/RED
PUR/WHT
RNG
A
E
D
RNG
BLK
DGN/WHT
DGN/WHT
BLK
LEFT
HEADLIGHT
(IF
EQUIPPED)
RIGHT
HEADLIGHT
(IF
EQUIPPED)
BRN
FLASHER
WHT/LGN
S
M
B
RED
RED
RED
RED
RED
BATTERY
STARTER
ENGINE HARNESS (BOSS) - 6702898
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
MC2572 (5-25-99)
853 BOSS - WIRING SCHEMATIC
S/N 508412361-12460
S/N 509711309-11334
(Printed June 1999)
MC2567
BACKUP
ALARM
RNG
RNG/DGN
PNK
DBL/WHT
BLK
A
B
C
A
C
B
PNK
BLK
DBL/WHT
TO OPTIONS
RED/WHT
RED/WHT
TO OPTIONS
RNG
LEFT
TAILLIGHT
RIGHT
TAILLIGHT
WORK
LIGHT
LEFT
WORK
LIGHT
REAR LIGHT HARNESS - 6577648
AUXILIARY
HOURMETER AND
HARNESS (IF EQUIPPED)
BLK h
RNG
B A
C121
B A
A B
C118
A B
LGN/WHT
LGN
RED
PUR
EXC
S
G
B
ALTERNATOR
RED
RED
PRE-FILTER
PRESSURE
HYDRAULIC
OIL
PRESSURE
HYDRAULIC
OIL
TEMPERATURE
HYDRAULIC
CHARGE
PRESSURE
CONTROLS HARNESS - 6703878
RIGHT HANDLE
(IF EQUIPPED)
DETENT
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
FRONT
AUX.
A
C
B
A
B
RNG
DGN
RNG
DGN/LGN
DGN/RED
LEFT HANDLE
(IF EQUIPPED)
HORN
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
REAR
AUX.
A
B
B
C
A
RNG
RNG/DBL
YEL
YEL/WHT
RNG
HORN
A B G J K H C D E F
C408
A B G J K H C D E F
A C E F B D
C407
A C E F B D
CONTROLS MODULE
C110
*
PIN NUMBER = 30 PIN CONNECTOR
* * * * * * * * * * # # # # #
BOSS
# # # # * * * * * * * *
C119
#
PIN NUMBER = 18 PIN CONNECTOR
* * * * * * * * * # # # #
FUEL SHUTOFF
SOLENOID
C D H G J K
C120
A E F B
C A B G J F K D H E
C122
COOLANT
LEVEL
FUEL
LEVEL
AIR
FILTER
ENGINE
COOLANT
DIODE
BLK
SHUTDOWN RELAY
86
RNG
30
85
87
87A
WHT/BLK
ENGINE RPM
(MAGNETIC PICKUP)
BLK
RNG
RNG
WHT
LBL/BLK
RED/WHT
BLK
DGN/LGN
B
A
B
A
BLK
DGN/RED
B
A
B
A
RED
E
F
B
A
D
C
E
F
B
A
D
C
LGN/RED
RNG
LGN/DBL
LGN/PNK
DGN/YEL
RED
YEL
BLK
B
A
B
A
BLK
YEL/WHT
B
A
B
A
WHT
BLK
RED/WHT
RNG
RNG
FRONT AUXILIARY
ROD SOLENOID
FRONT AUXILIARY
BASE SOLENOID
REAR AUXILIARY
BASE SOLENOID
REAR AUXILIARY
ROD SOLENOID
CAB HARNESS (BOSS) - 6704407
MODE LIGHT
DETENT LIGHT
ACC
OFF
RUN
START
SO
ST
I
IGNITION SWITCH
B
RED/WHT
RNG
PUR/RED
PUR/WHT
PNK
BLK
DBL/WHT
RED/WHT
RNG
PNK
RED/WHT
DBL/WHT
BLK
PUR/WHT
PUR/RED
WARNING
HEADLIGHT
TAIL
REAR WORK
B1
RED/WHT
B2
HORN
RNG/DBL BLK
RED/WHT
BLK
TO OPTIONS
(FRONT WIPER)
1
2
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
STARTER RELAY
86
WHT
WHT/LGN
85
87
87A
30
BLK
RED
BLK
RED
GLOW PLUG RELAY
86
30
85
87
87A
LBL/BLK
LBL/RNG
GLOW
PLUGS
HR
TO ENGINE
RNG/DBL
DIAGNOSTIC PORT
4
1
2
3
RED
PUR/RED
PUR/WHT
BLK
LCD DISPLAY MONITOR
BOSS DISPLAY
B
PUR/RED
C
A
E
D
PUR/WHT
RNG
RNG
BLK
DGN/WHT
DGN/WHT
BLK
LEFT
HEADLIGHT
(IF
EQUIPPED)
RIGHT
HEADLIGHT
(IF
EQUIPPED)
FLASHER
BRN
WHT/LGN
S
M
B
RED
RED
RED
RED
RED
BATTERY
STARTER
ENGINE HARNESS (BOSS) - 6702898
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
SOME CONNECTOR
FOR DRAWING CLARITY
MC2567 (5-25-99)
853 BOSS - WIRING SCHEMATIC
S/N 508412461-15055
S/N 509711335-15096
S/N 510250001-50161
S/N 510375001-75092
(Printed June 1999)
MC2563
CONTROLS HARNESS - 6703878
TO OPTIONS
RED/WHT
RED/WHT
TO OPTIONS
RNG
TRANSDUCER HARNESS - 6704345
HYDRAULIC
CHARGE
PRESSURE
BLK
YEL/LBL
B
A
B
A
TO OPTIONS
BACKUP
ALARM
LEFT
TAILLIGHT
RIGHT
TAILLIGHT
RIGHT
LIGHT
LEFT
WORK
LIGHT
RNG
RNG/DGN
PNK
DBL/WHT
BLK
C
D
E
A
F
B
C
D
E
A
B
F
RNG
RNG/DGN
PNK
BLK
DBL/WHT
AUXILIARY
HOURMETER AND
HARNESS (IF EQUIPPED)
BLK h
RNG
B A
C121
B A
REAR LIGHT HARNESS - 6704232
LGN/WHT
LGN
A B
C118
A B
RED
PUR
EXC
S
G
B
RED
ALTERNATOR
RETURN FILTER
PRESSURE
PRE-FILTER
PRESSURE
HYDRAULIC
OIL
PRESSURE
HYDRAULIC
TEMPERATURE
RESISTOR
5 OHM
RIGHT HANDLE
(IF EQUIPPED)
DETENT
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
FRONT
AUX.
B
A
B
A
C
RNG
DGN
RNG
DGN/LGN
DGN/RED
LEFT HANDLE
(IF EQUIPPED)
HORN
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
REAR
AUX.
A
B
B
C
A
RNG
RNG/DBL
YEL
YEL/WHT
RNG
HORN
BLK
DGN/LGN
B
A
B
A
BLK
DGN/RED
B
A
B
A
FRONT AUXILIARY
ROD SOLENOID
FRONT AUXILIARY
BASE SOLENOID
YEL
BLK
B
A
B
A
BLK
YEL/WHT
B
A
B
A
REAR AUXILIARY
BASE SOLENOID
REAR AUXILIARY
ROD SOLENOID
C110
*
PIN NUMBER = 30 PIN CONNECTOR
B
B
A
C122
A
ENGINE RPM
(MAGNETIC PICKUP)
COOLANT
LEVEL
FUEL
LEVEL
ENGINE OIL
PRESSURE
BOSS
A
A
B G
B G
J K H C
J
C408
K H C
D E
D E
F
F
A
A
C
C
E F B
C407
E F B
D
D
CONTROLS MODULE
C119
#
PIN NUMBER = 18 PIN CONNECTOR
AIR
FILTER
ENGINE
COOLANT
FUEL SHUTOFF
SOLENOID
C D H G J K A E F B
C120
C A B G J F K D H E
DIODE
BLK
SHUTDOWN RELAY
86
RNG
30
85
87
87A
WHT/BLK
RED
E
F
B
A
D
C
D
C
LGN/RED
RNG
E
F
B
A
LGN/DBL
LGN/PNK
DGN/YEL
RED
VACUUM SWITCH
6660316 WAS 6651570
BLK
RNG
RNG
RNG
WHT
LBL/BLK
RED/WHT
RNG
PUR/RED
PUR/WHT
PNK
BLK
DBL/WHT
RED/WHT
WHT
BLK
RED/WHT
RNG
RNG
RNG
PNK
RED/WHT
DBL/WHT
BLK
PUR/WHT
PUR/RED
CAB HARNESS (BOSS) - 6704407
MODE LIGHT
DETENT LIGHT
ACC
OFF
RUN
START
SO
ST
I
IGNITION SWITCH
B
RED/WHT
WARNING
HEADLIGHT
TAIL
REAR WORK
B1
RED/WHT
B2
STARTER RELAY
86
WHT
WHT/LGN
85
87
87A
30
BLK
RED
WHT/LGN
BLK
RED
GLOW PLUG RELAY
86
30
85
87
87A
LBL/BLK
LBL/RNG
M
RED
RED
RED
RED
RED
RED
S B
BATTERY
STARTER
6651664
ENGINE HARNESS (BOSS) - 6704234
GLOW
PLUGS
HR
WIRES CONNECT BY
LETTER ACROSS
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
SOME CONNECTOR
FOR DRAWING CLARITY
TO ENGINE
RNG/DBL
2
3
4
1
DIAGNOSTIC PORT
RED
PUR/RED
PUR/WHT
BLK
LCD DISPLAY MONITOR
BOSS DISPLAY
B
PUR/RED
C
A
E
D
PUR/WHT
RNG
RNG
BLK
DGN/WHT
DGN/WHT
HORN
RNG/DBL
BLK
RED/WHT
BLK
TO OPTIONS
(FRONT WIPER)
1
2
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
BLK
LEFT
HEADLIGHT
(IF
EQUIPPED)
RIGHT
HEADLIGHT
(IF
EQUIPPED)
FLASHER
BRN
MC2563 (5-25-99)
CONTROLS HARNESS - 6703878
853 BOSS - WIRING SCHEMATIC
S/N 508415056-15187
S/N 509715097-15221
S/N 510250162-50448
S/N 510375093-75213
(Printed June 1999)
MC2564
RIGHT HANDLE
(IF EQUIPPED)
DETENT
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
A
C
B
A
B
RNG
DGN
RNG
DGN/LGN
DGN/RED
LEFT HANDLE
(IF EQUIPPED)
HORN
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
A
B
B
C
A
RNG
RNG/DBL
YEL
YEL/WHT
RNG
BLK
DGN/LGN
BLK
DGN/RED
B
A
B
A
B
A
FRONT AUXILIARY
ROD SOLENOID
B
A
FRONT AUXILIARY
BASE SOLENOID
YEL
BLK
BLK
YEL/WHT
B
A
B
A
B
A
B
A
REAR AUXILIARY
BASE SOLENOID
REAR AUXILIARY
ROD SOLENOID
HORN
TO OPTIONS
RED/WHT
RED/WHT
TO OPTIONS
RNG
RETURN FILTER
PRESSURE
TRANSDUCER HARNESS - 6704345
CHARGE
PRESSURE
BLK
YEL/LBL
B
A
B
A
TO OPTIONS
BACKUP
ALARM
RNG
RNG/DGN
PNK
DBL/WHT
BLK
E
A
F
B
C
D
HERE OR
TO OPTIONS
C
D
RNG
RNG/DGN
E
A
B
F
PNK
BLK
DBL/WHT
HOURMETER AND
HARNESS (IF EQUIPPED)
BLK h
RNG
B A
C121
B A
RIGHT
TAILLIGHT RIGHT
WORK
LIGHT
WORK
LIGHT
REAR LIGHT HARNESS - 6704232
LGN/WHT
LGN
A B
C118
A B
RED
PUR
EXC
S
G
B
RED
ALTERNATOR
HYDRAULIC
OIL
PRESSURE
HYDRAULIC
OIL
TEMPERATURE
A B G J K H C D E F
C408
A B G J K H C D E F
A C E F B D
C407
A C E F B D
CONTROLS MODULE
C110
*
PIN NUMBER = 30 PIN CONNECTOR
* * * * * * * * * *
C120
# # # # #
BOSS
# # # # * * * * * * * *
C119
#
PIN NUMBER = 18 PIN CONNECTOR
* * * * * * * * * # # # #
FUEL SHUTOFF
SOLENOID
C D H G J K A E F B
C120
C A B G J F K D H E
COOLANT
LEVEL
B A
C122
B A
ENGINE RPM
(MAGNETIC PICKUP)
ENGINE OIL
PRESSURE
AIR
FILTER
ENGINE
COOLANT
DIODE
BLK
SHUTDOWN RELAY
86
RNG
30
85
87
87A
WHT/BLK
BLK
RNG
RNG
RNG
WHT
LBL/BLK
RED/WHT
RED
B
A
E
F
D
C
B
A
E
F
D
C
LGN/RED
RNG
LGN/DBL
LGN/PNK
DGN/YEL
RED
WHT
BLK
RED/WHT
RNG
RNG
STARTER RELAY
86
WHT
WHT/LGN
85
87
87A
30
BLK
RED
WHT/LGN
BLK
RED
GLOW PLUG RELAY
86
30
85
87
87A
LBL/BLK
LBL/RNG
S
M
B
RED
RED
RED
RED
RED
RED
BATTERY
STARTER
6651664
ENGINE HARNESS (BOSS) - 6705035
GLOW
PLUGS
HR
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
RNG
PUR/RED
PUR/WHT
PNK
BLK
DBL/WHT
RED/WHT
RNG
PNK
RED/WHT
DBL/WHT
BLK
PUR/WHT
PUR/RED
TO ENGINE
RNG/DBL
DIAGNOSTIC PORT
1
2
3
4
RED
PUR/RED
PUR/WHT
BLK
LCD DISPLAY MONITOR
BOSS DISPLAY
B
C
A
PUR/RED
PUR/WHT
RNG
E
D
RNG
BLK
DGN/WHT
DGN/WHT
LETTER ACROSS
CONNECTORS
CAB HARNESS (BOSS) - 6705136
AUXILIARY HYDRAULIC SWITCH
(IF EQUIPPED)
MODE LIGHT
DETENT LIGHT
ACC
OFF
RUN
START
SO
ST
I
IGNITION SWITCH
B
RED/WHT
RNG/DBL BLK
LIGHT SWITCH
(IF EQUIPPED)
WARNING
B1
RED/WHT
B2
HEADLIGHT
TAIL
REAR WORK
RED/WHT
BLK
1
2
BLK
LEFT
HEADLIGHT
(IF
EQUIPPED)
RIGHT
HEADLIGHT
(IF
EQUIPPED)
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
FLASHER
BRN
MC2564 (5-25-99)
853 BOSS - WIRING SCHEMATIC
S/N 508415188-15215
S/N 509715222-15292
S/N 510250449-50691
S/N 510375214-75404
(Printed June 1999)
MC2571
RIGHT HANDLE (IF EQUIPPED)
C
D
B
F
E
A
DGN
YEL
LGN
SKI CONTROL
FRONT
AUX.
WATER KIT
DETENT
DGN/LGN
DGN/RED
RNG
RNG/WHT
DGN
C
B
A
A
B
A
B
A
C
B
RNG
DGN/LGN
DGN/RED
RNG
DGN
SKI CONTROL
B
A
C
B
A
DBL
WHT
HORN
DGN
BRN
YEL
TURN
SIGNAL
REAR AUX.
LEFT HANDLE (IF EQUIPPED)
RNG/WHT
RNG/DBL
A
B
YEL/LGN
YEL/RED
RNG
C
B
A
A
B
RNG
RNG/DBL
HERE OR TO
ATTACHMENT
B
C
YEL
YEL/WHT
A RNG
HORN
WITH FRONT AUXILIARY VALVE
CONTROLS HARNESS - 6705283
BLK
DGN/RED
B
A
B
A
BLK
DGN/LGN
B
A
B
A
YEL
BLK
B
A
B
A
REAR AUXILIARY
BASE SOLENOID
BLK
YEL/WHT
B
A
B
A
REAR AUXILIARY
ROD SOLENOID
TO
ATTACHMENT
F
E
A
C
D
B
DGN
YEL
LGN
RIGHT HANDLE (IF EQUIPPED)
SKI CONTROL
FRONT
AUX.
WATER KIT
DETENT
DGN/LGN
DGN/RED
RNG
RNG/WHT
DGN
A
B
C
B
A
B
A
C
TO
ATTACHMENT
B
A
DBL
WHT
SKI CONTROL
HORN
DGN
BRN
YEL
TURN
SIGNAL
REAR AUX.
LEFT HANDLE (IF EQUIPPED)
RNG/WHT
RNG/DBL
A
B
YEL/LGN
YEL/RED
RNG
C
B
A
A
C
B
RNG
DGN/LGN
DGN/RED
TO
ATTACHMENT
A
RNG
B
DGN
A
B
RNG
RNG/DBL
HERE OR TO
ATTACHMENT
B
C
YEL
YEL/WHT
A RNG
HORN
WITHOUT FRONT AUXILIARY VALVE
CONTROLS HARNESS - 6702999
BLK
DGN/RED
B
A
B
A
FRONT AUXILIARY
BASE SOLENOID
BLK
DGN/LGN
B
A
B
A
FRONT AUXILIARY
ROD SOLENOID
BLK
LBL/RED
B
A
B
A
HIGH PRESSURE
RELIEF SOLENOID
TO OPTIONS
RED/WHT
RED/WHT
TO OPTIONS
RNG
TRANSDUCER HARNESS - 6704345
HYDRAULIC
CHARGE
PRESSURE
BLK
YEL/LBL
B
A
B
A
TO OPTIONS
BACKUP
ALARM
LEFT
TAILLIGHT
RIGHT
TAILLIGHT
WORK
LIGHT
LEFT
WORK
LIGHT
RNG
RNG/DGN
PNK
DBL/WHT
BLK
E
A
C
D
F
B
HERE OR
TO OPTIONS
C
D
RNG
RNG/DGN
A
E
PNK
B
F
BLK
DBL/WHT
AUXILIARY
HOURMETER AND
HARNESS (IF EQUIPPED)
BLK h
RNG
B A
C121
B A
REAR LIGHT HARNESS - 6704232
LGN/WHT
LGN
A B
C118
A B
RED
PUR
EXC
S
G
B
RED
ALTERNATOR
C408 C407
CONTROLS MODULE
C H G J K A D B E F
C120
*
PIN NUMBER = 30 PIN CONNECTOR
* * * * * * * * * * # # # # #
BOSS
# # # # * * * * * * * *
#
PIN NUMBER = 18 PIN CONNECTOR
* * * * * * * * * # # # #
RETURN FILTER
PRESSURE
PRE-FILTER
PRESSURE
HYDRAULIC
OIL
PRESSURE
B A
C122
B A
COOLANT
LEVEL
FUEL
LEVEL
AIR
FILTER
ENGINE
COOLANT
HYDRAULIC
OIL
TEMPERATURE
ENGINE OIL
PRESSURE
ENGINE RPM
(MAGNETIC PICKUP)
FUEL SHUTOFF
SOLENOID
DIODE
BLK
SHUTDOWN RELAY
86
RNG
30
85
87
87A
WHT/BLK
C120
C A B G J F K D H E
BLK
RNG
RNG
RNG
WHT
LBL/BLK
RED/WHT
RED
E
F
B
A
D
C
D
C
LGN/RED
RNG
E
F
B
A
LGN/DBL
LGN/PNK
DGN/YEL
RED
A
A
D F
D F
B G E C K H J
B
C408
G E C K H J
A C E F B D
C407
A C E F B D
CONTROLS MODULE
C D E H G J K A F B
C120
CAB HARNESS (BOSS) - 6705136
WHT
BLK
RED/WHT
RNG
RNG
MODE LIGHT
DETENT LIGHT
ACC
OFF
RUN
START
SO
ST
I
IGNITION SWITCH
B
RED/WHT
WHT
WHT/LGN
STARTER RELAY
86
85
87
87A
30
BLK
RED
BLK
RED
GLOW PLUG RELAY
86
30
85
87
87A
LBL/BLK
LBL/RNG
GLOW
PLUGS
HR
RNG
PUR/RED
PUR/WHT
PNK
BLK
DBL/WHT
RED/WHT
RNG
PNK
RED/WHT
DBL/WHT
BLK
PUR/WHT
PUR/RED
TO ENGINE
RNG/DBL
DIAGNOSTIC PORT
2
3
4
1 RED
PUR/RED
PUR/WHT
BLK
LCD DISPLAY MONITOR
BOSS DISPLAY
B
PUR/RED
C
A
E
D
PUR/WHT
RNG
RNG
BLK
DGN/WHT
DGN/WHT
RNG/DBL BLK
RED/WHT
BLK
TO OPTIONS
(FRONT WIPER)
2
1
WARNING
HEADLIGHT
TAIL
REAR WORK
B1
RED/WHT
B2
BLK
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
LEFT
HEADLIGHT
(IF
EQUIPPED)
RIGHT
HEADLIGHT
(IF
EQUIPPED)
FLASHER
WHT/LGN
M
RED
RED
RED
RED
RED
RED
S B
BATTERY
STARTER
6651664
ENGINE HARNESS (BOSS) - 6705035
LETTER ACROSS
CONNECTORS
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
BRN
MC2571 (5-25-99)
853 BOSS - WIRING SCHEMATIC
S/N 508415216-17999
S/N 509715293-17999
S/N 510250692 AND ABOVE
S/N 510375405 AND ABOVE
S/N 512815001-15999
(Printed June 1999)
MC2573
TO
ATTACHMENT
C
D
B
F
E
A
DGN
YEL
LGN
RIGHT HANDLE (IF EQUIPPED)
SKI CONTROL FRONT
AUX.
WATER KIT
DETENT
DGN/LGN
DGN/RED
RNG
RNG/WHT
DGN
C
B
A
A
B
A
B
A
C
B
RNG
DGN/LGN
DGN/RED
RNG
DGN
SKI CONTROL
B
A
C
B
A
DBL
WHT
HORN
DGN
BRN
YEL
TURN
SIGNAL
REAR AUX.
LEFT HANDLE (IF EQUIPPED)
RNG/WHT
RNG/DBL
A
B
YEL/LGN
YEL/RED
RNG
C
B
A
A
B
RNG
RNG/DBL
HERE OR TO
ATTACHMENT
B
C
YEL
YEL/WHT
A RNG
HORN
TO OPTIONS
RED/WHT
RED/WHT
TO OPTIONS
RNG
TO OPTIONS
B
F
A
E
C
D
RNG
RNG/DGN
PNK
BLK
DBL/WHT
AUXILIARY
HOURMETER AND
HARNESS (IF EQUIPPED)
BLK h
RNG
B A
C121
B A
LGN/WHT
LGN
A B
C118
A B
RED
PUR
EXC
S
G
B
RED
ALTERNATOR
COOLANT
LEVEL
B A
C122
B A
FUEL
LEVEL
ENGINE OIL
PRESSURE
ENGINE RPM
(MAGNETIC PICKUP)
VACUUM SWITCH
6660316 WAS 6651570
AIR
FILTER
WITHOUT FRONT AUXILIARY VALVE
CONTROLS HARNESS - 6702999
WITH FRONT AUXILIARY VALVE
CONTROLS HARNESS - 6705283
C408 C407
CONTROLS MODULE
C H G J K A D B E F
C120
C110
*
PIN NUMBER = 30 PIN CONNECTOR
BOSS
RETURN FILTER
PRESSURE
PRE-FILTER
PRESSURE
HYDRAULIC
OIL
PRESSURE
HYDRAULIC
TEMPERATURE
HYDRAULIC
CHARGE
PRESSURE
BLK
DGN/RED
B
A
B
A
FRONT AUXILIARY
BASE SOLENOID
BLK
DGN/LGN
B
A
B
A
FRONT AUXILIARY
ROD SOLENOID
YEL
BLK
B
A
B
A
REAR AUXILIARY
BASE SOLENOID
BLK
YEL/WHT
B
A
B
A
REAR AUXILIARY
ROD SOLENOID
C119
#
PIN NUMBER = 18 PIN CONNECTOR
ENGINE
COOLANT
TO
ATTACHMENT
B
F
E
A
C
D
DGN
YEL
LGN
RIGHT HANDLE (IF EQUIPPED)
SKI CONTROL
FRONT
AUX.
WATER KIT
DETENT
DGN/LGN
DGN/RED
RNG
RNG/WHT
DGN
A
B
C
B
A
A
C
B
RNG
DGN/LGN
DGN/RED
TO
ATTACHMENT
A
RNG
B
DGN
SKI CONTROL
B
A
C
B
A
DBL
WHT
HORN
DGN
BRN
YEL
REAR AUX.
LEFT HANDLE (IF EQUIPPED)
RNG/WHT
RNG/DBL
A
B
YEL/LGN
YEL/RED
RNG
C
B
A
A
B
B
C
A
RNG
RNG/DBL
YEL
YEL/WHT
RNG
HORN
BLK
DGN/RED
B
A
B
A
FRONT AUXILIARY
BASE SOLENOID
BLK
DGN/LGN
B
A
B
A
BLK
LBL/RED
B
A
B
A
HIGH PRESSURE
RELIEF SOLENOID
DIVERTER
(IF EQUIPPED)
SV1
B
A
B
A
BLK
YEL
FUEL SHUTOFF
SOLENOID
BLK
SHUTDOWN RELAY
86
RNG
30
85
87
87A
DIODE
WHT/BLK
C120
D C A B G J F K E H
RED
E
F
B
A
D
C
D
C
LGN/RED
RNG
E
F
B
A
LGN/DBL
LGN/PNK
DGN/YEL
RED
A
A
D F
D F
B G E C K
B
C408
G E C K
H J
H J
A
A
C
C
E F B
C407
E F B
D
D
CONTROLS MODULE
C D E H G J K A F B
C120
CAB HARNESS (BOSS) - 6705136
MODE LIGHT
DETENT LIGHT
ACC
OFF
RUN
START
SO
ST
I
IGNITION SWITCH
B
RED/WHT
RNG
RNG
BLK
RNG
WHT
LBL/YEL
RED/WHT
WHT
BLK
RED/WHT
RNG
RNG
RNG/DBL BLK
STARTER RELAY
86
WHT
WHT/LGN
85
87
87A
30
BLK
RED
BLK
RED
GLOW PLUG RELAY
86
30
85
87
87A
LBL/YEL
LBL/RNG
WHT/LGN
S
M
B
RED
RED
RED
RED
RED
BATTERY
STARTER
ENGINE HARNESS (BOSS) - 6706094
GLOW
PLUGS
HR
WIRES CONNECT BY
CONNECTORS
RNG
PUR/RED
PUR/WHT
PNK
BLK
DBL/WHT
RED/WHT
RNG
PNK
RED/WHT
DBL/WHT
BLK
PUR/WHT
PUR/RED
TO ENGINE
RNG/DBL
2
3
4
DIAGNOSTIC PORT
1 RED
PUR/RED
PUR/WHT
BLK
LCD DISPLAY MONITOR
BOSS DISPLAY
B
C
PUR/RED
PUR/WHT
A
E
D
RNG
RNG
BLK
DGN/WHT
DGN/WHT
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
WARNING
HEADLIGHT
TAIL
REAR WORK
B1
RED/WHT
B2
BLK
LEFT
HEADLIGHT
(IF
EQUIPPED)
RIGHT
HEADLIGHT
(IF
EQUIPPED)
RED/WHT
BLK
TO OPTIONS
(FRONT WIPER)
1
2
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
FLASHER
BRN
MC2573 (5-20-99)
853 WITHOUT BOSS - WIRING SCHEMATIC
S/N 510125001-25239
(Printed June 1999)
MC2568
A
B B
A
BLK
PUR
RNG
RNG/DGN
HERE OR
TO OPTIONS)
F
C
G
B
D
E
A
H
RNG/DGN
RNG
BLK
PNK
DBL/WHT
TO OPTIONS
RNG
TO OPTIONS
RNG
CONTROLS HARNESS - 6703878
RIGHT HANDLE
(IF EQUIPPED)
DETENT
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
FRONT
AUX.
LEFT HANDLE
(IF EQUIPPED)
HORN
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
REAR
AUX.
A
C
B
A
B
RNG
DGN
RNG
DGN/LGN
DGN/RED
B
C
A
A
B
RNG
RNG/DBL
YEL
YEL/WHT
RNG
HORN
BLK
DGN/LGN
B
A
B
A
BLK
DGN/RED
B
A
B
A
YEL
BLK B
A
B
A
BLK
YEL/WHT
B
A
B
A
FRONT AUXILIARY
ROD SOLENOID
REAR AUXILIARY
BASE SOLENOID
REAR AUXILIARY
ROD SOLENOID
HYDRAULIC
CHARGE
PRESSURE
CHARGE OIL
FILTER
DIFFERENTIAL
PRESSURE
HYDRAULIC OIL
FILTER
DIFFERENTIAL
PRESSURE
YEL/BLK
YEL/DBL
YEL
A B
A B
G
G
J
J
K H C
C408
K H C
D
D
E
E
F
F
A
A
C
C
E F B
C407
E F B
D
D
CONTROLS MODULE
STARTER RELAY
WHT
WHT/LGN
85
87
87A
86
30
BLK
RED
LGN
A B
C118
A B
RED
PUR
EXC
S
G
B
RED
WHT/LGN
S
M
B
STARTER
ALTERNATOR
ENGINE HARNESS (WITHOUT BOSS) - 6704587
LGN
RED
RED
RED
RED
ENGINE COOLANT
1075-2231 OHMS
B
A A
B BLK
PUR/WHT
YEL/DGN
GLOW PLUG RELAY
BLK
86
RED
30
85
87
87A
LBL/BLK
LBL/RNG HR
GLOW
PLUGS
BATTERY
WIRES CONNECT BY
CONNECTORS
DIODE
C D H G J K A E F B
C120
C A B G J F K D H E
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
FUEL SHUTOFF SOLENOID
WHT/BLK
WHT
RNG
RED
BLK
RED/WHT
PUR/WHT
YEL/DGN
YEL/BRN
YEL/DBL
PUR
PNK
DBL/WHT
LBL/BLK
D
B
C
F
A
E C
E
D
B
F
A
LGN/RED
RNG
LGN/DBL
LGN/PNK
DGN/YEL
CAB HARNESS (WITHOUT BOSS) - 6704494
AUXILIARY HYDRAULIC SWITCH
(IF EQUIPPED)
ACC
OFF
RUN
START
MODE LIGHT
DETENT LIGHT
ST
SO
ST
B
WHT
RED/WHT
RED/WHT
GLOW PLUG
BUTTON
I
IGNITION SWITCH
LBL/DGN
TO
OPTIONS
WHT
RNG
WHT/BLK
RED
BLK
RED/WHT
FUSE
IGNITION
FUSEHOLDER
LBL/BLK
YEL/DGN
PNK
DBL/WHT
YEL/DBL
PUR/WHT
PUR
YEL/BRN h
HOURMETER
RED/WHT
RED/WHT
BLK
TO OPTIONS
(FRONT WIPER)
1
2
TO OPTIONS
(SHUTDOWN
MODULE)
TRANSMISSION WARNING LIGHT
YEL/DBL
RNG
YEL/DGN
RNG
ENGINE WARNING LIGHT
FUEL GAUGE
S
LGHT
I
GND
BLK
BLK
PUR
GRY
GRY
RNG
RNG
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
ENGINE
TEMPERATURE
GAUGE
GND
S
LGHT
I
VOLTMETER
V
I
GND
LGHT
RNG
RNG
BLK
BLK
GRY
GRY
BLK
BLK
PUR/WHT
GRY
RNG
RNG
RNG
LEFT
HEAD
LIGHT
(IF
EQUIPPED)
DBL
RIGHT
HEAD
LIGHT
(IF
EQUIPPED)
N BR
FLASHER
BRN
WARNING
HEADLIGHT
TAIL
REAR WORK
B1
B2
RED/WHT
RED/WHT
RED/WHT
FUSE
ACCESSORY
FUSEHOLDER
MC2568 (5-14-99)
853 WITHOUT BOSS - WIRING SCHEMATIC
S/N 510125240-26110
(Printed June 1999)
MC2569
TO OPTIONS
RNG
TO OPTIONS
RNG
FUEL LEVEL
B
A A
B BLK
PUR
TO OPTIONS
(BACK-UP ALARM SWITCHES)
RNG
RNG/DGN
HERE OR
TO OPTIONS)
F
C
G
B
D
E
A
H
RNG/DGN
RNG
BLK
PNK
DBL/WHT
CONTROLS HARNESS - 6703878
RIGHT HANDLE
(IF EQUIPPED)
DETENT
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
FRONT
AUX.
B
A
B
A
C
RNG
DGN
RNG
DGN/LGN
DGN/RED
LEFT HANDLE
(IF EQUIPPED)
HORN
RNG/WHT
RNG/DBL
A
B
DGN
BRN
YEL
B
C
A
REAR
AUX.
A
B
B
C
A
RNG
RNG/DBL
YEL
YEL/WHT
RNG
HORN
BLK
DGN/LGN
B
A
B
A
BLK
DGN/RED
B
A
B
A
YEL
BLK
B
A
B
A
BLK
YEL/WHT
B
A
B
A
FRONT AUXILIARY
ROD SOLENOID
FRONT AUXILIARY
BASE SOLENOID
REAR AUXILIARY
BASE SOLENOID
REAR AUXILIARY
ROD SOLENOID
A B G J K H C D E F
C408
A B G J K H C D E F
A C E F B D
C407
A C E F B D
CONTROLS MODULE
CHARGE PRESSURE
HARNESS - 6704931
LGN
A B
C118
A B
RED
PUR
EXC
S
G
B
RED
HYDRAULIC
CHARGE
PRESSURE
HYDRAULIC OIL
TEMPERATURE
B
A
B
A
FILTER
DIFFERENTIAL
PRESSURE
HYDRAULIC OIL
FILTER
DIFFERENTIAL
PRESSURE
YEL/BLK
YEL/DBL
YEL
WHT
WHT/LGN
STARTER RELAY
85
87
87A
86
30
BLK
RED
WHT/LGN
S
M
B
STARTER
LGN
RED
RED
RED
RED
ALTERNATOR
ENGINE HARNESS (WITHOUT BOSS) - 6704932 OR 6705111
ENGINE COOLANT
ENGINE OIL
PRESSURE SWITCH
YEL/DGN
GLOW PLUG RELAY
86
BLK
RED
30
85
87
87A
LBL/BLK
LBL/RNG
BATTERY
PUR/WHT
HR
GLOW
PLUGS
DIODE
C D H G J K A E F B
C120
C A B G J F K D H E
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
SOME CONNECTOR
FOR DRAWING CLARITY
FUEL SHUTOFF SOLENOID
WHT/BLK
RNG
WHT
RED
BLK
RED/WHT
PUR/WHT
YEL/DGN
YEL/BRN
YEL/DBL
PUR
PNK
DBL/WHT
LBL/BLK
B
C
E
D
F
A
F
A
C
E
D
B
LGN/RED
RNG
LGN/DBL
LGN/PNK
DGN/YEL
CAB HARNESS (WITHOUT BOSS) - 6704494
AUXILIARY HYDRAULIC SWITCH
(IF EQUIPPED)
ACC
OFF
RUN
START
MODE LIGHT
DETENT LIGHT
ST
SO
ST
B
WHT
RED/WHT
RED/WHT
GLOW PLUG
BUTTON
I
IGNITION SWITCH
LBL/DGN
TO
OPTIONS
WHT
RNG
WHT/BLK
RED
BLK
RED/WHT
FUSE
IGNITION
FUSEHOLDER
LBL/BLK
YEL/DGN
PNK
DBL/WHT
YEL/DBL
PUR/WHT
PUR
YEL/BRN h
HOURMETER
RED/WHT
RED/WHT
BLK 2
1
TRANSMISSION WARNING LIGHT
TO OPTIONS
(SHUTDOWN
MODULE)
YEL/DBL
RNG
YEL/DGN
RNG
ENGINE WARNING LIGHT
FUEL GAUGE
GND
S
I
LGHT
BLK
BLK
PUR
GRY
GRY
RNG
RNG
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
ENGINE
TEMPERATURE
GAUGE
GND
S
I
LGHT
VOLTMETER
V
I
GND
LGHT
RNG
RNG
BLK
BLK
GRY
GRY
BLK
BLK
PUR/WHT
GRY
RNG
RNG
RNG
LEFT
HEAD
LIGHT
(IF
EQUIPPED)
DBL
RIGHT
HEAD
LIGHT
(IF
EQUIPPED)
FLASHER
BRN
LIGHT SWITCH
(IF EQUIPPED)
B1
RED/WHT
RED/WHT
RED/WHT
FUSE
WARNING
B2
HEADLIGHT
TAIL
REAR WORK
MC2569 (5-14-99)
853 WITHOUT BOSS - WIRING SCHEMATIC
S/N 510126111 AND ABOVE
S/N 512811001-14999
(Printed June 1999)
MC2570
TO
ATTACHMENT
E
A
B
F
C
D
DGN
YEL
LGN
RIGHT HANDLE (IF EQUIPPED)
SKI CONTROL
FRONT
AUX.
WATER KIT
DETENT
DGN/LGN
DGN/RED
RNG
RNG/WHT
DGN
A
B
C
B
A
B
A
A
B
C
RNG
DGN/LGN
DGN/RED
RNG
DGN
YEL
BLK
B
A
B
A
BLK
YEL/WHT
B
A
B
A
REAR AUXILIARY
ROD SOLENOID
WITHOUT FRONT AUXILIARY VALVE
CONTROLS HARNESS - 6702999
B
A
C
TO
ATTACHMENT
B
A
DBL
WHT
SKI CONTROL
HORN
DGN
BRN
YEL
REAR AUX.
LEFT HANDLE (IF EQUIPPED)
RNG/WHT
RNG/DBL
A
B
YEL/LGN
YEL/RED
RNG
C
B
A
A
B
RNG
RNG/DBL
HERE OR TO
ATTACHMENT
B
YEL
C
A
YEL/WHT
RNG
HORN
FUEL LEVEL
33-246 OHMS
B
A
B
A
BLK
PUR
TO OPTIONS
RNG
TO OPTIONS
RNG
RNG
RNG/DGN
B
D
E
A
H
F
C
G
HERE OR
TO OPTIONS)
RNG/DGN
RNG
BLK
PNK
DBL/WHT
WITH FRONT AUXILIARY VALVE
CONTROLS HARNESS - 6705283
BLK
DGN/RED
B
A
B
A
FRONT AUXILIARY
BASE SOLENOID
BLK
DGN/LGN
B
A
B
A
FRONT AUXILIARY
ROD SOLENOID
TO
ATTACHMENT
E
A
B
F
C
D
DGN
YEL
LGN
RIGHT HANDLE (IF EQUIPPED)
SKI CONTROL
FRONT
AUX.
WATER KIT
DETENT
DGN/LGN
DGN/RED
RNG
RNG/WHT
DGN
A
B
C
B
A
A
C
B
RNG
DGN/LGN
DGN/RED
A
B
RNG
DGN
B
A
C
TO
ATTACHMENT
B
A
DBL
WHT
SKI CONTROL
HORN
DGN
BRN
YEL
REAR AUX.
LEFT HANDLE (IF EQUIPPED)
RNG/WHT
RNG/DBL
A
B
YEL/LGN
YEL/RED
RNG
C
B
A
A
B
RNG
RNG/DBL
HERE OR TO
ATTACHMENT
B
YEL
C
A
YEL/WHT
RNG
HORN
BLK
DGN/RED
B
A
B
A
FRONT AUXILIARY
BASE SOLENOID
BLK
DGN/LGN
B
A
B
A
FRONT AUXILIARY
ROD SOLENOID
BLK
LBL/RED
B
A
B
A
C408 C407
CONTROLS MODULE
A
A
D F
D F
B G E C K
C408
B G E C K
H J
H J
A C E F B
A
C407
C E F B
D
D
CONTROLS MODULE
C H G J K A
C120
D B E F
C D E H G J K
C120
A F B
CHARGE PRESSURE
HARNESS - 6704931
HYDRAULIC
PRESSURE
CHARGE OIL
FILTER
DIFFERENTIAL
PRESSURE
DIFFERENTIAL
PRESSURE
A
B B
A
YEL/BLK
YEL/DBL
YEL
STARTER RELAY
WHT
WHT/LGN
85
87
87A
86
30
BLK
RED
LGN
A B
C118
A B
RED
PUR
EXC
S
G
B
RED
WHT/LGN
S
M
B
STARTER
ALTERNATOR
ENGINE HARNESS (WITHOUT BOSS) - 6706222
LGN
RED
RED
RED
RED
ENGINE COOLANT
1075-2231 OHMS
B
A
DIVERTER
(IF EQUIPPED)
SV1
B
A A
B
BLK
YEL
B
A
BLK
PUR/WHT
ENGINE OIL
PRESSURE SWITCH
YEL/DGN
GLOW PLUG RELAY
BLK
86
RED
30
85
87
87A
LBL/BLK
LBL/RNG
BATTERY
HR
GLOW
PLUGS
WIRES CONNECT BY
CONNECTORS
C120
D C A B G J F K E H
DIODE
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
FUEL SHUTOFF SOLENOID
WHT/BLK
RNG
WHT
RED
BLK
RED/WHT
PUR/WHT
YEL/DGN
YEL/BRN
YEL/DBL
PUR
PNK
DBL/WHT
LBL/BLK
F
A
E
D
B
C
F
A
C
E
D
B
LGN/RED
RNG
LGN/DBL
LGN/PNK
DGN/YEL
CAB HARNESS (WITHOUT BOSS) - 6704494
AUXILIARY HYDRAULIC SWITCH
(IF EQUIPPED)
ACC
OFF
RUN
START
MODE LIGHT
DETENT LIGHT
ST
SO
ST
B
WHT
RED/WHT
RED/WHT
GLOW PLUG
BUTTON
I
IGNITION SWITCH
LBL/DGN
TO
OPTIONS
WHT
RNG
WHT/BLK
RED
BLK
RED/WHT
FUSE
IGNITION
FUSEHOLDER
LBL/BLK
YEL/DGN
PNK
DBL/WHT
YEL/DBL
PUR/WHT
PUR
YEL/BRN h
HOURMETER
RED/WHT
RED/WHT
BLK
TO OPTIONS
(FRONT WIPER)
2
1
WHT
WHT/BLK
YEL/DGN
YEL/DGN
YEL/DBL
YEL/DBL
TRANSMISSION WARNING LIGHT
TO OPTIONS
(SHUTDOWN
MODULE)
YEL/DBL
RNG
YEL/DGN
RNG
ENGINE WARNING LIGHT
FUEL GAUGE
GND
S
I
LGHT
BLK
BLK
PUR
GRY
GRY
RNG
RNG
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
ENGINE
TEMPERATURE
GAUGE
GND
S
I
LGHT
VOLTMETER
V
I
GND
LGHT
RNG
RNG
BLK
BLK
GRY
GRY
BLK
BLK
PUR/WHT
GRY
RNG
RNG
RNG
LEFT
HEAD
LIGHT
(IF
EQUIPPED)
DBL
RIGHT
HEAD
LIGHT
(IF
EQUIPPED)
N BR
FLASHER
BRN
LIGHT SWITCH
(IF EQUIPPED)
WARNING
B1
B2
RED/WHT
RED/WHT
RED/WHT
FUSE
ACCESSORY
FUSEHOLDER
HEADLIGHT
TAIL
REAR WORK
MC2570 (5-14-99)
853 - WIRING SCHEMATIC
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
ATTACHMENT CONTROLS HARNESS - 6705901
DIODE MODULE
D
C
B
A
F
K
E
H
G
J
H
G
J
D
C
B
K
E
A
F
LBL
YEL
DGN
YEL/WHT
DBL
RNG/WHT
BRN
WHT
BRN/YEL
BLK
DBL
DGN
YEL
DGN
RNG
RED
RNG/DBL
BRN
LBL
RNG/WHT
TO OPTIONS
F
G
C
E
A
L
D
H
M
K
N
P
B
J
WIRES CONNECT BY
LETTER ACROSS
CONNECTORS
A B
B A
RED = RED
RNG = ORANGE
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
PNK = PINK
WHT = WHITE
TAN = TAN
PUR = PURPLE
SOME CONNECTOR
BODIES NOT SHOWN
FOR DRAWING CLARITY
RELAY 1 -
(EXAMPLE - ANGLE BROOM POWER)
87A
RED/WHT
30
87
RED
BLK
86
85
WHT
RELAY 2 -
(EXAMPLE - FRONT/REAR AUXILIARY - BASE END)
87A
YEL/WHT
30
87
YEL/RED
LGN
BLK
86
85
RNG/DBL
RELAY 3 -
(EXAMPLE - FRONT/REAR AUXILIARY - ROD END)
BRN/YEL
30
87A
87
YEL/LGN
LGN
BLK
86
85
RNG/DBL
RELAY 3 -
(EXAMPLE - STUMP GRINDER)
87A
LGN
30
87
DGN
BLK
86 85
DGN
TO WATER KIT
B
A
BLK
LGN/WHT
TO CONTROLS
YEL/RED
YEL/LGN
RNG
B
C
A
TO CONTROLS
(RIGHT HANDLE)
LGN/WHT
BLK
YEL
DGN
RNG
F
D
C
A
B
E
TO CONTROLS
(AUXILIARY RELIEF)
DGN/YEL
A
B
TO CONTROLS
(LEFT HANDLE)
DBL
WHT
B
A
TO CONTROLS
(LEFT HANDLE)
RNG
YEL/RED
YEL/LGN
A
B
C
TO CONTROLS
(USED WITH HIGH
FLOW MACHINES ONLY)
A
B
DGN/YEL
STUMP GRINDER OR GRADER
HARNESS - 6706552
FOR LOADERS WITH
APITECH VALVE ONLY
TO CONTROLS
(USED WITH HIGH
FLOW MACHINES ONLY)
A
B
TO CONTROLS
(USED WITH HIGH
FLOW MACHINES ONLY)
DGN/YEL
BLK
TO FR..AUX. BASE END SOLENOID
A
B
TO CONTROLS
(USED WITH HIGH
FLOW MACHINES ONLY)
DGN
A
B
TO CONTROLS
(USED WITH HIGH
FLOW MACHINES ONLY)
A
B
56SB
JUMPER WIRE - CONNECTS TO
10-PIN CONNECTOR (MODULE) J TERMINAL
STUMP GRINDER 50 ONLY
C106 C107
POWER
HARNESS
6706446
TO
ENGINE
C105
TO
ENGINE
C108
MC2574 (5-14-99)
853 - WIRING SCHEMATIC
OPTIONS
S/N 508411001-17999
S/N 509711001-17999
S/N 510125001 AND ABOVE
S/N 510250001 AND ABOVE
S/N 510375001 AND ABOVE
S/N 512811001-15999
(Printed June 1999)
MC2565
TO ATTACHMENT
A
D
C
E
F
G
P
M
H
L
K
B
J
N
WHT
BRN
BLK
DBL
RED
YEL
RNG
RNG
TO OLDER
MODEL ATTACHMENTS
S
LT
TM
CENTER
GD
RT
GRADER HARNESS
6707303
TO ATTACHMENT
P
M
C
B
J
N
TO OLDER
MODEL ATTACHMENTS
D
A
S
E
BRN
BLK
LT
TM
F
G
DBL
CENTER
H
RED
YEL
GD
RT
L
K
NEW TO OLD
ADAPTER HARNESS
6706391
TO ATTACHMENT
P
M
C
B
D
N
S
DGN A
LT
TM
BRN
BLK
J
E
CENTER
GD
RT
DBL
YEL
F
RED
OLD TO NEW
G
H
K
L
ADAPTER HARNESS
6706392
FRONT WIPER
BOTTLE AND TANK
M
2
1
C622
FRONT WIPER
MOTOR
V
M
2 1
FRONT WIPER
BOTTLE AND TANK
M
2 1
C625
FRONT WIPER
MOTOR
V
M
2 1
RED/WHT
FRONT WIPER
SWITCH
1
2
4
3
5
6
RNG/BLK
DBL/BLK
TO CAB
1
2
BLK
FRONT WIPER HARNESS
6712259
RED/WHT
FRONT WIPER
SWITCH
1
2
4
3
5
6
TO CAB
1
2
BLK
FRONT WIPER HARNESS
6708269 (LH HINGED DOOR)
REAR WIPER
SWITCH
1
2
3
4
5
6
RNG/BLK
DBL/BLK
TO ENGINE
DBL/BLK
RED/WHT
B
A
REAR WIPER HARNESS - 6708285
FRONT WIPER
MOTOR
A
B
A
B
DGN/LGN
BLK
DGN/RED
BLK
TO CAB
1
2
TO OPTIONS
RED/WHT
BLK
WIPER HARNESS
6708225
RED/WHT
FRONT WIPER
SWITCH
1
2
3
4
5
6
TO OPTIONS
1
2
BLK
FRONT WIPER HARNESS
6568739 (RH HINGED DOOR)
HIGH HORSEPOWER HYDRAULIC HARNESS - 6703166
BLK
LBL/RED
DIODE HARNESS - 6703898
B
A
A
B
BLK
RED BLK
RED
B
A
B
A
DIODE
BLK
DGN/LGN
BLK
DGN/RED
2
1
2
1
RNG/WHT
RNG/WHT
RNG/WHT
ON AND OFF SWITCH
BLK
LBL/RED
DIODE HARNESS - 6703898
A
B
B
A
BLK
RED BLK
RED
B
A
DIODE
B
A
TO
OPTIONS
C633
C105
TO
ENGINE
ROD RELAY
86
DGN/RED
LBL/RED
85
87
87A
30
BLK
BASE RELAY
86
DGN/RED
85
LBL/RED
87
87A
30
BLK
HIGH PRESSURE
SOLENOID
HIGH FLOW
SOLENOID
M
HEATER (OPT.)
BOTTLE/PUMP
M
BACKUP
ALARM
TO CAB
TO CAB RED
WHT
PUR
DBL
YEL
BLK
SHUTDOWN MODULE
RED
YEL
RNG
BLK
TO HEATER
FAN SWITCH
WHT
RNG
YEL
RED
WHT
BLK
HEATER RELAY
85
87
87A
86
30
RNG
RED/WHT
M
STARTER
B
RED
TO ACCESSORY
RNG
RNG
RED/WHT
BLK
A
B
C
HEATER WIRING HARNESS
(HEATER SECTION)
C
B
A
BLK
RED/WHT
RNG
25A
RED
HEATER WIRING HARNESS
(ENGINE SECTION)
HEATER WIRING HARNESSES - 6660894 AND 6660892
RNG
RNG
TO ENGINE
TO ENGINE
RNG/DGN
RNG
TO ENGINE
BLK
BLK
BACK-UP ALARM SWITCHES HARNESS - 6704815
BACK-UP ALARM SWITCHES HARNESS - 6702591
TO ENGINE
RNG
RNG
BLK
BUCKET LEVEL
SWITCH
BUCKET LEVEL SWITCH HARNESS- 6701376
BUCKET LEVEL SWITCH HARNESS- 6704411
RNG
RNG/DGN
DBL/BLK
BLK
E F D A B
C613
E F D
A
C
B C
B A
C614
FOR
FUTURE USE
F E D C B A
C615
F E D C B A
REGISTRATION
LAMP
BLK
LEFT WORK
DBL/WHT
RIGHT WORK
LEFT TAILLIGHT RIGHT TAILLIGHT
REAR TAILLIGHT HARNESS - 6709048
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
SOME CONNECTOR
FOR DRAWING CLARITY
DBL/BLK
TO ENGINE
RNG
RNG/DGN
C
F
G
YEL
PNK
DGN
DBL/WHT
BLK
E
A
D
H
B
MC2565 (5-17-99)
853 BOSS - WIRING SCHEMATIC
S/N 512811001 - 14999
(Printed January 2005)
V-0803
TO
ATTACHMENT
C
D
B
F
E
A
DGN
YEL
LGN
RIGHT HANDLE (IF EQUIPPED)
SKI CONTROL
FRONT
AUX.
WATER KIT
DETENT
DGN/LGN
DGN/RED
RNG
C
B
A
RNG/WHT
DGN
A
B
B
A
B
A
C
RNG
DGN/LGN
DGN/RED
RNG
DGN
WITH FRONT AUXILIARY VALVE
CONTROLS HARNESS - 6705283
BLK
DGN/RED
B
A
B
A
FRONT AUXILIARY
BASE SOLENOID
BLK
DGN/LGN
B
A
B
A
B
A
C
TO
ATTACHMENT
B
A
DBL
WHT
SKI CONTROL
HORN
DGN
BRN
YEL
TURN
SIGNAL
REAR AUX.
LEFT HANDLE (IF EQUIPPED)
RNG/WHT
RNG/DBL
A
B
YEL/LGN
YEL/RED
RNG
C
B
A
A
B
RNG
RNG/DBL
HERE OR TO
ATTACHMENT
B
YEL
C
A
YEL/WHT
RNG
HORN
YEL
BLK
B
A
B
A
REAR AUXILIARY
BASE SOLENOID
BLK
YEL/WHT
B
A
B
A
REAR AUXILIARY
ROD SOLENOID
TO OPTIONS
RED/WHT
RED/WHT
TO OPTIONS
RNG
TRANSDUCER HARNESS - 6704345
HYDRAULIC
CHARGE
PRESSURE
BLK
YEL/LBL
B
A
B
A
TO OPTIONS
BACKUP
ALARM
LEFT
TAILLIGHT
RIGHT
TAILLIGHT
RIGHT
LIGHT
LEFT
WORK
LIGHT
RNG
RNG/DGN
PNK
DBL/WHT
BLK
C
D
E
A
F
B
C
D
E
A
B
F
RNG
RNG/DGN
PNK
BLK
DBL/WHT
AUXILIARY
HOURMETER AND
HARNESS (IF EQUIPPED)
BLK h
RNG
B A
C121
B A
REAR LIGHT HARNESS - 6704232
LGN/WHT
LGN
A B
C118
A B
RED
PUR
EXC
S
G
B
RED
ALTERNATOR
RETURN FILTER
PRESSURE
PRE-FILTER
PRESSURE
HYDRAULIC
OIL
PRESSURE
HYDRAULIC
TEMPERATURE
RESISTOR
5 OHM
C408 C407
CONTROLS MODULE
C110
*
PIN NUMBER = 30 PIN CONNECTOR
C H G J K A
C120
D B E F
BOSS
B
B
A
C122
A
ENGINE RPM
(MAGNETIC PICKUP)
COOLANT
LEVEL
FUEL
LEVEL
ENGINE OIL
PRESSURE
STARTER RELAY
86
WHT
WHT/LGN
85
87
87A
30
BLK
RED
WHT/LGN
VACUUM SWITCH
6660316 WAS 6651570
AIR
FILTER
C119
#
PIN NUMBER = 18 PIN CONNECTOR
ENGINE
COOLANT
BLK
RED
GLOW PLUG RELAY
86
30
85
87
87A
LBL/BLK
LBL/RNG
M
RED
RED
RED
RED
RED
RED
S B
BATTERY
STARTER
6651664
ENGINE HARNESS (BOSS) - 6704234
GLOW
PLUGS
HR
C
D
B
F
E
A
DGN
YEL
LGN
RIGHT HANDLE (IF EQUIPPED)
SKI CONTROL
FRONT
AUX.
WATER KIT
DGN/LGN
DGN/RED
RNG
C
B
A
DETENT
RNG/WHT
DGN
A
B
A
C
B
RNG
DGN/LGN
DGN/RED
TO
ATTACHMENT
A
B
RNG
DGN
SKI CONTROL
B
A
C
B
A
DBL
WHT
HORN
DGN
BRN
YEL
TURN
SIGNAL
REAR AUX.
LEFT HANDLE (IF EQUIPPED)
RNG/WHT
RNG/DBL
A
B
YEL/LGN
YEL/RED
RNG
C
B
A
A
B
RNG
RNG/DBL
HERE OR TO
ATTACHMENT
B
YEL
C
A
YEL/WHT
RNG
HORN
FUEL SHUTOFF
SOLENOID
C120
C A B G J F K D H E
DIODE
BLK
SHUTDOWN RELAY
86
RNG
30
85
87
87A
WHT/BLK
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE
GRY = GREY
SOME CONNECTOR
BODIES NOT SHOWN
BLK
RNG
RNG
RNG
WHT
LBL/BLK
RED/WHT
RNG
PUR/RED
PUR/WHT
PNK
BLK
DBL/WHT
RED/WHT
RED
E
F
B
A
D
C
D
C
LGN/RED
RNG
E
F
B
A
LGN/DBL
LGN/PNK
DGN/YEL
RED
WITHOUT FRONT AUXILIARY VALVE
CONTROLS HARNESS - 6702999
WHT
BLK
RED/WHT
RNG
RNG
RNG
PNK
RED/WHT
DBL/WHT
BLK
PUR/WHT
PUR/RED
A D F
A D F
B G E C K
C408
B G E C K
H J
H J
A
A
C E F
C407
C E F
B
B
D
D
CONTROLS MODULE
TO ENGINE
RNG/DBL
2
3
4
1
DIAGNOSTIC PORT
RED
PUR/RED
PUR/WHT
BLK
LCD DISPLAY MONITOR
BOSS DISPLAY
B
PUR/RED
C
A
PUR/WHT
RNG
E
D
RNG
BLK
DGN/WHT
DGN/WHT
C D E H G J K
C120
A F B
CAB HARNESS (BOSS) - 6705136
AUXILIARY HYDRAULIC SWITCH
(IF EQUIPPED)
MODE LIGHT
DETENT LIGHT
ACC
OFF
RUN
START
SO
ST
I
IGNITION SWITCH
B
RED/WHT
BLK
DGN/RED
B
A
B
A
BLK
DGN/LGN
B
A
B
A
FRONT AUXILIARY
ROD SOLENOID
BLK
LBL/RED
B
A
B
A
HIGH PRESSURE
RELIEF SOLENOID
RNG/DBL
LIGHT SWITCH
(IF EQUIPPED)
WARNING
B1
RED/WHT
B2
HEADLIGHT
TAIL
REAR WORK
BLK
LEFT
HEADLIGHT
(IF
EQUIPPED)
RIGHT
HEADLIGHT
(IF
EQUIPPED)
RED/WHT
BLK
TO OPTIONS
(FRONT WIPER)
2
1
LEFT
FLASHER
LAMP
(IF
EQUIPPED)
RIGHT
FLASHER
LAMP
(IF
EQUIPPED)
FLASHER
BRN
V-0803 (12-12-05)
BLK
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.
Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.
W–2003–0199
Battery will not take a charge.
Alternator will not charge.
Starter will not turn the engine.
PROBLEM
KEY TO CORRECT THE CAUSE
1.
Alternator belt is loose or damaged.
2.
Battery connections are dirty or loose.
3.
Battery is damaged.
4.
The cable & wire connection are not making a good contact.
5.
The alternator is damaged.
6.
The engine is locked.
7.
The starter is damaged.
8.
The wiring or the solenoid is damaged.
9.
Check the fuses.
CAUSE
2, 3, 4
1, 4
2, 3, 4, 6, 7, 8, 9
–6–5–
853, 853H Loader
Service Manual
ELECTRICAL SYSTEM INFORMATION
Description
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.
Fuse Location
The electrical system for the (S/N 5102), (S/N 5103) and earlier model 853 loaders are protected by two fuses
(Item 1) [A] installed in the wiring harness located in the engine compartment.
The electrical system for the (S/N 5101) and (S/N 11010
& Below) loaders are protected by two fuses (Item 1) [B] installed in the instrument panel.
A
1
B
(S/N 5101)
1
P–00910
(S/N 11010 & Bel.)
1
B–13752 B–12883
–6–6–
853, 853H Loader
Service Manual
BATTERY
Removal And Installation
A
Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.
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.
W–2065–1296
Open the rear door.
Disconnect the negative(–) cable (Item 1) [A] from the battery.
Disconnect the positive (+) cable (Item 1) [B] from the battery.
Remove the nuts from the holddown clamp (Item 2) [B] and remove the battery holddown clamp.
Remove the battery from the loader [C].
B
C
1
2
1
CD–15008
CD–15136
CD–15137
–6–7–
853, 853H Loader
Service Manual
BATTERY (Cont’d)
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.
A
B
Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.
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.
W–2065–1296
Servicing The Electrical System
The battery cables must be clean and the connections tight. Remove acid or corrosion from the battery and cables with a sodium bicarbonate (baking soda) and water solution [C].
Clean the terminals and cable ends as shown in Fig. [A] and [B].
Check the electrolyte level in the battery. Add distilled water as needed.
Put Battery Saver (P/N 6664458) or grease on the battery terminals and cable ends to prevent corrosion.
C
P–09589
P–09590
P–09588
–6–8–
853, 853H Loader
Service Manual
BATTERY (Cont’d)
Using A Booster Battery (Jump Starting)
A
2
4
Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.
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.
W–2065–1296
Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection
(negative) at engine frame.
Do not jump start or charge a frozen or damaged battery. Warm battery to 60 o
F. (16 o
C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.
Never lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.
W–2066–1296
If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operator’s seat and one person to connect and disconnect the battery cables.
The ignition must be in the OFF position. The booster battery to be used must be 12 volt.
Connect the end of the first cable (Item 1) [A] to the positive (+) terminal of the booster battery. Connect the other end of the same cable (Item 2) [A] to the positive terminal on the starter solenoid.
Connect the end of the second cable (Item 3) [A] to the negative (–) terminal of the booster battery. Connect the other end of the same cable (Item 4) [A] to the engine.
Keep cables away from moving parts. Start the engine.
(Also see Cold Temperature Starting Condition,
Operation & Maintenance Manual.)
After the engine has started, remove the ground (–) cable
(Item 4) [A] first. Remove the cable from the positive terminal on the starter solenoid.
1
CD–15010
3
CD–15009
Damage to the alternator can occur if:
•
Engine is operated with battery cables disconnected.
•
Battery cables are connected when using a fast charger or when welding on the loader.
(Remove both cables from the battery.)
•
Extra battery cables (booster cables) are connected wrong.
I–2023–1285
–6–9–
853, 853H Loader
Service Manual
ALTERNATOR
Alternator Output Test
A
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
Lift and block the loader (See Page 1–1).
Disconnect the negative (–) cable from the battery.
Disconnect the red wire (Item 1) [A] from the alternator.
Connect the wire to the negative (–) side of the ammeter.
Connect the positive (+) side of the ammeter to the output terminal on the alternator (Item 1) [A].
Disconnect the fuel stop solenoid connector.
Connect the negative (–) cable to the battery.
Turn on the lights and crank the engine for 30 seconds to discharge the battery.
Connect the fuel stop solenoid, start the engine and run at 2600 RPM.
If ammeter reading is between 45–55 amps. @ 2600
RPM the alternator is good and no further testing is needed.
If the reading is low, remove the screws and pull the regulator cover away from the alternator and continue testing (below).
Rectifier (Diode) Test
NOTE: The alternator is removed from the loader for clarity purposes.
Disconnect the negative (–) cable from the battery.
Install the wire in their original location on the back of the alternator.
Connect a jumper wire (Item 1) [B] to the alternator output terminal and the regulator terminal.
Connect the battery negative (–) cable.
Start the engine and run at 2600 RPM.
If the reading is within 45–55 amps. @ 2600 RPM replace the rectifier (diode) assembly or replace the alternator.
If the reading is low, do the Alternator Regulator Test.
B
1
–6–10–
1
Output
Terminal
P–4944
Regulator
Terminal
P–1304
853, 853H Loader
Service Manual
ALTERNATOR (Cont’d)
Alternator Regulator Test
A
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.
W–2050–1285
Connect the positive (+) voltmeter lead to the positive (+) battery terminal [A].
Connect the negative (–) voltmeter lead to the negative
(–) battery terminal [A].
Start the engine and run at 1500–2000 RPM.
The voltmeter should read between 13.9–14.7 volts.
If the reading is low, stop the engine and disconnect the battery negative (–) cable.
NOTE: The alternator is removed from the loader for clarity purposes.
Remove the wires from the back of the alternator.
Remove the regulator cover from the back of the alternator.
Install the wires on the back of the alternator.
Connect a jumper wire (Item 1) [B] from the brush terminal to the ground stud.
Connect the negative (–) battery cable and start the engine. Run at 1500 RPM.
If the voltmeter reading is 14.5 or above, replace the regulator.
If the voltmeter reading is below 14.5, repair or replace the alternator.
B
Brush
Terminal
P–05054
Ground
Stud
1
P–01364
–6–11–
853, 853H Loader
Service Manual
ALTERNATOR
Removal And Installation
NOTE: The engine/hydrostatic pump assembly is shown removed for photo clarity purpose only.
A
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
B
1
Damage to the alternator can occur if:
•
Engine is operated with battery cables disconnected.
•
Battery cables are connected when using a fast charger or when welding on the loader
(Remove both cables from the battery).
•
Extra battery cables (booster cables) are connected wrong.
I–2023–1285
Raise the operator cab. (See Page 1–1.)
Open the rear door. Disconnect the negative (–) battery cable.
Disconnect the orange wire (Item 1) [A] from the alternator.
Disconnect the wiring harness connector (Item 2) [A].
Loosen the adjustment bolt (Item 1) [B].
Remove the alternator belt.
Remove the adjustment bolt (Item 1) [B].
Remove the mounting bolt, nut and spacer (Item 2) [B].
Remove the alternator.
2
1
P–04944
P–04945
–6–12–
853, 853H Loader
Service Manual
ALTERNATOR (Cont’d)
Disassembly
(Motorola or Prestolite 30 Amp., Enclosed)
Disassemble the alternator as shown in Fig. [A].
Remove the regulator cover and regulator.
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.
A
1011
12
13
15
14
1. Nut
2. Pulley
3. Fan
4. Bolt
5. Case Half (Front)
6. Bearing
7. Rotor
8. Slip Ring
9. Stator
10. Heat Sink (+)
11. Heat Sing (–)
12. Case Half (Rear)
13. Condenser Assy.
14. Brush Holder
15. Regulator
D–01760
B
Stator Continuity Test
Use an ohmmeter to test the stator.
Touch the probes to two of the bare stator wires [B].
Move one of the probes to the third wire.
The readings should be the same.
If there is no continuity, replace the stator.
4
1
5
6
2
7
3
6
8
9
16
P–01369
Stator Ground Test
Touch one probe to a bare stator lead and the other probe to the bare metal surface of the stator [C].
There should be no continuity.
Replace the stator if there is continuity.
C
–6–13–
P–01386
853, 853H Loader
Service Manual
ALTERNATOR (Cont’d)
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.
A
Rotor Ground Test
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.
B
Rectifier Continuity (Diode) Test
NOTE: In the diode tests there should be continuity in one direction only. If the diode being tested shows no continuity or continuity in both directions, replace the rectifier assembly.
Touch the probes to the terminals of each diode and read the meter [C].
Reverse the probes to check the diode in the other direction.
There should be continuity in one direction only.
Touch one probe to the diode and the other probe to the connected heat sink and read the meter [D].
Reverse the probes to check the diode in the other direction.
There should be continuity in one direction only.
C
D
–6–14–
P–01365
P–01378
P–01373
P–01370
853, 853H Loader
Service Manual
ALTERNATOR (Cont’d)
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.
A
P–01808
–6–15–
853, 853H Loader
Service Manual
STARTER
Checking The Starter
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.
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.
Connect a jumper wire between the M terminal and the
BAT terminal [B].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.
A
B
Bat
S
M
Jumper Wire
Cranking
Motor
Bat
S
M
A–01992
Jumper Wire
Cranking
Motor
A–01991
–6–16–
853, 853H Loader
Service Manual
STARTER (Cont’d)
Removal And Installation
Disconnect the negative (–) cable from the battery.
Disconnect the positive (+) cable (Item 1) [A] and starter wires from the starter solenoid.
A
Remove the starter mounting bolt (Item 1) [B] and engine harness ground wires from the starter.
B
Remove the other two mounting bolts (Item 1) [C].
Remove the starter from the engine.
C
1
1
CD–15138
CD–15140
1
CD–15139
–6–17–
853, 853H Loader
Service Manual
STARTER (Cont’d)
Parts Identification
28 29
27
30
4
3
2
1
9
5
41
6
8
7
19
10
11
26
25 24
12
13
14
15
16
17
22
21
18 20
23
31
34
35
22
21
34
38
39
32
33
36
37
40
1 Screw
2.
Solenoid
3.
Bolt
4.
Lever
5.
Washer
6.
Nut
7.
Plug
8.
Washer
9.
Housing Drive
10.
Washer
11.
Bushing
12.
Ring
13.
Stop
14.
Drive
15.
Drive Support
16.
Support
17.
Drive Shaft
18.
Washer
19.
Washer
20.
Washer
21.
Screw
22.
Brush
23.
Frame Assy.
24.
Gasket
25.
Pin
26.
Armature Support
27.
Bolt
28.
Spacer
29.
Bearing
30.
Armature
31.
Bearing
32.
Spring
33.
Holder Assy.
34.
Brush
35.
Screw
36.
O–ring
37.
Frame
38.
Washer
39.
Screw
40.
Bolt
41.
Ring
–6–18–
D–02119
853, 853H Loader
Service Manual
STARTER (Cont’d)
Disassembly And Assembly
Remove the starter thru–bolts [A].
A
Remove the screws for the brush holders [B].
B
Remove the starter end cap [C].
C
CD–08924
CD–08925
CD–08926
Remove the starter housing/armature assembly from the reduction gear drive [D].
D
–6–19–
CD–08927
853, 853H Loader
Service Manual
STARTER (Cont’d)
Disassembly And Assembly (Cont’d)
Remove the armature and brushes from the starter housing [A].
A
Remove the bolts from the reduction gear housing [B].
B
Remove the reduction gear housing [C].
C
CD–08928
CD–08929
CD–08930
–6–20–
853, 853H Loader
Service Manual
STARTER (Cont’d)
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.
Check the following items:
Armature
Broken or burned insulation
Loose connections at commutator
Open or grounded circuits [A] & [B]
Worn shaft or bearings
Rough commutator
Brush Holders
Broken springs
Broken insulation
Spring tension
Field Coils
Broken or burned insulation
Electrical continuity
Brush connections
Drive Gears
Worn teeth
Tooth engagement
A
B
A–01995
A–01994
–6–21–
853, 853H Loader
Service Manual
STANDARD INSTRUMENT PANEL
Removal And Installation
Pry the rubber light mount loose from the operator cab
(both sides) [A].
A
Lower the light from the operator cab and locate the three instrument panel mounting bolts (Item 1) [B] (both sides).
Remove the three mounting bolts (Item 1) [B].
Installation: Be careful not to overtighten the instrument panel mounting bolts to prevent stripping the threaded holes in the panels.
B
1
Pull the left instrument panel down and disconnect the wire harness connectors from the panel. Remove the panel [C].
C
Repeat steps [A] and [B]. Pull the right instrument panel down and disconnect the wire harness connectors from the panel. Remove the panel [D].
Reverse the removal procedure to install the instrument panel.
D
–6–22–
P–00962
P–00964
853, 853H Loader
Service Manual
1
P–03995
P–03955
FRONT LIGHTS
963 Service Manual #6724545–Electrical System Section Part 2 of 2
Removal And Installation
The front lights are mounted in the upper corners of the operator cab [A].
A
Pry the rubber light mount free from the operator cab [B].
B
P–03956
Pull the light down and remove the three mounting bolts
(Item 1) [C] from the instrument panel.
Disconnect the front light connector from the instrument panel. Remove the front light from the operator cab.
Reverse the removal procedure to install the front light.
C
1
1
P–03995
P–03955
–6–23–
853, 853H Loader
Service Manual
STEERING LEVER CONTROL HANDLE (Early Series)
Disassembly And Assembly
Remove all the screws and nuts from the control handle
[A].
A
EARLY MODELS
Remove one side of the control handle [B].
Disconnect the wires and remove the other half of the handle with the switch plate.
Assembly: When connecting the electrical wires to the switches, see AUXILIARY WIRING DIAGRAM for correct installation.
B
EARLY MODELS
B–10577
B–10650
–6–24–
853, 853H Loader
Service Manual
ENGINE SERVICE
Page
Number
AIR CLEANER HOUSING
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
BELT SHIELD
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38
CAMSHAFT
Camshaft Bearings
Checking
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation
Tappets
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tappet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–79
7–78
7–78
7–79
7–80
CAMSHAFT GEAR
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–76
COOLANT RECOVERY TANK
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
CRANKSHAFT
Checking The Crankshaft
Checking Tuffriding Coating
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–67
7–67
7–67
CRANKSHAFT GEAR
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–69
CYLINDER LINERS
Checking The Cylinder Bore
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–63
7–63
7–63
CYLINDER HEAD
Cylinder Head Surface Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–52
7–52
7–51
ENGINE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–30
ENGINE COMPRESSION
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
ENGINE MOUNTS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39
ENGINE MUFFLER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
ENGINE SPEED CONTROL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
ENGINE
SERVICE
–7–1–
853, 853H Loader
Service Manual
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
Disassembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–22
7–29
7–18
7–17
FLYWHEEL
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–37
7–37
FUEL INJECTOR NOZZLES
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–49
7–48
FUEL INJECTION PUMP
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–42
7–42
7–46
FUEL INJECTION PUMP IDLER GEAR
Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–75
7–75
GLOW PLUGS
Checking The Glow Plugs
Removal And Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–40
7–40
IDLER GEAR AND HUB
Checking
Removal
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–73
7–73
7–74
MAIN BEARINGS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft End Play
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–64
7–66
7–65
OIL PAN
Removal
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–81
7–81
–7–2–
853, 853H Loader
Service Manual
ENGINE SERVICE (Cont’d)
Page
Number
OIL PUMP
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter Housing And Block
Oil Pump Relief Valve
Removal And Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–82
7–83
7–84
7–84
7–82
7–84
PISTON AND CONNECTING ROD
Assembly
Checking
Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–61
7–58
7–57
7–62
7–57
RADIATOR
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10
ROCKER ARM AND SHAFT
Checking Rocker Arms And Push Rods
Disassembly And Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–56
7–56
TIMING GEARCASE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–77
TIMING GEARCASE COVER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–71
TIMING GEARCASE COVER SEAL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–70
THERMOSTAT
Checking The Thermostat
Removal And Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–88
7–88
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
VALVE CLEARANCE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
VALVE, VALVE SEAT AND GUIDE
Installation
Removal
Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seat Insert
Valve Spring
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconditioning The Valve And Valve Seat . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–53
7–53
7–53
7–54
7–54
7–55
WATER JACKET TUBE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–89
WATER PUMP
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7–86
7–85
7–85
–7–3–
853, 853H Loader
Service Manual
–7–4–
853, 853H Loader
Service Manual
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 CAUSE
Slow cranking speed.
Engine will not start.
Difficult to start.
No power for engine.
1, 2, 3, 4
2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis–firing.
8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption.
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust.
10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust.
Low oil pressure.
4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
4, 31, 32, 33, 34, 35, 37, 39, 52
Engine knocking.
Engine running rough.
Vibration.
High oil pressure warning.
Overheating.
13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
4, 33, 36
10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression.
Start and stop.
10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
9, 10, 11
KEY TO CORRECT THE CAUSE
1. Battery capacity low.
2. Bad electrical connections.
3. Faulty starter motor.
4. Incorrect grade of oil.
5. Low cranking speed.
6. Fuel tank empty.
7. Faulty stop control operation.
8. Plugged fuel line.
9. Plugged fuel filter.
10. Restriction in the air cleaner.
11.
Air in the fuel system.
12. Faulty fuel injection pump.
13. Faulty fuel injectors.
14. Broken injection pump drive.
15. Incorrect injection pump timing.
16. Incorrect valve timing.
17. Poor compression.
18. Plugged fuel tank vent.
19. Incorrect grade of fuel.
20. Exhaust pipe restriction.
21. Cylinder head gasket leaking.
22. Overheating.
23. Cold running.
24. Incorrect tappet adjustment.
25. Sticking valves.
26. Incorrect high pressure fuel pipes.
27. Worn cylinder bores.
28. Worn valve and seats.
29. Broken, worn or sticking piston rings.
30. Worn valve stems or guides.
31. Worn or damaged bearings.
32. Not enough oil in the oil pan.
33. Switch/sensor is defective.
34. Oil pump worn.
35. Pressure relief valve is sticking open.
36. Pressure relief valve is sticking closed.
37. Broken relief valve spring.
38. Faulty suction pipe.
39. Plugged oil filter.
40. Piston seizure.
41. Incorrect piston height.
42. Faulty engine mounting.
43. Incorrect alignment of flywheel.
44. Faulty thermostat.
45. Restriction in water jacket.
46. Loose alternator belt.
47. Plugged radiator.
48. Faulty water pump.
49. Plugged breather pipe.
50. Damaged valve stem oil deflectors.
51. Coolant level too low.
52. Plugged oil pump pipe strainer.
53. Broken valve spring.
–7–5–
853, 853H Loader
Service Manual
ENGINE SPEED CONTROL
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.
Installation: Tighten the bolts (Item 2) [A] evenly until the speed control lever moves back and forth at a comfortable tension.
Pull the speed control away from the loader frame and disconnect the speed control rod (Item 1) [B] from the control.
Installation: Be sure to install the control rod in the bottom hole of the speed control.
A
B
1
2
1
P–09326
Installation: Install the stop bracket (Item 1) [C] in the same location. It is necessary for the front and rear stop on the bracket to be located correctly.
Reverse the removal procedure to install the engine speed control.
Loosen the two control lever mounting bolts and remove the mounting nuts (Item 2) [C].
Do not lubricate the engine speed control.
Replace any worn or damaged parts if necessary.
C
1
1
P–09327
2
P–04068
–7–6–
853, 853H Loader
Service Manual
ENGINE MUFFLER
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].
Disconnect the exhaust pipe from the muffler.
A
Remove the mounting bolt (Item 1) [B] from the muffler
(both sides).
Remove the muffler from the loader.
B
1
P–04892
1
P–04888
–7–7–
853, 853H Loader
Service Manual
AIR CLEANER HOUSING
Removal And Installation
Loosen the hose clamp (Item 1) [A].
Disconnect the hose from the intake manifold.
A
1
P–04889
Loosen the hose clamp (Item 1) [B].
Disconnect the intake hose from the air cleaner housing.
B
1
P–04890
NOTE: The manual indicator (Item 1) [C] is equipped on the 853 standard loader only.
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.
C
1
NOTE: Disconnect the wires (Item 1) [D] from the sensor at the rear of the air cleaner housing.
The sensor is equipped on 853 BOSS
®
option loaders only.
–7–8–
D
2
P–04891
BOSS
®
1
P–05194
853, 853H Loader
Service Manual
COOLANT RECOVERY TANK
Removal And Installation
Open the rear door.
Raise the rear grill.
Lift the coolant recovery tank from the bracket [A].
A
Disconnect the overflow hose (Item 1) [B].
B
1
P–09369
1
P–04898
Remove the two mounting bolts (Item 1) [C] from the recovery tank mounting bracket.
Remove the mounting bracket.
C
1
P–04899
–7–9–
853, 853H Loader
Service Manual
RADIATOR
Removal And Installation
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].
Open the block drain (Item 1) [A] and drain coolant into a container.
NOTE: Early S/N Loaders use a hex plug in this location for the drain.
A
B
1
1
Disconnect the hose (Item 1) [B].
Disconnect the hose (Item 1) [C].
C
P–04896
P–04894
1
Remove the radiator mounting bolts (Item 1) [D] (both sides).
Installation: Mix coolant in a separate container. (See
Specifications for correct capacity Page 9–1.)
Propylene Glycol
Add premixed coolant: 47% water and 53% propylene glycol to the recovery tank if the coolant level is low.
One gallon and one pint of propylene glycol mixed with one gallon of water is the correct mixture of coolant to provide a –34
°
F (–37
°
C) freeze protection.
Use a refractometer to check the condition of propylene glycol in your cooling system.
Ethylene Glycol
Add premixed coolant: 50% water and 50% ethylene glycol to the recovery tank if the coolant level is low.
–7–10–
D
1
P–04895
P–04893
853, 853H Loader
Service Manual
RADIATOR (Cont’d)
Removal And Installation (Cont’d)
Disconnect the over–fill hose (Item 1) [A].
A
2
1
P–04904
If so equipped, disconnect the wires from the water level sensor (Item 1) [B].
Remove the radiator from the loader.
B
BOSS
®
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.
C
1
1
1
P–05191
P–04905
–7–11–
853, 853H Loader
Service Manual
FAN DRIVE TENSION PULLEY
Removal And Installation
Remove the fan drive belt.
Remove the idler pulley bolt (Item 1) [A].
A
Remove the spacers, bolt and washers from the arm [B].
Installation: Put a small amount of grease around the outside edge on the grease rings (Item 1) [B] between ring and bearing.
B
1
P–04954
1
P–00581
P–04956
Remove the bolt (Item 1) [C], spring and arm.
Check all parts for damage or wear. Replace the parts as needed.
C
Installation: Grease the pivot bolt (Item 1) [D] thrust washer (Item 2) [D] and O–rings (Item 3) [D].
D
–7–12–
1
3
P–04955
3
2
1
N–00303
853, 853H Loader
Service Manual
FAN GEARBOX/BLOWER HOUSING
Removal And Installation
A
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
Raise the operator cab. (See Page 1–1.)
Remove the mounting bolts (Item 1) [A] from the gas cylinder mounting bracket.
Installation: Tighten the mounting bolts to 80–90 in.–lbs.
(9–10 Nm) torque.
Remove the hydraulic fluid reservoir. (See Page 2–1.)
Disconnect the wiring harness connectors (Item 1) [B].
Remove the harness clamp (Item 2) [B].
Disconnect the breather hose from the fan drive housing.
Move the electrical harness down for clearance at the blower housing.
Remove the clamp and belt shield (Item 1) [C] for the fan drive.
Remove the fan drive belt.
Installation: When checking the fan gearbox oil level, make sure the level does not go above the top of the shaft in the gearbox [C]. Use 90W gear lube oil if the level is low.
B
C
2
Oil Level
1
1
Use a putty knife to remove the sealant from the blower housing and loader frame [D].
D
CD–15015
P–04860
1
P–04863
–7–13–
P–04862
853, 853H Loader
Service Manual
FAN GEARBOX/BLOWER HOUSING (Cont’d)
Removal And Installation (Cont’d)
Installation: Use R.T.V. sealant to reseal the blower housing to the loader frame [A].
A
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.
Installation: Use sealant on each end of the inside spacer tubes to prevent the tubes from falling out of the housing during installation.
Installation: Tighten the mounting bolts to 25–28 ft.–lbs.
(34–38 Nm) torque.
B
1
Slide the blower housing forward and remove the fan/fan gearbox assembly [C].
Remove the blower housing.
C
1
P–4877
P–4859
The blower housing must be moved away from the loader frame if the side grills have to be replaced.
To replace the side grill, remove the four mounting screws
(Item 1) [D] from the blower housing.
Install the new grill and replace the screws.
D
1
–7–14–
P–4864
1
P–4876
853, 853H Loader
Service Manual
FAN GEARBOX/BLOWER HOUSING (Cont’d)
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.
A
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.
W–2108–1186
Install the nut (Item 1) [B] on the tapered shaft to protect the shaft and threads.
Install the puller on the fan as shown [B].
As the center bolt (Item 2) [B] is tightened, periodically strike the bolt head to loosen the fan from the shaft .
Remove the fan from the tapered shaft [C].
C
1
P–03006
CD–09953
To remove the blower housing mounting plate, remove the six bolts (Item 1) [D].
D
1
–7–15–
1
1
CD–09954
853, 853H Loader
Service Manual
FAN GEARBOX/BLOWER HOUSING (Cont’d)
Removal And Installation (Cont’d)
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].
A
0.562–0.570 “
(14,3–14,5 mm)
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.
Use a 1/4 inch NC bottom tap to cut maximum threads in the holes.
B
1
1
Drive
Shaft
P–03007
–7–16–
853, 853H Loader
Service Manual
FAN GEARBOX
Parts Identification
1.
Seal
2.
Snap Ring (Small)
3.
Shims (1.0 inch O.D.)
4.
Bearing
5.
Shaft (Long)
6.
Shims (2.0 inch O.D.)
7.
Long Key
8.
Shaft (Short)
9.
Short Key
10.
Long Housing
11.
Nut
12.
Gear
13.
Washer
14.
Screw
15.
Square Shim
*16.
Short Housing
17.
Bolt
18.
Snap Ring (Large)
19.
Cap
20.
Long Housing Assy.
21.
Short Housing Assy.
22.
Fill Plug
1
2
22
3
4
5
4
12
13
14
10
11
15
7
20
* Individual Part not available
–7–17–
8
1
18
6
4
17
*16
12
2
21
12
17
20
3
13
4
14
18
19
TS–01002
853, 853H Loader
Service Manual
FAN GEARBOX (Cont’d)
Disassembly
NOTE: When repairing the gearbox order the following as needed:
1. Complete Assembly
2. Long Housing Assembly
3. Long Housing
4. Short Housing Assembly (See Note
Below)
5. Internal Parts
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.)
NOTE: Be sure to count the number and thickness of shims during disassembly. Install the shims in the original location during assembly.
Remove the fan and blower housing mounting plate. (See
Page 7–15.)
Long Housing
Loosen the set screws (Item 1) [A] and remove the pulley
(Item 2) [A].
Remove the long key (Item 3) [A].
Remove the four mounting bolts and the part number tag
[B].
Remove the oil from the gearbox.
A
B
Part Number
Tag
C
3
1
AVOID INJURY OR DEATH
Wear safety goggles to prevent eye injury when drilling or grinding.
W–2108–1186
Drill an 1/8 inch (13 mm) hole in the seal. Use a slide hammer tool to remove the seal [C].
Remove the small snap ring [D].
D
2
P–03005
P–02983
P–02999
–7–18–
P–02964
853, 853H Loader
Service Manual
FAN GEARBOX (Cont’d)
Disassembly (Cont’d)
Remove the small shims [A].
A
Remove the screw and washer from the shaft [B].
B
Support the lower flange and press the shaft from the bearing [C].
NOTE: The gear and the other bearing (pulley end) will be removed with the shaft.
C
Support the bearing and press the shaft from the bearing
[D].
D
–7–19–
P–02963
P–02966
P–03004
P–03298
853, 853H Loader
Service Manual
FAN GEARBOX (Cont’d)
Disassembly (Cont’d)
Short Housing
Remove the end cap [A].
Use care not to damage the housing.
A
AVOID INJURY OR DEATH
Wear safety goggles to prevent eye injury when drilling or grinding.
W–2108–1186
Drill an 1/8 inch (3 mm) hole in the seal. Use a slide hammer tool to remove the seal [B].
B
Remove the large snap ring from the flange end of the housing [C].
C
P–02997
P–02996
P–02970
Remove the large shims from the housing [D].
NOTE: Use the same size and thickness of shims during assembly.
D
–7–20–
P–02969
853, 853H Loader
Service Manual
FAN GEARBOX (Cont’d)
Disassembly (Cont’d)
Remove the screw and washer (Item 1) [A] from the shaft.
A
Remove the snap ring from the cap end of the housing
[B].
B
1
P–02978
P–02973
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.
C
Press the bearing from the tapered end of the shaft [D].
D
P–02998
–7–21–
P–03088
853, 853H Loader
Service Manual
FAN GEARBOX (Cont’d)
Disassembly (Cont’d)
Press the bearing, shims and gear from the shaft [A].
A
Remove the key (Item 1) [B] from the shaft.
B
Assembly
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].
Support the lower bearing and press the other bearing in the housing until the bearings seat in the housing [C].
Install on the bearing, the same number and size shims that were removed during disassembly [D].
C
D
–7–22–
1
P–03001
P–02972
P–02961
P–02960
853, 853H Loader
Service Manual
FAN GEARBOX (Cont’d)
Assembly (Cont’d)
Install the small snap ring in the groove above the shims
[A].
A
Install the gear key in the flange end of the shaft [B].
B
P–02964
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
Install the washer [D].
Put LOCTITE #242 adhesive on the screw threads. Install and tighten the screw [D].
D
–7–23–
P–02967
P–02966
853, 853H Loader
Service Manual
FAN GEARBOX (Cont’d)
Assembly (Cont’d)
Short Housing
Install a bearing in the flanged end of the housing [A].
A
Install the large shims on the bearing (flanged end) [B].
B
P–02968
P–02969
Install the large snap ring in the groove above the shims
[C].
C
P–02970
Install the short key (Item 1) [D].
Align and press the gear on the shaft (teeth toward the tapered end of the shaft) [D].
D
–7–24–
1
P–02971
853, 853H Loader
Service Manual
FAN GEARBOX (Cont’d)
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.
A
Install the shaft in the housing, tapered end in the bearing at the round flange end of the housing [B].
B
Install on the shaft, the same number and size shims that were removed during disassembly [C].
C
P–02975
P–02976
P–02977
Install a bearing on the gear end of the shaft [D].
D
–7–25–
P–02974
853, 853H Loader
Service Manual
FAN GEARBOX (Cont’d)
853, 853H Service Manual #6720755 – Engine Service Section Part 1 of 4
Assembly (Cont’d)
Install the snap ring in the groove above the bearing [A].
A
Install the washer (Item 1) [B] on the shaft. Put liquid adhesive (LOCTITE #242) on the screw threads and install the screw [B].
B
P–02973
1
P–02978
–7–26–
853, 853H Loader
Service Manual
FAN GEARBOX (Cont’d)
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].
Install the same size and number of square shims (if present during disassembly) between the two housings
[B].
Set the long housing on the short housing with a small amount of liquid adhesive (LOCTITE #242) between the mounting surfaces.
NOTE: If square shims are used, put a small amount of the liquid adhesive on both sides of all shims.
A
B
Install the four mounting bolts through the flange holes
[C].
Install the part number tag [C].
Install and tighten the nut to 25–28 ft.–lbs. (34–38 Nm) torque.
C
Part Number
Tag
Install the long key (Item 1) [D] and the pulley (Item 2) [D].
Install a bolt in the set screw hole to maintain a 1.0 inch
(25,0 mm) distance from the shaft center to the bolt head
(to be used with a dial indicator) [D].
D
–7–27–
P–02987
P–02981
1
1.0”
(25,0 mm)
2
P–02983
P–02984
853, 853H Loader
Service Manual
FAN GEARBOX (Cont’d)
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].
A
Using a magnetic based dial indicator mounted on a bench vise, touch the dial stem on the bolt (Item 1) [B].
Hold the locking pliers against the long housing and rotate the pulley back and forth to read the dial gauge [B].
If the backlash is GREATER than 0.008 inch (0,203 mm), do the following:
1. Remove a square shim(s) (if present) between the two housings.
2. Remove a large shim(s) from the tapered end of the short shaft and add a small shim(s) of the same thickness between the bearing and the gear on the screw end of the shaft.
If the backlash is LESS than 0.005 inch (0,127 mm) do the following:
1. Add a square shim(s) between the two housings.
2. Remove a small shim(s) between the bearing and the gear on the screw end of the short shaft and add a large shim(s) of the same thickness between the snap ring and the bearing on the tapered end of the shaft.
B
1
P–02982
1
P–02979
–7–28–
853, 853H Loader
Service Manual
FAN GEARBOX (Cont’d)
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].
A
Install the seal(s) flush with the housing surface [B] & [C].
Clean any oil from the flange surface.
Install the long housing on the short housing flange.
Install the four bolts and part number tag.
Install and tighten the nuts to 25–28 ft.–lbs. (34–38 Nm) torque.
B
C
P–03089
LONG HOUSING
P–02985
SHORT HOUSING
P–02986
–7–29–
853, 853H Loader
Service Manual
ENGINE
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
A
B
Raise the operator cab. (See Page 1–1.)
Disconnect the case drain hose (Item 1) [A] and drain the hydraulic fluid into a container.
After the fluid is removed from the reservoir, loosen both hose clamps and remove the hose (Item 2) [A] from the reservoir and hydrostatic pump.
Loosen both hose clamps and remove the fuel vent hose
(Item 1) [B].
Loosen both hose clamps and remove the fuel fill hose
(Item 2) [B].
Remove the fan drive belt (Item 1) [C].
C
2
2
1
P–04856
1
P–04855
1
P–04863
Loosen the hose clamps and remove the hose (Item 1)
[D] from the filter and the hydrostatic pump.
D
1
–7–30–
P–04861
853, 853H Loader
Service Manual
ENGINE (Cont’d)
Removal And Installation (Cont’d)
Disconnect the wires (Item 1 & 2) [A] at the filter.
A
1
2
CD–10993
Disconnect the electrical harness connectors (Item 1)
[B].
Disconnect the ground wire and harness clamp (Item 2)
[B].
NOTE: The electrical harness will be removed with the engine.
B
1
1
2
Disconnect the hose (Item 1) [C] from the oil cooler.
Disconnect the hose (Items 2 & 3) [C] from the hydrostatic pump.
C
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.
I–2003–0284
2
3
P–00883
P–04867
–7–31–
853, 853H Loader
Service Manual
ENGINE (Cont’d)
Removal And Installation (Cont’d)
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.
A
Disconnect the high pressure hose (Item 1) [B] from the hydraulic pump.
B
1
2
2
1
P–04878
2
P–04870
Disconnect the case drain filter hose (Item 1) [C] from the pump.
Remove the bolt and nut (Item 2) [B] at the left front engine mount.
C
1
P–04879
Remove the bolt (Item 1) [D] at the right front engine mount.
NOTE: The nut is held in the housing and will not turn (Inset) [D].
Installation: Tighten the mounting bolts and nuts to
90–100 ft.–lbs. (125–130 Nm) torque.
D
–7–32–
P–04934
1
P–05008
853, 853H Loader
Service Manual
ENGINE (Cont’d)
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.
Plug the intake manifold to prevent material from falling into manifold.
Remove the rear grill. (See Page 5–1.)
Remove the muffler. (See Page 7–7.)
Loosen the radiator cap.
Connect a hose to the engine block drain (Item 1) [B].
Open the drain and drain coolant into a container.
A
B
1
1
P–04889
P–04896
Loosen the hose clamp and disconnect the radiator hose
(Item 1) [C].
C
1
P–04895
Loosen the hose clamp and disconnect the radiator hose
(Item 1) [D].
D
1
–7–33–
P–04894
853, 853H Loader
Service Manual
ENGINE (Cont’d)
Removal And Installation (Cont’d)
Disconnect the electrical connector (Item 1) [A].
Remove the coolant recovery tank and bracket (Page
7–9).
A
1
Disconnect the throttle linkage (Item 1) [B] from the bellcrank.
B
1
P–05042
Disconnect the ground cable (Item 1) [C] from the loader frame.
Disconnect the fuel hose (Item 2) [C] from the fuel filter.
C
2
P–04900
1
P–04901
Disconnect the fuel return hose (Item 1) [D] from the injection pump.
Installation: Remove the air from the fuel system (Page
1–1).
D
–7–34–
1
P–04906
853, 853H Loader
Service Manual
ENGINE (Cont’d)
Removal And Installation (Cont’d)
Remove the left rear engine mount bolt and nut [A].
A
P–04903
Remove the right rear engine mount bolt (Item 1) [B].
Installation: Tighten the bolts and nuts to 65–70 ft.–lbs.
(88–95 Nm) torque.
B
Use the dimensions from Figure [C] to make the engine
Removal And Installation brackets.
C
13.0
(330)
INCHES
(MM)
2.5
(64)
1–1/2’’ I.S. Dia.
2–1/2’’ O.S. Dia.
1–1/2’’ Square Tubing
1/4’’ (4)
Thick Gusset
2.5 (64)
1.0
(25)
16.0
(406)
2.0
(51)
4.0
(102)
0.5
(12,7)
1.0 (25)
0.3125 Dia. (2)
0.375
(9,5)
Use Two 3/8’’ x 1–1/4’’ Bolts for Drilled and Tapped Holes
4.0
(102)
2.0 (51)
1.0
(25)
4.25
(108)
0.5
(12,7)
0.6875
(17,5)
1.75
(44,5)
Revised June 97
1
0.75
(19,05)
0.50 (12,7)
3/8 Dia. (3)
P–04902
2–1/2 x 2–1/2 x 6
1/4’’ Angle Iron
45
°
3.1
(78,7)
0.60
(15,2)
0.60 (15,2)
9.0
(229)
1.125
(28,6)
1.75
(44,5)
–7–35–
1.375
(35,0)
0.66 (16,8)
(2) 2 x 2 x 1/4
Gusset
17.750
4.5
(114)
8.525
(218)
1.125
(28,6)
0.775
(19,7)
9/16
Dia. Hole (2)
3/8 Dia. Hole (4)
Gusset
2–1/2 x 2–1/2 x 22
1/4’’ Thick
MC–01801
MC–01799
B–13452
853, 853H Loader
Service Manual
ENGINE (Cont’d)
Removal And Installation (Cont’d)
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.
A
1
3
2
Remove the engine/hydrostatic pump assembly from the loader [B].
B
B–13488
–7–36–
P–04923
853, 853H Loader
Service Manual
FLYWHEEL
Removal And Installation
Remove the drive belt. (See Page 3–1.)
Remove the bolts (Item 1) [A] from the flywheel.
Installation: Put LOCTITE on the flywheel bolts. Tighten the bolts to 83–90 ft.–lbs. (113–122 Nm) torque.
A
Remove the flywheel from the engine crankshaft [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.
Clean the outer surface of the flywheel to give it a smooth fit.
Clean the new ring gear and heat it to a temperature of
450–500
°
F (232–260
°
C).
Fit the ring gear over the flywheel. Make sure the gear is on the seat correctly.
NOTE: Early S/N Loader does not have cooling fins in flywheel.
B
1
P–04928
P–04939
–7–37–
853, 853H Loader
Service Manual
BELT SHIELD
Removal And Installation
Remove the mounting bolt (Item 1) [A] from the thermostat housing.
Remove the mounting bolt (Item 2) [A] from the cylinder head.
Remove the mounting bolt (Item 3) [A].
A
1
2
3
Remove the mounting bolt (Item 1) [B] from the alternator mounting bracket.
Remove the belt shield from the engine.
B
P–04947
1
P–04945
–7–38–
853, 853H Loader
Service Manual
ENGINE MOUNTS
Removal And Installation
There is a kit available to replace the existing engine mounts in older model 853 loaders.
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.
Replace all four engine mounts (2 front and 2 rear).
Use the parts shown to install the new engine mounts [A].
Item 1 – Square Nut – Used on left side engine mounts
Item 2 – Hex Nut – Used on right side engine mounts
Item 3 – Mount Washer
Item 4 – Engine Mount
Item 5 – Tube Spacer – Front 1.47 inch (37,3 mm)
Rear 1.57 inch (39,9 mm)
Item 6 – Snubbing Washer
Item 7 – Mounting Bolt
Install the new engine mount as shown in the cut away side view [B].
Tighten the mounting bolts to 90–100 ft.–lbs. (125–130
Nm) torque.
A
B
Washer
Loader
Frame
Snubbing
Washer
6
5
7
3
4
1
2
MC–01771
Engine
Mounting
Bracket
Engine
Mount
Spacer
MC–01765
–7–39–
853, 853H Loader
Service Manual
GLOW PLUGS
Removal And Installation
Disconnect the negative (–) cable from the battery.
Remove the electrical bar holddown nuts at the glow plugs [A].
A
Remove the electrical connector bar [B].
B
B–08957
B–08919
Remove the glow plug from the cylinder head [C].
C
B–08923
Checking The Glow Plugs
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. If the resistance is zero ohms the glow plug has a short circuit.
If the resistance is infinite, the coil of the glow plug is broken.
D
–7–40–
B–11571
853, 853H Loader
Service Manual
VALVE CLEARANCE
Adjustment
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].
A
Put the correct size feeler gauge between the rocker arm and the valve stem. Turn the adjustment bolt until the clearance is correct [B].
Use the following sequence to set the valve clearance:
Front Rear
1 2 3 4
I E I E I E I E
Cylinder No.
Valve arrangement
Piston in No. 1 cylinder is at TDC on compression stroke
Piston in No. 4 cylinder is at TDC on compression stroke
• • •
• •
•
• •
ENGINE COMPRESSION
Checking
The tools listed will be needed to do the following procedure:
OEM1074 – Engine Compression Kit
MEL1268 – Compression Gauge Test Adapter
The engine must be at operating temperature.
Remove the glow plugs [C]. (See Page 7–40.)
Install the correct compression adapter into the cylinder head.
Connect the compression gauge [D].
The engine must be turning at about 175 RPM.
The compression must be between 300–500 PSI
(2069–3448 kPa) with no more than 50 PSI (345 kPa) difference between cylinders.
The engine has an open crankcase ventilation system.
The ventilation hose comes from the valve cover tube
(Item 1) [D] and passes down the side of the engine block.
B
C
D
1
–7–41–
0.016 inch
(0,41 mm)
Cold
B–04123
B–08934
B–08922
B–08920
853, 853H Loader
Service Manual
FUEL INJECTION PUMP
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.
A
Do not attempt to maintain or adjust unless you are trained and have the correct equipment.
I–2028–0289
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. 1 cylinder are not moving and have clearance [B].
B
The TDC mark (Item 1) [C] 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.
Use the timing marks located at the 3 o’clock position
(Inset) [C].
C
1
B–08976
2
B–08935
12 o’clock Position
12
°
14
°
TDC
16
°
3 o’clock
Position
MC–01665
P–04949
–7–42–
853, 853H Loader
Service Manual
FUEL INJECTION PUMP (Cont’d)
Removal And Installation (Cont’d)
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.
A
B
1
1
P–04949
Early S/N Loader:
Disregard the pointer (Item 1) [C] in the belt shield for timing reference.
C
1
P–04952
Align the mark on the injection pump gear with the pointer in the window [D].
D
–7–43–
B–08939
853, 853H Loader
Service Manual
FUEL INJECTION PUMP (Cont’d)
Removal And Installation (Cont’d)
A
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].
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
Remove the high pressure fuel lines from the engine [C].
C
B–08975
B–08917
B–08915
Align the mark in the window before removing the injection pump [A].
Remove the bolts at the front of the timing case cover [D].
Installation: Tighten bolts & nuts to 10–17 ft.–lbs. (14–23
Nm) torque.
D
–7–44–
B–08938
853, 853H Loader
Service Manual
FUEL INJECTION PUMP (Cont’d)
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.)
A
B–08913
–7–45–
853, 853H Loader
Service Manual
FUEL INJECTION PUMP (Cont’d)
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].
A
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.
Use the timing mark located at the 3 o’clock position
(Inset) [B].
B
1
12 o’clock Position
B–08935
2
12
°
14
°
TDC
16
°
3 o’clock
Position
MC–01665
P–04949
Use the parting line (off–set) (Item 2) [B] or (Item 1) [C] of the timing case cover to make alignment of the TDC mark.
Disregard the pointer (Item 2) [C] in the belt shield for timing reference.
C
2
1
Remove the plug at the rear of the injection pump [D].
D
–7–46–
B–08921
853, 853H Loader
Service Manual
FUEL INJECTION PUMP (Cont’d)
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.
A
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
If not, loosen the bolts at the injection pump flange [C].
Move the injection pump to obtain the 0.020–0.022 inch
(0,51–0,59 mm) reading at the dial indicator with the front pulley marks at the 17
°
BTDC.
Repeat the procedure until the timing is correct.
C
B–08977
B–08977
B–08910
–7–47–
853, 853H Loader
Service Manual
FUEL INJECTOR NOZZLES
Removal And Installation
A
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.
W–2074–1285
Some problems caused by faulty injector nozzles:
The engine is hard to start or will not start.
Rough engine operation and idle.
The engine will not have full power.
The engine exhaust smoke is black, white or blue.
B
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 fuel injection pump [A].
Installation: Tighten the fittings on the high pressure fuel lines to 14–29 ft.–lbs. (19–39 Nm) torque.
Disconnect the fuel lines at the fuel injectors [B].
Remove the high pressure fuel lines from the engine [C].
Remove the low pressure hoses from the fuel injector nozzles [D].
C
D
–7–48–
B–08975
B–08917
B–08915
B–08918
853, 853H Loader
Service Manual
FUEL INJECTOR NOZZLES (Cont’d)
853, 853H Service Manual #6720755 – Engine System Section Part 2 of 4
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.
A
Use a screwdriver and pry the injector from the cylinder head [B].
B
B–08914
B–08924
Remove the injector nozzle from the head [C].
Checking
C
Do not disassemble or test the fuel injector nozzles unless you have the correct service and testing tools.
I–2027–0284
The tools listed will be needed to do the following procedure:
OEM1064 – Injection Nozzle Tester
OEM1065 – Accessory Set
Connect the nozzle to the test pump, in a down position
[D].
Operate the test pump until the nozzle valve opens:
Injection Pressure: 2630 PSI (18134 kPa)
D
–7–49–
B–08916
B–08971
853, 853H Loader
Service Manual
FUEL INJECTOR NOZZLES (Cont’d)
Checking (Cont’d)
If the pressure is not correct, do the following:
Disassemble the injector nozzle and clean.
Replace the shim (Item 6) [A].
Check the pressure again.
A
6
5
3
4
2
1
7
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.
W–2072–1285
Tighten the retaining nut (Item 1) [A] when assembling the injector nozzle to 29–32 ft.–lbs. (39–43 Nm) torque.
Checking nozzles spray pattern [B]:
Does not come out the side of the nozzle. Does not have drops coming from the nozzle. Does not have a solid stream coming from nozzle.
Any of the above conditions show a defect or dirty injector nozzle. Clean or replace any injector nozzle that does not operate correctly.
1.
Retaining Nut
2.
Injection Nozzle
3.
Spacer
4.
Push Rod
5.
Spring
6.
Adjusting Shim
7.
Nozzle Holder
B
CORRECT INCORRECT
B–08959
B–08895
–7–50–
853, 853H Loader
Service Manual
CYLINDER HEAD
Removal And Installation
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.)
Remove the valve cover nuts in the correct sequence [A].
Installation: Tighten the nuts to 6–13 ft.–lbs. (8–17 Nm) torque in the correct sequence [A].
Remove the rocker arm assembly bolts in the correct sequence [B].
Installation: Tighten the bolts in the correct sequence to
36–43 ft.–lbs. (49–58 Nm) torque.
A
B
1
3
2
B–08186
1 3
4
2
Remove the cylinder head bolts in the correct sequence
[C].
C
2
6
10
14
18
15
11
7
3
B–08188
Installation: Lubricate the bolts and tighten them in two steps as listed, in the correct numerical sequence [D].
Step 1 Step 2
New Bolts
Used Bolts
29 ft.–lbs. (39 Nm)
62 ft.–lbs. (83 Nm)
59–67 ft.–lbs.
(80–91 Nm)
72–80 ft.–lbs.
(97–108 Nm)
NOTE: When removing the head, do not use a sharp tool between the head and the engine block.
Always put the cylinder head on a flat surface, such as wood, to prevent damage to the machined surface.
Remove the head from the engine.
See Page 7–53 for removing and reconditioning the valves.
After the cylinder head is installed, adjust the valve clearance. (See Page 7–41.)
–7–51–
D
1
5
17
13
9
13
17
16
12
8
4
B–08189
9
18
14
10
6
5
1
4
8
12
16
2
3
15
7
11
B–08189
853, 853H Loader
Service Manual
CYLINDER HEAD (Cont’d)
Cylinder Head Surface Alignment
Check the surface of the head with the straight edge [A].
A
B–08198
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).
B
Exhaust Manifold
If the exhaust manifold has been removed, use the correct torque sequence and tighten the bolts to 10–17 ft.–lbs. (14–23 Nm) torque [C].
C
4
3
7
8 5
B–08197
1
6
2
B–08187
–7–52–
853, 853H Loader
Service Manual
VALVES, VALVE SEAT AND GUIDE
Removal
The tools listed will be needed to do the following procedure:
MEL1266 – Valve Stem Seal Installer
Mark the valves and parts so they are returned to their original position when assembling.
Remove the valve spring locks [A], using a spring compressor [B].
Remove the valve springs, spring seats, oil seal and valve
[A].
Before reassembly, check the valves, valve seats and guides.
Installation
Make sure the head is clean.
Put oil on the valve guides and valve stems.
Put each valve in the correct location.
Install the valve springs, spring seats and oil seals [A].
NOTE: Install the valve springs with their closed pitched (painted side) end toward the cylinder head.
Use a valve spring compressor and install the valve spring locks.
Tap the valve stem with a hammer a small amount to seat the valve stem locks.
B
A
1.
Spring Seat
2.
Springs
3.
Valve
4.
Oil Seal
5.
Spring Seat
5
4
4
1
2
B–08192
B–08193
Reconditioning The Valve And Valve Seats
Use the correct equipment to grind the valve and valve seats.
The angle of the intake and exhaust valves is 45
°
[C].
The valve head thickness is as listed [C]:
Standard – 0.071 inch (1,8 mm)
Limit – 0.059 inch (1,5 mm)
C
–7–53–
Thickness
45
°
B–08202
853, 853H Loader
Service Manual
VALVES, VALVE SEAT AND GUIDE (Cont’d)
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 0.029 inch (0,74 mm)
Limit 0.05 inch (1,27 mm)
Exhaust – Standard 0.028 inch (0,71 mm)
Limit 0.047 inch (1,20 mm
Check the valve seat contact width [A]:
Intake – Standard 0.067 inch (1,70 mm)
Limit 0.087 inch (2,21 mm)
Exhaust – Standard
Limit
0.079 inch (2,0 mm)
0.098 inch (2,48 mm)
Valve Seat Insert
To remove the valve seat insert, put a bead of weld around the inner face of the insert and allow to cool a few minutes, then pry them out [B].
Press the new valve seat insert into the bore using a hydraulic press.
After installation, grind the insert to the correct angle and check the depth of the valve.
A
B
Valve Seat
Insert
Depression
Welding
Bead
Contact
Width
B–08199
B–08201
0.40 ”
(10 mm)
Valve Guide
The tools listed will be needed to do the following procedure:
MEL1259 – Valve Guide Remover
Check the valve guides for wear with a dial indicator [C].
If the movement is more than the listed specifications, replace the guide.
Intake – Standard 0.0015–0.0027 inch
(0,038–0,069 mm)
Limit 0.008 inch (0,2 mm)
Exhaust – Standard 0.0025–0.0038 inch
(0,064–0,96 mm)
Limit 0.010 inch (0,25 mm)
NOTE: Check the valve stem for wear before replacing the valve guide [D].
C
D
B–08205
–7–54–
Intake
Standard
Exhaust
Standard
0.3128–0.3134 ”
(7,946–7,961 mm)
0.3119–0.3124 ”
(7,921–7,936 mm)
Limit 0.310 ”
(7,88 mm)
B–08204
853, 853H Loader
Service Manual
VALVES, VALVE SEAT AND GUIDE (Cont’d)
Valve Guide (Cont’d)
Remove the guide [A].
A
B–08206
Install the new guide [B].
The height of the valve guide top edge to the cylinder is
0.51 inch. (13,0 mm).
B
Valve Spring
Check the free length and inclination [C].
Free Length
Inner
Outer
Std.
1.783 inch
(45,3 mm)
1.957 inch
(49,7 mm)
––– Inner
Inclination
Outer –––
Limit
1.748 inch
(44,4 mm)
1.898 inch
(48,2 mm)
0.118 inch
(3,0 mm)
0.126 inch
(3,2 mm)
Check the valve spring tension [D].
Inner
Outer
Set Length
1.46 inch
(37,0 mm)
1.54 inch
(39,1 mm)
Std.
13 lbs.
(5,9 kg)
46 lbs.
(20,9 kg)
Limit
11 lbs.
(5,02 kg)
40 lbs.
(18,1 kg)
C
D
–7–55–
Inclination
B–08207
Square
B–08208
B–08209
853, 853H Loader
Service Manual
ROCKER ARM AND SHAFT
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].
Remove the rocker arms (Items 2 & 4) and support brackets (Item 3) [A].
Assembly: The support bracket with the oil hole is toward the front of the engine.
Inspect all the parts for wear or damage.
Check the rocker arm O.D. [B].
Standard – 0.7478–0.7486 inch (18,98–19,0 mm)
Limit – 0.7427 inch (18,85 mm)
A
B
1
2
3
4
5
B–08191
B–08214
Checking Rocker Arm And Push Rods
Check the rocker arm [C].
Rocker arm diameter.
Standard – 0.7489–0.7497 inch (19,01–19,03 mm)
Limit – 0.7505 inch (19,05 mm)
Clearance between rocker arm and shaft.
Standard – 0.0003–0.002 inch (0,008–0,051 mm)
Limit – 0.0078 inch (0,20 mm)
Replace the parts as needed.
Check the push rods for run–out [D].
Limit – 0.012 inch (0,3 mm)
C
D
B–08215
–7–56–
B–08213
853, 853H Loader
Service Manual
PISTON AND CONNECTING ROD
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.
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.
Remove the nuts and remove the bearing caps [B].
NOTE: If the bearings are to be used again, they must be identified so they are returned to their original location.
A
B
F
1
F
2
F
3
F
4
B–03248
A–02344
Using a hammer handle, push the piston and rod out of the block [C].
After the pair has been removed, rotate the engine crankshaft and remove the other pair of pistons.
C
B–08909
Disassembly
Remove the rings from the pistons [D].
D
–7–57–
B–08194
853, 853H Loader
Service Manual
PISTON AND CONNECTING ROD (Cont’d)
Disassembly (Cont’d)
Remove the piston pin snap ring [A].
A
Drive out the piston pin using a brass rod [B].
B
B–08195
P–08196
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)
2nd
Compression
Oil
0.002–0.0033 inch
(0,05–0,085 mm)
0.001–0.003 inch
(0,03–0,07 mm)
Check the piston diameter [D].
0.006 inch
(0,15 mm)
0.006 inch
(0,15 mm)
0.006 inch
(0,15 mm)
Pistons are available in two sizes.
Piston Grade A 3.6608–3.6616 inch
(92,985–93,004 mm)
Piston Grade C 3.6616–3.6624 inch
(93,005–93,024 mm)
Refer to parts fiche when ordering pistons, piston rods and cylinder liners.
C
D
–7–58–
B–08228
2.9 ”
(74 mm)
B–08227
853, 853H Loader
Service Manual
PISTON AND CONNECTING ROD (Cont’d)
Checking (Cont’d)
Check the ring gap in the cylinder bore [A].
Standard
Compression 0.008–0.016 inch
(0,20–0,40 mm)
Limit
0.059 inch
(1,50 mm)
Oil 0.004–0.012 inch
(0,10–0,30 mm)
0.059 inch
(1,50 mm)
A
Check the piston pin diameter [B].
Standard – 1.220 inch (31,0 mm)
Limit – 1.219 inch (30,97 mm)
B
Check the clearance between piston pin and piston pin bore [C].
Clearance – 0.00008–0.00006 inch
(0,002–0,015 mm)
C
Check the connecting rod alignment [D].
Standard – 0.002 inch (0,50 mm) or less
Limit – 0.0079 inch (0,20 mm)
D
–7–59–
B–08229
P–08230
B–08231
B–08232
853, 853H Loader
Service Manual
PISTON AND CONNECTING ROD (Cont’d)
Checking (Cont’d)
Check the connecting rod small end bushing [A].
Standard – 1.2208–1.2211 inch (31,008–31,015 mm)
A
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)
B
Replace the small end bushing if not within specifications using a hydraulic press [C].
C
After installation of a new bushing, finish the bushing bore to the correct specifications [D].
D
–7–60–
B–08233
P–08230
B–08200
B–08203
853, 853H Loader
Service Manual
PISTON AND CONNECTING ROD (Cont’d)
Assembly
Heat the piston to about 140
°
F (60
°
C) [A].
A
Assemble the piston and connecting rod [B].
B
–7–61–
B–08251
C–02936
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.
C
1
2
Install the piston pin. Install the snap rings [D].
D
B–08252
B–08195
853, 853H Loader
Service Manual
PISTON AND CONNECTING ROD (Cont’d)
Assembly (Cont’d)
Install the rings on the piston [A].
The face with the mark NPR or TOP must be turned up for the 1st and 2nd compression rings.
A
Marked Side Up
1st Comp.
2nd Comp.
Oil
B–08253
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
B–03337
Put oil on the bearings. Install the bearing cap [C].
C
B–03208
Tighten the nuts to 58–65 ft.–lbs. (78–88 Nm) torque [D].
Rotate the crankshaft to put the other pair of crank pins at bottom dead center. Repeat the procedure and install the other pair of pistons.
D
–7–62–
58–65 ft.–lbs.
(78–88 Nm)
B–03325
853, 853H Loader
Service Manual
CYLINDER LINERS
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].
Measuring point is done approximately 0.75 inch (20 mm) below the top of the cylinder bore.
Standard – 3.6622–3.6638 inch (93,021–93,060 mm
Limit – 3.6653 inch (93,10 mm)
Removal
Remove all the parts from the engine.
Using a cylinder liner tool, remove the cylinder liner from the engine block [B].
There is only one size liner available.
Installation
The tools listed will be needed to do the following procedure:
MEL1262 – Cylinder Liner Installer
Clean the bore and remove any metal burrs.
Clean the grease from the cylinder liner and dry it.
Use dry ice to cool the cylinder liner, so it will install easier and smoothly into the engine block.
Using the correct tool, install the cylinder liner [C].
First apply a load of 1103 lbs. (500 kg) using a hydraulic press.
NOTE: Do Not use a hammer to install the cylinder liners.
Then, apply a final load of 5513 lbs. (2500 kg). Push the liner in until 0–0.0039 inch (0–0,10 mm) of the liner is above the block face [D].
NOTE: The liners are chrome plated and must not be honed after installation.
Measure the inside diameter of the liner and select the correct size piston for the liner.
Minimum Diameter
Piston Grade A 3.6622–3.6630 inch
(93,021–93,040 mm)
Piston Grade C 3.6630–3.6638 inch
(93,041–93,060 mm)
Refer to parts fiche when ordering pistons, piston rods and cylinder liners.
–7–63–
A
B
C
D
0.75 ”
(20 mm)
B–08223
B–08224
B–08225
B–08226
853, 853H Loader
Service Manual
MAIN BEARINGS
Description
The crankshaft has five main bearings. The end play is controlled by a thrust washer on both sides of the center main bearing.
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.
A
FRONT
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.
Remove the main bearing cap and remove the bearing from the cap half.
Remove the top half of the bearing by pushing on one side of the bearing half and rotating the crankshaft [B].
B
On the center main bearing, remove the cap.
Remove the top half of the bearing and thrust washers by pushing on one side of the bearing and rotating the crankshaft [C].
C
B–08256
B–01865
B–08255
–7–64–
853, 853H Loader
Service Manual
MAIN BEARINGS (Cont’d)
Installation
Check the bearing spread as listed [A].
Limit – 2.93 inch (74,5 mm)
A
Check to see if the bearing has enough tension, so that finger pressure is needed to fit the bearing into the cap
[B].
B
B–08241
B–08242
Fit Correctly
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].
Lubricate the new bearings. Install them by putting the end without the tab into the block and rotating the crankshaft until the tab is on its seat.
Install the other bearing half in the bearing cap. Lubricate the bearing and install the cap on the engine block.
Lubricate the bolts, install them finger tight only.
Install the center main bearing and thrust washers [D].
The thrust washer must be installed so that their oil grooves are turned to the rotating face of the crankshaft.
Repeat the procedure until all the main bearings and caps are installed.
C
With Oil Hole and Groove
(Upper Side)
D
No Oil Groove and Hole
(Lower Side)
B–08254
–7–65–
B–08255
853, 853H Loader
Service Manual
MAIN BEARINGS (Cont’d)
Installation (Cont’d)
Tighten the crankshaft bearing cap bolts in the correct sequence [A].
Torque – 116–130 ft.–lbs. (157–176 Nm).
A
10
9
5
6
2
3
1
7
4
8
B–08257
Crankshaft End Play
The end play can be checked by either a feeler gauge [B] or dial indicator [C].
Standard End Play
Limit
. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
0.004 inch (0,10 mm)
0.012 inch (0,30 mm)
The fitting of oversize thrust washer can be used to correct the end play if it is over the specifications.
B
B–03347
C
B–03291
–7–66–
853, 853H Loader
Service Manual
CRANKSHAFT
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.)
Remove the flywheel.
Remove the connecting rod cap. (See Page 7–57.)
Remove the main bearing cap. (See Page 7–64.)
Lift the crankshaft out of the engine block.
Checking Tuffriding (Soft Nitriding) Coating
Clean the crankshaft thoroughly using an organic solvent.
Make sure there is no oil or grease in the area to be tested.
Using a glass rod, put a drop of cupric ammonium chloride
5/10% solution at the test location [A].
If no change takes place after an interval of 30–40 seconds, the crankshaft can be re–used if within specifications.
Replace the crankshaft, if within the 30–40 seconds, the original color of the solution (light blue in color) becomes transparent where the test solution was dropped and will discolor to a copper color.
Immediately after the test is completed, wipe off the area with a cloth and thoroughly rinse with water.
NOTE: Since the crankshaft is tuffride coated it cannot be reground.
Checking The Crankshaft
Check the crankshaft connecting rod journals [B].
Standard – 2.0833–2.0839 inch (52,915–52,930 mm)
Limit – 2.0829 inch (52,906 mm)
A
The portion to be tested shall be held horizontally so as not to let the test solution flow.
No testing solution near the oil hole.
The sliding surface of the pin or journal
Approximately
0.393 inch (10 mm)
B–08243
B
B–08244
–7–67–
853, 853H Loader
Service Manual
CRANKSHAFT (Cont’d)
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)
A
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 – 0.0011–0.0026 inch (0,029–0,066 mm)
Limit – 0.004 inch (0,10 mm)
B
Check the clearance between main bearings and crankshaft journals [C].
Install the main bearing and caps and tighten the bolts to
116–130 ft.–lbs. (157–176 Nm) torque. Put oil on the main bearings and measure.
Nominal Diameter – 2.76 inch (70,0 mm)
Clearance between the journal and bearing:
Standard – 0.0014–0.0031 inch (0,035–0,080 mm)
Limit – 0.0043 inch (0,11 mm)
C
Check the crankshaft run–out [D].
Standard – 0.0019 inch (0,05 mm) or less
Limit – 0.003 inch (0,08 mm)
D
–7–68–
B–08246
B–08245
B–08247
B–08248
853, 853H Loader
Service Manual
CRANKSHAFT GEAR
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].
A
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.
Install the main bearing caps and bolts. (See Page 7–64.)
Check the crankshaft so that it rotates freely. Check the end play. (See Page 7–66.)
Install a new rear oil seal [C]. Using the correct size driver tool.
Lubricate the connecting rod bearings. Install the bearings and rod caps. (See Page 7–62.)
Install the oil pump. (See Page 7–82.)
Install the oil pan. (See Page 7–81.)
Install the timing gears, timing gearcase cover and new front seal. (See Page 7–81.)
Install the flywheel. (See Page 7–37.)
B
C
B–08249
B–08250
B–08261
–7–69–
853, 853H Loader
Service Manual
TIMING GEARCASE COVER SEAL
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.
Install a standard puller and remove the crankshaft pulley
[B].
A
B
Use a screwdriver and pry the front seal out of the timing case cover [C].
C
Use the seal installation tool and install the new seal [D].
D
–7–70–
B–08946
B–08948
853, 853H Loader
Service Manual
B–08945
B–08983
B–08943
TIMING GEARCASE COVER
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.
A
Use a puller to remove the crankshaft pulley [B].
B
Remove the bolts which fasten the noise dampening shield to the timing case cover [C].
C
Remove the noise dampening shield [D].
D
–7–71–
B–08945
B–08943
B–08947
B–08942
853, 853H Loader
Service Manual
TIMING GEARCASE COVER (Cont’d)
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.
A
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
Remove the timing gearcase cover [C].
C
B–08940
B–08941
B–08974
Installation: Put the O–ring gasket in the groove and hold it in position using Form–A–Gasket so it will not fall out when installing the cover [D].
D
–7–72–
B–08956
853, 853H Loader
Service Manual
IDLER GEAR AND HUB
Removal
Remove the timing gearcase cover. (See Page 7–71.)
Remove the bolts at the tube for gear lubrication [A].
A
Remove the tube [B].
B
B–08929
B–08928
Remove the bolts at the idler gear [C].
Installation: Tighten the bolts to 10–12 ft.–lbs. (14–16
Nm) torque.
C
Remove the idler gear and hub [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.
Limit – 0.0079 inch (0,20 mm)
Check the end play at the gear and hub.
Standard – 0.003 inch (0,07 mm)
Limit – 0.008 inch (0,20 mm)
–7–73–
D
B–08926
B–08933
853, 853H Loader
Service Manual
IDLER GEAR AND HUB (Cont’d)
853, 853H Service Manual #6720755 – Engine Service Section Part 3 of 4
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).
A
B–08995
–7–74–
853, 853H Loader
Service Manual
FUEL INJECTION PUMP IDLER GEAR
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.
A
Remove the idler gear and bearing [B].
B
B–08930
B–08927
If the bearing needs replacement, remove the snap ring at the bearing [C].
Use a press to remove and install the new bearing.
C
Bearing Installation
When installing the new bearing, make sure the projection and height is correct [D].
Projection – 0.016–0.024 inch (0,40–0,60 mm)
Height – 0.933–0.945 inch (23,7–24,0 mm)
D
–7–75–
B–08955
Projection
B–08896
853, 853H Loader
Service Manual
CAMSHAFT GEAR
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.
A
Install the puller and remove the gear [B].
B
B–08931
B–08932
Remove the bolts at the retainer plate [C].
Installation: Tighten the bolts to 11–17 ft.–lbs. (15–23
Nm) torque.
C
Remove the retainer plate [D].
Installation: Check the camshaft end play.
Standard – 0.002–0.0045 inch (0,05–0,114 mm)
Limit – 0.0079 inch (0,20 mm)
D
–7–76–
B–08980
B–08979
853, 853H Loader
Service Manual
TIMING GEARCASE
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.)
Remove the oil pan. (See Page 7–81.)
Remove the bolts at the timing case [A].
Installation: Tighten the bolts to 11–17 ft.–lbs. (15–23
Nm) torque.
Remove the timing case [B].
A
B
Installation: After the timing case cover is installed with the new gasket, cut the excess gasket at the engine block
[C].
C
B–08925
B–08937
B–08952
–7–77–
853, 853H Loader
Service Manual
CAMSHAFT
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.
Checking
Check the camshaft journals [A].
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 – 1.9685–1.9697 inch (50,0–50,03 mm)
Clearance between camshaft journal and bearing:
Standard – 0.002 inch. (0,05 mm)
Limit – 0.0047 inch (0,12 mm)
A
B
C
Check camshaft run–out [C].
Limit – 0.0039 inch (0,10 mm)
Check cam lobe height [D].
Standard – 1.654 inch (42,02 mm)
Limit – 1.640 inch (41,65 mm)
D
–7–78–
B–08217
B–08218
B–08221
B–08222
853, 853H Loader
Service Manual
CAMSHAFT (Cont’d)
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].
A
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].
B
B–08219
1
B–08220
Tappets
Remove the tappets from the engine block. Mark the cylinder number on each tappet after removal [C].
C
B–08190
Inspect the tappets for wear, damage or abnormal conditions [D].
D
Pitted
Crack Normal Contact
–7–79–
Irregular Contact
B–08210
853, 853H Loader
Service Manual
CAMSHAFT (Cont’d)
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)
A
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
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. (See Page 7–76.)
Check the camshaft end play using a feeler gauge [C].
Standard – 0.0002–0.0045 inch (0,05–0,114 mm)
Limit – 0.0079 inch (0,20 mm)
After the rocker arm assembly is installed, make sure to set the valve clearance. (See Page 7–41.)
C
B–08211
B–08212
B–08216
–7–80–
853, 853H Loader
Service Manual
OIL PAN
Removal
Remove the oil drain plug and remove the oil.
Remove the fastening bolts and nuts from the oil pan [A].
A
B–08953
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].
Put liquid gasket on the oil pan surface area of the engine block.
B
C
1
1
B–08418
Install the oil pan. Install and tighten the bolts in the sequence shown [D].
Tighten the bolts and nuts to 13–18 ft.–lbs. (19–26 Nm) torque.
D
1
B–08911
–7–81–
B–12200
853, 853H Loader
Service Manual
OIL PUMP
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.
A
Remove the oil pump assembly from the engine block [B].
B
B–08912
Checking
Disassemble the oil pump as illustrated [C].
C
1.
Oil Pipe
2.
Strainer
3.
Pump Cover
4.
Vane
1
B–08982
–7–82–
2
4
3
B–08420
853, 853H Loader
Service Manual
OIL PUMP (Cont’d)
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)
A
B–08421
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 – 0.0079 inch (0,2 mm)
B
Gear Replacement
File off one end of the roll pin at the gear. Use a punch and hammer and remove the pin [C].
C
B–08422 B–08423
B–08424
NOTE: It may be necessary to drill a hole in one side of the gear for service as it does not have a hole on both sides [D].
Installation: Install the gear and new pin. Peen the end of the pin after installation.
D
–7–83–
B–08425
853, 853H Loader
Service Manual
OIL PUMP (Cont’d)
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.
A
Oil Pump Relief Valve
Remove the relief valve from the oil filter housing [B].
Check the relief valve and clean. Replace as needed.
B
B–08426 B–08427
Oil Filter Housing And Block
To remove the oil filter block & housing, disconnect the tubelines (Item 1) [C] & [D].
remove the four mounting bolts (Item 2) [C] at the block.
C
2
Remove the two mounting bolts (Item 2) [D] at the oil filter housing.
D
B–08949
2
1
P–04943
–7–84–
1
2
P–04953
853, 853H Loader
Service Manual
WATER PUMP
Removal And Installation
Remove the alternator belt.
Remove the water pump pulley [A].
A
Remove the water pump bolts [B].
Installation: Tighten the bolts to 11–18 ft.–lbs. (15–24
Nm) torque.
B
Remove the water pump from the engine block [C].
C
B–08951
B–08950
B–08972
Disassembly
Remove the hub for the pulley using a press [D].
D
–7–85–
B–08429
853, 853H Loader
Service Manual
WATER PUMP (Cont’d)
Disassembly (Cont’d)
Disassemble the water pump [A].
A
Check the bearing for abnormal noise, binding or wear
[B].
Replace the parts as needed.
B
Assembly
Apply a thin coat of liquid gasket cement to the outer surface of the seal unit before assembly [C].
C
Press the bearing assembly into position by aligning the set screw hole in the bearing with that in the pump body
[D].
D
–7–86–
B–08428
B–08430
B–08432
B–08431
853, 853H Loader
Service Manual
WATER PUMP (Cont’d)
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)
A
Check the distance between the pulley hub and pump body [B].
Distance – 3.12–3.14 inch (79,2–79,8 mm)
B
0.98 ”
(24,8 mm)
B–08433
3.12–3.14 ”
(79,2–79,8 mm)
B–08434
–7–87–
853, 853H Loader
Service Manual
THERMOSTAT
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.
A
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
If the thermostat housing assembly is removed, tighten the bolts to 10–17 ft.–lbs. (14–34 Nm) torque [C].
C
B–08954
B–08435
B–08419
–7–88–
853, 853H Loader
Service Manual
WATER JACKET TUBE
853, 853H Service Manual #6720755 – Engine Service Section Part 4 of 4
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.)
Remove the water pump. (See Page 7–85.)
Grip the edge of the water jacket tube with a vise grip. Use a screwdriver to pry the jacket from the engine block [A].
Remove the water jacket tube from the engine block [B].
A
B
B–08981
B–08936
–7–89–
853, 853H Loader
Service Manual
–7–90–
853, 853H Loader
Service Manual
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
RPM SENSOR
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
SENDER AND SENSOR
Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8–3
8–3
TROUBLESHOOTING THE BOSS
®
& LCD DISPLAY
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7
B.O.S.S. – Bobcat Operation Sensing System
L.C.D. – Liquid Crystal Diode
SYSTEMS
ANALYSIS
–8–1–
853,853H Loader
Service Manual
–8–2–
853, 853H Loader
Service Manual
BOSS
®
DIAGNOSTIC TOOL
Procedure
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.
NOTE: Early S/N loaders have the diagnostic plug located at rear window as shown in Fig. [B].
Use the instructions from the BOSS Operation &
Maintenance Manual to make service checks of BOSS system operating unit and other components [A].
SENDER AND SENSOR
Service Checks
Use the following information when checking the senders and sensor with a volt/ohmmeter:
Component Value
TEMPERATURE SENDER
70 degree F. (21 degree C.)
80 degree F. (27 degree C.)
. . . . . . . . . . . . .
. . . . . . . . . . . .
970 ohms
1013 ohms
ENGINE OIL PRESSURE SENDER
0 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 PSI (41 kPa) . . . . . . . . . . . . . . . . . . . . . . .
50 PSI (345 kPa)
70 PSI (483 kPa)
3 ohms Max.
7 ohms Min.
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
49 ohms
59 ohms
TRANSMISSION CHARGE PRESSURE SENDER
0 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100 PSI (690 kPa)
130 PSI (896 kPa)
150 PSI (1034 kPa)
0–5 ohms
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
58 ohms
75 ohms
87 ohms
FUEL SENDER
Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 ohms
270 ohms
A
B
1
P–03871
CD–09025
–8–3–
853,853H Loader
Service Manual
RPM SENSOR
Adjustment
Continuity Resistance of 3000–3500 ohms.
Disconnect the connector [A] from the engine harness.
Loosen the jam nut (Item 1) [A] on the RPM sensor.
A
Turn the RPM sensor (Item 1) [B] in until it makes contact with the engine flywheel.
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.
Turn the RPM sensor and the jam nut out from the flywheel. Set a clearance of 0.050’’ (1,27 mm) between the jam nut and the housing with a feeler gauge [B].
Retighten the jam nut.
NOTE: The plastic tip is used as a gauge to set a new
RPM SENSOR. The plastic tip is designed to come off after the engine is started.
B
1
1
P–05193
P–05192
–8–4–
853, 853H Loader
Service Manual
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. 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
SUBJECT
Engine Coolant Level
Engine Coolant Temp.
DISPLAY READS
ECL 1
Engine Oil Pressure
Engine Speed
Air Filter
Battery
Fuel Level
ES–2.1
ES–6
ES–7
AF 2
AF 6 b–2.1
b–2.2
FUEL2
FUEL3
FUEL4
FUEL5
FUEL7
EP 1
EP 2
EP 3
EP 4
EP 5
EP 7
ES 1
EC–1.1
EC–2.1
EC 3
EC 4
EC 5
EC 7
–8–5–
CONDITION
SHUTDOWN, No Coolant
SHUTDOWN, Engine Temperature
WARNING, Engine Temperature
Wiring Not Connected
Wiring Shorted
High Sensor Voltage
Sensor Out Of Range
SHUTDOWN, Pressure
WARNING, Pressure
Wiring Not Connected
Wiring Shorted
High Sensor Voltage
Sensor Out Of Range
SHUTDOWN, Engine Speed Too High
WARNING, Engine Speed Slightly High
Sensor No Signal
Sensor Out Of Range
WARNING, Restriction Too High
Sensor No Signal
WARNING, Bad Battery
WARNING, Battery Voltage
WARNING, Low Level
Wiring Not Connected
Wiring Shorted
High Sensor Voltage
Sensor Out Of Range
853,853H Loader
Service Manual
SUBJECT
Hydrostatic Charge
Filter Condition
DISPLAY READS
HF1–2
HF1–6
Hydrostatic Fluid
Hydrostatic Fluid
Temperature
HP 1
HP 2
HP 3
HP 4
HP 5
HP 7
HC 1
HC 2
HC 3
HC 4
HC 5
HC 7
CONDITION
WARNING, High Restriction
Sensor No Signal
SHUTDOWN, Pressure
WARNING, Pressure
Wiring Not Connected
Wiring Shorted
High Sensor Voltage
Sensor Out Of Range
SHUTDOWN, Temperature
WARNING, Temperature
Wiring Not Connected
Wiring Shorted
High Sensor Voltage
Sensor Out Of Range
–8–6–
853, 853H Loader
Service Manual
TROUBLESHOOTING THE BOSS
®
& LCD DISPLAY
Chart
SUBJECT
BOSS
LCD Display
SYMPTOM INDICATES TO CORRECT SYMPTOM
Temperature related shutdown codes when no heating occurs.
12 volt supply and
BOSS failure.
*
NOTE: You may have some or all of the codes listed. You will have high temps, high press, low voltage and low fuel.
1.
Check stored defects with the BOSS tool.
*2.
If defect list has EC1, HC1, EC2.1, HC2. EP3,
EP7, HP7, B2.2, low fuel, Fuel 7 and last occurrence hr. readings are within a hundredth, the BOSS is defective and must be replaced.
3.
Using a voltmeter, check the alternator output.
Intermittent code of
ES6 while engine running.
Display is dead – No
Icons, Bar Graphs,
Hourmeter.
Sensor No Signal or
No RPM’s.
1.
ES6 will occur if the loader is stalled or shutdown during run cycle. The code is generated due to the lack of RPM and the existence of residual pressure in the system.
LCD DISPLAY
CONNECTOR
A B C D E
Lack of 5.0 volts regulated power.
1.
Check pin A for 5.0 volts. If 5.0 volts is present replace the display.
2.
If no power exists at pin A, install BOSS backup to confirm the BOSS system.
3.
If the problem still exists, check the harness for continuity.
12 Volt – Back Light
Ground
Negative Com. .5 to 1.5 Volts
Positive Com. 3.5 to 4 Volts
5.0 Volts Regulated Power
Power Display Operation
During an active
WARNING display, reset occurs and the hourmeter becomes all zero’s.
Low voltage (5.0) triggered reset.
1.
Turn the ignition switch OFF. Re–starting will return hourmeter reading.
2.
If re–starting will not return hourmeter reading, check pins B & C as stated in Step 5 below.
Garbled message, missing segments, etc.
The display is not fault tolerant. Also can be an indication of poor internal connections.
1.
Turn the ignition switch OFF and re–start. A fault is an invalid message that the display tries to display. Generally a fault occurs if communications of two messages are combined on the display.
After glow sequence or after a WARNING goes away, the Icon remains ON.
1.
Turn the key OFF and re–start.
No Bar Graphs, no
Hours.
Bad display or BOSS is not communicating.
*
NOTE: The display has caused the problem by locking the communication lines and stopping communications from the BOSS.
1.
Plug in the BOSS tool and start the engine.
2.
If data is being received by the BOSS tool, the
BOSS unit is not the cause of the problem.
3.
If no data is received at the BOSS tool.
disconnect the LCD display.
*4.
If messages are now received at the tool, the display is the problem. If problem still exists go to
Step 5.
5.
Check pins B & C for signal.
6.
If there is no signal, install BOSS backup unit.
7.
If the problem still exists, check the harness for continuity.
–8–7–
853,853H Loader
Service Manual
BOSS
®
UNIT
Removal And Installation
Raise the loader operator cab. (See Page 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.
A
1
2
Remove the two connectors (Item 1) [B] from the sensing system unit (Item 2) [B].
Installation: Put the heads of the mounting bolts into the slots of the operator cab and slide the unit back into place.
Tighten the three mounting nuts to 80–90 in.–lbs. (9–10
Nm) torque.
B
1
1
P–04043
2
1
P–04042
–8–8–
853, 853H Loader
Service Manual
BOSS
®
INSTRUMENT PANEL
853, 853H Service Manual #6720755 – BICS System Section
Removal And Installation
Pry the rubber light mount from the operator cab (both sides) [A].
A
Lower the light from the operator cab and remove the three panel mounting bolts (Item 1) [B] (both sides.)
B
1
Pull the left panel (Item 1) [C] down from the operator cab.
Installation: Do not overtighten the panel mounting bolts to prevent stripping the threaded holes of the panels.
Disconnect the wire harness connectors from the panel and remove the panel.
C
Remove the three mounting bolts and pull the right panel
(Item 1) [D] down from the operator cab.
Installation: Do not overtighten the panel mounting bolts to prevent stripping the threaded holes of the panels.
Disconnect the wire harness connectors from the panel and remove the panel.
D
1
–8–9–
1
P–03995
P–03955
1
P–03958
P–03959
853,853H Loader
Service Manual
–8–10–
853, 853H Loader
Service Manual
SPECIFICATIONS
Page
Number
DECIMAL & MILLIMETER EQUIVALENTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
ENGINE SPECIFICATIONS
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod & Bearing
Crankshaft
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head
Cylinder Liners
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System
Idler Gear
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons, Pins & Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arm
Tappets
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, Valve Guide & Seat Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9–6
9–6
9–7
9–5
9–6
9–7
9–7
9–7
9–6
9–5
9–5
9–5
9–5
HYDRAULIC CONNECTION SPECIFICATIONS
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O–ring Face Seal Connection
O–ring Flare Fitting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Straight Thread O–ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9–12
9–12
9–13
9–15
9–12
9–12
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–16
LOADER SPECIFICATIONS
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical
Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System
Loader Dimensions
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation & Performance
Tires
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9–4
9–3
9–4
9–4
9–3
9–4
9–3
9–3
9–4
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9–10
9–11
TORQUE SPECIFICATIONS FOR LOADER
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
U.S. TO METRIC CONVERSION
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
SPECIFICATIONS
–9–1–
853, 853H Loader
Service Manual
–9–2–
853, 853H Loader
Service Manual
LOADER SPECIFICATIONS
Loader Dimensions
•
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.
95 o
153.5
(3899)
63.3
(1608)
119.6
(3038)
76.7
(1948)
40 o
23.4
(594)
48.4
(1229)
93.07
(2364)
80.9
(2055)
45 o
38.0
(965)
61.5
(1562)
25 o
36.1
(917)
30 o
8.0
(204)
38.6
(980)
6.2
(157)
51.6
(1311)
*101.8
(2586)
60.8
(1544)
128.7
(3269)
MC–1113
* Overall Length W/O Bucket
This loader was designed without counterweights or ballasts. Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.
Performance
Operating Weight
Rated Operating Capcity
Tipping Load
. . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . .
Controls
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loader Function . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake . . . . . . . . . . . . . . . . . . . . . .
Engine
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model
Fuel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horsepower
Maximum Governed RPM
Torque
. . . . . . . . . . . . . . . . . . . . . . . .
Number of Cylinders
. . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .
Bore/Stroke
Displacement
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
Cooling System
Lubrication
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Ventilation
Air Cleaner
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
Ignition
Low Idle
High Idle
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
–9–3–
6497 lbs. (2950 kg)
1700 lbs. (772 kg)
3420 lbs. (1533 kg)
Infinitely variable 0–6.3 MPH (10,1 km/hr.)
Direction & speed controlled by two hand levers.
Lift, tilt functions controlled by separate foot pedals. Auxiliary functions controlled by electrical push buttons on steering levers
Hand lever throttle; key–type starter switch.
Hydrostatic
Mechanical disc, foot operated pedal
Isuzu
4JB1 PK–03
Diesel
62 HP (46 kW)
2600 RPM
137 ft.–lbs. (186 Nm) @ 1800 RPM
Four
3.66/4.02 (93/102)
169 cu.in. (2769 cu. cm.)
Liquid
Pressure System W/Filter
External
Dry replaceable cartridge, dual safety element
Diesel–Compression
1150 RPM
2750 RPM
853, 853H Loader
Service Manual
LOADER SPECIFICATIONS (Cont’d)
Hydraulic System
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Capacity . . . . . . . . . . . . . . . . . . . . .
System Main Relief . . . . . . . . . . . . . . . . . .
Filters (charge & implement) . . . . . . . . . .
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . .
Bore Diameter:
Lift Cylinder (2)
Tilt Cylinder (1)
Rod Diameter:
Lift Cylinder (2)
Tilt Cylinder (1)
Stroke:
Lift Cylinder (2)
Tilt Cylinder (1)
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
Control Valve . . . . . . . . . . . . . . . . . . . . . . .
Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Function Time:
Raise Lift Arms to Maximum Height . . . .
Lower Lift Arms from Maximum Height .
Move Empty Bucket to Dump Position
Move Bucket to Retracted Position
.
. . . .
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical
Alternator
Battery
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive System
Transmission
Final Drive
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
Total Engine to Wheel Reduction . . . . . .
Capacities
Cooling System
Fuel
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil W/Filter
Hydraulic Reservoir
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
Hydraulic/Hydrostatic System
Chaincase Reservoir
. . . . . . . . .
. . . . . . . . . . . . . . . .
Tires
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure
Flotation
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .
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
Doubleacting
2.25 (57,2)
3.25 (82,6)
1.50 (38,1)
1.50 (38,1)
33.5 (851)
18.9 (480)
3–spool, open center, series type W/float detent on lift, single spool electrical control front auxiliaries.
SAE standard tubes, hoses & fittings
4.0 Seconds
3.4 Seconds
2.3 Seconds
1.9 Seconds
Bobcat Fluid (P/N 6563328); If fluid is not available, use
10W–30/10W–40 Class SE, SF, SG Motor Oil for temperatures above 0 o
F (–18 o
C)
& 5W–30 Motor Oil for temperatures below 0 o
F (–18 o
C).
Belt drive, 55 amps. Open
12 volt, 700 cold crank amps. @ 0 o
F (–18 o
C) 170 min. reserve capacity
12 volt
,
3.7 HP (2,8 kW)
Tandem hydro. pumps infinitely variable, driving 2 fully reversing hydrostatic motors
Gear Reduction & #100 HS roller chain & sprockets in sealed chaincase with oil lubrication
47:27:1
22 qts. (20,8 L)
25 gals. (95 L)
8 qts. (7,6 L)
15.5 qts. (14.7 L)
8 gals. (30,3 L)
9 gals. (34,1 L)
8.25–15, 6 Ply Rating, Nylon with Bar Lug Tread
45–50 PSI (310–345 kPa)
12:00–16,5, 6 Ply Rating, Nylon with Sure Grip Lug
30–35 PSI (207–240 kPa)
–9–4–
853, 853H Loader
Service Manual
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Seat Angle
Limit 0.012 (0,30)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
Valve, Valve Guide & Seat Insert
Valve Seat Width
Intake
Exhaust
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Std. 0.067 (1,70)
Limit 0.087 (2,20)
Std. 0.079 (2,00)
Limit 0.098 (2,50)
Valve Head Depth
Intake
Exhaust
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Std. 0.029 (0,73)
Limit 0.05 (1,28)
Std. 0.028 (0,70)
Limit 0.047 (1,20)
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Head Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 degrees
Std. 0.07 (1,80)
Limit 0.059 (1,50)
Valve Stem Diameter
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.3128–0.3134 (7,945–7,960)
Limit 0.310 (7,87)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.3119–0.3124 (7,922–7,935)
Limit 0.310 (7,87)
Valve & Valve Guide Clearance
Intake
Exhaust
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Guide Height
Std. 0.0015–0.0027 (0,038–0,069)
Limit 0.008 (0,20)
Std. 0.0025–0.0038 (0,064–0,097)
Limit 0.010 (0,25)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51 (13,0)
Valve Springs
Free Length
Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 1.783 (45,3)
Limit 1.748 (44,4)
Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 1.957 (49,7)
Limit 1,898 (48,2)
Inclination
Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit 0.118 (3,00)
Limit 0.126 (3,20)
Tension
Inner – Set Length
Outer – Set Length
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.46 (37) Std. 13 lbs. (5,9 kg)
Limit 11 lbs. (5,02 kg)
1.54 (39) Std. 46 lbs. (20,9 kg)
Limit 40 lbs. (18,2 kg)
Rocker Arm
Shaft Diameter
Rocker Arm I.D.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Std. 0.7478–0.7486 (18,99–19,01)
Limit 0.7427 (18,86)
Std. 0.7489–0.7497 (19,02–19,04)
Limit 0.7505 (19,06)
Clearance Between Rocker Arm & Shaft
Push Rod Run–Out
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.0003–0.0020 (0,008–0,05)
Limit 0.0078 (0,2)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limit 0.012 (0,3)
Tappets
Diameter
Clearance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.511–0.5114 (12,98–12,99)
Limit 0.510 (12,95)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.0012 (0,03)
Limit 0.0039 (0,10)
–9–5–
853, 853H Loader
Service Manual
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
Piston Grade C
Clearance in Bore
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance Between Ring & Piston Groove
3.661–3.662 (92,99–93,015)
3.662–3.663 (93,015–93,04)
Std. 0.001–0.0018 (0,025–0,04)
1st Compression
2nd Compression
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Std. 0.0035–0.0049 (0,09–0,124)
Limit 0.006 (0,15)
Std. 0.002–0.0033 (0,05–0,084)
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit 0.006 (0,15)
Std. 0.001–0.003 (0,03–0,08)
Limit 0.006 (0,15)
Piston Ring Gap
Compression
Oil
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Std. 0.008–0.016 (0,20–0,40)
Limit 0.059 (1,50)
Std. 0.004–0.012 (0,1–0,30)
Limit 0.0059 (1,50)
Piston Pin O.D.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 1.220 (30,99)
Inference Fit Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit 1.219 (30,96)
0.00008–0.0006 (0,002–0,015)
Connecting Rod & Bearing
Connecting Rod Misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.002 (0,05) or less
Limit 0.0079 (0,20)
Small End Bushing I.D.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance Between Piston Pin &
Small End Bushing
Std. 12208–1.2211 (31,008–31,06)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . St. 0.0003–0.00079 (0,008–0,20)
Limit 0.0002 (0,05)
Clearance Between Crankshaft Journal &
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.001–0.0026 (0,029–0,066)
Limit 0.004 (0,10)
Cylinder Liners
Cylinder Liner I.D.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Std. 3.6622–2.6638 (93,02–93,06)
Inference Fit in Block
Projection Above Block
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit 3.6653 (93,10)
0.00004–0.00075 (0,001–0,019)
0.0–0.0039 (0,0–0,01)
Cylinder Liner Bore I.D.
Piston Grade A
Piston Grade C
Min. Dia. 3.6622–3.6630 (93,01–93,04)
Min. Dia. 3.6630–3.6638 (93,04–93,06)
Camshaft
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.004–0.007 (0,10–0,17)
Limit 0.012 (0,30)
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Journal Diameter
Std. 0.0002–0.0045 (0,05–0,114)
Limit 0.0079 (0,20)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 1.9663–1.9675 (49,944–49,975)
Camshaft Bearing I.D.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit 1.9528 (49,60)
Std. 1.9685–1.9697 (50,0–50,03)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.0020 (0,05)
Limit 0.0047 (0,12)
Camshaft Run–Out
Cam Lobe Height
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit 0.0039 (0,10)
Std. 1.654 (42,010)
Limit 1.640 (41,66)
–9–6–
853, 853H Loader
Service Manual
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.
Main Bearing Journal O.D.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance Between Journal & Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Std. 2.0833–2.0839 (52,92–52,93)
Limit 2.0829 (52,91)
Std. 2.7526–2.7532 (69,92–69,93)
Limit 2.7524 (69,91)
Std. 0.0014–0.0041 (0,035–0,080)
Crankshaft Run–Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit 0.0043 (0,11)
Std. 0.002 (0,05) or less
Limit 0.003 (0,08)
Idler Gear
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.003 (0,07)
Limit 0.008 (0,20)
Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Gear Hub O.D.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Std. 0.004–0.007 (0,10–0,017)
Limit 0.012 (0,30)
Std. 1.7695–1.7707 (44,95–44,98)
Limit 1.7656 (44,85)
Clearance Between Hub & Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.0009–0.003 (0,025–0,085)
Limit 0.0079 (0,20)
Bearing Replacement
Projection
Height
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.016–0.024 (0,40–0,60)
0.933–0.945 (23,7–24,0)
Oil Pump
End Play Between Vane & Body
Clearance Between Rotor & Vane
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.0008–0.0028 (0,02–0,07)
Limit 0.0059 (0,15)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.0055 (0,14) or less
Clearance Between Vane & Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance Between Rotor Shaft & Body
Std. 0.0079–0.0105 (0,20–0,27)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Std. 0.0016 (0,04)
Oil Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit 0.0079 (0,20)
57–71 PSI (393–490 kPa) @ 1400 RPM
21 PSI (145 kPa) @ Idle RPM
Fuel System
Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch VE
Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector Pressure (Opening)
Bosch Multi–hole (4 orifices)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2630 PSI (18134 kPa)
Supple Pump Pressure
Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 PSI (255 kPa)
High Idler RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection Pump Timing
71 PSI (490 kPa)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
°
BTDC
–9–7–
853, 853H Loader
Service Manual
TORQUE SPECIFICATIONS FOR LOADER
Specifications
Item
Air Cleaner Mounting Bolts
Alternator Pulley Nut
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Hub Mounting Bolt
Axle Sprocket Bolt
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ft.–Lbs.
25–28
50
175–190
475–525
Nm
34–38
68
237–258
644–711
Bob–Tach Pivot Pin Bolts
Bob–Tach Lever Pivot Bolt
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Block Mounting Bolts
Brake Lever Bolt
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pad Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Gear Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft Retainer Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chaincase to Main Frame Bolts & Nuts
Connecting Rod Bolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Pedal Linkage Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valve Mounting Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley Nut
Cylinder Head Bolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Pipe to Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injector Holddown Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Pressure Tubeline Fittings
Hydraulic Housing Mounting Bolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Reservoir Strap Bolts
Hydrostatic Motor Mounting Bolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic Pump Mounting Bolts
Hydrostatic Pump Pulley Bolt
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idler Gear Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injector Nozzle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection Pump Gear Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection Pump Idler Gear Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injection Pump Mounting Bolts
Intake Manifold Bolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bearing Cap Bolts
Main Relief Valve
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter Housing Bolts
Oil Pan Nuts & Bolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Bolts (Hollow)
Oil Pump Mounting Bolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Cab Fastening Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Cab Pivot Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pedal Lock Linkage to Main Frame Bolts
Pedal Lock Linkage Tab Bolt
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pivot Pins Lock Bolt & Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rocker Arm Adjustment Nut
Rocker Arm Bracket Bolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belt Fastening Bolts
Seat Mounting Bolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat Bar Pivot Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
–9–8–
220–245
25–28
65–70
65–70
65–70
72–87
11–17
90–100
58–65
21–25
15–16
123–152
New 57–67
Used 72–80
10–17
20–35
83–90
16–20
23–32
15–18
14–29
25
16–20
65–70
65–70
175–200
10–12
36–51
43–58
43–51
72–87
10–17
10–17
116–130
35–40
10–17
14–19
9–12
10–17
40–50
25–35
7–8
25
18–20
12–14
36–43
157–176
19–26
12–16
14–23
54–68
34–47
9,5–10,8
34
24–27
16–19
49–58
40–45
9–11
25–28
54–61
12–15
34–38
853, 853H Loader
Service Manual
298–332
34–38
88–95
88–95
88–95
98–118
15–23
122–136
79–88
28–34
20–22
167–206
77–91
98–108
14–23
27–47
113–122
22–27
31–43
20–24
19–39
34
22–27
88–95
88–95
237–271
14–16
46–69
59–79
58–69
98–118
14–23
14–23
157–176
47–54
TORQUE SPECIFICATIONS FOR LOADER (Cont’d)
Specifications (Cont’d)
Item (Cont’d)
Thermostat Housing Bolts
Timing Case Bolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Case Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Cover Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Jacket Tube (Outside)
Water Pump Bolts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ft.–Lbs.
10–17
11–17
11–17
6–13
10–17
11–18
105–115
Nm
14–23
15–23
15–23
8–18
14–23
15–24
142–156
–9–9–
853, 853H Loader
Service Manual
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)
1.125
1.250
1.375
1.500
1.625
1.750
1.875
2.000
.625
.750
.875
1.000
THREAD
SIZE
.250
.3125
.375
.4375
.500
.5625
SAE GRADE 5
475–525
(645–710)
650–720
(880–975)
900–1000
(1200–1360)
1200–1350
(1630–1830)
1500–1650
(2040–2240)
2000–2800
(2720–2980)
2500–2750
(3390–3730)
3150–3500
(4270–4750)
3800–4200
(5150–5700)
80–90
(9,0–10,2)
180–200
(20,3–22,6)
25–28
(34–38)
40–45
(54–61)
65–70
(88–95)
90–100
(122–136)
125–140
(170–190)
220–245
(300–330)
330–360
(450–490)
SAE GRADE 8
725–800
(985–1085)
1050–1175
(1425–1600)
1475–1625
(2000–2200)
2000–2200
(2720–2980)
2600–2850
(3530–3870)
3450–3800
(4680–5150)
4300–4800
(5830–6500)
5500–6100
(7450–8300)
6500–7200
(8800–9800)
110–120
(12,4–13,6)
215–240
(24,2–27,1)
35–40
(47–54)
60–65
(81–88)
90–100
(122–136)
125–140
(170–190)
175–190
(240–260)
300–330
(410–450)
475–525
(645–710)
–9–10–
853, 853H Loader
Service Manual
TORQUE SPECIFICATIONS FOR BOLTS (Cont’d)
Torque For General Metric Bolts
Thread Size
(Dia. x Pitch)
M 5 x 0.8
M 6 x 1.0
M 8 x 1.25
M 10 x 1.25
M 12 x 1.25
M 14 x 1.25
Head Mark 4
6–9 ft.–lbs.
(8–12 Nm)
13–18 ft.–lbs.
(18–24 Nm)
22–30 ft.–lbs.
(30–41 Nm)
36–50 ft.–lbs.
(49–68 Nm)
Material
Head Mark 7
3–4 ft.–lbs.
(4–5 Nm)
6–7 ft.–lbs.
(8–9 Nm)
11–16 ft.–lbs.
(15–22 Nm)
22–30 ft.–lbs.
(30–41 Nm)
40–54 ft.–lbs.
(54–73 Nm)
58–80 ft.–lbs.
(79–108 Nm)
Head Mark 10
6–9 ft.–lbs.
(8–12 Nm)
18–25 ft.–lbs.
(24–34 Nm)
36–50 ft.–lbs.
(49–68 Nm)
69–87 ft.–lbs.
(94–118 Nm)
116–137 ft.–lbs.
(157–186 Nm)
–9–11–
853, 853H Loader
Service Manual
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
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. Use vaseline petroleum jelly to hold the
O–ring in position until the fittings are assembled [A].
Straight Thread O–ring Fitting
Lubricate the O–ring before installing the fitting. Loosen the jam nut and install the fitting. Tighten the jam nut until the washer is tight against the surface [B].
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will restrict flow, which will slow hydraulic action and cause heat.
Replace hoses which show signs of wear, damage or weather cracked rubber.
Always use two wrenches when loosening and tightening hose or tubeline fittings.
Flare Fitting
Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat. Make a mark across the flats of both the male and female parts of the connection (Item 1) [C].
Use the chart below to find the correct tightness needed
(Item 2) [C]. If the fitting leaks after tightening, disconnect it and inspect the seat area for damage.
B
Nut
O–ring
Washer
C
1
2
B–07575
Nut
Washer
O–ring
A–01852
TS–01619
–9–12–
853, 853H Loader
Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS (CONT’D)
O–ring Flare Fitting
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.
A
Primary
Seal
O–ring Flare
Use the following procedure to tighten the O–ring flare fitting.
Tighten the nut until it contacts with the seat. Make a mark across the flats of both the male and female parts of the connection (Item 1) [B].
Use the chart below to find the correct tightness needed
(Item 2) [B]. If the fitting leaks after tightening, disconnect it and inspect the seat area for damage.
Secondary
Seal
B
1
Hex Flat Tightening Method
P–13009
2
TS–01619
–9–13–
853, 853H Loader
Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS (CONT’D)
O–ring Flare Fitting (Cont’d)
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.
Use a standard flare fitting (Item 1) [A] as shown.
When a O–ring flare fitting is used as a straight thread port adapter the O–ring flare face is not used to seal. The
O–ring may come off the fitting and enter the system.
Always remove the O–ring (Item 1) [B] from the flare face as shown.
An O–ring (Item 2) [B] is added to the flat boss of the fitting to seal the connection in this application.
A
B
Copper Bonnet Orifice
1
2
P–13572
1
P–13573
–9–14–
853, 853H Loader
Service Manual
HYDRAULIC CONNECTION SPECIFICATIONS (CONT’D)
Port Seal Fitting
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.
If a torque wrench cannot be used, use the following method.
Tighten the nut until it just makes metal to metal contact, you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat maximum.
Do not over tighten the port seal fitting.
A
Nut Seals to Fitting
Nut Seals to Port
NOTE: If a torque wrench cannot be used, use the hex flat tightening method as an approximate guideline.
NOTE: Port seal fittings are not recommended in all applications. Use O–ring boss fittings in these applications.
Do not use port seal fittings when a thread in orifice (Item
1) [B] is used in the port. The orifice may interfere with the fitting and prevent it from sealing.
Use an O–ring boss fitting (Item 2) [B] as shown.
Secondary O–ring Seal
P–13008
Port Seal and O–ring Boss
Tightening Torque
Fitting
Nut
Wrench Size
11/16’’
15/16’’
1–1/8’’
1–1/4’’
1–1/2’’
Thread Size
9/16’’ – 18
3/4’’ – 16
7/8’’ – 14
1–1/16’’ – 12
1–5/16’’ – 12
TORQUE
Ft.–lbs.
(Nm)
22 (30)
40 (54)
60 (81)
84 (114)
118 (160)
B
2
1
–9–15–
P–13571
853, 853H Loader
Service Manual
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.
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.
W–2074–1285
When temperatures below zero degree F (–18
°
C) are common, the loader must be kept in a warm building. Extra warm–up time must be used each time the loader is started during cold temperature conditions. Cold fluid will not flow easily and it makes action of the hydraulic function slower. Loss of fluid flow to the hydrostatic transmission pump (indicated by ‘‘TRANS’’ light ‘‘ON’’) can cause transmission damage in less than 60 seconds.
During cold weather 32
°
F (0
°
C) and below, do not operate machine until the engine has run for at least five (5) minutes at less than half throttle.
This warm–up period is necessary for foot pedal operation and safe stopping. Do not operate controls during warm–up period. When temperatures are below –20
°
F
(30
°
C), the hydrostatic oil must be heated or kept warm. The hydrostatic system will not get enough oil at low temperatures. Park the machine in an area where the temperature will be above 0
°
F
(–18
°
C), if possible.
W–2027–1285
–9–16–
853, 853H Loader
Service Manual
DECIMAL AND MILLIMETER EQUIVALENTS
1/16
1/8
3/16
1/4
FRACTIONS
1/32
3/32
5/32
7/32
1/64
3/64
5/64
7/64
9/64
11/64
13/64
15/64
17/64
9/32
5/16
3/8
7/16
11/32
13/32
15/32
19/64
21/64
23/64
25/64
27/64
29/64
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
—
0.397
0.794
1.191
1.588
1.984
2.381
0.390625 — 9.922
0.40625
— 10.319
0.421875 — 10.716
0.4375
— 11.112
0.453125 — 11.509
0.46875
— 11.906
0.484375 — 12.303
0.5000
— 12.700
2.778
3.175
3.572
3.969
4.366
4.762
5.159
5.556
5.953
6.350
6.747
7.144
7.541
7.938
8.334
8.731
9.128
9.525
1 mm = 0.03937’’
LINEAR
MEASUREMENT
AREA
VOLUME
WEIGHT
PRESSURE
WORK
LIQUID VOLUME
LIQUID FLOW
TEMPERATURE
9/16
5/8
11/16
3/4
13/16
7/8
15/16
1
FRACTIONS
17/32
19/32
21/32
23/32
25/32
27/32
29/32
31/32
33/64
35/64
37/64
39/64
41/64
43/64
45/64
47/64
49/64
51/64
53/64
55/64
57/64
59/64
61/64
63/64
DECIMALS MM
0.515625 — 13.097
0.53125
— 13.494
0.546875 — 13.891
0.5625
— 14.288
0.578125 — 14.684
0.59375
— 15.081
0.609375 — 15.478
0.6250
— 15.875
0.640625 — 16.272
0.65625
— 16.669
0.671875 — 17.066
0.6875
— 17.462
0.703125 — 17.859
0.71875
— 18.256
0.734375 — 18.653
0.7500
— 19.050
0.765625 — 19.447
0.78125
— 19.844
0.796875 — 20.241
0.8125
— 20.638
0.828125 — 21.034
0.84375
— 21.431
0.859375 — 21.828
0.8750
— 22.225
0.890625 — 22.622
0.90625
— 23.019
0.921875 — 23.416
0.9375
— 23.812
0.953125 — 24.209
0.96875
— 24.606
0.984375 — 25.003
1.000
— 25.400
0.001’’ = 0.0254 mm
U.S. TO METRIC CONVERSION
TO CONVERT
Miles
Yards
Feet
Feet
Inches
Inches
Inches
Square Miles
Square Feet
Square Inches
Acre
Cubic Yards
Cubic Feet
Cubic Inches
Tons (Short)
Pounds
Ounces (Avdp.)
Pounds/Sq. In.
Foot–Pounds
Quarts
Gallons
Gallons/Minute
Fahrenheit
INTO
Kilometers
Meters
Meters
Centimeters
Meters
Centimeters
Millimeters
Square Kilometers
Square Meters
Square Centimeters
Hectare
Cubic Meters
Cubic Meters
Cubic Centimeters
Metric Tons
Kilograms
Grams
Kilopascal
Newton–Metre
Liters
Liters
Liters/Minute
Celsius
MULTIPLY BY
1.609
0.9144
0.3048
30.48
0.0254
2.54
25.4
2.59
0.0929
6.452
0.4047
0.7646
0.02832
16.39
0.9078
0.4536
28.3495
6.895
1.356
0.9463
3.785
3.785
1.Subtract 32
°
2. Multiply by 5/9
–9–17–
853, 853H Loader
Service Manual
853, 853H Service Manual #6720755 – Specifications Section
–9–18–
853, 853H Loader
Service Manual
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (2–91)
®
850–001
Revision Number
29 April 1991
Date
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
X
Revise your Service Manual with the enclosed page(s) as shown below.
TAKE OUT
1–21, 1–22
PUT IN
1–21, 1–22 (Revised Apr. 91)
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (2–91)
®
850–002
Revision Number
10 July 1991
Date
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
X
Revise your Service Manual with the enclosed page(s) as shown below.
TAKE OUT
1–25, 1–26
1–29
HYDRAULIC/HYDROSTATIC FLOW CHART
For Model
853
Chart #6720800 (Printed February 1991)
CHART LEGEND
3–7, 3–8
3–9, 3–10
4–9, 4–10
5–7, 5–8
8–7, 8–8
PUT IN
1–25 (Revised July 91), 1–26 (Revised July 91)
1–29 (Revised July 91)
HYDRAULIC/HYDROSTATIC FLOW CHART
For Model
853
Chart #6720800 (Printed July 1991)
CHART LEGEND & FLUID FLOW EXPLANATION
3–7, 3–8 (Revised July 91)
3–9 (Revised July 91), 3–10
4–9 (Revised July 91), 4–10 (Revised July 91)
5–7 (Revised July 91), 5–8
8–7 (Revised July 91), 8–8
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (2–91)
®
850–003
Revision Number
20 September 1991
Date
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
X
Revise your Service Manual with the enclosed page(s) as shown below.
TAKE OUT
WIRING DIAGRAM (P/N 6720801)
Model 853 (S/N 11001 & Above)
(Printed February 1991) 3 Of 3 Pages
ENGINE SERVICE – TAB PAGE
7–23, 7–24
PUT IN
HYDRAULIC/HYDROSTATIC FLOW CHART
For Model
853H
Chart #6720956 (Printed September 1991)
HYDRAULIC/HYDROSTATIC SYSTEM OPERATION
To Be Used With
HYDRAULIC/HYDROSTATIC FLOW CHART
For Model
853H
Chart #6720956 (Printed September 1991)
WIRING DIAGRAM (P/N 6720801)
Model 853 (S/N 11011 Thru 11353)
(Printed September 1991) 3 Of 3 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed September 1991) 4 Of 4 Pages
ENGINE SERVICE – TAB PAGE
(Revised September 1991)
7–23 (Revised Sept. 1991), 7–24 (Revised Sept. 1991)
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (2–91)
®
850–004
Revision Number
6 January 1992
Date
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
X
Revise your Service Manual with the enclosed pages as shown below.
TAKE OUT
MAINTENANCE SAFETY
MAINTENANCE SAFETY (Cont’d)
PREVENTIVE MAINTENANCE–TAB PAGE
1–1, 1–2
1–3, 1–4
1–5. 1–6
1–9, 1–10
1–11, 1–12
1–21, 1–22
HYDRAULIC SYSTEM – TAB PAGE
2–19
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed September 1991) 1 Of 4 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed September 1991) 2 Of 4 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed September 1991) 3 Of 4 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed September 1991) 4 Of 4 Pages
8–1, 8–2
PUT IN
MAINTENANCE SAFETY (Revised Jan. 92)
MAINTENANCE SAFETY (Cont’d)
PREVENTIVE MAINTENANCE–TAB PAGE
(Revised Jan. 92)
1–1 (Revised Jan. 92), 1–2
1–3 (Revised Jan. 92), 1–4 (Revised Jan. 92)
1–5 (Revised Jan. 92), 1–6 (Revised Jan. 92)
1–9, 1–10 (Revised Jan. 92)
1–11 (Revised Jan.. 92), 1–12
1–21, 1–22 (Revised Jan. 92)
HYDRAULIC SYSTEM – TAB PAGE (Revised Jan. 92)
2–19 (Revised Jan. 92)
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed January 1992) 1 Of 4 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed January 1992) 2 Of 4 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed January 1992) 3 Of 4 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed January 1992) 4 Of 4 Pages
8–1 (Revised Jan. 92), 8–2
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (2–91)
®
850–005
Revision Number
10 April 1992
Date
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
X
Revise your Service Manual with the enclosed pages as shown below.
TAKE OUT
PREVENTIVE MAINTENANCE – TAB PAGE
(Revised Jan. 92)
1–29 (Revised July 91)
HYDROSTATIC SYSTEM – TAB PAGE
3–17, 3–18
3–19
PUT IN
PREVENTIVE MAINTENANCE – TAB PAGE
(Revised April 92)
1–29 (Revised July 91), 1–30 (Added April 92)
HYDROSTATIC SYSTEM – TAB PAGE
(Revised April 92)
3–17, 3–18 (Revised April 92)
3–19 thru 3–26 (Added April 92)
*WIRING DIAGRAM (P/N 6722195)
BUCKET POSITION VALVE LOCKOUT (Optional)
Model 753, 7753, 843, 843B & 853
(Printed April 1992)
* NOTE: Put the WIRING DIAGRAM (P/N 6722195) at the beginning of Section 6.
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (2–91)
®
850–006
Revision Number
29 June 1992
Date
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
X
Revise your Service Manual with the enclosed pages as shown below.
TAKE OUT
6–11, 6–12
7–23 (Revised Sept. 92), 7–24 (Revised Sept. 91)
7–27, 7–28
PUT IN
6–11 (Revised June 92), 6–12
7–23 (Revised Sept. 91), 7–24 (Revised June 92)
7–27 (Revised June 92), 7–28 (Revised June 92)
®
850–007
Revision Number
30 December 1992
Date
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (2–91)
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
X
Revise your Service Manual with the enclosed pages as shown below.
TAKE OUT
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed January 1992) 1 Of 4 Pages
PUT IN
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 Thru 12360) & 853H (S/N 11308 & Below)
(Printed December 1992) 1 Of 4 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed January 1992) 2 Of 4 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed January 1992) 3 Of 4 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 & Above) & 853H
(Printed January 1992) 4 Of 4 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 Thru 12360) & 853H (S/N 11308 & Below)
(Printed December 1992) 2 Of 4 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853 (S/N 11354 Thru 12360) & 853H (S/N 11308 & Below)
(Printed December 1992) 3 Of 4 Pages
WIRING DIAGRAM (P/N 6720958)
Model 853H (S/N 11308 & Below)
(Printed December 1992) 4 Of 4 Pages
WIRING DIAGRAM (P/N 6722313)
Model 853 Base (S/N 25001 & Above)
(Printed December 1992) 1 Of 3 Pages
WIRING DIAGRAM (P/N 6722313)
Model 853 Base (S/N 25001 & Above)
(Printed December 1992) 2 Of 3 Pages
WIRING DIAGRAM (P/N 6722313)
Model 853 Base (S/N 25001 & Above)
(Printed December 1992) 3 Of 3 Pages
WIRING DIAGRAM (P/N 6722312)
Model 853 (S/N 12361 & Above) & 853H (S/N 11309 & Above)
Model 853 Plus (S/N 50001 & Above) & 853H Plus (S/N 75001 & Above)
(Printed December 1992) 1 Of 4 Pages
WIRING DIAGRAM (P/N 6722312)
Model 853 (S/N 12461 & Above) & 853H (S/N 11335 & Above)
Model 853 Plus (S/N 50001 & Above) & 853H Plus (S/N 75001 & Above)
(Printed December 1992) 2 Of 4 Pages
WIRING DIAGRAM (P/N 6722312)
Model 853 (S/N 12361 & Above) & 853H (S/N 11309 & Above)
Model 853 Plus (S/N 50001 & Above) & 853H Plus (S/N 75001 & Above)
(Printed December 1992) 3 Of 4 Pages
WIRING DIAGRAM (P/N 6722312)
Model 853H (S/N 11309 & Above) & 853H Plus (S/N 75001 & Above)
(Printed December 1992) 4 Of 4 Pages
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)
®
850–008
Revision Number
5 March 1993
Date
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (2–91)
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
Revise your Service Manual with the enclosed pages as shown below.
TAKE OUT
Foreword Page
Contents Page
Page i, Page ii
Page iii
Preventive Maintenance Contents (Revised Apr. 92)
1–1 (Revised Jan. 92), 1–2
1–5 (Revised Jan. 92), 1–6 (Revised Jan. 92)
1–7, 1–8
1–17, 1–18
1–25 (Revised July 91), 1–26 (Revised July 91)
Hydraulic System Contens (Revised Jan. 92)
2–1, 2–2
2–7, 2–8
2–9, 2–10
2–11, 2–12
2–13, 2–14
2–15, 2–16
2–17, 2–18
2–19 (Revised Jan. 92)
Hydrostatic System Contens (Revised Apr. 92)
3–1, 3–2
3–3, 3–4
3–7, 3–8 (Revised July 91)
3–9 (Revised July 91), 3–10
3–11, 3–12
3–13, 3–14
3–15, 3–16
PUT IN
Foreword Page
Contents Page (Revised Mar. 93)
Page i, Page ii (Revised Mar. 93)
Page iii (Revised Mar. 93), Page iv (Added Mar. 93)
Page v (Added Mar. 93), Page vi (Added Mar. 93)
Preventive Maintenance Contents (Revised Mar. 93)
1–1 (Revised Mar. 93), 1–2
1–5 (Revised Mar. 93), 1–6 (Revised Mar. 93)
1–7 (Revised Mar. 93), 1–8 (Revised Mar. 93)
1–17, 1–18 (Revised Mar. 93)
1–25 (Revised Mar. 93), 1–26 (Revised Mar. 93)
Hydraulic System Contents (Revised Mar. 93)
2–1 (Revised Mar. 93), 2–2
2–7 (Revised Mar. 93), 2–8 (Revised Mar. 93)
2–9 (Revised Mar. 93), 2–10 (Revised Mar. 93)
2–11 (Revised Mar. 93), 2–12 (Revised Mar. 93)
2–13 (Revised Mar. 93), 2–14 (Revised Mar. 93)
2–15 (Revised Mar. 93), 2–16 (Revised Mar. 93)
2–17 (Revised Mar. 93), 2–18 (Revised Mar. 93)
2–19 (Revised Mar. 93), 2–20 (Added Mar. 93)
2–21 (Added Mar. 93)
Hydrostatic System Contens (Revised Mar. 93)
3–1 (Revised Mar. 93), 3–2
3–3 (Revised Mar. 93), 3–4
3–7, 3–8 (Revised Mar. 93)
3–9 (Revised Mar. 93), 3–10 (Revised Mar. 93)
3–11 (Revised Mar. 93), 3–12
3–13 (Revised Mar. 93), 3–14
3–15 (Revised Mar. 93), 3–16
Drive System Contents
4–1, 4–2
Main Frame Contents
5–1, 5–2
5–3, 5–4
5–5, 5–6
Electrical System Contents
6–1, 6–2
6–11 (Revised June 92), 6–12
6–13, 6–14
Drive System Contents (Revised Mar. 93)
4–1 (Revised Mar. 93), 4–2
Main Frame Contents (Revised Mar. 93)
5–1, 5–2 (Revised Mar. 93)
5–3 (Revised Mar. 93), 5–4 (Revised Mar. 93)
5–5 (Revised Mar. 93), 5–6
Electrical System Contents (Revised Mar. 93)
6–1 (Revised Mar. 93), 6–2 (Revised Mar. 93)
6–11 (Revised Mar. 93), 6–12 (Revised Mar. 93)
6–13 (Revised Mar. 93), 6–14 (Revised Mar. 93)
6–15 (Added Mar. 93)
X
TAKE OUT
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
Specifications Contents
PUT IN
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. 93)
7–17 (Revised Mar. 93), 7–18 (Revised Mar. 93)
7–19 (Revised Mar. 93), 7–20 (Revised Mar. 93)
7–21 (Revised Mar. 93), 7–22
Specifications Contents (Revised Mar. 93)
®
850–009
Revision Number
5 January 1994
Date
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (2–91)
NOTICE
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
X
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
HYDRAULIC/HYDROSTATIC FLOW CHART
Chart #6722825 (Printed November 1993)
®
850–010
Revision Number
17 February 1994
Date
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (2–91)
NOTICE
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
X
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
HYDRAULIC/HYDROSTATIC SYSTEM OPERATION
CHART LEGEND and FLUID FLOW EXPLANATION
PUT IN
HYDRAULIC/HYDROSTATIC SYSTEM OPERATION
CHART LEGEND and
FLUID FLOW EXPLANATION (Revised Feb. 94)
®
850–011
Revision Number
25 May 1994
Date
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (2–91)
NOTICE
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
X
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
3–7, 3–8 (Revised Mar. 93)
3–9 (Revised Mar. 93), 3–10 (Revised Mar. 93)
4–15, 4–16
ENGINE SERVICE – TAB PAGES
7–5 (Revised Mar. 93), 7–6
7–39, 7–40
8–3, 8–4
PUT IN
3–7, 3–8 (Revised May 94)
3–9 (Revised Mar. 93), 3–9a (Added May 94)
3–9b (Added May 94), 3–9C (Added May 94)
3–10 (Revised Mar. 93)
4–15 (Revised May 94), 4–16
ENGINE SERVICE – TAB PAGES (Revised May 94)
7–5 (Revised Mar. 93), 7–6 (Revised May 94)
7–6a thru 7–6m (Added May 94)
7–39, 7–40 (Revised May 94)
8–3, 8–4 (Revised May 94)
®
850–012
Revision Number
2 November 1998
Date
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (2–91)
NOTICE
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
X
Insert This Sheet With The Above Listed Manual For Future Reference.
The following pages are a revision to the above Service Manual.
Take out existing pages and put in the new pages as listed below:
TAKE OUT
All of Hydraulic/Hydrostatic
Flow Charts, System Operations and Fluid Flow Explanations
PUT IN
Glossary Of Hydraulic/Hydrostatic
Symbols For Loaders
(Place immediately after
HYDRAULIC SYSTEM – TAB PAGE
All of the enclosed
Hydraulic/Hydrostatic Schematics
(Printed November 1998)
®
850–13
Revision Number
1 June 1999
Date
SERVICE MANUAL
REVISION
AFFECTING:
Product
BOBCAT LOADER
Model
853
Manual No.
6720755 (6–99)
NOTICE
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANAGER
SALES MANAGER
X
Insert This Sheet With The Above Listed Manual For Future Reference.
TAKE OUT
853 Service Manual 6720755 (2–91)
Includes revisions 850–1 through 850–12
PUT IN
853 Service Manual 6720755 (6–99)
Includes revision 850–13
Replace your existing 853 Service Manual 6720755 (2–91) including revisions
850–1 through 850–12 with 853 Service Manual 6720755 (6–99) includes revision
850–13.
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Key features
- Covers servicing and adjustments
- Provides detailed instructions
- Ensures proper operation and safety
- Includes information on component parts
- Essential for maintaining your loader