Bobcat 853, 853H HIGH-FLOW Skid-Steer Loader Repair Service Manual - 6724012

(S/N: 512816001 and Above) - (S/N: 508418001 and Above) - (S/N: 509718001 and Above) 
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This workshop repair service manual PDF download for the 853, 853H Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Loader 853, 853H 
HIGH FLOW
S/N: 512816001 and Above
S/N: 508418001 and Above
S/N: 509718001 and Above


TABLE OF CONTENTS :

FOREWORD 
SAFETY INSTRUCTIONS 
SERIAL NUMBER LOCATIONS 
DELIVERY REPORT 
BOBCAT LOADER IDENTIFICATION 
PREVENTIVE MAINTENANCE 
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM
DRIVE SYSTEM 
MAIN FRAME 
ELECTRICAL SYSTEM
ENGINE SERVICE
SYSTEM ANALYSIS 
SPECIFICATIONS 
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6724012 (4–95)
Total Pages : 460


This 853, 853H Bobcat Loader Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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MAINTENANCE SAFETY
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
    SERIAL NUMBER LOCATIONS
    LOADER SERIAL NUMBER
    ENGINE SERIAL NUMBER
    DELIVERY REPORT
    BOBCAT LOADER IDENTIFICATION
    OPTIONS AND ACCESSORIES
    
PREVENTIVE MAINTENANCE
    SERVICE SCHEDULE
    LIFTING AND BLOCKING THE LOADER
        Procedure
    TRANSPORTING THE LOADER
        Procedure
    TOWING THE LOADER
        Procedure
    STOPPING THE BOBCAT LOADER
    LIFTING THE LOADER
        Four Point Lift
        Single Point Lift
    LIFT ARM SUPPORT DEVICE
        Engaging The Lift Arm Support Device
        Disengaging The Lift Arm Support Device
    OPERATOR CAB
        Description
        Raising The Operator Cab
        Lowering The Operator Cab
        Emergency Exit
    SEAT BAR RESTRAINT SYSTEM
        Description
        Seat Bar Inspection
        Seat Bar Maintenance
    AIR CLEANER SERVICE
        Replacing Filter Element
    FUEL SYSTEM
        Fuel Specifications
        Filling The Fuel Tank
        Fuel Filter
        Removing Air From The Fuel System
    ENGINE LUBRICATION SYSTEM
        Checking Engine Oil
        Replacing Oil And Filter
    ENGINE COOLING SYSTEM
        Cleaning The Cooling System
        Checking The Coolant Level
        Removing Coolant From The Cooling System
        Propylene Glycol
    ALTERNATOR BELT
        Adjusting The Alternator Belt
    USING A BOOSTER BATTERY (Jump Starting)
        Procedure
    HYDRAULIC/HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Replacing Hydraulic/Hydrostatic Filters
        Replacing Hydraulic Fluid
        Hydraulic Reservoir Breather Cap
    SPARK ARRESTOR MUFFLER
        Cleaning Procedure
    TIRE MAINTENANCE
        Wheel Nuts
        Tire Rotation
        Tire Mounting
    FINAL DRIVE TRANSMISSION (CHAINCASE)
        Checking And Adding Oil
        Removing Oil From The Chaincase
    FAN GEARBOX
        Checking And Maintaining
    LUBRICATING THE LOADER
        Procedure
    REMOTE START SWITCH
        Procedure
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    TROUBLESHOOTING
    HYDRAULIC SYSTEM INFORMATION
        Flare Connections
        O–ring Face Seal Connection
        Straight Thread O–ring Fitting
        Tubelines And Hoses
    LIFT CYLINDER(S)
        Checking The Lift Cylinder
        Removal And Installation
    TILT CYLINDER
        Checking The Tilt Cylinder
        Removal And Installation
        Rod End Seal
    HYDRAULIC CYLINDER
        Lift Cylinder Identification
        Tilt Cylinder Identification
        Disassembly
        Assembly
    MAIN RELIEF VALVE
        Checking The Main Relief Valve
        Checking The Main Relief Valve Without Auxiliaries
        Removal And Installation
    DUAL PRESSURE MAIN RELIEF VALVE – 853H
        Checking The Low Setting
        Checking The High Setting
        Adjusting The Low Setting
        Adjusting The High Setting
    SELECT VALVE (G.E.M. Block) 853H
        Checking The Main Relief Valve
    HYDRAULIC CONTROL VALVE
        Removal And Installation
        Identification Chart
        Disassembly And Assembly
        Main Relief Valve
        Port Relief Valve
        Anti–Cavitation Valve
        Rubber Boot
        Lift Spool And Detent
        Tilt Spool And Centering Spring
        Auxiliary Spool
        Auxiliary Electric Solenoid
        H Port – Auxiliary Section
        Base End Restrictor
        Inspection
        Spool Seal Installation
    HYDRAULIC PUMP
        Checking The Output Of The Pump
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
    HYDRAULIC PUMP (Double Gear) 853H
        Checking The Output Of The Pump
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
    BUCKET POSITION VALVE (Optional)
        Removal And Installation
    HYDRAULIC FLUID RESERVOIR
        Removal And Installation
    HYDROSTATIC FILTER HOUSING
        Removal And Installation
    HYDRAULIC FILTER HOUSING
        Removal And Installation
    CONTROL PEDALS
        Removal And Installation
        Pedal Adjustment
    PEDAL INTERLOCK LINKAGE
        Removal And Installation
        Pedal Interlock Linkage Adjustment
        
HYDROSTATIC SYSTEM
    TROUBLESHOOTING
    HYDROSTATIC SYSTEM INFORMATION
        Replenishing Valve Function
    FRONT PANEL
        Removal And Installation
    STEERING LEVERS
        Disassembly And Assembly
        Pre–Adjustment Checks
        Adjusting Lever Freeplay
        Adjusting The Wheel RPM Forward Compared To Reverse Travel
        Adjusting The Steering Neutral Setting
        Adjusting The Wheel RPM Left Compared To Right Side
    HYDROSTATIC MOTOR
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
        Timing The Hydrostatic Motor
    HYDROSTATIC PUMP
        Removal And Installation
        Replenishing/High Pressure Relief Valve
        Parts Identification
        Hydraulic Pump Removal
        Hydrostatic Pump Separation
        Charge Pump Disassembly
        Disassembly
        Inspection
        Assembly
        Charge Pump Assembly
        Hydrostatic Pump Connection
        Hydraulic Pump Installation
        Hydrostatic Pump Neutral Adjustment
    DRIVE BELT SHIELD
        Removal And Installation
    DRIVE BELT
        Adjusting The Drive Belt
        Replacing The Drive Belt
    DRIVE BELT TENSIONER PULLEY
        Removal And Installation
        Disassembly
        Assembly
        Checking Pulley End Play
    OIL COOLER
        Removal And Installation
        
DRIVE SYSTEM
    PARKING BRAKE PEDAL
        Removal And Installation
        Disassembly And Assembly
    PARKING BRAKE DISC
        Removal And Installation
    FRONT CHAINCASE COVER
        Removal And Installation
    REAR CHAINCASE COVER
        Removal And Installation
    AXLE SEAL
        Removal And Installation
    AXLE, SPROCKET AND BEARINGS
        Removal And Installation
    REDUCTION GEARCASE
        Reduction Gearcase Seal
        Removal And Installation
        Checking Reduction Gearcase
        Disassembly
        Assembly
    DRIVE CHAIN
        Removal And Installation
    CHAINCASE FLUID
        Removing The Fluid From The Chaincase
        
MAIN FRAME
    SEAT BAR
        Removal And Installation
        Assembly
        Compressing The Gas Cylinder
    OPERATOR CAB GAS CYLINDER
        Removal And Installation
        Disassembly And Assembly
    OPERATOR CAB
        Removal And Installation
    OPERATOR SEAT
        Removal And Installation
    BOB–TACH
        Removal And Installation
        Bob–Tach Lever And Wedge
        Bob–Tach Stops
    LIFT ARMS
        Removal And Installation
    REAR GRILL
        Removal And Installation
    REAR DOOR
        Removal And Installation
        Hood Removal And Installation
        Bumper Removal And Installation
        Door Latch Removal And Installation
        Door Latch And Catch Adjustment
    FUEL TANK
        Removal And Installation
        Inlet Screen
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    TROUBLESHOOTING
    ELECTRICAL SYSTEM INFORMATION
        Description
        Fuse Location (Standard & BOSS® Option)
    BATTERY
        Removal And Installation
    ALTERNATOR
        Alternator Output Test
        Rectifier (Diode) Test
        Alternator Regulator Test
        Removal And Installation
        Disassembly And Inspection
        Stator Continuity Test
        Stator Ground Test
        Rotor Continuity Test
        Rotor Ground Test
        Rectifier Continuity (Diode) Test
        Assembly
    STARTER
        Removal And Installation
        Checking The Starter
        Parts Identification
        Disassembly And Assembly
        Cleaning And Inspection
    STANDARD INSTRUMENT PANEL
        Removal And Installation
    FRONT LIGHTS
        Removal And Installation
    RELAY SWITCHES
        Location
        
ENGINE SERVICE
    TROUBLESHOOTING
    ENGINE SPEED CONTROL
        Removal And Installation
        Disassembly
    RADIATOR
        Removal And Installation
    COOLANT RECOVERY TANK
        Removal And Installation
    ENGINE MUFFLER
        Removal And Installation
    AIR CLEANER HOUSING
        Removal And Installation
    BLOWER HOUSING/FAN GEARBOX
        Removal And Installation
    FAN DRIVE TENSION PULLEY
        Removal And Installation
    BLOWER FAN
        Removal And Installation
    FAN GEARBOX
        Parts Identification
        Disassembly
        Assembly
        Checking Backlash
    ENGINE
        Removal And Installation
        Engine Mount Replacement
    FLYWHEEL
        Removal And Installation
        Flywheel Ring Gear
    BELT SHIELD
        Removal And Installation
    VALVE CLEARANCE
        Adjustment
    ENGINE COMPRESSION
        Checking
    GLOW PLUGS
        Removal And Installation
        Checking The Glow Plugs
    FUEL INJECTION PUMP
        Description
        Removal And Installation
        Timing The Injection Pump
    FUEL INJECTOR NOZZLES
        Removal And Installation
        Checking
    CYLINDER HEAD
        Removal And Installation
        Cylinder Head Surface Alignment
        Exhaust Manifold
    VALVES, VALVE SEAT AND GUIDE
        Removal
        Installation
        Reconditioning The Valve And Valve Seats
        Valve Seat Insert
        Valve Guide
        Valve Spring
    ROCKER ARM AND SHAFT
        Disassembly And Assembly
        Checking Rocker Arm And Push Rods
    PISTON AND CONNECTING ROD
        Removal
        Disassembly
        Checking
        Assembly
        Installation
    CYLINDER LINERS
        Checking The Cylinder Bore
        Removal
        Installation
    MAIN BEARINGS
        Description
        Removal
        Installation
        Crankshaft End Play
    CRANKSHAFT
        Removal And Installation
        Checking Tuffriding (Soft Nitriding) Coating
        Checking the Crankshaft
    CRANKSHAFT GEAR
        Removal And Installation
    TIMING GEARCASE COVER SEAL
        Removal And Installation
    TIMING GEARCASE COVER
        Removal And Installation
    IDLER GEAR AND HUB
        Removal
        Checking
        Installation
    FUEL INJECTION PUMP IDLER GEAR
        Removal And Installation
        Bearing Installation
    CAMSHAFT GEAR
        Removal And Installation
    TIMING GEARCASE
        Removal And Installation
    CAMSHAFT
        Removal And Installation
        Checking
        Camshaft Bearings
        Tappets
        Tappet Installation
    OIL PAN
        Removal
        Installation
    OIL PUMP
        Removal And Installation
        Checking
        Gear Replacement
        Rotor Replacement
        Oil Pump Relief Valve
        Oil Filter Housing And Block
    WATER PUMP
        Removal And Installation
        Disassembly
        Assembly
    THERMOSTAT
        Removal And Installation
        Checking The Thermostat
    WATER JACKET TUBE
        Removal And Installation
        
SYSTEMS ANALYSIS
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
        Inspecting The BICS System Controller (Engine STOPPED – Key ON)
        Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
        Inspecting The Traction Lock (Engine RUNNING)
        Inspecting The Lift Arm By–Pass Control
        Maintenance
        Troubleshooting Chart
        Troubleshooting Guide
            BICS SYSTEM CONTROLLER
            TRACTION LOCK
            SEAT SENSOR
            SEAT BAR SENSOR
            LIFT LOCK BY–PASS VALVE
    BICS™ SYSTEM CONTROLLER
        Removal And Installation
        Controller Test
    SEAT BAR SENSOR
        Removal And Installation
        Seat Bar Sensor Test
    SEAT SENSOR
        Removal And Installation
        Seat Sensor Test
    TRACTION LOCK
        Removal And Installation
    LIFT LOCK BY–PASS VALVE
        Removal And Installation
        Disassembly And Assembly
    TILT LOCK VALVE
        Removal And Installation
        Disassembly And Assembly
    BOSS® DIAGNOSTIC TOOL
        Procedure
    SENDER AND SENSOR
        Service Checks
        Component
    RPM SENSOR
        Adjustment
    MONITOR SERVICE CODES
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY
    OPERATION SENSING SYSTEM UNIT
        Removal And Installation
    BOSS® INSTRUMENT PANEL
        Removal And Installation
    PWM MODULE
        Description
    PWM TROUBLESHOOTING
        Conditions
        Chart
    PWM CONTROL HANDLE
        Handle Testing
    PWM ELECTRIC SOLENOID
        Solenoid Coil Testing
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
        Controls Identification Chart
        
SPECIFICATIONS
    LOADER SPECIFICATIONS
        LOADER DIMENSIONS
        OPERATION & PERFORMANCE
        ENGINE
        HYDRAULIC SYSTEM
        ELECTRICAL
        DRIVE SYSTEM
        CAPACITIES
        TIRES
        VIBRATION DATA
    ENGINE SPECIFICATIONS
        Cylinder Head
        Valve, Valve Guide & Seat Insert
        Valve Springs
        Rocker Arm
        Tappets
        Piston, Pin & Rings
        Connecting Rod & Bearing
        Cylinder Liners
        Camshaft
        Crankshaft
        Idler Gear
        Oil Pump
        Fuel System
        Torque For General Metric Bolts
    TORQUE SPECIFICATIONS FOR LOADER
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS
    DECIMAL AND MILLIMETER EQUIVALENTS
    U.S. TO METRIC CONVERSION
    
SERVICE MANUAL REVISIONS
    850–001
    850–002
    850–003
    850–004
    850–005
    
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