Bobcat 843, 843B Loader Factory Service & Shop Manual
Catalog:
Model:
Complete workshop repair & service manual with electrical wiring diagrams for Bobcat 843, 843B Loader. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
This Bobcat 843, 843B Loader service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.
6556864 (12-82) - 843 Operator's Manual.pdf
6566091 (12-85) - 843, 843B Service Manual.pdf
6566408 (11-82) - Operation & Maintenance Manual.pdf
6566611 (1-84) - 843 Operator's Manual.pdf
6566894 (4-97) - 843 Operation & Maintenance Manual.pdf
6570536 (3-97) - 843 Operation & Maintenance Manual.pdf
6720547 (7-97) - 843B Operation & Maintenance Manual.pdf
EXCERPT:
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.)
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 3–59 for the pump neutral adjustment.
4. Stop the engine. Remove the socket [B].
…
6549899 (12-83) - 825 Service Manual...2
MAINTENANCE SAFETY...4
CONTENTS...6
FOREWORD...6
PREVENTIVE MAINTENANCE...8
INTRODUCTION...10
Symbols...10
Serial Number Identification...10
Loader Serial Number...10
Engine Serial Number...11
Pre-Delivery Inspection...11
30 Hour Inspection...11
SERVICE SCHEDULE...12
REAR GRILL...13
TILTING THE OPERATOR GUARD...13
ROPS Tilt Motor...14
ENGINE MAINTENANCE...14
Engine Oil...14
Specifications...14
ENGINE OIL AND FILTER REPLACEMENT...16
ENGINE AIR INLET SYSTEM (AIR CLEANER)...17
ENGINE COOLING SYSTEM...18
FAN BELT ADJUSTMENT...18
FLUSHING THE COOLING SYSTEM...18
FUEL SYSTEM...19
FUEL SPECIFICATIONS...19
Water In The Fuel Tank...19
TO SERVICE THE FUEL SYSTEM...20
REMOVE THE AIR FROM THE FUEL SYSTEM...20
ELECTRICAL SYSTEM MAINTENANCE...21
Electrical System...21
HYDRAULIC SYSTEM...22
Hydraulic/Hydrostatic Transmission Fluid...22
CHECKING AND ADDING HYDRAULIC FLUID...22
HYDRAULIC FLUID FILTERS...22
Replacement Of The Suction (25 Micron) Filter ...23
Replacement Of The Return Line Filter (10 Micron)...23
DRAINING THE FLUID RESERVOIR...23
LEAKS...24
OIL COOLER...24
CARE OF THE HYDROSTATIC TRANSMISSION...24
Loader Start–Up...25
Cold Weather Start–Up...25
FINAL DRIVE CHAIN...25
TIRES...25
TIRE MAINTENANCE...26
TIRE ROTATION...26
TIRE REPLACEMENT...26
LUBRICATION...26
WHEEL MOUNTING NUTS...26
BOB–TACH...27
PARK BRAKE...27
HYDRAULIC SYSTEM...28
HYDRAULIC / HYDROSTATIC SCHEMATICS...30
HYDRAULIC SYSTEM...40
TUBELINES, HOSES, FITTINGS...40
37° Flare Connection...40
Straight Thread O–Ring Fitting (Elbows, Adapter, Etc.)...41
Pipe Thread Fittings...41
Tubelines And Hoses...41
HYDRAULIC SYSTEM TROUBLESHOOTING...41
GEAR PUMP...43
Testing...43
Removal...43
DISASSEMBLY OF GEAR PUMP...44
TO INSPECT PARTS FOR WEAR...44
General...44
Gear Assembly...44
Front And Back Plates...44
Body...45
Assembly Of Gear Pump...45
CONTROL VALVE...45
Relief Valve Check...45
Internal Leaks...46
Control Valve Repair...46
Removal...46
Disassembly...46
LIFT VALVE SPOOL (Float Detent)...47
Repair Of The Float Detent Of The Lift Spool...47
To Assemble The Detent Assembly...47
Inspection, Repair And Assembly Of Control Valve...47
CONTROL PEDALS...48
Adjustment...48
Removal Of Pedal Assembly...49
HYDRAULIC CYLINDERS...49
Checking For Internal Leak (Lift Cylinder)...49
Removal Of Lift Cylinder...49
Removal Of Tilt Cylinder...49
HYDRAULIC CYLINDER REPAIR...49
To Disassemble A Hydraulic Lift Or Tilt Cylinder...50
To Replace The Cylinder Seals...50
To Assemble The Hydraulic Cylinder...50
OIL COOLER...51
Cleaning Of Grill...51
Removal Of Oil Cooler...51
By–Pass Valve...51
Cooler By-Pass Hose...51
HYDROSTATIC SYSTEM...52
HYDROSTATIC DRIVE SYSTEM...54
Description...54
HYDROSTATIC TRANSMISSION TROUBLESHOOTING...54
CONTROL LINKAGE...59
Adjustment Of Steering Linkage...59
ADJUSTMENT OF SPEED RANGE LINKAGE...59
STEERING CONTROLLINKAGE...60
Removal...60
CHECKING HYDROSTATIC SYSTEM...61
Test Kit...61
Charge Pressure Check...63
Charge Pump Inlet Pressure...63
CHECKING RELIEF VALVES...64
Charge Relief Valve...64
Filter Relief Valve...64
Charge Inlet Relief Valve...64
High Pressure Relief Valve...64
MICRON FINAL FILTER ELEMENT REPLACEMENT...65
TEMPERATURE AND PRESSURE SWITCHES...65
REMOVAL OF HYDROSTATIC PUMP ASSEMBLY...66
INSTALLING HYDROSTATIC PUMP...66
REMOVAL OF HYDROSTATIC MOTOR...67
INSTALLING HYDROSTATICMOTOR...68
New Hydrostatic Pump & Motor...68
HYDROSTATIC PUMP OR MOTOR DISASSEMBLY ...70
INSPECT PARTS FOR WEAR...71
TO ASSEMBLE PUMP OR MOTOR...71
STARTING PROCEDURE, AFTER REPAIR...72
FINAL DRIVE SYSTEM...74
FINAL DRIVE SYSTEM...76
Description...76
REMOVAL OF REDUCTION HOUSING...76
DISASSEMBLY OF REDUCTION HOUSING ...76
Removal Of The Intermediate Gear (6)...76
Removal Of Input Drive Gear (7)...77
Removal Of Output Gear (14)...77
ASSEMBLY OF REDUCTION HOUSING...77
Installing The Output Shaft And Gear...77
Installing Input Shaft And Gear...77
Installing Intermediate Gear...77
Drive Chain Adjustment (Internal Adjustment Type)...77
Drive Chain Adjustment (External Adjustment Type)...78
Drive Chain Idler Removal (Internal Adjustment Type)...78
To Disassemble The Idler Gear (Internal)...79
Drive Chain Idler Removal (External Adjustment Type)...79
REMOVAL OF DRIVE CHAIN...80
INSTALLING DRIVE CHAIN...80
REMOVAL OF AXLE...81
Removal Of Rear Axle...81
Removal Of Front Axle...81
Installation Of The Axle...82
AXLE BEARING AND SEAL REPLACEMENT...82
NSTALLATION OF AXLES PROCKET...83
PARK BRAKE REMOVAL...83
MAIN FRAME...84
MAIN FRAME...86
Description ...86
REMOVAL OF ROPS...86
PIVOT PIN AND BUSHING REPLACEMENT ...86
BOB–TACH REMOVAL...86
LIFT ARMS REMOVAL...87
FUEL TANK REMOVAL...87
Removing Fuel Tank On Loader S/N 16999 & Below ...87
Removing Fuel Tank On Loader S/N 17001 & Above...87
ELECTRIC MOTOR FOR ROPS (Cab Tilt – S/N 19126 & Below)...87
Removal Of Tilt Mechanism...88
MECHANICAL TILT FOR THE ROPS (S/N 19127 & Above)...88
ELECTRICAL SYSTEM...90
ELECTRICAL SCHEMATICS...94
ELECTRICAL CIRCUITRY...98
PROBLEM ANALYSIS...98
FAN BELT...100
TO CHECK ALTERNATOR OUTPUT...100
TO CHECK THE REGULATOR...100
ALTERNATOR SERVICE...101
Removal (ROPS Must Be Tilted)...101
Disassembly...101
To Check Rotor...101
To Check Stator ...101
To Check Diode Trio...102
To Check Rectifier...102
Assembly...102
STARTER SERVICE...103
To Check The Starter...103
To Remove Starter...103
Disassembly And Inspection...103
Assembly...103
ENGINE SERVICE...104
INTRODUCTION...106
Engine Parts...106
Engine Number Location...106
STARTING A NEW OR RECONDITIONED ENGINE...106
ENGINE OVERHAUL...106
Engine Removal...106
Cylinder Head Maintenance...107
To Remove The Valves...108
Combustion Chamber Inserts...108
Reconditioning Cylinder Heads...109
Cleaning...109
Inspection...109
Reconditioning Of Valves AndValve Seats...110
Valve Seat Inserts...110
To Install Inserts...110
To Disassemble The Rocker Shaft Assembly...111
To Assemble The Rocker Shaft Assembly...112
Push Rods...112
To Install The Valves...112
INSTALLING CYLINDER HEAD...113
Cylinder Head Gasket...113
To Install The Cylinder Head...113
CONNECTING RODS AND PISTONS...114
To Remove Pistons And Connecting Rods...114
To Remove Pistons And Rings From The Connecting Rods...115
Inspection...115
To Install The Pistons To The Connecting Rods...115
Installing The Piston Rings...116
To Install Rings...116
To Install Piston And Connecting Rod Assemblies...117
Installing New Pistons...117
Cylinder Liners...118
To Install New Cylinder Liners...118
CRANKSHAFT AND MAIN BEARINGS...118
Description...118
To Install Main Bearings And Thrust Washers...119
To Install Thrust Washers...119
To Remove The Crankshaft...120
To Reinstall The Crankshaft...121
Crankshaft Rear End Oil Seal...122
FLYWHEEL AND FLYWHEEL HOUSING...122
To Remove The Flywheel...122
To Replace The Flywheel Ring Gear...122
To Reinstall The Flywheel...123
To Install The Flywheel Housing...123
TIMING CASE AND DRIVE...123
To Remove The Timing Case Cover...123
Replacement Of The Crankshaft Front Oil Seal...124
To Install The Timing Case Cover...124
To Remove The Idler Gear And Hub...124
To Install The Idler Gear And Hub...124
To Remove The Camshaft Gear...125
To Install The Camshaft Gear...125
To Remove The Fuel Pump Gear...125
To Install The Fuel Pump Gear...125
To Remove The Fuel Pump Drive Hub...126
To Install The Fuel Pump Drive Hub...126
To Remove The Timing CaseBack Plate...126
To Install The Timing Case Back Plate...127
To Remove The Camshaft And Tappets...127
To Install The Tappets And Camshaft...127
Timing Marks...128
To Reset The Engine To The Original Timing...128
Timing Pin...129
Check Valve Timing...129
Adjusting Valve Clearance...130
Valve Adjustment Sequence...130
LUBRICATION SYSTEM...130
The Lubricating Oil Pump...130
To Remove The Sump...130
To Install The Oil Pan...130
To Remove The Oil Pump...131
To Dismantle The Oil Pump...131
Inspection...131
To Assemble The Oil Pump...132
To Install The Oil Pump...132
Oil Pressure Relief Valve...132
To Dismantle The Oil Pressure Relief Valve...133
To Assemble The Oil Pressure Relief Valve...133
COOLING SYSTEM...133
Fan Belt...133
Adjustment Of Fan Belt...133
Water Pump...134
Remove The Water Pump...134
To Disassemble The Water Pump...134
Inspection...134
To Assemble The Water Pump...135
To Install The Water Pump...135
Thermostat...135
To Remove The Thermostat...135
To Test The Thermostat...136
Replacement Of The Thermostat...136
FUEL SYSTEM...136
To Test Fuel Lift Pump...136
To Remove The Lift Pump...136
Fuel Injection Pump...137
To Remove The Fuel Injection Pump...137
To Install The Fuel Injection Pump...137
Checking Fuel Injection Pump Timing...137
Timing The fuel Injection Pump (Using Timing Tool MS 67123)...138
Checking The Timing Mark On The Flange Of The Injection Pump...140
Injector Problems...141
Testing For Faulty Injector...141
Injector Removal...141
Injector Installation...141
Fuel Pipes (High Pressure)...141
Using C.A.V. Thermostart Units...142
Charging The Fuel System...143
SPECIFICATIONS...144
SPECIFICATIONS...146
Cylinder Block...146
Cylinder Liner (Cast Iron)...146
Pistons...146
Piston Rings...146
Piston Pin Bushing...146
Connecting Rod...146
Connecting Rod Alignment...147
Crankshaft...147
Crankshaft Thrust Washers...147
Main Bearings...147
Connecting Rod Bearings...147
Camshaft...148
Camshaft Thrust Plates...148
Cylinder Head...148
Combustion Chamber Inserts...148
Valve Guides (Inlet)...148
Valve Guides (Exhaust)...148
Valves (Inlet)...149
Valves (Exhaust)...149
Inner Valve Springs...149
Outer Valve Springs...149
Rocker Levers...149
Valve Clearance...149
Rocker Shaft...149
Push Rods...149
Lifters...149
TIMING GEARS...150
Injector Pump Gear...150
Crankshaft Gear...150
Timing Gear Backlash...150
LUBRICATION SYSTEM...150
Lubricating Oil Pump...150
Pump Clearances...150
Lubricating Oil Pump Drive Gear...150
Relief Valve (Lube Oil)...150
Lubricating Oil Filter...150
COOLING SYSTEM...150
Thermostat...150
FUEL SYSTEM...150
Fuel Lift Pump...151
Final Fuel Filter...151
Fuel Injection Pump...151
Injectors...151
Starting Aid...151
SERVICE WEAR LIMITS...151
DE–RATING FOR ALTITUDE...152
TORQUE SPECIFICATIONS...152
Hydrostatic Pump and Motor...152
High Pressure Relief Valves...152
Loader Torque Specs...152
STANDARD TORQUE SPECIFICATIONS FOR BOLTS...153
DECIMAL AND MILLIMETER EQUIVALENTS...154
U.S. TO METRIC CONVERSION...154
SPECIAL TOOLS...155
825 LOADER SPECIFICATIONS...156
SPECIFICATIONS...156
ENGINE...156
LOADER HYDRAULICS...157
ELECTRICAL...157
DRIVE SYSTEM...157
CAPACITIES...157
TIRES...157
ALPHABETICAL INDEX...158
SERVICE BULLETINS...162
825-001...162
825-002...164
825-003...166
825-004...168
825-005...170
SERVICE MANUAL REVISIONS...162
825-1...172
825-2...174
825-3...176
6720755 (6-99) - 853; 853H Service Manual...178
MAINTENANCE SAFETY...180
ALPHABETICAL INDEX...182
CONTENTS...184
FOREWORD...185
SAFETY INSTRUCTIONS...188
SERIAL NUMBER LOCATIONS...190
LOADER SERIAL NUMBER...190
ENGINE SERIAL NUMBER...190
DELIVERY REPORT...190
BOBCAT LOADER IDENTIFICATION...191
PREVENTIVE MAINTENANCE...192
SERVICE SCHEDULE...194
LIFTING AND BLOCKING THE LOADER...195
Procedure...195
TRANSPORTING THE LOADER...196
Procedure...196
TOWING THE LOADER...196
Procedure...196
LIFTING THE LOADER...197
Four Point Lift...197
Single Point Lift...197
LIFT ARM SUPPORT DEVICE...198
Engaging The Lift Arm Support Device...198
Disengaging The Lift Arm Support Device...199
OPERATOR CAB...200
Description...200
Raising The Operator Cab...200
Lowering The Operator Cab...201
Emergency Exit...201
SEAT BAR RESTRAINT SYSTEM...202
Description...202
Inspecting The Seat Bar...202
Maintaining The Seat Bar...202
AIR CLEANER SERVICE...203
Replacing Filter Element...203
FUEL SYSTEM...205
Fuel Specifications...205
Filling The Fuel Tank...205
Fuel Filter...205
Removing Air From The Fuel System...206
ENGINE LUBRICATION SYSTEM...207
Checking Engine Oil...207
Replacing Oil And Filter...207
ENGINE COOLING SYSTEM...209
Checking The Coolant Level...209
Cleaning The Cooling System...209
Replacing The Coolant...210
ALTERNATOR BELT...211
Adjusting The Alternator Belt...211
HYDRAULIC/HYDROSTATIC SYSTEM...212
Checking And Adding Fluid...212
Replacing Hydraulic/Hydrostatic Filters...212
Replacing The Hydraulic Fluid...213
Hydraulic Reservoir Breather Cap...214
SPARK ARRESTOR MUFFLER...215
Cleaning Procedure...215
TIRE MAINTENANCE...216
Wheel Nuts...216
Tire Rotation...216
Tire Mounting...216
FINAL DRIVE TRANSMISSION (CHAINCASE)...217
Checking And Adding Oil...217
FAN GEARBOX...217
Checking And Maintaining...217
LUBRICATING THE LOADER...218
Procedure...218
REMOTE START SWITCH...220
Procedure...220
HYDRAULIC SYSTEM...222
HYDRAULIC/HYDROSTATIC SCHEMATICS...224
TROUBLESHOOTING...250
HYDRAULIC SYSTEM INFORMATION...251
Tighten Procedures...251
LIFT CYLINDER(S)...252
Checking The Lift Cylinder...252
Removal And Installation...252
TILT CYLINDER...254
Checking The Tilt Cylinder...254
Rod End Seal...255
HYDRAULIC CYLINDER...256
Lift Cylinder Identification...256
Tilt Cylinder Identification...257
Disassembly...258
Assembly...260
MAIN RELIEF VALVE...263
Checking The Main Relief Valve...263
Checking The Main Relief Valve Without Auxiliaries...264
Removal And Installation...265
DUAL PRESSURE MAIN RELIEF VALVE (S/N 512811001 & Above) W/ Select Valve (JEM)...266
Checking The Low Setting...266
Checking The High Setting...267
Adjusting The Low Setting...269
Adjusting The High Setting...270
HYDRAULIC CONTROL VALVE...271
Removal And Installation...271
SELECT VALVE (S/N 512811001 & Above) W/SelectValve (JEM)...273
Checking The Relief Valve...273
Removal And Installation...275
Disassembly And Assembly...276
Solenoid Testing...277
HYDRAULIC FILTER HOUSING...278
Removal And Installation...278
HYDRAULIC PUMP...279
Checking The Output Of The Pump...279
Removal And Installation...280
HYDRAULIC FLUID RESERVOIR...281
Removal And Installation...281
LOCK VALVE (S/N 5103)...282
Removal And Installation...282
BUCKET POSITION VALVE (S/N 5102) & (S/N 5103)...283
Removal And Installation...283
FRONT AUXILIARY CONTROL VALVE (Apitech)...284
Removal And Installation...284
CONTROL PEDALS...285
Removal And Installation...285
Pedal Adjustment...285
PEDAL INTERLOCK LINKAGE...286
Removal And Installation...286
Pedal Interlock Linkage Adjustment...287
HYDROSTATIC SYSTEM...288
TROUBLESHOOTING...290
HYDROSTATIC SYSTEM INFORMATION...291
Replenishing Valve Function...291
Tow Valves...291
FRONT PANEL...292
Removal And Installation...292
STEERING LEVERS...294
Disassembly And Assembly...294
Neutral Pre–Adjustment Checks...296
Adjusting Lever Freeplay...297
Adjusting The Wheel RPM Forward Compared To Reverse Travel...298
Adjusting The Steering Neutral Setting...300
Adjusting The Wheel RPM Left Compared To Right Side...301
Hydrostatic Pump Neutral Adjustment...302
HYDROSTATIC MOTOR...304
Removal And Installation...304
HYDROSTATIC CHARGE OIL FILTER...306
Removal And Installation...306
COLD OIL BY–PASS VALVE...308
Removal And Installation...308
HYDROSTATIC PUMP...310
Removal And Installation...310
Replenishing/High Pressure Relief Valve...312
DRIVE BELT SHIELD...313
Removal And Installation...313
DRIVE BELT ...314
Replacing The Drive Belt...314
SPRING LOADED TENSIONER PULLEY...315
Parts Identification...315
Disassembly...316
Assembly...317
Adjusting The Drive Belt...319
FIXED TENSIONER PULLEY...320
Removal And Installation...320
Disassembly...321
Assembly...323
Checking Pulley End Play...327
Adjusting The Drive Belt...328
OIL COOLER...329
Removal And Installation...329
DRIVE SYSTEM...330
PARKING BRAKE PEDAL...332
Adjustment...332
PARKING BRAKE...333
Removal And Installation...333
Brake Block And Pads...335
Brake Discs...336
FRONT CHAINCASE COVER...337
Removal And Installation...337
REAR CHAINCASE COVER...337
Removal And Installation...337
AXLE SEAL...338
Removal And Installation...338
AXLE, SPROCKET AND BEARINGS...340
Removal And Installation...340
REDUCTION GEARCASE...344
Reduction Gearcase Seal...344
Removal And Installation...345
Checking Reduction Gearcase...346
Disassembly...346
Assembly...351
DRIVE CHAIN...355
Removal And Installation...355
CHAINCASE FLUID...356
Removing The Fluid From The Chaincase...356
MAIN FRAME...358
OPERATOR CAB GAS CYLINDER...360
Removal And Installation...360
Disassembly And Assembly...361
OPERATOR CAB...362
Removal And Installation...362
BOB–TACH...364
Removal And Installation...364
Bob–Tach Lever And Wedge...366
Bob–Tach Stops...367
LIFT ARMS...368
Removal And Installation...368
REAR GRILL...369
Removal And Installation...369
REAR DOOR...370
Removal And Installation...370
Hood Removal And Installation...371
Bumper Removal And Installation...371
Door Latch Removal And Installation...371
Door Latch And Catch Adjustment...371
FUEL TANK...372
Removal And Installation...372
Inlet Screen...373
ELECTRICAL SYSTEM...374
ELECTRICAL SCHEMATICS...376
TROUBLESHOOTING...408
ELECTRICAL SYSTEM INFORMATION...409
Description...409
Fuse Location...409
BATTERY...410
Removal And Installation...410
Servicing The Electrical System...411
Using A Booster Battery (Jump Starting)...412
ALTERNATOR...413
Alternator Output Test...413
Rectifier (Diode) Test...413
Alternator Regulator Test...414
Removal And Installation...415
Disassembly ...416
Stator Continuity Test...416
Stator Ground Test...416
Rotor Continuity Test...417
Rotor Ground Test...417
Rectifier Continuity (Diode) Test...417
Assembly...418
STARTER...419
Checking The Starter...419
Removal And Installation...420
Parts Identification...421
Disassembly And Assembly...422
Cleaning And Inspection...424
STANDARD INSTRUMENT PANEL...425
Removal And Installation...425
FRONT LIGHTS...426
Removal And Installation...426
STEERING LEVER CONTROL HANDLE (Early Series)...427
Disassembly And Assembly...427
ENGINE SERVICE...428
TROUBLESHOOTING...432
ENGINE SPEED CONTROL...433
Removal And Installation...433
ENGINE MUFFLER...434
Removal And Installation...434
AIR CLEANER HOUSING...435
Removal And Installation...435
COOLANT RECOVERY TANK...436
Removal And Installation...436
RADIATOR...437
Removal And Installation...437
FAN DRIVE TENSION PULLEY...439
Removal And Installation...439
FAN GEARBOX/BLOWER HOUSING...440
Removal And Installation...440
FAN GEARBOX...444
Parts Identification...444
Disassembly...445
Assembly...449
Checking Backlash...454
ENGINE...457
Removal And Installation...457
FLYWHEEL...464
Removal And Installation...464
Flywheel Ring Gear...464
BELT SHIELD...465
Removal And Installation...465
ENGINE MOUNTS...466
Removal And Installation...466
GLOW PLUGS...467
Checking The Glow Plugs...467
Removal And Installation...467
VALVE CLEARANCE...468
Adjustment...468
ENGINE COMPRESSION...468
Checking...468
FUEL INJECTION PUMP...469
Description...469
Removal And Installation...469
Timing The Injection Pump...473
FUEL INJECTOR NOZZLES...475
Checking...476
Removal And Installation...475
CYLINDER HEAD...478
Removal And Installation...478
Cylinder Head Surface Alignment...479
Exhaust Manifold...479
VALVES, VALVE SEAT AND GUIDE...480
Removal...480
Installation...480
Reconditioning The Valve And Valve Seats...480
Valve Seat Insert...481
Valve Guide...481
Valve Spring...482
ROCKER ARM AND SHAFT...483
Disassembly And Assembly...483
Checking Rocker Arm And Push Rods...483
PISTON AND CONNECTING ROD...484
Removal...484
Disassembly...484
Checking...485
Assembly...488
Installation...489
CYLINDER LINERS...490
Checking The Cylinder Bore...490
Removal...490
Installation...490
MAIN BEARINGS...491
Description...491
Removal...491
Installation...492
Crankshaft End Play...493
CRANKSHAFT...494
Removal And Installation...494
Checking The Crankshaft...494
CRANKSHAFT GEAR...496
Removal And Installation...496
TIMING GEARCASE COVER SEAL...497
Removal And Installation...497
TIMING GEARCASE COVER...498
Removal And Installation...498
IDLER GEAR AND HUB...500
Checking...500
Installation...501
FUEL INJECTION PUMP IDLER GEAR...502
Removal And Installation...502
Bearing Installation...502
CAMSHAFT GEAR...503
Removal And Installation...503
TIMING GEARCASE...504
Removal And Installation...504
CAMSHAFT...505
Removal And Installation...505
Checking...505
Camshaft Bearings...506
Tappets...506
Tappet Installation...507
OIL PAN...508
Removal...508
Installation...508
OIL PUMP...509
Removal And Installation...509
Checking...509
Gear Replacement...510
Rotor Replacement...511
Oil Pump Relief Valve...511
Oil Filter Housing And Block...511
WATER PUMP...512
Removal And Installation...512
Disassembly...512
Assembly...513
THERMOSTAT...515
Removal And Installation...515
Checking The Thermostat...515
WATER JACKET TUBE...516
Removal And Installation...516
SYSTEM ANALYSIS...518
BOSS® DIAGNOSTIC TOOL...520
Procedure...520
SENDER AND SENSOR...520
Service Checks...520
Component...520
RPM SENSOR...521
Adjustment...521
SERVICE CODES ...522
Chart...522
TROUBLESHOOTING THE BOSS® & LCD DISPLAY...524
BOSS® UNIT...525
Removal And Installation...525
BOSS® INSTRUMENT PANEL...526
Removal And Installation...526
SPECIFICATIONS...528
LOADER SPECIFICATIONS...530
Loader Dimensions...530
Performance...530
Controls...530
Engine...530
Hydraulic System...531
Electrical...531
Drive System...531
Capacities...531
Tires...531
ENGINE SPECIFICATIONS...532
Cylinder Head...532
Valve, Valve Guide & Seat Insert...532
Valve Springs...532
Rocker Arm...532
Tappets...532
Piston, Pin & Rings...533
Connecting Rod & Bearing...533
Cylinder Liners...533
Camshaft...533
Crankshaft...534
Idler Gear...534
Oil Pump...534
Fuel System...534
TORQUE SPECIFICATIONS FOR LOADER...535
TORQUE SPECIFICATIONS FOR BOLTS...537
Torque For General SAE Bolts...537
Torque For General Metric Bolts...538
HYDRAULIC CONNECTION SPECIFICATIONS...539
O–ring Face Seal Connection...539
Straight Thread O–ring Fitting...539
Tubelines And Hoses...539
Flare Fitting...539
O–ring Flare Fitting...540
Port Seal Fitting...542
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...543
DECIMAL AND MILLIMETER EQUIVALENTS...544
U.S. TO METRIC CONVERSION...544
SERVICE MANUAL REVISIONS...546
850–001...546
850–002...548
850–003...550
850–004...552
850–005...554
850–006...556
850–007...558
850–008...560
850–009...562
850–010...564
850–011...566
850–012...568
850–13...570
850-14...572
6724012 (4-95) - 853; 853H Service Manual...574
MAINTENANCE SAFETY...576
CONTENTS...578
FOREWORD...579
SAFETY INSTRUCTIONS...582
SERIAL NUMBER LOCATIONS...584
LOADER SERIAL NUMBER...584
ENGINE SERIAL NUMBER...584
DELIVERY REPORT...584
BOBCAT LOADER IDENTIFICATION...585
OPTIONS AND ACCESSORIES...586
PREVENTIVE MAINTENANCE...588
SERVICE SCHEDULE...590
LIFTING AND BLOCKING THE LOADER...591
Procedure...591
TRANSPORTING THE LOADER...592
Procedure...592
TOWING THE LOADER...592
Procedure...592
STOPPING THE BOBCAT LOADER...592
LIFTING THE LOADER...593
Four Point Lift...593
Single Point Lift...593
LIFT ARM SUPPORT DEVICE...594
Engaging The Lift Arm Support Device...594
Disengaging The Lift Arm Support Device...594
OPERATOR CAB...595
Description...595
Raising The Operator Cab...595
Lowering The Operator Cab...596
Emergency Exit...596
SEAT BAR RESTRAINT SYSTEM...597
Description...597
Seat Bar Inspection...597
Seat Bar Maintenance...597
AIR CLEANER SERVICE...598
Replacing Filter Element...598
FUEL SYSTEM...600
Fuel Specifications...600
Filling The Fuel Tank...600
Fuel Filter...600
Removing Air From The Fuel System...601
ENGINE LUBRICATION SYSTEM...602
Checking Engine Oil...602
Replacing Oil And Filter...602
ENGINE COOLING SYSTEM...604
Cleaning The Cooling System...604
Checking The Coolant Level...604
Removing Coolant From The Cooling System...605
Propylene Glycol...605
ALTERNATOR BELT...605
Adjusting The Alternator Belt...605
USING A BOOSTER BATTERY (Jump Starting)...606
Procedure...606
HYDRAULIC/HYDROSTATIC SYSTEM...607
Checking And Adding Fluid...607
Replacing Hydraulic/Hydrostatic Filters...607
Replacing Hydraulic Fluid...608
Hydraulic Reservoir Breather Cap...609
SPARK ARRESTOR MUFFLER...610
Cleaning Procedure...610
TIRE MAINTENANCE...611
Wheel Nuts...611
Tire Rotation...611
Tire Mounting...611
FINAL DRIVE TRANSMISSION (CHAINCASE)...612
Checking And Adding Oil...612
Removing Oil From The Chaincase...612
FAN GEARBOX...612
Checking And Maintaining...612
LUBRICATING THE LOADER...613
Procedure...613
REMOTE START SWITCH...615
Procedure...615
HYDRAULIC SYSTEM...618
HYDRAULIC / HYDROSTATIC SCHEMATICS...620
TROUBLESHOOTING...628
HYDRAULIC SYSTEM INFORMATION...629
Flare Connections...629
O–ring Face Seal Connection...629
Straight Thread O–ring Fitting...629
Tubelines And Hoses...629
LIFT CYLINDER(S)...630
Checking The Lift Cylinder...630
Removal And Installation...630
TILT CYLINDER...632
Checking The Tilt Cylinder...632
Removal And Installation...632
Rod End Seal...633
HYDRAULIC CYLINDER...634
Lift Cylinder Identification...634
Tilt Cylinder Identification...635
Disassembly...636
Assembly...638
MAIN RELIEF VALVE...644
Checking The Main Relief Valve...644
Checking The Main Relief Valve Without Auxiliaries...645
Removal And Installation...646
DUAL PRESSURE MAIN RELIEF VALVE – 853H...647
Checking The Low Setting...647
Checking The High Setting...648
Adjusting The Low Setting...650
Adjusting The High Setting...651
SELECT VALVE (G.E.M. Block) 853H...652
Checking The Main Relief Valve...652
HYDRAULIC CONTROL VALVE...653
Removal And Installation...653
Identification Chart...655
Disassembly And Assembly...656
Main Relief Valve...657
Port Relief Valve...657
Anti–Cavitation Valve...658
Rubber Boot...659
Lift Spool And Detent...660
Tilt Spool And Centering Spring...665
Auxiliary Spool...666
Auxiliary Electric Solenoid...667
H Port – Auxiliary Section...668
Base End Restrictor...668
Inspection...668
Spool Seal Installation...669
HYDRAULIC PUMP...670
Checking The Output Of The Pump...670
Removal And Installation...671
Parts Identification...672
Disassembly...673
Inspection...675
Assembly...676
HYDRAULIC PUMP (Double Gear) 853H...678
Checking The Output Of The Pump...678
Removal And Installation...679
Parts Identification...680
Disassembly...681
Inspection...685
Assembly...686
BUCKET POSITION VALVE (Optional)...689
Removal And Installation...689
HYDRAULIC FLUID RESERVOIR...690
Removal And Installation...690
HYDROSTATIC FILTER HOUSING...691
Removal And Installation...691
HYDRAULIC FILTER HOUSING...692
Removal And Installation...692
CONTROL PEDALS...693
Removal And Installation...693
Pedal Adjustment...693
PEDAL INTERLOCK LINKAGE...694
Removal And Installation...694
Pedal Interlock Linkage Adjustment...695
HYDROSTATIC SYSTEM...696
TROUBLESHOOTING...698
HYDROSTATIC SYSTEM INFORMATION...699
Replenishing Valve Function...699
FRONT PANEL...700
Removal And Installation...700
STEERING LEVERS...702
Disassembly And Assembly...702
Pre–Adjustment Checks...704
Adjusting Lever Freeplay...705
Adjusting The Wheel RPM Forward Compared To Reverse Travel...706
Adjusting The Steering Neutral Setting...708
Adjusting The Wheel RPM Left Compared To Right Side...709
HYDROSTATIC MOTOR...710
Removal And Installation...710
Parts Identification...711
Disassembly...712
Inspection...717
Assembly...718
Timing The Hydrostatic Motor...721
HYDROSTATIC PUMP...722
Removal And Installation...722
Replenishing/High Pressure Relief Valve...724
Parts Identification...725
Hydraulic Pump Removal...730
Hydrostatic Pump Separation...730
Charge Pump Disassembly...731
Disassembly...732
Inspection...741
Assembly...743
Charge Pump Assembly...752
Hydrostatic Pump Connection...753
Hydraulic Pump Installation...754
Hydrostatic Pump Neutral Adjustment...755
DRIVE BELT SHIELD...757
Removal And Installation...757
DRIVE BELT...758
Adjusting The Drive Belt...758
Replacing The Drive Belt...759
DRIVE BELT TENSIONER PULLEY...760
Removal And Installation...760
Disassembly...761
Assembly...763
Checking Pulley End Play...767
OIL COOLER...768
Removal And Installation...768
DRIVE SYSTEM...770
PARKING BRAKE PEDAL...772
Removal And Installation...772
Disassembly And Assembly...773
PARKING BRAKE DISC...774
Removal And Installation...774
FRONT CHAINCASE COVER...776
Removal And Installation...776
REAR CHAINCASE COVER...776
Removal And Installation...776
AXLE SEAL...777
Removal And Installation...777
AXLE, SPROCKET AND BEARINGS...779
Removal And Installation...779
REDUCTION GEARCASE...783
Reduction Gearcase Seal...783
Removal And Installation...784
Checking Reduction Gearcase...785
Disassembly...785
Assembly...790
DRIVE CHAIN...794
Removal And Installation...794
CHAINCASE FLUID...795
Removing The Fluid From The Chaincase...795
MAIN FRAME...796
SEAT BAR...798
Removal And Installation...798
Assembly...800
Compressing The Gas Cylinder...801
OPERATOR CAB GAS CYLINDER...802
Removal And Installation...802
Disassembly And Assembly...803
OPERATOR CAB...804
Removal And Installation...804
OPERATOR SEAT...806
Removal And Installation...806
BOB–TACH...807
Removal And Installation...807
Bob–Tach Lever And Wedge...809
Bob–Tach Stops...810
LIFT ARMS...811
Removal And Installation...811
REAR GRILL...812
Removal And Installation...812
REAR DOOR...813
Removal And Installation...813
Hood Removal And Installation...814
Bumper Removal And Installation...814
Door Latch Removal And Installation...814
Door Latch And Catch Adjustment...814
FUEL TANK...815
Removal And Installation...815
Inlet Screen...816
ELECTRICAL SYSTEM...818
ELECTRICAL SCHEMATICS...820
TROUBLESHOOTING...872
ELECTRICAL SYSTEM INFORMATION...873
Description...873
Fuse Location (Standard & BOSS® Option)...873
BATTERY...874
Removal And Installation...874
ALTERNATOR...875
Alternator Output Test...875
Rectifier (Diode) Test...875
Alternator Regulator Test...876
Removal And Installation...877
Disassembly And Inspection...878
Stator Continuity Test...878
Stator Ground Test...878
Rotor Continuity Test...879
Rotor Ground Test...879
Rectifier Continuity (Diode) Test...879
Assembly...880
STARTER...881
Removal And Installation...881
Checking The Starter...882
Parts Identification...883
Disassembly And Assembly...884
Cleaning And Inspection...886
STANDARD INSTRUMENT PANEL...887
Removal And Installation...887
FRONT LIGHTS...888
Removal And Installation...888
RELAY SWITCHES...889
Location...889
ENGINE SERVICE...890
TROUBLESHOOTING...892
ENGINE SPEED CONTROL...893
Removal And Installation...893
Disassembly...893
RADIATOR...894
Removal And Installation...894
COOLANT RECOVERY TANK...896
Removal And Installation...896
ENGINE MUFFLER...897
Removal And Installation...897
AIR CLEANER HOUSING...898
Removal And Installation...898
BLOWER HOUSING/FAN GEARBOX...899
Removal And Installation...899
FAN DRIVE TENSION PULLEY...901
Removal And Installation...901
BLOWER FAN...902
Removal And Installation...902
FAN GEARBOX...903
Parts Identification...903
Disassembly...904
Assembly...909
Checking Backlash...914
ENGINE...917
Removal And Installation...917
Engine Mount Replacement...924
FLYWHEEL...925
Removal And Installation...925
Flywheel Ring Gear...925
BELT SHIELD...926
Removal And Installation...926
VALVE CLEARANCE...927
Adjustment...927
ENGINE COMPRESSION...927
Checking...927
GLOW PLUGS...928
Removal And Installation...928
Checking The Glow Plugs...928
FUEL INJECTION PUMP...929
Description...929
Removal And Installation...929
Timing The Injection Pump...933
FUEL INJECTOR NOZZLES...935
Removal And Installation...935
Checking...936
CYLINDER HEAD...938
Removal And Installation...938
Cylinder Head Surface Alignment...939
Exhaust Manifold...939
VALVES, VALVE SEAT AND GUIDE...940
Removal...940
Installation...940
Reconditioning The Valve And Valve Seats...940
Valve Seat Insert...941
Valve Guide...941
Valve Spring...942
ROCKER ARM AND SHAFT...943
Disassembly And Assembly...943
Checking Rocker Arm And Push Rods...943
PISTON AND CONNECTING ROD...944
Removal...944
Disassembly...944
Checking...945
Assembly...948
Installation...949
CYLINDER LINERS...950
Checking The Cylinder Bore...950
Removal...950
Installation...950
MAIN BEARINGS...951
Description...951
Removal...951
Installation...952
Crankshaft End Play...953
CRANKSHAFT...954
Removal And Installation...954
Checking Tuffriding (Soft Nitriding) Coating...954
Checking the Crankshaft...954
CRANKSHAFT GEAR...956
Removal And Installation...956
TIMING GEARCASE COVER SEAL...957
Removal And Installation...957
TIMING GEARCASE COVER...958
Removal And Installation...958
IDLER GEAR AND HUB...960
Removal...960
Checking...960
Installation...961
FUEL INJECTION PUMP IDLER GEAR...962
Removal And Installation...962
Bearing Installation...962
CAMSHAFT GEAR...963
Removal And Installation...963
TIMING GEARCASE...964
Removal And Installation...964
CAMSHAFT...965
Removal And Installation...965
Checking...965
Camshaft Bearings...966
Tappets...966
Tappet Installation...967
OIL PAN...968
Removal...968
Installation...968
OIL PUMP...969
Removal And Installation...969
Checking...969
Gear Replacement...970
Rotor Replacement...971
Oil Pump Relief Valve...971
Oil Filter Housing And Block...971
WATER PUMP...972
Removal And Installation...972
Disassembly...972
Assembly...973
THERMOSTAT...975
Removal And Installation...975
Checking The Thermostat...975
WATER JACKET TUBE...976
Removal And Installation...976
SYSTEMS ANALYSIS...978
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...980
Inspecting The BICS System Controller (Engine STOPPED – Key ON)...980
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)...980
Inspecting The Traction Lock (Engine RUNNING)...980
Inspecting The Lift Arm By–Pass Control...980
Maintenance...980
Troubleshooting Chart...981
Troubleshooting Guide...982
BICS SYSTEM CONTROLLER...982
TRACTION LOCK...983
SEAT SENSOR...984
SEAT BAR SENSOR...985
LIFT LOCK BY–PASS VALVE...986
BICS™ SYSTEM CONTROLLER...987
Removal And Installation...987
Controller Test...988
SEAT BAR SENSOR...989
Removal And Installation...989
Seat Bar Sensor Test...990
SEAT SENSOR...991
Removal And Installation...991
Seat Sensor Test...992
TRACTION LOCK...993
Removal And Installation...993
LIFT LOCK BY–PASS VALVE...994
Removal And Installation...994
Disassembly And Assembly...995
TILT LOCK VALVE...996
Removal And Installation...996
Disassembly And Assembly...997
BOSS® DIAGNOSTIC TOOL...998
Procedure...998
SENDER AND SENSOR...998
Service Checks...998
Component...998
RPM SENSOR...998
Adjustment...998
MONITOR SERVICE CODES...999
TROUBLESHOOTING THE BOSS® & LCD DISPLAY...1002
OPERATION SENSING SYSTEM UNIT...1003
Removal And Installation...1003
BOSS® INSTRUMENT PANEL...1004
Removal And Installation...1004
PWM MODULE...1005
Description...1005
PWM TROUBLESHOOTING...1006
Conditions...1006
Chart...1007
PWM CONTROL HANDLE...1008
Handle Testing...1008
PWM ELECTRIC SOLENOID...1008
Solenoid Coil Testing...1008
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...1009
Controls Identification Chart...1009
SPECIFICATIONS...1010
LOADER SPECIFICATIONS...1012
LOADER DIMENSIONS...1012
OPERATION & PERFORMANCE...1012
ENGINE...1012
HYDRAULIC SYSTEM...1013
ELECTRICAL...1013
DRIVE SYSTEM...1013
CAPACITIES...1013
TIRES...1013
VIBRATION DATA...1013
ENGINE SPECIFICATIONS...1014
Cylinder Head...1014
Valve, Valve Guide & Seat Insert...1014
Valve Springs...1014
Rocker Arm...1014
Tappets...1014
Piston, Pin & Rings...1015
Connecting Rod & Bearing...1015
Cylinder Liners...1015
Camshaft...1015
Crankshaft...1016
Idler Gear...1016
Oil Pump...1016
Fuel System...1016
Torque For General Metric Bolts...1017
TORQUE SPECIFICATIONS FOR LOADER...1018
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1020
STANDARD TORQUE SPECIFICATIONS FOR BOLTS...1021
DECIMAL AND MILLIMETER EQUIVALENTS...1022
U.S. TO METRIC CONVERSION...1022
SERVICE MANUAL REVISIONS...1024
850–001...1024
850–002...1026
850–003...1028
850–004...1030
850–005...1032
6566091 (12-85) - 843; 843B Service Manual...1034
MAINTENANCE SAFETY...1036
CONTENTS...1038
FOREWORD...1040
SAFETY INSTRUCTIONS...1042
FIRE PREVENTION...1043
SERIAL NUMBER LOCATIONS...1044
LOADER SERIAL NUMBER...1044
ENGINE SERIAL NUMBER...1044
DELIVERY REPORT...1044
BOBCAT LOADER IDENTIFICATION...1045
PREVENTIVE MAINTENANCE...1046
SERVICE SCHEDULE...1048
LIFTING AND BLOCKING THE LOADER...1049
Procedure...1049
TRANSPORTING THE BOBCAT LOADER...1050
Procedure...1050
LIFT ARM STOP...1051
Procedure...1051
OPERATOR CAB...1052
Seat Bar System...1052
Seat Bar Inspection...1052
Seat Bar Maintenance...1053
Raising The Operator Cab...1054
Lowering The Operator Cab...1054
USING AN EXTRA BATTERY (JUMP STARTING)...1055
Procedure...1055
REMOTE START SWITCH...1056
Procedure...1056
HYDRAULIC SYSTEM...1058
HYDRAULIC / HYDROSTATIC SCHEMATICS...1060
TROUBLESHOOTING...1112
HYDRAULIC SYSTEM INFORMATION...1113
Flare Connections...1113
Straight Thread O-Ring Fitting...1113
Tubelines And Hoses...1113
LIFT CYLINDER...1114
Checking The Lift Cylinder(s)...1114
Removal And Installation...1114
TILT CYLINDERS...1116
Checking The Tilt Cylinder...1116
Removal And Installation...1116
Rod End Seal...1117
TILT CYLINDER (CESSNA)...1118
Disassembly...1118
Assembly...1120
HYDRAULIC CYLINDER REPAIR...1124
Disassembly...1124
Assembly...1126
HYDRAULIC CONTROL VALVE (CESSNA)...1129
Checking The Main Relief Valve...1129
Main Relief Valve Removal And Installation...1130
Removal And Installation...1130
Disassembly...1132
Inlet Section...1133
Tilt Section...1134
Lift Section...1136
Auxiliary Section...1138
Valve Spool Bolt...1139
Assembly...1140
HYDRAULIC CONTROL VALVE (MELROE)...1141
Checking The Main Relief Valve...1141
Main Relief Valve Removal And Installation...1142
Removal And Installation...1142
Disassembly And Assembly...1144
Detent Assembly...1146
Centering Mechanism...1149
HYDRAULIC PUMP (SINGLE STAGE)...1150
Checking The Output Of The Hydraulic Pump...1150
Removal And Installation...1151
Disassembly And Assembly...1151
Inspection...1153
HYDRAULIC PUMP (DOUBLE STAGE)...1154
Removal And Installation...1155
Disassembly And Assembly...1157
Inspection...1159
BUCKET POSITION VALVE (S/N 15001 & ABOVE)...1160
Removal And Installation...1160
Disassembly And Assembly...1160
PORT BLOCK (S/N 14999 & BELOW)...1162
40 Micron Filter (Bronze)...1162
Neutral By-Pass Valve...1163
Removal And Installation...1163
PORT BLOCK (S/N 15001 & ABOVE)...1166
Removal And Installation...1166
Charge By-Pass...1167
Cold Oil By-Pass...1167
HYDRAULIC FLUID FILTER HOUSING (S/N 15001 & ABOVE)...1168
Removal And Installation...1168
By-Pass Valve...1168
HYDRAULIC/HYDROSTATIC RESERVOIR (S/N 21514 & BELOW)...1169
Removal And Installation...1169
HYDRAULIC CONTROL PEDALS (S/N 14999 & BELOW)...1171
Removal And Installation...1171
Adjustment...1171
HYDRAULIC CONTROL PEDALS (S/N 15001 & ABOVE)...1172
Removal And Installation...1172
Adjustment...1172
PEDAL LOCK LINKAGE...1173
Adjustment...1173
HYDROSTATIC SYSTEM...1174
TROUBLESHOOTING...1176
HYDROSTATIC SYSTEM INFORMATION...1177
High Pressure Relief/Replenishing Valves Function...1177
FRONT AND SIDE PANELS (S/N 19999 & BELOW)...1178
Removal And Installation...1178
STEERING LEVERS (S/N 16191 & BELOW)...1179
Removal And Installation...1179
Repairing The Steering Levers...1180
Steering Linkage Adjustment...1181
Removal And Installation...1182
RepairingThe Pintle Lever...1183
FRONT AND SIDE PANEL (ONE PIECE) (S/N 20001 & ABOVE) & 843B...1184
Removal And Installation...1184
STEERING LEVERS - 843-(S/N 16192 THRU 25999), 843-(STARTING WITH S/N 34222) & 843B...1187
Removal And Installation...1187
Repairing The Steering Levers...1188
STEERING LINKAGE 843-(S/N 16192 THRU 25999), 843-(STARTING WITH S/N 34222) & 843B...1189
Steering Linkage Adjustment...1189
Removal And Installation...1190
Repairing The Pintle Lever...1191
STEERING LINKAGE (S/N 26000 THRU 29869)...1192
Description...1192
Neutral Adjustment...1192
Steering Lever Centering Spring Mechanism...1194
Removal And Installation (Creep Mechanism)...1195
SERVO CONTROL...1198
Removal And Installation...1198
Disassembly And Assembly...1199
PINTLE LEVER ARMS (S/N 26000 - 29869)...1200
Removal And Installation...1200
STEERING LINKAGE (S/N 29870 - 31863)...1202
Description...1202
Neutral Adjustment...1202
Steering Lever Centering Spring Mechanism...1204
Creep Centering Spring Mechanism...1204
Pintle Arm...1204
STEERING LINKAGE (S/N 31864-34221)...1205
Hydrostatic Pump Centering Spring Adjustment...1206
Servo Control Unit Adjustment...1207
Steering Lever Centering Spring Adjustment...1208
Wheel RPM Adjustment (Left To Right)...1209
HYDROSTATIC MOTOR...1211
Removal And Installation...1211
Disassembly And Assembly...1212
Inspection...1216
Timing The Hydrostatic Motor...1217
High Pressure Hose Routing...1217
HYDROSTATIC PUMPS...1218
Checking The High Pressure Relief/Replenishing Valve...1218
Checking Charge Pressure...1219
Removal And Installation...1219
Disassembly And Assembly...1220
Rear Pump...1222
Front Pump...1222
Inspection...1225
Tow Valves...1226
Hydrostatic Pump Rear Mount (S/N 21574 & Above)...1227
HYDROSTATIC FLUID FILTER HOUSING...1228
Removal And Installation...1228
DRIVE SYSTEM...1230
PARKING BRAKE...1232
Adjustment...1232
Removal And Installation...1232
Block And Pucks...1233
AXLES, SEALS AND BEARINGS...1235
Removal...1235
Installation...1236
FINAL DRIVE CHAIN...1239
Removal...1239
Installation...1239
REDUCTION GEARCASE...1241
Removal And Installation...1241
Checking Reduction Gearcase...1242
Disassembly And Assembly...1242
Installation...1247
Reduction Gearcase Seal...1248
MAIN FRAME...1250
OPERATOR CAB (S/N 19999 & BELOW)...1252
Removal And Installation...1252
OPERATOR CAB (S/N 20001 & ABOVE)...1254
Removal And Installation...1254
OPERATOR CAB GAS CYLINDER...1257
Removal And Installation...1257
REAR DOOR...1258
Door Latch Adjustment...1258
Removal And Installation...1259
LIFT ARMS...1260
Removal And Installation...1260
BOB-TACH...1262
Removal And Installation...1262
Tilt Cylinder Rod End Seal...1263
Disassembly And Assembly...1264
FUEL TANK (S/N 19999 & BELOW)...1266
Removal And Installation...1266
FUEL TANK (S/N 20001 & ABOVE)...1267
Removal And Installation...1267
Fuel Tank Sender Switch...1268
ELECTRICAL SYSTEM...1270
ELECTRICAL SCHEMATICS...1273
ELECTRICAL SYSTEM INFORMATION...1300
Description...1300
TROUBLESHOOTING...1300
BATTERY...1301
Checking The Battery...1301
Removal And Installation...1301
ALTERNATOR...1302
Alternator Belt Adjustment...1302
Checking The Alternator Wire Harness...1303
Checking Alternator Output...1303
Checking Alternator Regulator...1303
Removal And Installation...1304
Disassembly And Assembly...1305
MELROE ALTERNATOR...1307
Checking The Alternator Output...1307
Checking The Alternator Regulator...1308
Removal And Installation...1309
Disassembly And Assembly...1310
MANDO ALTERNATOR...1312
STARTER...1313
Checking The Starter...1313
Removal And Installation...1313
Disassembly And Assembly...1315
Cleaning And Inspection...1315
Replacing The Brushes...1316
ENGINE SERVICE...1318
ENGINE SERVICE (PERKINS ENGINE)...1320
TROUBLESHOOTING...1322
VALVE CLEARANCE...1323
Adjustment...1323
ENGINE COMPRESSION...1324
Checking...1324
FUEL FILTER...1325
Removal And Installation...1325
Water Trap...1325
FUEL LIFT PUMP...1326
Checking...1326
Removal And Installation...1326
REMOVING AIR FROM FUEL SYSTEM...1327
Procedure...1327
FUEL INJECTION PUMP...1328
Removal And Installation...1328
ENGINE TIMING TO INJECTION PUMP (USING DIAL INDICATOR)...1329
Procedure...1329
EMGINE TIMING TO INJECTOR PUMP (USING TIMING TOOL)...1330
Procedure...1330
CHECKING TIMING MARK ON INJECTION PUMP FLANGE...1331
Procedure...1331
FUEL INJECTOR NOZZLES...1332
Removal And Installation...1332
Checking...1333
ENGINE...1334
Removal And Installation...1334
RADIATOR...1338
Removal And Installation...1338
OIL COOLER...1339
Removal And Installation...1339
ENGINE MUFFLER...1340
Removal And Installation...1340
ENGINE BLOWER HOUSING...1341
Removal And Installation...1341
ENGINE FLYWHEEL & U-JOINT...1342
Removal And Installation...1342
Flywheel Ring Gear...1342
CYLINDER HEAD...1343
Removing The Cylinder Head...1343
Cylinder Head Surface Alignment...1343
Installing The Cylinder Head...1344
VALVES...1345
Removal Of The Valves...1345
Installing The Valves...1345
Reconditioning The Valves And Valve Seats...1345
Installing Valve Guides...1346
Changing The Valve Springs...1347
COMBUSTION CHAMBER INSERTS...1348
Removal And Installation...1348
ROCKER ARMS...1349
Disassembly...1349
Assembly...1349
PISTON AND CONNECTING RODS...1350
Removal...1350
Disassembly...1351
Inspection...1351
Installation...1352
CYLINDER LINERS...1353
Checking...1353
Removal And Installation...1353
MAIN BEARINGS...1354
Removal...1354
Installation...1355
Crankshaft End Play...1355
CRANKSHAFT...1356
Removal...1356
Checking...1356
Installation...1357
REAR MAIN OIL SEAL...1358
Removal And Installation...1358
TIMING CASE COVER...1359
Removal And Installation...1359
IDLER GEAR AND HUB...1360
Removal...1360
Installation...1360
CAMSHAFT GEAR...1362
Removal...1362
Installation...1362
FUEL INJECTION PUMP DRIVE GEAR...1363
Removal And Installation...1363
CRANKSHAFT GEAR...1363
Removal...1363
TIMING CASE...1364
Removal And Installation...1364
CAMSHAFT AND TAPPETS...1365
Removal...1365
Inspection...1366
Installation...1366
LUBRICATION SYSTEM...1367
Description...1367
OIL PUMP...1368
Removal And Installation...1368
Disassembly And Assembly...1368
Checking...1368
WATER PUMP...1370
Removal And Installation...1370
Disassembly...1370
Checking...1371
Assembly...1371
THERMOSTAT...1372
Removal...1372
Testing The Thermostat...1372
Installation...1372
ENGINE SERVICE (PERKINS ENGINE - 200 SERIES)...1374
TROUBLESHOOTING...1376
VALVE CLEARANCE...1377
Adjustment...1377
ENGINE COMPRESSION...1378
Checking...1378
FUEL FILTER (S/N 13315 & BELOW)...1379
Removal And Installation...1379
Water Trap...1379
FUEL FILTER (S/M 13316 & ABOVE)...1379
Removal And Installation...1379
REMOVING AIR FROM THE FUEL SYSTEM (S/N 13315 & BELOW)...1380
Procedure...1380
REMOVING AIR FROM THE FUEL SYSTEM (S/N 13316 & ABOVE)...1381
Procedure...1381
FUEL INJECTION PUMP...1382
Removal And Installation...1382
Maximum Speed Setting...1383
TIMING THE FUEL INJECTION PUMP...1384
Procedure...1384
FUEL INJECTOR NOZZLES...1386
Removal And Installation...1386
Checking...1387
GLOW PLUGS...1388
Checking...1388
ENGINE...1389
Removal And Installation...1389
RADIATOR...1392
Removal And Installation...1392
OIL COOLER...1394
Removal And Installation...1394
ENGINE MUFFLER...1395
Removal And Installation...1395
ENGINE BLOWER HOUSING...1396
Removal And Installation...1396
ENGINE FLYWHEEL & U-JOINT...1397
Removal And Installation...1397
Flywheel Ring Gear...1397
CYLINDER HEAD...1398
Removing The Cylinder Head...1398
Cylinder Head Surface Alignment...1398
Installing The Cylinder Head...1399
VALVES...1400
Removing The Valves...1400
Installing The Valves...1400
Reconditioning The Valves And Valve Seats...1400
Installing The Valve Guides...1401
Checking The Valve Springs...1402
CONBUSTION CHAMBER INSERTS...1403
Removal And Installation...1403
ROCKER ARMS...1404
Disassembly...1404
Assembly...1404
PISTON AND CONNECTING RODS...1405
Removal...1405
Disassembly...1406
Inspection...1406
Installation...1407
CYLINDER LINERS...1408
Checking...1408
Removal And Installation...1408
MAIN BEARINGS...1409
Removal...1409
Installation...1410
Crankshaft End Play...1410
CRANKSHAFT...1411
Removal...1411
Installation...1412
REAR MAIN OIL SEAL...1413
Removal And Installation...1413
TIMING CASE COVER...1414
Removal And Installation...1414
Front Seal...1415
IDLER GEAR AND HUB...1416
Removal...1416
Installation...1417
CAMSHAFT GEAR...1418
Removal...1418
Installation...1418
FUEL INJECTION PUMP DRIVE GEAR...1419
Removal And Installation...1419
CRANKSHAFT GEAR...1419
Removal...1419
TIMING CASE...1420
Removal And Installation...1420
CAMSHAFT AND TAPPETS...1421
Removal...1421
Inspection...1422
Installation...1422
LUBRICATION SYSTEM...1423
Description...1423
OIL PUMP...1424
Removal And Installation...1424
Inspection...1425
OIL FILTER ADAPTER HOUSING...1426
Removal And Installation...1426
WATER PUMP...1427
Removal And Installation...1427
Disassembly...1427
Checking...1428
Assembly...1428
THERMOSTAT...1429
Removal...1429
Testing The Thermostat...1429
Installation...1429
ENGINE SERVICE (ISUZU ENGINE)...1430
TROUBLESHOOTING...1432
VALVE CLEARANCE...1433
Adjustment...1433
ENGINE COMPRESSION...1434
Checking...1434
FUEL FILTER...1435
Water Trap...1435
Fuel Filter Element...1435
REMOVING AIR FROM FUEL SYSTEM...1436
Procedure...1436
FUEL INJECTION PUMP...1437
Removal And Installation...1437
ENGINE TIMING TO INJECTION PUMP...1440
Procedure...1440
FUEL INJECTOR NOZZLES...1442
Removal And Installation...1442
Checking...1443
GLOW PLUGS...1445
Removal And Installation...1445
ENGINE OIL AND FILTER...1446
Removal And Installation...1446
ENGINE...1448
Removal And Installation...1448
RADIATOR...1453
Removal And Installation...1453
OIL COOLER...1455
Removal And Installation...1455
ENGINE MUFFLER...1456
Removal And Installation...1456
ENGINE FLYWHEEL & U-JOINT...1457
Removal And Installation...1457
Flywheel Ring Gear...1457
ENGINE BLOWER HOUSING...1458
Removal And Installation...1458
ENGINE MOUNTS...1459
Removal And Installation...1459
CYLINDER HEAD...1460
Removal And Installation...1460
Cylinder Head Surface Alignment...1461
Exhaust Manifold...1461
VALVES...1462
Removal And Installation...1462
Reconditioning The Valves And Valve Seats...1462
Valve Seat Insert...1463
Valve Guides...1463
Valve Springs...1464
ROCKER ARMS...1465
Disassembly And Assembly...1465
Push Rods...1465
PISTON AND CONNECTING ROD...1466
Removal...1466
Disassembly...1466
Inspection...1467
Assembly...1470
Installation...1471
CYLINDER LINERS...1472
Checking...1472
Removal...1472
Installation...1472
MAIN BEARINGS...1473
Removal...1473
Installation...1474
Crankshaft End Play...1475
CRANKSHAFT...1476
Removal...1476
Checking Tuffriding (Soft Nitriding) Coating...1476
Checking...1476
Crankshaft Gear...1478
Removal And Installation...1478
Installation...1478
TIMING CASE COVER SEAL...1479
Removal And Installation...1479
TIMING CASE COVER...1480
Removal And Installation...1480
IDLER GEAR AND HUB...1482
Removal And Installation...1482
Checking...1482
FUEL INJECTION PUMP IDLER GEAR...1484
Removal And Installation...1484
Bearing Installation...1484
CAMSHAFT GEAR...1485
Removal And Installation...1485
TIMING CASE...1486
Removal And Installation...1486
CAMSHAFT...1487
Removal And Installation...1487
Checking...1487
Camshaft Bearing...1488
Tappets...1488
Installation...1489
OIL PAN...1490
Removal...1490
Installation...1490
OIL PUMP...1491
Removal And Installation...1491
Checking...1491
Gear Replacement...1492
Rotor Replacement...1493
Oil Pump Relief Valve...1493
WATER PUMP...1494
Removal And Installation...1494
Disassembly...1494
Assembly...1495
THERMOSTAT...1497
Removal And Installation...1497
Inspection...1497
WATER JACKET TUBE...1498
Removal And Installation...1498
TECHNICAL DATA...1500
GENERAL SPECIFICATIONS...1502
TORQUE SPECIFICATIONS...1504
Seat Bar, Fuel Tank & Panel Group...1504
Steering Levers, Linkage & Pedal Group...1505
Brakem Axle & Chaincase Group...1506
Operator Guard, Lift Arm & Main Frame Group...1507
Hydraulic/Hydrostatic Group...1508
Engine Group (Perkins)...1509
Engine Group (200 Series Perkins)...1511
Engine Group (Isuzu)...1513
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1515
DECIMAL AND MILLIMETER EQUIVALENTS...1516
U.S. TO METRIC CONVERSION...1516
STANDARD TORQUE SPECIFICATIONS FOR BOLTS...1517
TECHNICAL DATA (PERKINS ENGINE)...1518
LOADER SPECIFICATIONS...1520
Specifications...1520
Engine...1520
Loader Hydraulics...1521
Electrical...1521
Drive System...1521
Capacities...1521
Tires...1521
ENGINE SPECIFICATIONS...1522
Cylinder Head Dimensions...1522
Piston And Connecting Rod Dimensions...1523
Cylinder Block And Liner Dimensions...1524
crankshaft And Main Bearings Dimensions...1524
Timing Case, Camshaft And Drive Dimensions...1525
Oil Pump Dimensions...1526
Cooling System and Wster Pump Dimensions...1527
Fuel System Specifications...1527
De-Rating For Altitude...1528
Engine Torque...1528
Grinding Specifications For Crankshaft...1529
TECHNICAL DATA (PERKINS ENGINE - 200 SERIES)...1530
LOADER SPECIFICATIONS...1532
Specifications...1532
Engine...1532
Loader Hydraulics...1533
Electrical...1533
Drive System...1533
Capacities...1533
Tires...1533
ENGINE SPECIFICATIONS...1534
Cylinder Head Dimensions...1534
Pistons And Connecting Rod Dimensions...1534
Cylinder Block And Liner Dimensions...1535
Crankshaft And Main Bearing Dimensions...1535
Timing Case, Camshaft And Drive Dimensions...1536
Oil Pump Dimensions...1536
Cooling System And Water Pump Dimensions...1536
Fuel System Specifications...1537
De-Rating For Altitude...1537
Engine Torques...1537
Grinding Specifications For Crankshaft...1538
TECHNICAL DATA (iSUZU ENGINE)...1540
LOADER SPECIFICATIONS...1542
Operation And Performance...1542
Engine...1542
Loader Hydraulics...1543
Electrical...1543
Drive System...1543
Capacities...1543
Tires...1543
ENGINE SPECIFICATIONS...1544
Cylinder Head...1544
Valve, Vale Guide And Seat Insert...1544
Valve Springs...1544
Rocker Arm...1544
Tappets...1545
Piston, Pin And Rings...1545
Connecting Rod & Bearing...1545
Cylinder Liners...1545
Camshaft...1545
Crankshaft...1546
Idler Gear...1546
Oil Pump...1546
Fuel System...1546
Engine Torque...1547
SERVICE MANUAL REVISIONS...1548
843-1...1548
843-2...1550
843-3...1552
843-4...1554
843-5...1556
843-6...1558
843-7...1560
843-8...1562
843-9...1564
843-10...1566
843-11...1568
843-12...1570
843-13...1572
843-14...1574
843-15...1576
843-16...1578
6549634 (11-98) - 825 Operation & Maintenance Manual...1579
OPERATOR SAFETY WARNINGS...1581
FOREWORD...1583
CONTENTS...1583
825 BOBCAT LOADER PICTORIAL NOMENCLATURE...1584
DECAL LOCATIONS & SAFETY SIGNS...1585
OPERATING INSTRUCTIONS...1586
OPERATING INSTRUCTIONS...1587
SAFETY...1587
MOUNTING AND DISMOUNTING...1587
DASH PANEL...1588
LIFT, TILT AND AUXILIARY CONTROLS...1588
DRIVE CONTROLS...1589
Steering Controls...1589
Range Control...1589
Throttle Control...1589
PRE-STARTING INSPECTION...1590
STARTING PROCEDURE...1590
NORMAL STARTING CONDITIONS...1590
COLD WEATHE STARTING CONDITIONS...1590
STOPPING THE ENGINE...1591
BOB-TACH OPERATION...1591
Installing Attachment...1591
To Remove Attachment...1592
FILLING BUCKET FROM A PILE...1592
OPERATION HINTS...1592
DIGGING WITH A BUCKET...1593
LEVELING AND BACKFILLING...1593
DUMPING THE BUCKET...1593
TOWING...1594
TRANSPORTING BY TRAILER...1594
SERVICE INSTRUCTIONS...1595
SERVICE & MAINTENANCE...1596
MAINTENANCE SAFETY...1597
SERVICING INSTRUCTIONS...1599
SERVICE SCHEDULE...1599
REAR GRILL...1600
TILTING THE ROPS...1600
ENGINE MAINTENANCE...1600
Engine Oil...1600
Specifications...1600
CHANGING OIL AND FILTER...1601
ENGINE AIR INLET SYSTEM (AIR CLEANER)...1602
ENGINE COOLING SYSTEM...1603
FAN BELT ADJUSTMENT...1603
FLUSHING THE COOLING SYSTEM...1604
FUEL SYSTEM...1604
Safety Precautions...1604
FUEL SPECIFICATIONS...1604
Condensation In The Fuel Tank...1604
TO SERVICE THE FUEL SYSTEM...1605
VENTING THE FUEL SYSTEM...1605
ELECTRICAL SYSTEM MAINTENANCE...1606
Electrical System...1606
HYDRAULIC SYSTEM...1607
Hydraulic / Hydrostatic Transmission Fluid...1607
CHECKING AND ADDING HYDRAULIC FLUID...1607
HYDRAULIC FLUID FILTERS...1607
To Replace The Suction (25 Micron) Filter ...1608
To Replace The Hydrostatic Transmission Filter...1608
DRAINING THE FLUID RESERVOIR...1608
LEAKS...1609
QUICK COUPLERS...1609
HYDRAULIC CYLINDER MAINTENANCE...1609
OIL COOLER...1609
CARE OF THE HYDROSTSATIC TRANSMISSION...1610
Loader Start-Up...1610
Cold Weather Start-Up...1610
FINAL DRIVE CHAIN...1610
TIRES...1611
TIRE MAINTENANCE...1611
TIRE ROTATION...1611
TIRE REPLACEMENT...1611
LUBRICATION...1611
WHEEL TORQUING...1612
BOB-TACH...1612
TECHNICAL DATA...1612
CAPACITIES...1612
ADJUSTMENTS...1612
LOADER SPECIFICATIONS...1612
TROUBLESHOOTING...1613
TROUBLESHOOTING THE ENGINE...1615
TROUBLESHOOTING THE HYDROSTATIC SYSTEM...1617
TROUBLESHOOTING THE HYDRAULIC SYSTEM...1618
MAJOR PARTS...1619
MAIN FRAME PARTS...1621
HYDRAULIC SYSTEM...1622
ENGINE PARTS...1623
ELECTRICAL SYSTEM...1624
HYDROSTATIC SYSTEM...1625
DRIVE SYSTEM...1626
LOADER SPECIFICATIONS...1627
OPERATIONAL SPECIFICATIONS...1627
ENGINE...1627
HYDRULIC SYSTEM...1627
ELECTRICAL...1627
CAPACITIES...1627
HYDRAULIC SYSTEM...1627
HYDROSTATIC DRIVE SYSTEM...1627
ELECTRICAL SYSTEM...1627
WARRANTY...1629
6549635 (11-98) - 825 Operation & Maintenance Manual...1631
OPERATOR SAFETY WARNINGS...1633
FOREWORD...1635
CONTENTS...1635
REFERENCE INFORMATION...1635
825 BOBCAT LOADER IDENTIFICATION...1636
SAFETY INSTRUCTIONS...1637
SAFETY IS YOUR RESPONSIBILITY...1637
BEFORE OPERATING THE BOBCAT LOADER...1637
OPERATING INSTRUCTIONS...1639
OPERATING INSTRUCTIONS...1641
SAFTY SIGNS (DECAL) LOCATION...1643
CONTROLS...1644
DASH PANEL...1644
THROTTLE CONTROL...1645
STOPPING THE ENGINE...1645
PARKING BRAKE...1645
SPEED-RANGE CONTROL...1645
STEERING CONTROLS...1646
HYDRAULIC CONTROLS...1647
Foot Pedal (Hydraulic)...1647
Lift Arm Operation...1647
Tilt Operation...1647
Auxiliary Pedal...1648
BEFORE YOU START THE ENGINE...1648
STARTING THE ENGINE...1649
Normal Starting Condition...1650
Making Cold Temperature Starting Easier...1650
Cold Weather Starting Procedure...1651
BOBCAT LOADER OPERATION...1651
Bucket Size...1652
Installation Of Attachment...1652
Removal Of The Attachment...1652
OPERATION OF THE BOBCAT LOADER...1653
OPERATING PROCEDURE...1653
Filling The Bucket...1654
To Empty The Bucket...1654
Digging Into The Ground...1655
Making The Ground Level...1655
Filling A Hole...1655
TO PULL THE LOADER...1656
STOPPING THE BOBCAT LOADER...1656
TRANSPORTING THE BOBCAT LOADER...1656
LIFT ARM STOP...1657
LIFTING THE OPERATOR GUARD...1658
PREVENTIVE MAINTENANCE...1659
MAINTENANCE SAFETY...1660
SERVICE SCHEDULE...1661
ENGINE SERVICE...1662
AIR CLEANER SERVICE...1662
FUEL SYSTEM...1663
FUEL SYSTEM SERVICE...1663
FUEL FILTERS...1663
REMOVING THE AIR FROM THE FUEL SYSTEM...1664
ENGINE LUBRICTION SYSTEM...1665
REPLACEMENT OF THE ENGINE OIL AND FILTER...1665
ENGINE COOLING SYSTEM...1666
Coolant level...1666
Removing Coolant From The Cooling System...1666
ALTERNATOR BELT...1666
ELECTRICAL SYSTEM...1667
USING AN EXTRA BATTERY (JUMP STARTING)...1669
TO INSTALL NEW BATTERIES...1670
HYDRAULIC/HYDROSTATIC SYSTEM...1671
HYDRAULIC/HYDROSTATIC FLUID RESERVOIR...1671
Checking And Adding Hydraulic Fluid...1673
Removing Hydraulic Fluid...1673
REPLACEMENT OF THE HYDRAULIC FILTERS...1674
OIL COOLER...1674
FINAL DRIVE CHAIN...1675
TIRE MAINTENANCE...1675
Tire Rotation...1675
LUBRICATION OF THE BOBCAT LOADER...1676
BOB-TACH...1676
SPARK ARRESTOR MUFFLER...1677
SERIAL NUMBER...1677
DELIVERY REPORT...1677
TROUBLESHOOTING...1679
TROUBLESHOOTING THE ENGINE...1681
TROUBLESHOOTING THE DRIVE SYSTEM...1682
TROUBLESHOOTING THE HYDRAULIC SYSTEM...1682
MAJOR PARTS...1683
MAIN FRAME...1685
FUEL SYSTEM...1686
DRIVE TRAIN...1687
BRAKES...1688
HYDRAULIC CIRCUITRY...1689
HYDROSTATIC CIRCUITRY...1691
STEERING LEVERS...1692
ELECTRICAL SYSTEM...1693
POWER UNIT...1694
DECALS...1695
DECALS...1697
WARNING - 6563484...1699
WARNING - 6561380...1700
IMPORTANT - 6560573...1701
GENERAL INFORMATION...1703
LOADER SPECIFICATIONS...1705
OPERATION & PERFORMANCE...1705
ENGINE...1705
LOADER HYDRAULICS...1706
ELECTRICAL...1706
DRIVE SYSTEM...1706
CAPACITIES...1706
TIRES...1706
ADDITIONAL PUBLICATIONS...1707
WARRANTY...1709
6722906 (2-94) - 853 Operation & Maintenance Manual...1711
6724034 (6-00) - 853; 853H Operation & Maintenance Manual...1810
OPERATOR SAFETY WARNINGS...1812
CONTENTS...1814
FOREWORD...1816
BOBCAT COMPANY IS ISO 9001 CERTIFIED...1818
REGULAR MAINTENANCE ITEMS...1818
MOTOR OIL...1818
SERIAL NUMBER LOCATIONS...1820
LOADER SERIAL NUMBER...1820
ENGINE SERIAL NUMBER...1820
DELIVERY REPORT...1820
BOBCAT LOADER IDENTIFICATION...1821
OPTIONS AND ACCESSORIES...1822
Tires...1822
Operator Cab...1822
Hydraulics...1822
Other...1822
Instrumentation...1822
SAFETY...1824
SAFETY INSTRUCTIONS FOR BOBCAT SKID-STEER LOADERS AND ATTACHMENTS...1826
SAFETY IS THE OPERATOR’S RESPONSIBILITY...1826
BEFORE OPERATING THE BOBCAT LOADER...1827
SAFE OPERATION NEEDS A QUALIFIED OPERATOR*...1827
FIRE PREVENTION...1828
MACHINE SIGNS (DECALS)...1829
OPERATING INSTRUCTIONS...1832
INSTRUMENT PANELS...1834
Standard...1834
Boss® Option...1835
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...1837
Description...1837
Lift Arm By-Pass Control...1838
Traction Lock Override...1838
Seat Sensor Override (If Equipped)...1838
ENGINE SPEED CONTROL...1839
Operation...1839
PARKING BRAKE...1839
Operation...1839
STEERING LEVERS...1841
Operation...1841
STOPPING THE BOBCAT LOADER...1841
Procedure...1841
SEAT BAR RESTRAINT SYSTEM...1842
HYDRAULIC CONTROLS...1844
Foot Pedals...1844
Lift Arm Operation...1844
Lift Arm Float Position...1844
Tilt Operation...1844
Bucket Position Valve Operation (Optional)...1844
Auxiliary Hydraulics (Optional)...1845
Auxiliary Hydraulic Button...1846
Front Auxiliary Control (Optional)...1847
Rear Auxiliary Control (Optional)...1847
Front Auxiliary Hydraulics Continuous Operation (Detent)...1847
Attachment Functions Control...1848
AUXILIARY HIGH HORSEPOWER HYDRAULICS OPERATION...1849
Secondary Front Auxiliary Hydraulics (853H Only)...1850
DAILY INSPECTION...1851
GETTING READY FOR OPERATION...1852
STARTING THE ENGINE...1854
Normal Starting Condition (Standard)...1854
Cold Temperature Starting Condition (Standard)...1856
Normal Starting Condition (BOSS® Option)...1857
Cold Temperature Starting Condition (BOSS® Option)...1858
Warming The Hydraulic/Hydrostatic System...1858
STOPPING THE ENGINE...1858
ATTACHMENTS AND BUCKETS...1859
Choosing The Correct Bucket...1859
Installing And Removal...1860
OPERATING PROCEDURE...1862
Filling The Bucket...1863
Emptying the Bucket...1863
Digging Into The Ground...1864
Leveling The Ground (Using Lift Arms In Float Position)...1864
Backfilling...1865
PARKING THE BOBCAT LOADER...1865
STOPPING THE BOBCAT LOADER...1865
TRANSPORTING THE BOBCAT LOADER...1866
Loading Onto Transport Vehicle...1866
Fastening To Transport Vehicle...1866
TOWING THE LOADER...1867
STOPPING THE BOBCAT LOADER...1867
LIFTING THE LOADER...1868
Four Point Lift...1868
Single Point Lift...1868
PREVENTIVE MAINTENANCE...1870
MAINTENANCE SAFETY...1872
SERVICE SCHEDULE...1874
Chart...1874
LIFT ARM SUPPORT DEVICE...1875
Engaging The Lift Arm Support Device...1875
Disengaging The Lift Arm Support Device...1876
OPERATOR CAB...1877
Raising The Operator Cab...1877
Lowering The Operator Cab...1878
Emergency Exit...1879
SEAT BAR RESTRAINT SYSTEM...1880
Inspecting The Seat Bar...1880
Maintaining The Seat Bar...1880
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...1881
Inspecting The BICS™ Controller (Engine Stopped - Key ON)...1881
Inspecting The Seat and Seat Bar Sensors (Engine RUNNING)...1881
Inspecting The Traction Lock (Engine RUNNING)...1881
Inspecting The Lift Arm By-Pass Control...1881
Maintenance...1882
REAR DOOR...1883
Opening The Rear Door...1883
Adjusting The Rear Door...1883
REAR GRILL...1884
AIR CLEANER SERVICE...1885
FUEL SYSTEM...1887
Fuel Specifications...1887
Filling The Fuel Tank...1887
Fuel Filter...1888
Removing Air From The Fuel System...1889
ENGINE LUBRICATION SYSTEM...1890
Checking Engine Oil...1890
Oil Chart...1890
Replacment Of Oil And Filter...1890
COOLING SYSTEM...1892
Cleaning The Cooling System...1892
Checking The Coolant Level...1892
Removing Coolant From The Cooling System...1893
Propylene Glycol...1893
ALTERNATOR BELT...1893
Adjusting The Alternator Belt...1893
ELECTRICAL SYSTEM...1894
Description...1894
Servicing The Electrical System...1894
Fuse Location - (Standard & BOSS® Option)...1894
Using A Booster Battery (Jump Starting)...1895
Removing And Installing The Battery...1896
HYDRAULIC / HYDROSTATIC SYSTEM...1897
Checking And Adding Fluid...1897
Hydraulic/Hydrostatic Filter Replacement...1897
Hydraulic Fluid Replacement...1898
Hydraulic Reservoir Breather Cap...1900
SPARK ARRESTOR MUFFLER...1901
Maintenance...1901
TIRE MAINTENANCE...1902
Wheel Nuts...1902
Tire Rotation...1902
Tire Mounting...1902
FINAL DRIVE TRANSMISSION (CHAINCASE)...1903
Checking And Adding Oil...1903
Removing Oil From The Chaincase...1903
FAN GEARBOX...1904
Checking And Maintaining...1904
DRIVE BELT...1904
Adjusting The Drive Belt...1904
Replacing The Drive Belt...1905
LUBRICATING THE BOBCAT LOADER...1906
PIVOT PINS...1907
BOB-TACH...1908
SYSTEM SETUP & ANALYSIS...1910
SERVICE CODES...1912
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...1914
Troubleshooting Chart...1914
ADVANCED HAND CONTROLS (AHC)...1915
Troubleshooting Chart...1915
MACHINE SIGN TRANSLATIONS...1916
IMPORTANT (6560573)...1918
WARNING (6579511)...1919
SERVICE SCHEDULE (6708212)...1920
WARNING (6579510)...1922
DANGER (6579528)...1923
WARNING (6577754)...1923
WARNING (6579639)...1924
WARNING (6579509)...1924
SPECIFICATIONS...1926
LOADER SPECIFICATIONS...1928
Machine Dimensions...1928
Performance...1929
Controls...1929
Engine...1929
Hydraulic System...1930
Electrical...1930
Drive System...1931
Capacities...1931
Tires...1931
Floor Pressure...1931
MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES - For use on 853 Bobcat Loaders...1932
ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS...1935
WARRANTY...1936
6722906 (6-00) - 853; 853H Operation & Maintenance Manual...1938
OPERATOR SAFETY WARNINGS...1940
CONTENTS...1942
REFERENCE INFORMATION...1942
BOBCAT COMPANY IS ISO 9001 CERTIFIED...1943
REGULAR MAINTENANCE ITEMS...1943
FOREWORD...1944
SERIAL NUMBER LOCATIONS...1946
LOADER SERIAL NUMBER...1946
ENGINE SERIAL NUMBER...1946
DELIVERY REPORT...1946
BOBCAT SKID STEER LOADER IDENTIFICATION...1947
SAFETY...1948
SAFETY INSTRUCTIONS...1950
SAFETY IS THE OPERATOR’S RESPONSIBILITY...1950
BEFORE OPERATING THE BOBCAT LOADER...1951
SAFE OPERATION NEEDS A QUALIFIED OPERATOR *...1951
FIRE PREVENTION...1952
MACHINE SIGNS (DECALS)...1953
OPERATING INSTRUCTIONS...1956
INSTRUMENT PANEL...1958
Standard...1958
Optional BOSS®...1959
ENGINE SPEED CONTROL...1960
PARKING BRAKE...1960
STEERING LEVERS...1961
HYDRAULIC CONTROLS...1962
Foot Pedals...1962
Lift Arm Operation...1962
Tilt Operation (Bucket)...1962
Bucket Position Valve Operation (Optional)...1962
Auxiliary Hydraulics Operation (Optional)...1963
Auxiliary Hydraulics Operation (With OptionalBOSS®)...1964
Auxiliary Hydraulics Operation – 853H (Optional)...1965
DAILY INSPECTION...1967
SEAT BAR RESTRAINT SYSTEM...1968
GETTING READY FOR OPERATION...1969
STARTING THE ENGINE...1970
Normal Starting Condition – (Standard)...1971
Cold Temperature Starting Condition – (Standard)...1972
Normal Starting Condition – (Optional)...1973
Warming The Hydraulic/Hydrostatic System...1972
Normal Starting Condition – (Optional)...1973
Cold Temperature Starting Condition (Optional)...1974
STOPPING THE ENGINE...1974
ATTACHMENTS AND BUCKETS...1975
Installation And Removal...1976
OPERATING PROCEDURES...1977
Filling The Bucket...1978
Emptying The Bucket...1978
Digging Into The Ground...1979
Leveling The Ground (Using Lift Arms In Float Position)...1979
Backfilling...1980
PARKING THE BOBCAT LOADER...1980
TRANSPORTING THE BOBCAT LOADER...1980
LIFTING THE LOADER...1981
Four Point Lift...1981
Single Point Lift...1981
PREVENTIVE MAINTENANCE...1982
MAINTENANCE SAFETY...1983
SERVICE SCHEDULE...1984
LIFT ARM SUPPORT DEVICE...1985
To Engage Lift Arm Support Device...1985
To Disengage Lift Arm Support Device...1985
OPERATOR CAB...1986
Raising The Operator Cab...1986
Lowering The Operator Cab...1986
Emergency Exit...1987
SEAT BAR RESTRAINT SYSTEM...1988
Seat Bar Inspection...1988
Seat Bar Maintenance...1988
REAR DOOR...1989
Adjustment...1989
REAR GRILL...1989
AIR CLEANER SERVICE...1990
Standard...1990
Optional...1990
Servicing The Air Cleaner ...1991
FUEL SYSTEM...1992
Fuel Specifications...1992
Filling The Fuel Tank...1992
Fuel Filter...1992
Removing Air From The Fuel System...1993
ENGINE LUBRICATION SYSTEM...1994
Checking Engine Oil...1994
Replacing Oil And Filter...1994
COOLING SYSTEM...1996
Cleaning The Cooling System...1996
Checking The Coolant Level...1996
Removing Coolant From The Cooling System...1997
Propylene Glycol...1997
ALTERNATOR BELT...1998
Adjusting The Alternator Belt...1998
ELECTRICAL SYSTEM...1999
Description...1999
Servicing The Electrical System...1999
Fuse Location – 853 (Optional) & 853H (Option)...1999
Fuse Location – 853 (Standard)...1999
Using A Booster Battery (Jump Starting)...2000
Battery Removal And Installation...2001
HYDRAULIC/HYDROSTATIC SYSTEM...2002
Checking And Adding Fluid...2002
Hydraulic/Hydrostatic Filter Replacement...2002
Hydraulic Fluid Replacement...2003
Hydraulic Reservoir Breather Cap...2003
SPARK ARRESTOR MUFFLER...2004
TIRE MAINTENANCE...2005
Wheel Nuts...2005
Tire Rotation...2005
Tire Mounting...2005
FINAL DRIVE TRANSMISSION (CHAINCASE)...2006
Checking And Adding Oil...2006
FAN GEARBOX...2006
DRIVE BELT ...2007
Adjustment...2007
Drive Belt Replacement...2007
LUBRICATION OF THE BOBCAT LOADER...2008
PIVOT PINS...2009
BOB–TACH...2010
PARKING BRAKE PEDAL...2010
Adjustment...2010
SYSTEMS ANALYSIS...2012
SERVICE CODES...2014
MACHINE SIGN TRANSLATIONS...2016
IMPORTANT - 6560573...2018
WARNING - 6579511...2019
SERVICE SCHEDULE - 6708212...2020
WARNING - 6579510...2022
WARNING - 6579639...2023
WARNING - 6577754...2023
DANGER - 6702302...2023
DANGER - 6702301...2023
SPECIFICATIONS...2024
LOADER DIMENSIONS...2026
OPERATION & PERFORMANCE...2026
ENGINE...2026
HYDRAULIC SYSTEM...2027
ELECTRICAL...2027
DRIVE SYSTEM...2027
CAPACITIES...2027
TIRES...2027
BOBCAT COMPANY APPROVED ATTACHMENTS & ACCESSORIES...2028
ATTACHMENTS & ACCESSORIES...2031
ADDITIONAL PUBLICATIONS...2032
WARRANTY...2034
6722406 (6-97) - 853; 853H Operation & Maintenance Manual...2036
OPERATOR SAFETY WARNINGS...2038
CONTENTS...2040
REFERENCE INFORMATION...2040
MELROE COMPANY IS ISO 9001 CERTIFIED...2041
REGULAR MAINTENANCE ITEMS...2041
FOREWORD...2042
SERIAL NUMBER LOCATIONS...2044
LOADER SERIAL NUMBER...2044
ENGINE SERIAL NUMBER...2044
DELIVERY REPORT...2044
BOBCAT SKID STEER LOADER IDENTIFICATION...2045
OPTIONS AND ACCESSORIES...2046
SAFETY...2048
SAFETY INSTRUCTIONS...2050
SAFETY IS THE OPERATOR’S RESPONSIBILITY...2050
BEFORE OPERATING THE BOBCAT LOADER...2051
SAFE OPERATION NEEDS A QUALIFIED OPERATOR*...2051
FIRE PREVENTION...2052
MACHINE SIGNS (DECALS)...2053
OPERATING INSTRUCTIONS...2056
MONITOR SERVICE CODES...2057
INSTRUMENT PANEL...2058
ENGINE SPEED CONTROL...2060
PARKING BRAKE...2060
STEERING LEVERS...2061
HYDRAULIC CONTROLS...2062
Foot Pedals...2062
Lift Arm Operation...2062
Tilt Operation (Bucket)...2062
Bucket Position Valve Operation...2062
Auxiliary Hydraulics Operation ...2063
Auxiliary Hydraulics Operation – 853H Plus (5103)...2064
DAILY INSPECTION...2066
SEAT BAR RESTRAINT SYSTEM...2067
GETTING READY FOR OPERATION...2068
STARTING THE ENGINE...2069
Normal Starting Condition – 853 Plus (5102), 853H Plus (5103)...2070
Cold Temperature Starting Condition – 853 Plus (5102), 853H (5103)...2071
Normal Starting Condition – 853 Base (5101)...2072
Cold Temperature Starting Condition – 853 Base (5101)...2073
STOPPING THE ENGINE...2073
ATTACHMENTS AND BUCKETS...2074
Installation And Removal...2075
OPERATING PROCEDURES...2076
Filling The Bucket...2077
Emptying The Bucket...2077
Digging Into The Ground...2078
Leveling The Ground (Using Lift Arms In Float Position)...2078
Backfilling...2079
PARKING THE BOBCAT LOADER...2079
TRANSPORTING THE BOBCAT LOADER...2079
LIFTING THE LOADER...2080
Four Point Lift...2080
Single Point Lift...2080
PREVENTIVE MAINTENANCE...2082
MAINTENANCE SAFETY...2083
SERVICE SCHEDULE...2084
LIFT ARM SUPPORT DEVICE...2085
To Engage Lift Arm Support Device...2085
To Disengage Lift Arm Support Device...2085
OPERATOR CAB...2086
Raising The Operator Cab...2086
Lowering The Operator Cab...2086
Emergency Exit...2087
SEAT BAR RESTRAINT SYSTEM...2088
Seat Bar Inspection...2088
Seat Bar Maintenance...2088
REAR DOOR...2089
Adjustment...2089
REAR GRILL...2089
AIR CLEANER SERVICE...2090
853 Plus (5102), 853H Plus (5103)...2090
853 Base (5101)...2091
FUEL SYSTEM...2092
Fuel Specifications...2092
Filling The Fuel Tank...2092
Fuel Filter...2092
Removing Air From The Fuel System...2093
ENGINE LUBRICATION SYSTEM...2094
Checking Engine Oil...2094
Replacing Oil And Filter...2094
COOLING SYSTEM...2096
Cleaning The Cooling System...2096
Checking The Coolant Level...2096
Removing Coolant From The Cooling System...2097
ALTERNATOR BELT...2098
Adjusting The Alternator Belt...2098
ELECTRICAL SYSTEM...2099
Description...2099
Electrical System Service...2099
Fuses...2099
Using A Booster Battery (Jump Starting)...2100
Battery Removal And Installation...2101
HYDRAULIC/HYDROSTATIC SYSTEM...2102
Checking And Adding Fluid...2102
Hydraulic/Hydrostatic Filter Replacement...2102
Hydraulic Fluid Replacement...2103
Hydraulic Reservoir Breather Cap...2103
SPARK ARRESTOR MUFFLER...2104
TIRE MAINTENANCE...2105
Wheel Nuts...2105
Tire Rotation...2105
Tire Mounting...2105
FINAL DRIVE TRANSMISSION (CHAINCASE)...2106
Checking And Adding Oil...2106
FAN GEARBOX...2106
DRIVE BELT ...2107
Adjustment...2107
Drive Belt Replacement...2107
LUBRICATION OF THE BOBCAT LOADER...2108
PIVOT PINS...2109
BOB–TACH...2110
PARKING BRAKE PEDAL...2110
Adjustment...2110
SYSTEMS ANALYSIS...2112
MONITOR SERVICE CODES...2113
SERVICE CODES...2114
MACHINE SIGN TRANSLATIONS...2116
IMPORTANT - 6560573...2118
WARNING - 6579511...2119
WARNING - 6579510...2120
SERVICE SCHEDULE - 6708212...2121
WARNING - 6579528...2123
WARNING - 6577754...2123
DANGER - 6722302...2123
DANGER - 6702301...2123
SPECIFICATIONS...2124
853 Base (5101) & 853 Plus (5102)...2126
LOADER DIMENSIONS...2126
OPERATION & PERFORMANCE...2126
ENGINE...2126
HYDRAULIC SYSTEM...2127
ELECTRICAL...2127
DRIVE SYSTEM...2127
CAPACITIES...2127
TIRES...2127
853H Plus (5103)...2128
LOADER DIMENSIONS...2128
OPERATION & PERFORMANCE...2128
ENGINE...2128
HYDRAULIC SYSTEM...2129
ELECTRICAL...2129
DRIVE SYSTEM...2129
CAPACITIES...2129
TIRES...2129
MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES...2130
ADDITIONAL PUBLICATIONS...2133
WARRANTY...2134
6556864 (12-82) - 843 Operator's Manual...2135
WARNINGS...2137
SAFETY INSTRUCTIONS...2139
SAFETY IS YOUR RESPONSIBILITY...2139
BEFORE YOU OPERATE THE BOBCAT LOADER...2139
FOREWORD...2141
CONTENTS...2141
843 BOBCAT LOADER IDENTIFICATION...2142
OPERATING INSTRUCTIONS...2143
OPERATING INSTRUCTIONS...2145
CONTROLS...2146
SAFETY SIGNS (DECALS) LOCATION...2147
DASH PANEL...2148
THROTTLE CONTROL...2148
STOPPING THE ENGINE...2148
PARKING BRAKE...2148
STEERING LEVERS...2149
HYDRAULIC CONTROLS...2150
Foot Pedals (Hydraulic)...2150
Lift Arm Operation...2150
Float Position...2150
Tilt (Bucket) Operation...2150
Auxiliary Lever...2151
BEFORE YOU START THE ENGINE...2151
STARTING THE ENGINE...2152
Normal Starting Condition...2153
Making Cold Temperature Starting Easier...2153
Cold Weather Starting Condition...2154
BOBCAT LOADER OPERATION...2154
Bucket Size...2154
Installation Of Attachments...2155
Removal Of Attachments...2155
OPERATING PROCEDURE...2156
Filling The Bucket...2157
To Empty The Bucket...2157
Digging Into The Ground...2158
Making The Ground Level...2158
Filling A Hole...2158
STOPPING THE BOBCAT LOADER...2159
TRANSPORTING THE BOBCAT LOADER...2159
LIFT ARM STOP...2160
LIFTING THE OPERATOR GUARD...2161
LOWERING THE OPERATOR GUARD...2161
PREVENTIVE MAINTENANCE...2163
WARNINGS...2165
SERVICE SCHEDULE...2167
ENGINE SERVICE...2168
ADJUSTING DOOR LATCH...2168
AIR CLEANER SERVICE...2168
FUEL SYSTEM...2169
FUEL SYSTEM SERVICE...2169
FUEL FILTER...2170
REMOVING THE AIR FROM THE FUEL SYSTEM...2170
ENGINE LUBRICATION SYSTEM...2171
REPLACEMENT OF ENGINE OIL AND FILTER...2171
ENGINE COOLING SYSTEM...2172
Coolant Level...2172
Removing Coolant From The Cooling System...2172
ALTERNATOR BELT...2172
ELECTRICAL SYSTEM...2172
USING AN EXTRA BATTERY...2175
HYDRAULIC SYSTEM...2177
HYDRAULIC/HYDROSTATIC FLUID RESERVOIR...2177
Checking And Adding Hydraulic Fluid...2179
Removing The Hydraulic Fluid...2179
REPLACEMENT OF HYDRAULIC FILTER...2179
FINAL DRIVE TRANSMISSION (CHAINCASE)...2180
TO DRAIN CHAINCASE FLUID...2180
TIRE MAINTENANCE...2180
Tire Rotation...2181
LUBRICATION OF THE BOBCAT LOADER...2181
SPARK ARRESTOR MUFFLER...2182
OPERATOR GUARD...2182
BOB-TACH...2182
PIVOT PINS...2183
AUXILIARY CONTROL LOCKBOLT...2183
BRAKE PEDAL ADJUSTMENT...2183
LOADER SERIAL NUMBER...2184
DELIVERY REPORT...2184
THIRTY HOUR INSPECTION...2184
TROUBLESHOOTING...2185
TROUBLESHOOTING THE ENGINE...2187
TROUBLESHOOTING THE DRIVE SYSTEM...2188
TROUBLESHOOTING THE HYDRAULIC SYSTEM...2189
MAJOR PARTS...2191
MAIN FRAME...2193
OPERATOR GUARD ELECTRICAL...2194
ENGINE ELECTRICAL...2195
HYDRAULIC SYSTEM...2196
CONTROL PEDALS...2197
DRIVE SYSTEM...2198
HYDROSTATIC SYSTEM...2199
HAND CONTROLS...2200
SEAT & FUEL SYSTEM...2201
ENGINE & ATTACHING PARTS...2202
DECALS...2204
DECALS...2205
WARNING - 6563484...2207
SERVICE SCHEDULE - 6561387...2208
WARNING - 6563380...2210
WARNING - 6561380...2211
IMPORTANT - 6560573...2212
GENERAL INFORMATION...2213
LOADER SPECIFICATIONS...2215
SPECIFICATIONS...2215
ENGINE...2215
LOADER HYDRAULICS...2216
ELECTRICAL...2216
DRIVE SYSTEM...2216
CAPACITIES...2216
TIRES...2216
ADDITIONAL PUBLICATIONS...2217
6720547 (7-97) - 843B Operation & Maintenance Manual...2221
OPERATOR SAFETY WARNINGS...2223
CONTENTS...2225
REFERENCE INFORMATION...2225
FOREWORD...2227
SERIAL NUMBER LOCATIONS...2229
LOADER SERIAL NUMBER...2229
ENGINE SERIAL NUMBER...2229
DELIVERY REPORT...2229
BOBCAT LOADER IDENTIFICATION...2230
OPTIONS AND ACCESSORIES...2231
SAFETY...2233
SAFETY INSTRUCTIONS...2235
SAFETY IS THE OPERATOR’S RESPONSIBILITY...2235
BEFORE OPERATING THE BOBCAT LOADER...2236
SAFE OPERATION NEEDS A QUALIFIED OPERATOR*...2236
FIRE PREVENTION...2237
MACHINE SIGNS (DECALS)...2238
OPERATING INSTRUCTIONS...2241
INSTRUMENT PANEL...2243
THROTTLE CONTROL...2243
PARKING BRAKE...2244
STEERING LEVERS...2245
HYDRAULIC CONTROLS...2246
Foot Pedals...2246
Lift Arm Operation...2246
Tilt Operation (Bucket)...2246
Auxiliary Lever Operation (Opt.)...2246
DAILY INSPECTION...2247
SEAT BAR RESTRAINT SYSTEM...2248
GETTING READY FOR OPERATION...2249
STARTING THE ENGINE...2251
Normal Starting Condition...2251
Cold Temperature Starting Condition...2252
Warming The Hydraulic/Hydrostatic System...2253
STOPPING THE ENGINE...2253
ATTACHMENTS AND BUCKETS...2254
Removal And Installation...2255
OPERATING PROCEDURE...2257
Filling The Bucket...2258
Emptying The Bucket...2258
Digging Into The Ground...2259
Leveling The Ground (Using Lift Arms In Float Position)...2260
Backfilling...2260
PARKING THE BOBCAT LOADER...2261
TRANSPORTING THE BOBCAT LOADER...2261
LIFTING THE LOADER...2262
TOWING THE LOADER...2262
PREVENTIVE MAINTENANCE...2263
MAINTENANCE SAFETY...2264
SERVICE SCHEDULE...2265
LIFT ARM SUPPORT DEVICE...2266
OPERATOR CAB...2266
Raising The Operator Cab...2267
Lowering The Operator Cab...2267
SEAT BAR SYSTEM...2268
Seat Bar Inspection...2268
Seat Bar Maintenance...2268
REAR DOOR...2269
Adjustment...2269
AIR CLEANER SERVICE...2270
FUEL SYSTEM...2271
Fuel Specifications...2271
Filling The Fuel Tank...2271
Fuel Filter...2271
Removing Air From The Fuel System...2272
ENGINE LUBRICATION SYSTEM...2273
Replacing Oil And Filter...2273
COOLING SYSTEM...2275
Checking The Coolant Level...2275
Removing Coolant From The Cooling System...2275
Cleaning The Cooling System...2276
ALTERNATOR BELT...2277
Adjusting The Alternator Belt...2277
ELECTRICAL SYSTEM...2278
Description...2278
Electrical System Service...2278
Using A Booster Battery (Jump Starting)...2278
Battery Removal And Installation...2279
HYDRAULIC/HYDROSTATIC SYSTEM...2280
Checking And Adding Fluid...2280
Hydraulic Filter Replacement...2280
Hydrostatic Filter Replacement...2280
Hydraulic Fluid Replacement...2281
SPARK ARRESTOR MUFFLER...2282
TIRE MAINTENANCE...2283
Wheel Nuts...2283
Tire Rotation...2283
Tire Inflation...2283
FINAL DRIVE TRANSMISSION (CHAINCASE)...2284
Checking And Adding Oil...2284
LUBRICATION OF THE BOBCAT LOADER...2285
BOB–TACH...2286
PIVOT PINS...2286
PARKING BRAKE ADJUSTMENT...2286
TROUBLESHOOTING...2287
TROUBLESHOOTING THE ENGINE...2289
TROUBLESHOOTING THE DRIVE SYSTEM...2290
TROUBLESHOOTING THE HYDRAULIC SYSTEM...2291
SPECIFICATIONS...2293
SPECIFICATIONS...2295
PERFORMANCE...2295
ENGINE...2295
HYDRAULIC SYSTEM...2296
ELECTRICAL...2296
DRIVE SYSTEM...2296
CAPACITIES...2296
TIRES...2296
ADDITIONAL PUBLICATIONS...2297
WARRANTY...2299
6570536 (3-97) - 843 Operation & Maintenance Manual...2301
OPERATOR SAFETY WARNINGS...2303
FOREWORD...2305
CONTENTS...2305
REFERENCE INFORMATION...2305
SAFETY INSTRUCTIONS...2307
SAFETY IS THE OPERATOR'S RESPONSIBILITY...2307
BEFORE OPERATING THE BOBCAT LOADER...2307
SAFE OPERATION NEEDS A QUALIFIED OPERATOR...2308
FIRE PREVENTION...2308
SERIAL NUMBER LOCATIONS...2309
Loader Serial Number...2309
Engine Serial Number...2309
DELIVERY REPORT...2309
BOBCAT SKID STEER LOADER IDENTIFICATION...2310
SAFETY SIGNS (DECALS)...2311
OPERATING INSTRUCTIONS...2313
INSTRUMENT PANEL...2315
LEARNING THE CONTROLS...2316
THROTTLE CONTROL...2316
STOPPING THE ENGINE...2316
STEERING LEVERS...2317
HYDRAULIC CONTROLS...2318
Foot Pedals...2318
Lift Arm Operation...2318
Tilt Operation (Bucket)...2318
Auxiliary Lever Operation...2318
High Horse Power Hydraulics (Optional)...2318
BEFORE STARTING THE ENGINE...2319
SEAT BAR RESTRAINT SYSTEM...2320
OPERATING INSTRUCTIONS...2322
GETTING ON AND OFF THE LOADER...2322
GETTING READY FOR OPERATION...2322
STARTING THE ENGINE...2324
Normal Starting Condition...2324
Cold Starting Condition...2325
Warming The Hydrostatic Transmission...2325
ATTACHMENTS & BUCKETS...2326
Installation And Removal...2327
OPERATING PROCEDURE...2328
Filling The Bucket...2329
Emptying The Bucket...2329
Digging Into The Ground...2329
Leveling The Ground...2330
Backfilling...2330
PARKING THE BOBCAT LOADER...2331
TRANSPORTING THE BOBCAT LOADER...2331
LIFTING THE LOADER...2332
TOWING THE LOADER...2332
PREVENTIVE MAINTENANCE...2333
MAINTENANCE SAFETY...2334
SERVICE SCHEDULE...2335
LIFT ARM SUPPORT DEVICE...2336
OPERATOR CAB...2337
Raising The Operator Cab...2337
Lowering The Operator Cab...2337
SEAT BAR SYSTEM...2338
Seat Bar Inspection...2338
Seat Bar Maintenance...2338
REAR DOOR...2339
Adjustment...2339
AIR CLEANER SERVICE...2340
FUEL SYSTEM...2341
Fuel Specifications...2341
Filling The Fuel Tank...2341
Fuel Filter...2341
Removing Air From The Fuel System...2342
ENGINE LUBRICATION SYSTEM...2343
Replacing Engine Oil And Filter...2343
COOLING SYSTEM...2345
Coolant Removal...2345
Cleaning...2345
ALTERNATOR BELT ADJUSTMENT...2347
ELECTRICAL SYSTEM...2348
Electrical System Service...2348
Using An Extra Battery (Jump Starting)...2348
Battery Replacement...2349
Operator Cab Wiring Diagram...2350
Engine Wiring Diagram...2352
HYDRAULIC / HYDROSTATIC SYSTEM...2354
Checking And Adding Fluid...2354
Hydraulic Filter Replacement...2354
Hydrostatic Filter Replacement...2354
Hydraulic Fluid Replacement...2355
Hydraulic / Hydrostatic Flow Chart...2356
SPARK ARRESTOR MUFFLER...2360
FINAL DRIVE TRANSMISSION (CHAINCASE)...2361
TIRE MAINTENANCE...2361
Tire Rotation...2361
Tire Installation On Rim...2361
Tire Pressure...2361
Wheel Nuts...2361
LOADER LUBRICATION...2362
BOB-TACH...2363
PIVOT PINS...2363
BRAKE PEDAL ADJUSTMENT...2363
TROUBLESHOOTING...2365
TROUBLESHOOTING THE ENGINE...2367
TROUBLESHOOTING THE DRIVE SYSTEM...2368
TROUBLESHOOTING THE HYDRAULIC SYSTEM...2369
MAJOR PARTS...2371
MAIN FRAME...2373
PANELS, SEAT, SEAT BAR & FUEL SYSTEM...2374
DRIVE SYSTEM...2375
HYDRAULIC SYSTEM...2376
HYDROSTATIC SYSTEM...2377
HAND CONTROLS AND CONTROL PEDALS...2379
OPERATOR CAB ELECTRICAL SYSTEM...2380
ENGINE ELECTRICAL...2382
ENGINE & ATTACHING PARTS...2383
SAFETY SIGNS...2385
WARNING - 6565980...2387
SERVIC SCHEDULE - 6567875...2388
WARNING - 6575855...2390
WARNING - 6575854...2391
IMPORTANT - 6560573...2392
DANGER - 6575694...2392
SPECIFICATIONS...2393
843...2395
OPERATION & PERFORMANCE...2395
ENGINE...2395
HYDRAULIC SYSTEM...2396
ELECTRICAL...2396
DRIVE SYSTEM...2396
CAPACITIES...2396
TIRES...2396
843 HIGH HORSE POWER HYDRULICS...2397
OPERATION AND PERFORMANCE...2397
ENGINE...2397
HYDRAULIC SYSTEM...2398
ELECTRICAL...2398
DRIVE SYSTEM...2398
CAPACITIES...2398
TIRES...2398
WARRANTY...2399
6566894 (4-97) - 843 Operation & Maintenance Manual...2401
OPERATOR SAFETY WARNINGS...2403
CONTENTS...2405
FOREWORD...2407
SERIAL NUMBER LOCATIONS...2409
LOADER SERIAL NUMBER...2409
ENGINE SERIAL NUMBER...2409
DELIVERY REPORT...2409
BOBCAT LOADER IDENTIFICATION...2410
SAFETY...2411
SAFETY INSTRUCTIONS...2413
Safety Is The Operator's Responsibility...2413
Before Operating The Bobcat Loader...2414
Safe Operation Needs A Qualified Operator...2414
FIRE PREVENTION...2415
OPERATING INSTRUCTIONS...2417
OPERATING INSTRUCTIONS...2419
GETTING ON AND OFF THE LOADER...2419
SAFETY SIGNS (DECALS)...2420
LEARNING THE CONTROLS...2420
DASH PANEL...2423
THROTTLE CONTROL...2423
PARKING BRAKE...2423
STEERING LEVERS...2424
HYDRAULIC CONTROLS...2425
Left Foot Pedal / Lift Arm Operation...2425
Left Foot Pedal / Float Position For the Lift Arms...2425
Right Foot Pedal / Tilt (Bucket) Operation...2425
Right Lever / Auxiliary Operation...2426
BEFORE STARTING THE ENGINE...2426
STARTING THE ENGINE...2428
Cold Temperature Starting...2429
ATTACHMENTS & BUCKETS...2430
Bucket Or Fork Installation...2431
Bucket Or Fork Removal...2431
OPERATING PROCEDURES...2432
Filling The Bucket...2433
Emptying The Bucket...2433
Digging Into The Ground...2434
Leveling The Ground (Using Float Position For The Lift Arms)...2434
Backfilling...2435
PARKING THE LOADER...2435
TOWING THE LOADER...2435
TRANSPORTING THE LOADER...2435
LIFTING THE LOADER...2436
PREVENTIVE MAINTENANCE...2437
MAINTENANCE SAFETY...2439
SERVICE SCHEDULE...2441
LIFT ARM STOP...2442
OPERATOR CAB...2442
Raising The Operator Cab...2443
Lowering The Operator Cab...2443
SEAT BAR SYSTEM...2443
Inspection Of The Seat Bar System...2444
Service Of The Seat Bar System...2444
REAR DOOR...2444
Door Latch Adjustment...2445
AIR CLEANER...2445
FUEL SYSTEM...2446
Filling The Fuel Tank...2446
Fuel Filter...2447
Removing Air From The Fuel System...2448
ENGINE LUBRICATION SYSTEM...2449
Engine Oil And Filter Replacement...2449
COOLING SYSTEM...2450
Coolant Level...2450
Coolant Replacement...2450
Cooling System Maintenance...2450
ALTERNATOR BELT ADJUSTMENT...2451
ELECTRICAL SYSTEM...2454
Electrical System Service...2454
Using An Extra Battery (Jump Starting)...2454
Battery Replacement...2456
HYDRAULIC / HYDROSTATIC SYSTEM...2456
Hydraulic / Hydrostatic Fluid Reservoir...2456
Checking And Adding Fluid...2456
Hydraulic Fluid Replacement...2458
Hydraulic (10 Micron) Filter Replacement...2458
Hydrostatic (#3 Element) Filter Replacement...2459
SPARK ARRESTOR MUFFLER...2460
FINAL DRIVE TRANSMISSION (CHAINCASE)...2460
Chaincase Fluid Level...2460
TIRE MAINTENANCE...2461
Tire Rotation...2461
Wheel Nuts...2461
LOADER LUBRICATION...2462
BOB-TACH...2463
PIVOT PINS...2463
BRAKE PEDAL ADJUSTMENT...2463
TROUBLESHOOTING...2465
TROUBLESHOOTING THE ENGINE...2467
TROUBLESHOOTING THE DRIVE SYSTEM...2468
TROUBLESHOOTING THE HYDRAULIC SYSTEM...2469
MAJOR PARTS...2471
MAIN FRAME...2473
PANELS, SEAT, SEAT BAR & FUEL SYSTEM...2474
DRIVE SYSTEM...2475
HYDRAULIC SYSTEM...2476
HYDROSTATIC SYSTEM...2477
HAND CONTROLS AND CONTROL PEDALS...2478
OPERATOR CAB ELECTRICAL SYSTEM...2479
ENGINE ELECTRICAL...2480
ENGINE & ATTACHING PARTS...2481
SAFETY SIGNS...2483
WARNING - 6565980...2485
SERVICE SCHEDULE - 6567875...2486
WARNING - 6568692...2488
WARNING - 6568691...2489
IMPORTANT - 6560573...2490
SPECIFICATIONS...2491
OPERATION AND PERFORMANCE...2493
ENGINE...2493
HYDRAULIC SYSTEM...2494
ELECTRICAL...2494
DRIVE SYSTEM...2494
CAPACITIES...2494
TIRES...2494
WARRANTY...2495
6566611 (1-84) - 843 Operator's Manual...2497
WARNINGS...2499
FOREWORD...2501
CONTENTS...2501
SAFETY INSTRUCTIONS...2503
SAFETY IS YOUR RESPONSIBILITY...2503
BEFORE YOU OPERATE THE BOBCAT LOADER...2503
SAFE OPERATION NEEDS A QUALIFIED OPERATOR...2504
FIRE PREVENTION...2504
SERIAL NUMBER LOCATIONS...2505
DELIVERY REPORT...2505
843 BOBCAT LOADER IDENTIFICATION...2506
OPERATING INSTRUCTIONS...2507
OPERATING INSTRUCTIONS...2509
CONTROLS...2510
SAFETY SIGNS (DECALS)...2511
DASH PANEL...2513
THROTTLE CONTROL...2513
TO STOP THE ENGINE...2513
PARKING BRAKE...2513
STEERING LEVERS...2514
HYDRAULIC CONTROLS...2515
Foot Pedal (Hydraulic)...2515
Lift Arm Operation...2515
Tilt (Bucket) Operation...2515
Auxiliary Lever Operation...2515
BEFORE YOU START THE ENGINE...2516
STARTING THE ENGINE...2517
Normal Starting Condition...2518
Cold Temperature Starting Condition...2519
ATTACHMENTS AND BUCKETS...2519
Installation Of Attachments...2520
Installation Of Bucket...2520
Removal Of The Bucket...2521
OPERATING PROCEDURES...2521
Filling A Bucket...2522
To Empty The Bucket...2522
Digging Into The Ground...2523
Filling A Hole...2524
PARKING THE BOBCAT LOADER...2524
TRANSPORTING THE BOBCAT LOADER...2524
LIFTING THE BOBCAT LOADER...2525
PREVENTIVE MAINTENANCE...2527
WARNINGS...2528
SERVICE SCHEDULE...2529
LIFT ARM STOP...2530
LIFTING THE OPERATOR CAB...2530
LOWERING THE OPERATOR CAB...2531
ROLL OVER & FALLING OBJECT PROTECTION STRUCTURE (ROPS & FOPS)...2531
ENGINE SERVICE...2532
ADJUSTING THE REAR DOOR LATCH...2532
AIR CLEANER SERVICE...2532
FUEL SYSTEM...2533
FUEL SYSTEM SERVICE...2533
FUEL FILTER...2534
REMOVING AIR FROM THE FUEL SYSTEM...2534
ENGINE LUBRICATION SYSTEM...2535
REPLACEMENT OF ENGINE OIL AND FILTER...2535
ENGINE COOLING SYSTEM...2536
Coolant Level...2536
REMOVING COOLANT FROM THE COOLING SYSTEM...2536
BELT ADJUSTMENT...2537
ELECTRICAL SYSTEM...2537
USING AN EXTRA BATTERY (JUMP STARTING)...2540
INSTALLING A NEW BATTERY...2541
SPARK ARRESTOR MUFFLER...2542
HYDRAULIC/HYDROSTATIC SYSTEM...2544
REPLACEMENT OF THE HYDRAULIC FILTER...2544
REPLACMENT OF THE HYDROSTATIC FILTER...2545
HYDRAULIC/HYDROSTATIC FLUID RESERVOIR...2545
Checking And Adding Fluid...2545
Removing The Hydraulic/Hydrostatic Fluid...2545
FINAL DRIVE TRANSMISSION...2546
Chaincase...2546
Reduction Gearcase...2546
TIRE MAINTENANCE...2546
Tire Rotation...2546
Wheel Nuts...2547
LUBRICATION OF THE BOBCAT LOADER...2547
BOB-TACH...2548
PIVOT PINS...2548
BRAKE PEDAL ADJUSTMENT...2549
AUXILIARY LOCKBOLT...2549
TROUBLESHOOTING...2551
TROUBLESHOOTING THE HYDRAULIC SYSTEM...2553
TROUBLESHOOTING THE HYDROSTATIC SYSTEM...2554
TROUBLESHOOTING THE ENGINE...2555
MAJOR PARTS...2557
MAIN FRAME...2559
OPERATOR GUARD ELECTRICAL...2560
ENGINE ELECTRICAL...2561
HYDRAULIC SYSTEM...2562
DRIVE SYSTEM...2563
CONTROL PEDALS...2564
HYDROSTATIC SYSTEM...2565
HAND CONTROLS...2566
SEAT & FRAME SYSTEM...2567
ENGINE & ATTACHING PARTS...2568
WARNING SIGNS...2571
WARNING - 6565980...2573
SERVICE SCHEDULE - 6567875...2574
WARNING - 6563380...2576
WARNING - 6561380...2577
IMPORTANT - 6560573...2578
GENERAL INFORMATION...2579
LOADER SPECIFICATIONS...2581
OPERATION & PERFORMANCE...2581
ENGINE...2581
LOADER HYDRAULICS...2582
ELECTRICAL...2582
DRIVE SYSTEM...2582
CAPACITIES...2582
TIRES...2582
ADDITIONAL PUBLICATIONS...2583
WARRANTY...2585
6566408 (11-82) - 843 Operation & Maintenance Manual...2587
WARNINGS...2589
SAFETY INSTRUCTIONS...2591
FOREWORD...2593
CONTENTS...2593
REFERENCE INFORMATION...2593
843 BOBCAT LOADER IDENTIFICATION...2594
OPERATING INSTRUCTIONS...2595
OPERATING INSTRUCTIONS...2597
CONTROLS...2598
DECAL LOCATIONS...2599
DASH PANEL...2600
THROTTLE CONTROL...2600
STOPPING THE ENGINE...2600
PARKING BRAKE...2600
STEERING LEVERS...2601
HYDRAULIC CONTROLS...2602
Foot Pedals (Hydraulic)...2602
Lift Arm Operation...2602
Float Position...2602
Tilt (Bucket) Operation...2602
Auxiliary Lever...2603
BEFORE YOU START THE ENGINE...2603
STARTING THE ENGINE...2604
Normal Starting Condition...2605
Making Cold Temperature Starting Easier...2605
Cold Weather Starting Condition...2606
BOBCAT LOADER OPERATION...2606
Bucket Size...2606
Installation Of Attachments...2607
Removal Of Attachments...2607
OPERATING PROCEDURE...2608
Filling The Bucket...2609
To Empty The Bucket...2609
Digging Into The Ground...2610
Making The Ground Level...2610
Filling A Hole...2610
STOPPING THE BOBCAT LOADER...2611
TRANSPORTING THE BOBCAT LOADER...2611
LIFT ARM STOP...2612
LIFTING THE OPERATOR GUARD...2613
LOWERING THE OPERATOR GUARD...2613
PREVENTIVE MAINTENANCE...2615
WARNINGS...2616
SERVICE SCHEDULE...2617
ENGINE SERVICE...2618
ADJUSTING THE DOOR LATCH...2618
AIR CLEANER SERVICE...2618
FUEL SYSTEM...2619
FUEL SYSTEM SERVICE...2619
FUEL FILTER...2620
REMOVING AIR FROM THE FUEL SYSTEM...2620
ENGINE LUBRICATION SYSTEM...2621
REPLACEMENT OF ENGINE OIL AND FILTER...2621
ENGINE COOLING SYSTEM...2622
Coolant Level...2622
REMOVING COOLANT FROM THE COOLING SYSTEM...2622
ALTERNATOR BELT...2623
ELECTRICAL SYSTEM...2623
USING AN EXTRA BATTERY (JUMP STARTING)...2626
TO INSTALL A NEW BATTERY...2627
SPARK ARRESTOR MUFFLER...2628
HYDRAULIC SYSTEM...2628
REPLACEMENT OF THE HYDRAULIC FILTER...2630
HYDRAULIC/HYDROSTATIC FLUID RESERVOIR...2630
Removing The Hydraulic/Hydrostatic Fluid...2630
FINAL DRIVE TRANSMISSION (CHAINCASE)...2631
TIRE MAINTENANCE...2631
Tire Rotation...2631
Wheel Nuts...2631
LUBRICATION OF THE BOBCAT LOADER...2632
ROLL OVER PROTECTION STRUCTURE (ROPS & FOPS)...2632
BOB-TACH...2633
PIVOT PINS...2633
AUXILIARY CONTROL LOCKBOLT...2633
BRAKE PEDAL ADJUSTMENT...2634
SERIAL NUMBER IDENTIFICATION...2634
DELIVERY REPORT...2634
MAJOR PARTS...2635
MAIN FRAME...2637
OPERATOR GUARD ELECTRICAL...2638
ENGINE ELECTRICAL...2639
HYDRAULIC SYSTEM...2640
DRIVE SYSTEM...2641
CONTROL PEDALS...2642
HYDROSTATIC SYSTEM...2643
HAND CONTROLS...2644
SEAT & FUEL SYSTEM...2645
ENGINE & ATTACHING PARTS...2646
DECALS...2648
DECALS...2649
WARNING - 6563484...2651
SERVICE SCHEDULE - 6561387...2652
WARNING - 6563380...2654
WARNING - 6561380...2655
IMPORTANT - 6560573...2656
GENERAL INFORMATION...2657
LOADER SPECIFICATIONS...2659
OPERATION & PERFORMANCE...2659
ENGINE...2659
LOADER HYDRAULICS...2660
ELECTRICAL...2660
DRIVE SYSTEM...2660
CAPACITIES...2660
TIRES...2660
ADDITIONAL PUBLICATIONS...2661
WARRANTY...2663
6549899 (6-12) - 825 Service Manual...2665
MAINTENANCE SAFETY...2667
CONTENTS...2669
FOREWORD...2669
PREVENTIVE MAINTENANCE...2671
INTRODUCTION...2673
Symbols...2673
Serial Number Identification...2673
Loader Serial Number...2673
Engine Serial Number...2674
Pre-Delivery Inspection...2674
30 Hour Inspection...2674
SERVICE SCHEDULE...2675
REAR GRILL...2676
TILTING THE OPERATOR GUARD...2676
ROPS Tilt Motor...2677
ENGINE MAINTENANCE...2677
Engine Oil...2677
Specifications...2677
ENGINE OIL AND FILTER REPLACEMENT...2679
ENGINE AIR INLET SYSTEM (AIR CLEANER)...2680
ENGINE COOLING SYSTEM...2681
FAN BELT ADJUSTMENT...2681
FLUSHING THE COOLING SYSTEM...2681
FUEL SYSTEM...2682
FUEL SPECIFICATIONS...2682
Water In The Fuel Tank...2682
TO SERVICE THE FUEL SYSTEM...2683
REMOVE THE AIR FROM THE FUEL SYSTEM...2683
ELECTRICAL SYSTEM MAINTENANCE...2684
Electrical System...2684
HYDRAULIC SYSTEM...2685
Hydraulic/Hydrostatic Transmission Fluid...2685
CHECKING AND ADDING HYDRAULIC FLUID...2685
HYDRAULIC FLUID FILTERS...2685
Replacement Of The Suction (25 Micron) Filter ...2686
Replacement Of The Return Line Filter (10 Micron)...2686
DRAINING THE FLUID RESERVOIR...2686
LEAKS...2687
OIL COOLER...2687
CARE OF THE HYDROSTATIC TRANSMISSION...2687
Loader Start–Up...2688
Cold Weather Start–Up...2688
FINAL DRIVE CHAIN...2688
TIRES...2688
TIRE MAINTENANCE...2689
TIRE ROTATION...2689
TIRE REPLACEMENT...2689
LUBRICATION...2689
WHEEL MOUNTING NUTS...2689
BOB–TACH...2690
PARK BRAKE...2690
HYDRAULIC SYSTEM...2691
HYDRAULIC / HYDROSTATIC SCHEMATICS...2693
HYDRAULIC SYSTEM...2703
TUBELINES, HOSES, FITTINGS...2703
37° Flare Connection...2703
Straight Thread O–Ring Fitting (Elbows, Adapter, Etc.)...2704
Pipe Thread Fittings...2704
Tubelines And Hoses...2704
HYDRAULIC SYSTEM TROUBLESHOOTING...2704
GEAR PUMP...2706
Testing...2706
Removal...2706
DISASSEMBLY OF GEAR PUMP...2707
TO INSPECT PARTS FOR WEAR...2707
General...2707
Gear Assembly...2707
Front And Back Plates...2707
Body...2708
Assembly Of Gear Pump...2708
CONTROL VALVE...2708
Relief Valve Check...2708
Internal Leaks...2709
Control Valve Repair...2709
Removal...2709
Disassembly...2709
LIFT VALVE SPOOL (Float Detent)...2710
Repair Of The Float Detent Of The Lift Spool...2710
To Assemble The Detent Assembly...2710
Inspection, Repair And Assembly Of Control Valve...2710
CONTROL PEDALS...2711
Adjustment...2711
Removal Of Pedal Assembly...2712
HYDRAULIC CYLINDERS...2712
Checking For Internal Leak (Lift Cylinder)...2712
Removal Of Lift Cylinder...2712
Removal Of Tilt Cylinder...2712
HYDRAULIC CYLINDER REPAIR...2712
To Disassemble A Hydraulic Lift Or Tilt Cylinder...2713
To Replace The Cylinder Seals...2713
To Assemble The Hydraulic Cylinder...2713
OIL COOLER...2714
Cleaning Of Grill...2714
Removal Of Oil Cooler...2714
By–Pass Valve...2714
Cooler By-Pass Hose...2714
HYDROSTATIC SYSTEM...2715
HYDROSTATIC DRIVE SYSTEM...2717
Description...2717
HYDROSTATIC TRANSMISSION TROUBLESHOOTING...2717
CONTROL LINKAGE...2722
Adjustment Of Steering Linkage...2722
ADJUSTMENT OF SPEED RANGE LINKAGE...2722
STEERING CONTROLLINKAGE...2723
Removal...2723
CHECKING HYDROSTATIC SYSTEM...2724
Test Kit...2724
Charge Pressure Check...2726
Charge Pump Inlet Pressure...2726
CHECKING RELIEF VALVES...2727
Charge Relief Valve...2727
Filter Relief Valve...2727
Charge Inlet Relief Valve...2727
High Pressure Relief Valve...2727
MICRON FINAL FILTER ELEMENT REPLACEMENT...2728
TEMPERATURE AND PRESSURE SWITCHES...2728
REMOVAL OF HYDROSTATIC PUMP ASSEMBLY...2729
INSTALLING HYDROSTATIC PUMP...2729
REMOVAL OF HYDROSTATIC MOTOR...2730
INSTALLING HYDROSTATICMOTOR...2731
New Hydrostatic Pump & Motor...2731
HYDROSTATIC PUMP OR MOTOR DISASSEMBLY ...2733
INSPECT PARTS FOR WEAR...2734
TO ASSEMBLE PUMP OR MOTOR...2734
STARTING PROCEDURE, AFTER REPAIR...2735
FINAL DRIVE SYSTEM...2737
FINAL DRIVE SYSTEM...2739
Description...2739
REMOVAL OF REDUCTION HOUSING...2739
DISASSEMBLY OF REDUCTION HOUSING ...2739
Removal Of The Intermediate Gear (6)...2739
Removal Of Input Drive Gear (7)...2740
Removal Of Output Gear (14)...2740
ASSEMBLY OF REDUCTION HOUSING...2740
Installing The Output Shaft And Gear...2740
Installing Input Shaft And Gear...2740
Installing Intermediate Gear...2740
Drive Chain Adjustment (Internal Adjustment Type)...2740
Drive Chain Adjustment (External Adjustment Type)...2741
Drive Chain Idler Removal (Internal Adjustment Type)...2741
To Disassemble The Idler Gear (Internal)...2742
Drive Chain Idler Removal (External Adjustment Type)...2742
REMOVAL OF DRIVE CHAIN...2743
INSTALLING DRIVE CHAIN...2743
REMOVAL OF AXLE...2744
Removal Of Rear Axle...2744
Removal Of Front Axle...2744
Installation Of The Axle...2745
AXLE BEARING AND SEAL REPLACEMENT...2745
NSTALLATION OF AXLES PROCKET...2746
PARK BRAKE REMOVAL...2746
MAIN FRAME...2747
MAIN FRAME...2749
Description ...2749
REMOVAL OF ROPS...2749
PIVOT PIN AND BUSHING REPLACEMENT ...2749
BOB–TACH REMOVAL...2749
LIFT ARMS REMOVAL...2750
FUEL TANK REMOVAL...2750
Removing Fuel Tank On Loader S/N 16999 & Below ...2750
Removing Fuel Tank On Loader S/N 17001 & Above...2750
ELECTRIC MOTOR FOR ROPS (Cab Tilt – S/N 19126 & Below)...2750
Removal Of Tilt Mechanism...2751
MECHANICAL TILT FOR THE ROPS (S/N 19127 & Above)...2751
ELECTRICAL SYSTEM...2753
ELECTRICAL SCHEMATICS...2757
ELECTRICAL CIRCUITRY...2761
PROBLEM ANALYSIS...2761
FAN BELT...2763
TO CHECK ALTERNATOR OUTPUT...2763
TO CHECK THE REGULATOR...2763
ALTERNATOR SERVICE...2764
Removal (ROPS Must Be Tilted)...2764
Disassembly...2764
To Check Rotor...2764
To Check Stator ...2764
To Check Diode Trio...2765
To Check Rectifier...2765
Assembly...2765
STARTER SERVICE...2766
To Check The Starter...2766
To Remove Starter...2766
Disassembly And Inspection...2766
Assembly...2766
ENGINE SERVICE...2767
INTRODUCTION...2769
Engine Parts...2769
Engine Number Location...2769
STARTING A NEW OR RECONDITIONED ENGINE...2769
ENGINE OVERHAUL...2769
Engine Removal...2769
Cylinder Head Maintenance...2770
To Remove The Valves...2771
Combustion Chamber Inserts...2771
Reconditioning Cylinder Heads...2772
Cleaning...2772
Inspection...2772
Reconditioning Of Valves AndValve Seats...2773
Valve Seat Inserts...2773
To Install Inserts...2773
To Disassemble The Rocker Shaft Assembly...2774
To Assemble The Rocker Shaft Assembly...2775
Push Rods...2775
To Install The Valves...2775
INSTALLING CYLINDER HEAD...2776
Cylinder Head Gasket...2776
To Install The Cylinder Head...2776
CONNECTING RODS AND PISTONS...2777
To Remove Pistons And Connecting Rods...2777
To Remove Pistons And Rings From The Connecting Rods...2778
Inspection...2778
To Install The Pistons To The Connecting Rods...2778
Installing The Piston Rings...2779
To Install Rings...2779
To Install Piston And Connecting Rod Assemblies...2780
Installing New Pistons...2780
Cylinder Liners...2781
To Install New Cylinder Liners...2781
CRANKSHAFT AND MAIN BEARINGS...2781
Description...2781
To Install Main Bearings And Thrust Washers...2782
To Install Thrust Washers...2782
To Remove The Crankshaft...2783
To Reinstall The Crankshaft...2784
Crankshaft Rear End Oil Seal...2785
FLYWHEEL AND FLYWHEEL HOUSING...2785
To Remove The Flywheel...2785
To Replace The Flywheel Ring Gear...2785
To Reinstall The Flywheel...2786
To Install The Flywheel Housing...2786
TIMING CASE AND DRIVE...2786
To Remove The Timing Case Cover...2786
Replacement Of The Crankshaft Front Oil Seal...2787
To Install The Timing Case Cover...2787
To Remove The Idler Gear And Hub...2787
To Install The Idler Gear And Hub...2787
To Remove The Camshaft Gear...2788
To Install The Camshaft Gear...2788
To Remove The Fuel Pump Gear...2788
To Install The Fuel Pump Gear...2788
To Remove The Fuel Pump Drive Hub...2789
To Install The Fuel Pump Drive Hub...2789
To Remove The Timing CaseBack Plate...2789
To Install The Timing Case Back Plate...2790
To Remove The Camshaft And Tappets...2790
To Install The Tappets And Camshaft...2790
Timing Marks...2791
To Reset The Engine To The Original Timing...2791
Timing Pin...2792
Check Valve Timing...2792
Adjusting Valve Clearance...2793
Valve Adjustment Sequence...2793
LUBRICATION SYSTEM...2793
The Lubricating Oil Pump...2793
To Remove The Sump...2793
To Install The Oil Pan...2793
To Remove The Oil Pump...2794
To Dismantle The Oil Pump...2794
Inspection...2794
To Assemble The Oil Pump...2795
To Install The Oil Pump...2795
Oil Pressure Relief Valve...2795
To Dismantle The Oil Pressure Relief Valve...2796
To Assemble The Oil Pressure Relief Valve...2796
COOLING SYSTEM...2796
Fan Belt...2796
Adjustment Of Fan Belt...2796
Water Pump...2797
Remove The Water Pump...2797
To Disassemble The Water Pump...2797
Inspection...2797
To Assemble The Water Pump...2798
To Install The Water Pump...2798
Thermostat...2798
To Remove The Thermostat...2798
To Test The Thermostat...2799
Replacement Of The Thermostat...2799
FUEL SYSTEM...2799
To Test Fuel Lift Pump...2799
To Remove The Lift Pump...2799
Fuel Injection Pump...2800
To Remove The Fuel Injection Pump...2800
To Install The Fuel Injection Pump...2800
Checking Fuel Injection Pump Timing...2800
Timing The fuel Injection Pump (Using Timing Tool MS 67123)...2801
Checking The Timing Mark On The Flange Of The Injection Pump...2803
Injector Problems...2804
Testing For Faulty Injector...2804
Injector Removal...2804
Injector Installation...2804
Fuel Pipes (High Pressure)...2804
Using C.A.V. Thermostart Units...2805
Charging The Fuel System...2806
SPECIFICATIONS...2807
SPECIFICATIONS...2809
Cylinder Block...2809
Cylinder Liner (Cast Iron)...2809
Pistons...2809
Piston Rings...2809
Piston Pin Bushing...2809
Connecting Rod...2809
Connecting Rod Alignment...2810
Crankshaft...2810
Crankshaft Thrust Washers...2810
Main Bearings...2810
Connecting Rod Bearings...2810
Camshaft...2811
Camshaft Thrust Plates...2811
Cylinder Head...2811
Combustion Chamber Inserts...2811
Valve Guides (Inlet)...2811
Valve Guides (Exhaust)...2811
Valves (Inlet)...2812
Valves (Exhaust)...2812
Inner Valve Springs...2812
Outer Valve Springs...2812
Rocker Levers...2812
Valve Clearance...2812
Rocker Shaft...2812
Push Rods...2812
Lifters...2812
TIMING GEARS...2813
Injector Pump Gear...2813
Crankshaft Gear...2813
Timing Gear Backlash...2813
LUBRICATION SYSTEM...2813
Lubricating Oil Pump...2813
Pump Clearances...2813
Lubricating Oil Pump Drive Gear...2813
Relief Valve (Lube Oil)...2813
Lubricating Oil Filter...2813
COOLING SYSTEM...2813
Thermostat...2813
FUEL SYSTEM...2813
Fuel Lift Pump...2814
Final Fuel Filter...2814
Fuel Injection Pump...2814
Injectors...2814
Starting Aid...2814
SERVICE WEAR LIMITS...2814
DE–RATING FOR ALTITUDE...2815
TORQUE SPECIFICATIONS...2815
Hydrostatic Pump and Motor...2815
High Pressure Relief Valves...2815
Loader Torque Specs...2815
STANDARD TORQUE SPECIFICATIONS FOR BOLTS...2816
DECIMAL AND MILLIMETER EQUIVALENTS...2817
U.S. TO METRIC CONVERSION...2817
SPECIAL TOOLS...2818
825 LOADER SPECIFICATIONS...2819
SPECIFICATIONS...2819
ENGINE...2819
LOADER HYDRAULICS...2820
ELECTRICAL...2820
DRIVE SYSTEM...2820
CAPACITIES...2820
TIRES...2820
ALPHABETICAL INDEX...2821
SERVICE BULLETINS...2825
825-001...2825
825-002...2827
825-003...2829
825-004...2831
825-005...2833
SERVICE MANUAL REVISIONS...2825
825-1...2835
825-2...2837
825-3...2839
825-4...2841
6566091 (6-12) - 843; 843B Service Manual...2843
MAINTENANCE SAFETY...2845
CONTENTS...2847
FOREWORD...2849
SAFETY INSTRUCTIONS...2851
FIRE PREVENTION...2852
SERIAL NUMBER LOCATIONS...2853
LOADER SERIAL NUMBER...2853
ENGINE SERIAL NUMBER...2853
DELIVERY REPORT...2853
BOBCAT LOADER IDENTIFICATION...2854
PREVENTIVE MAINTENANCE...2855
SERVICE SCHEDULE...2857
LIFTING AND BLOCKING THE LOADER...2858
Procedure...2858
TRANSPORTING THE BOBCAT LOADER...2859
Procedure...2859
LIFT ARM STOP...2860
Procedure...2860
OPERATOR CAB...2861
Seat Bar System...2861
Seat Bar Inspection...2861
Seat Bar Maintenance...2862
Raising The Operator Cab...2863
Lowering The Operator Cab...2863
USING AN EXTRA BATTERY (JUMP STARTING)...2864
Procedure...2864
REMOTE START SWITCH...2865
Procedure...2865
HYDRAULIC SYSTEM...2867
HYDRAULIC / HYDROSTATIC SCHEMATICS...2869
TROUBLESHOOTING...2921
HYDRAULIC SYSTEM INFORMATION...2922
Flare Connections...2922
Straight Thread O-Ring Fitting...2922
Tubelines And Hoses...2922
LIFT CYLINDER...2923
Checking The Lift Cylinder(s)...2923
Removal And Installation...2923
TILT CYLINDERS...2925
Checking The Tilt Cylinder...2925
Removal And Installation...2925
Rod End Seal...2926
TILT CYLINDER (CESSNA)...2927
Disassembly...2927
Assembly...2929
HYDRAULIC CYLINDER REPAIR...2933
Disassembly...2933
Assembly...2935
HYDRAULIC CONTROL VALVE (CESSNA)...2938
Checking The Main Relief Valve...2938
Main Relief Valve Removal And Installation...2939
Removal And Installation...2939
Disassembly...2941
Inlet Section...2942
Tilt Section...2943
Lift Section...2945
Auxiliary Section...2947
Valve Spool Bolt...2948
Assembly...2949
HYDRAULIC CONTROL VALVE (MELROE)...2950
Checking The Main Relief Valve...2950
Main Relief Valve Removal And Installation...2951
Removal And Installation...2951
Disassembly And Assembly...2953
Detent Assembly...2955
Centering Mechanism...2958
HYDRAULIC PUMP (SINGLE STAGE)...2959
Checking The Output Of The Hydraulic Pump...2959
Removal And Installation...2960
Disassembly And Assembly...2960
Inspection...2962
HYDRAULIC PUMP (DOUBLE STAGE)...2963
Removal And Installation...2964
Disassembly And Assembly...2966
Inspection...2968
BUCKET POSITION VALVE (S/N 15001 & ABOVE)...2969
Removal And Installation...2969
Disassembly And Assembly...2969
PORT BLOCK (S/N 14999 & BELOW)...2971
40 Micron Filter (Bronze)...2971
Neutral By-Pass Valve...2972
Removal And Installation...2972
PORT BLOCK (S/N 15001 & ABOVE)...2975
Removal And Installation...2975
Charge By-Pass...2976
Cold Oil By-Pass...2976
HYDRAULIC FLUID FILTER HOUSING (S/N 15001 & ABOVE)...2977
Removal And Installation...2977
By-Pass Valve...2977
HYDRAULIC/HYDROSTATIC RESERVOIR (S/N 21514 & BELOW)...2978
Removal And Installation...2978
HYDRAULIC CONTROL PEDALS (S/N 14999 & BELOW)...2980
Removal And Installation...2980
Adjustment...2980
HYDRAULIC CONTROL PEDALS (S/N 15001 & ABOVE)...2981
Removal And Installation...2981
Adjustment...2981
PEDAL LOCK LINKAGE...2982
Adjustment...2982
HYDROSTATIC SYSTEM...2983
TROUBLESHOOTING...2985
HYDROSTATIC SYSTEM INFORMATION...2986
High Pressure Relief/Replenishing Valves Function...2986
FRONT AND SIDE PANELS (S/N 19999 & BELOW)...2987
Removal And Installation...2987
STEERING LEVERS (S/N 16191 & BELOW)...2988
Removal And Installation...2988
Repairing The Steering Levers...2989
Steering Linkage Adjustment...2990
Removal And Installation...2991
RepairingThe Pintle Lever...2992
FRONT AND SIDE PANEL (ONE PIECE) (S/N 20001 & ABOVE) & 843B...2993
Removal And Installation...2993
STEERING LEVERS - 843-(S/N 16192 THRU 25999), 843-(STARTING WITH S/N 34222) & 843B...2996
Removal And Installation...2996
Repairing The Steering Levers...2997
STEERING LINKAGE 843-(S/N 16192 THRU 25999), 843-(STARTING WITH S/N 34222) & 843B...2998
Steering Linkage Adjustment...2998
Removal And Installation...2999
Repairing The Pintle Lever...3000
STEERING LINKAGE (S/N 26000 THRU 29869)...3001
Description...3001
Neutral Adjustment...3001
Steering Lever Centering Spring Mechanism...3003
Removal And Installation (Creep Mechanism)...3004
SERVO CONTROL...3007
Removal And Installation...3007
Disassembly And Assembly...3008
PINTLE LEVER ARMS (S/N 26000 - 29869)...3009
Removal And Installation...3009
STEERING LINKAGE (S/N 29870 - 31863)...3011
Description...3011
Neutral Adjustment...3011
Steering Lever Centering Spring Mechanism...3013
Creep Centering Spring Mechanism...3013
Pintle Arm...3013
STEERING LINKAGE (S/N 31864-34221)...3014
Hydrostatic Pump Centering Spring Adjustment...3015
Servo Control Unit Adjustment...3016
Steering Lever Centering Spring Adjustment...3017
Wheel RPM Adjustment (Left To Right)...3018
HYDROSTATIC MOTOR...3020
Removal And Installation...3020
Disassembly And Assembly...3021
Inspection...3025
Timing The Hydrostatic Motor...3026
High Pressure Hose Routing...3026
HYDROSTATIC PUMPS...3027
Checking The High Pressure Relief/Replenishing Valve...3027
Checking Charge Pressure...3028
Removal And Installation...3028
Disassembly And Assembly...3029
Rear Pump...3031
Front Pump...3031
Inspection...3034
Tow Valves...3035
Hydrostatic Pump Rear Mount (S/N 21574 & Above)...3036
HYDROSTATIC FLUID FILTER HOUSING...3037
Removal And Installation...3037
DRIVE SYSTEM...3039
PARKING BRAKE...3041
Adjustment...3041
Removal And Installation...3041
Block And Pucks...3042
AXLES, SEALS AND BEARINGS...3044
Removal...3044
Installation...3045
FINAL DRIVE CHAIN...3048
Removal...3048
Installation...3048
REDUCTION GEARCASE...3050
Removal And Installation...3050
Checking Reduction Gearcase...3051
Disassembly And Assembly...3051
Installation...3056
Reduction Gearcase Seal...3057
MAIN FRAME...3059
OPERATOR CAB (S/N 19999 & BELOW)...3061
Removal And Installation...3061
OPERATOR CAB (S/N 20001 & ABOVE)...3063
Removal And Installation...3063
OPERATOR CAB GAS CYLINDER...3066
Removal And Installation...3066
REAR DOOR...3067
Door Latch Adjustment...3067
Removal And Installation...3068
LIFT ARMS...3069
Removal And Installation...3069
BOB-TACH...3071
Removal And Installation...3071
Tilt Cylinder Rod End Seal...3072
Disassembly And Assembly...3073
FUEL TANK (S/N 19999 & BELOW)...3075
Removal And Installation...3075
FUEL TANK (S/N 20001 & ABOVE)...3076
Removal And Installation...3076
Fuel Tank Sender Switch...3077
ELECTRICAL SYSTEM...3079
ELECTRICAL SCHEMATICS...3082
ELECTRICAL SYSTEM INFORMATION...3109
Description...3109
TROUBLESHOOTING...3109
BATTERY...3110
Checking The Battery...3110
Removal And Installation...3110
ALTERNATOR...3111
Alternator Belt Adjustment...3111
Checking The Alternator Wire Harness...3112
Checking Alternator Output...3112
Checking Alternator Regulator...3112
Removal And Installation...3113
Disassembly And Assembly...3114
MELROE ALTERNATOR...3116
Checking The Alternator Output...3116
Checking The Alternator Regulator...3117
Removal And Installation...3118
Disassembly And Assembly...3119
MANDO ALTERNATOR...3121
STARTER...3122
Checking The Starter...3122
Removal And Installation...3122
Disassembly And Assembly...3124
Cleaning And Inspection...3124
Replacing The Brushes...3125
ENGINE SERVICE...3127
ENGINE SERVICE (PERKINS ENGINE)...3129
TROUBLESHOOTING...3131
VALVE CLEARANCE...3132
Adjustment...3132
ENGINE COMPRESSION...3133
Checking...3133
FUEL FILTER...3134
Removal And Installation...3134
Water Trap...3134
FUEL LIFT PUMP...3135
Checking...3135
Removal And Installation...3135
REMOVING AIR FROM FUEL SYSTEM...3136
Procedure...3136
FUEL INJECTION PUMP...3137
Removal And Installation...3137
ENGINE TIMING TO INJECTION PUMP (USING DIAL INDICATOR)...3138
Procedure...3138
EMGINE TIMING TO INJECTOR PUMP (USING TIMING TOOL)...3139
Procedure...3139
CHECKING TIMING MARK ON INJECTION PUMP FLANGE...3140
Procedure...3140
FUEL INJECTOR NOZZLES...3141
Removal And Installation...3141
Checking...3142
ENGINE...3143
Removal And Installation...3143
RADIATOR...3147
Removal And Installation...3147
OIL COOLER...3148
Removal And Installation...3148
ENGINE MUFFLER...3149
Removal And Installation...3149
ENGINE BLOWER HOUSING...3150
Removal And Installation...3150
ENGINE FLYWHEEL & U-JOINT...3151
Removal And Installation...3151
Flywheel Ring Gear...3151
CYLINDER HEAD...3152
Removing The Cylinder Head...3152
Cylinder Head Surface Alignment...3152
Installing The Cylinder Head...3153
VALVES...3154
Removal Of The Valves...3154
Installing The Valves...3154
Reconditioning The Valves And Valve Seats...3154
Installing Valve Guides...3155
Changing The Valve Springs...3156
COMBUSTION CHAMBER INSERTS...3157
Removal And Installation...3157
ROCKER ARMS...3158
Disassembly...3158
Assembly...3158
PISTON AND CONNECTING RODS...3159
Removal...3159
Disassembly...3160
Inspection...3160
Installation...3161
CYLINDER LINERS...3162
Checking...3162
Removal And Installation...3162
MAIN BEARINGS...3163
Removal...3163
Installation...3164
Crankshaft End Play...3164
CRANKSHAFT...3165
Removal...3165
Checking...3165
Installation...3166
REAR MAIN OIL SEAL...3167
Removal And Installation...3167
TIMING CASE COVER...3168
Removal And Installation...3168
IDLER GEAR AND HUB...3169
Removal...3169
Installation...3169
CAMSHAFT GEAR...3171
Removal...3171
Installation...3171
FUEL INJECTION PUMP DRIVE GEAR...3172
Removal And Installation...3172
CRANKSHAFT GEAR...3172
Removal...3172
TIMING CASE...3173
Removal And Installation...3173
CAMSHAFT AND TAPPETS...3174
Removal...3174
Inspection...3175
Installation...3175
LUBRICATION SYSTEM...3176
Description...3176
OIL PUMP...3177
Removal And Installation...3177
Disassembly And Assembly...3177
Checking...3177
WATER PUMP...3179
Removal And Installation...3179
Disassembly...3179
Checking...3180
Assembly...3180
THERMOSTAT...3181
Removal...3181
Testing The Thermostat...3181
Installation...3181
ENGINE SERVICE (PERKINS ENGINE - 200 SERIES)...3183
TROUBLESHOOTING...3185
VALVE CLEARANCE...3186
Adjustment...3186
ENGINE COMPRESSION...3187
Checking...3187
FUEL FILTER (S/N 13315 & BELOW)...3188
Removal And Installation...3188
Water Trap...3188
FUEL FILTER (S/M 13316 & ABOVE)...3188
Removal And Installation...3188
REMOVING AIR FROM THE FUEL SYSTEM (S/N 13315 & BELOW)...3189
Procedure...3189
REMOVING AIR FROM THE FUEL SYSTEM (S/N 13316 & ABOVE)...3190
Procedure...3190
FUEL INJECTION PUMP...3191
Removal And Installation...3191
Maximum Speed Setting...3192
TIMING THE FUEL INJECTION PUMP...3193
Procedure...3193
FUEL INJECTOR NOZZLES...3195
Removal And Installation...3195
Checking...3196
GLOW PLUGS...3197
Checking...3197
ENGINE...3198
Removal And Installation...3198
RADIATOR...3201
Removal And Installation...3201
OIL COOLER...3203
Removal And Installation...3203
ENGINE MUFFLER...3204
Removal And Installation...3204
ENGINE BLOWER HOUSING...3205
Removal And Installation...3205
ENGINE FLYWHEEL & U-JOINT...3206
Removal And Installation...3206
Flywheel Ring Gear...3206
CYLINDER HEAD...3207
Removing The Cylinder Head...3207
Cylinder Head Surface Alignment...3207
Installing The Cylinder Head...3208
VALVES...3209
Removing The Valves...3209
Installing The Valves...3209
Reconditioning The Valves And Valve Seats...3209
Installing The Valve Guides...3210
Checking The Valve Springs...3211
CONBUSTION CHAMBER INSERTS...3212
Removal And Installation...3212
ROCKER ARMS...3213
Disassembly...3213
Assembly...3213
PISTON AND CONNECTING RODS...3214
Removal...3214
Disassembly...3215
Inspection...3215
Installation...3216
CYLINDER LINERS...3217
Checking...3217
Removal And Installation...3217
MAIN BEARINGS...3218
Removal...3218
Installation...3219
Crankshaft End Play...3219
CRANKSHAFT...3220
Removal...3220
Installation...3221
REAR MAIN OIL SEAL...3222
Removal And Installation...3222
TIMING CASE COVER...3223
Removal And Installation...3223
Front Seal...3224
IDLER GEAR AND HUB...3225
Removal...3225
Installation...3226
CAMSHAFT GEAR...3227
Removal...3227
Installation...3227
FUEL INJECTION PUMP DRIVE GEAR...3228
Removal And Installation...3228
CRANKSHAFT GEAR...3228
Removal...3228
TIMING CASE...3229
Removal And Installation...3229
CAMSHAFT AND TAPPETS...3230
Removal...3230
Inspection...3231
Installation...3231
LUBRICATION SYSTEM...3232
Description...3232
OIL PUMP...3233
Removal And Installation...3233
Inspection...3234
OIL FILTER ADAPTER HOUSING...3235
Removal And Installation...3235
WATER PUMP...3236
Removal And Installation...3236
Disassembly...3236
Checking...3237
Assembly...3237
THERMOSTAT...3238
Removal...3238
Testing The Thermostat...3238
Installation...3238
ENGINE SERVICE (ISUZU ENGINE)...3239
TROUBLESHOOTING...3241
VALVE CLEARANCE...3242
Adjustment...3242
ENGINE COMPRESSION...3243
Checking...3243
FUEL FILTER...3244
Water Trap...3244
Fuel Filter Element...3244
REMOVING AIR FROM FUEL SYSTEM...3245
Procedure...3245
FUEL INJECTION PUMP...3246
Removal And Installation...3246
ENGINE TIMING TO INJECTION PUMP...3249
Procedure...3249
FUEL INJECTOR NOZZLES...3251
Removal And Installation...3251
Checking...3252
GLOW PLUGS...3254
Removal And Installation...3254
ENGINE OIL AND FILTER...3255
Removal And Installation...3255
ENGINE...3257
Removal And Installation...3257
RADIATOR...3262
Removal And Installation...3262
OIL COOLER...3264
Removal And Installation...3264
ENGINE MUFFLER...3265
Removal And Installation...3265
ENGINE FLYWHEEL & U-JOINT...3266
Removal And Installation...3266
Flywheel Ring Gear...3266
ENGINE BLOWER HOUSING...3267
Removal And Installation...3267
ENGINE MOUNTS...3268
Removal And Installation...3268
CYLINDER HEAD...3269
Removal And Installation...3269
Cylinder Head Surface Alignment...3270
Exhaust Manifold...3270
VALVES...3271
Removal And Installation...3271
Reconditioning The Valves And Valve Seats...3271
Valve Seat Insert...3272
Valve Guides...3272
Valve Springs...3273
ROCKER ARMS...3274
Disassembly And Assembly...3274
Push Rods...3274
PISTON AND CONNECTING ROD...3275
Removal...3275
Disassembly...3275
Inspection...3276
Assembly...3279
Installation...3280
CYLINDER LINERS...3281
Checking...3281
Removal...3281
Installation...3281
MAIN BEARINGS...3282
Removal...3282
Installation...3283
Crankshaft End Play...3284
CRANKSHAFT...3285
Removal...3285
Checking Tuffriding (Soft Nitriding) Coating...3285
Checking...3285
Crankshaft Gear...3287
Removal And Installation...3287
Installation...3287
TIMING CASE COVER SEAL...3288
Removal And Installation...3288
TIMING CASE COVER...3289
Removal And Installation...3289
IDLER GEAR AND HUB...3291
Removal And Installation...3291
Checking...3291
FUEL INJECTION PUMP IDLER GEAR...3293
Removal And Installation...3293
Bearing Installation...3293
CAMSHAFT GEAR...3294
Removal And Installation...3294
TIMING CASE...3295
Removal And Installation...3295
CAMSHAFT...3296
Removal And Installation...3296
Checking...3296
Camshaft Bearing...3297
Tappets...3297
Installation...3298
OIL PAN...3299
Removal...3299
Installation...3299
OIL PUMP...3300
Removal And Installation...3300
Checking...3300
Gear Replacement...3301
Rotor Replacement...3302
Oil Pump Relief Valve...3302
WATER PUMP...3303
Removal And Installation...3303
Disassembly...3303
Assembly...3304
THERMOSTAT...3306
Removal And Installation...3306
Inspection...3306
WATER JACKET TUBE...3307
Removal And Installation...3307
TECHNICAL DATA...3309
GENERAL SPECIFICATIONS...3311
TORQUE SPECIFICATIONS...3313
Seat Bar, Fuel Tank & Panel Group...3313
Steering Levers, Linkage & Pedal Group...3314
Brakem Axle & Chaincase Group...3315
Operator Guard, Lift Arm & Main Frame Group...3316
Hydraulic/Hydrostatic Group...3317
Engine Group (Perkins)...3318
Engine Group (200 Series Perkins)...3320
Engine Group (Isuzu)...3322
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...3324
DECIMAL AND MILLIMETER EQUIVALENTS...3325
U.S. TO METRIC CONVERSION...3325
STANDARD TORQUE SPECIFICATIONS FOR BOLTS...3326
TECHNICAL DATA (PERKINS ENGINE)...3327
LOADER SPECIFICATIONS...3329
Specifications...3329
Engine...3329
Loader Hydraulics...3330
Electrical...3330
Drive System...3330
Capacities...3330
Tires...3330
ENGINE SPECIFICATIONS...3331
Cylinder Head Dimensions...3331
Piston And Connecting Rod Dimensions...3332
Cylinder Block And Liner Dimensions...3333
crankshaft And Main Bearings Dimensions...3333
Timing Case, Camshaft And Drive Dimensions...3334
Oil Pump Dimensions...3335
Cooling System and Wster Pump Dimensions...3336
Fuel System Specifications...3336
De-Rating For Altitude...3337
Engine Torque...3337
Grinding Specifications For Crankshaft...3338
TECHNICAL DATA (PERKINS ENGINE - 200 SERIES)...3339
LOADER SPECIFICATIONS...3341
Specifications...3341
Engine...3341
Loader Hydraulics...3342
Electrical...3342
Drive System...3342
Capacities...3342
Tires...3342
ENGINE SPECIFICATIONS...3343
Cylinder Head Dimensions...3343
Pistons And Connecting Rod Dimensions...3343
Cylinder Block And Liner Dimensions...3344
Crankshaft And Main Bearing Dimensions...3344
Timing Case, Camshaft And Drive Dimensions...3345
Oil Pump Dimensions...3345
Cooling System And Water Pump Dimensions...3345
Fuel System Specifications...3346
De-Rating For Altitude...3346
Engine Torques...3346
Grinding Specifications For Crankshaft...3347
TECHNICAL DATA (iSUZU ENGINE)...3349
LOADER SPECIFICATIONS...3351
Operation And Performance...3351
Engine...3351
Loader Hydraulics...3352
Electrical...3352
Drive System...3352
Capacities...3352
Tires...3352
ENGINE SPECIFICATIONS...3353
Cylinder Head...3353
Valve, Vale Guide And Seat Insert...3353
Valve Springs...3353
Rocker Arm...3353
Tappets...3354
Piston, Pin And Rings...3354
Connecting Rod & Bearing...3354
Cylinder Liners...3354
Camshaft...3354
Crankshaft...3355
Idler Gear...3355
Oil Pump...3355
Fuel System...3355
Engine Torque...3356
SERVICE MANUAL REVISIONS...3357
843-1...3357
843-2...3359
843-3...3361
843-4...3363
843-5...3365
843-6...3367
843-7...3369
843-8...3371
843-9...3373
843-10...3375
843-11...3377
843-12...3379
843-13...3381
843-14...3383
843-15...3385
843-16...3387
843-17...3389
6720755 (6-12) - 853; 853H Service Manual...3391
MAINTENANCE SAFETY...3393
ALPHABETICAL INDEX...3395
CONTENTS...3397
FOREWORD...3398
SAFETY INSTRUCTIONS...3401
SERIAL NUMBER LOCATIONS...3403
LOADER SERIAL NUMBER...3403
ENGINE SERIAL NUMBER...3403
DELIVERY REPORT...3403
BOBCAT LOADER IDENTIFICATION...3404
PREVENTIVE MAINTENANCE...3405
SERVICE SCHEDULE...3407
LIFTING AND BLOCKING THE LOADER...3408
Procedure...3408
TRANSPORTING THE LOADER...3409
Procedure...3409
TOWING THE LOADER...3409
Procedure...3409
LIFTING THE LOADER...3410
Four Point Lift...3410
Single Point Lift...3410
LIFT ARM SUPPORT DEVICE...3411
Engaging The Lift Arm Support Device...3411
Disengaging The Lift Arm Support Device...3412
OPERATOR CAB...3413
Description...3413
Raising The Operator Cab...3413
Lowering The Operator Cab...3414
Emergency Exit...3414
SEAT BAR RESTRAINT SYSTEM...3415
Description...3415
Inspecting The Seat Bar...3415
Maintaining The Seat Bar...3415
AIR CLEANER SERVICE...3416
Replacing Filter Element...3416
FUEL SYSTEM...3418
Fuel Specifications...3418
Filling The Fuel Tank...3418
Fuel Filter...3418
Removing Air From The Fuel System...3419
ENGINE LUBRICATION SYSTEM...3420
Checking Engine Oil...3420
Replacing Oil And Filter...3420
ENGINE COOLING SYSTEM...3422
Checking The Coolant Level...3422
Cleaning The Cooling System...3422
Replacing The Coolant...3423
ALTERNATOR BELT...3424
Adjusting The Alternator Belt...3424
HYDRAULIC/HYDROSTATIC SYSTEM...3425
Checking And Adding Fluid...3425
Replacing Hydraulic/Hydrostatic Filters...3425
Replacing The Hydraulic Fluid...3426
Hydraulic Reservoir Breather Cap...3427
SPARK ARRESTOR MUFFLER...3428
Cleaning Procedure...3428
TIRE MAINTENANCE...3429
Wheel Nuts...3429
Tire Rotation...3429
Tire Mounting...3429
FINAL DRIVE TRANSMISSION (CHAINCASE)...3430
Checking And Adding Oil...3430
FAN GEARBOX...3430
Checking And Maintaining...3430
LUBRICATING THE LOADER...3431
Procedure...3431
REMOTE START SWITCH...3433
Procedure...3433
HYDRAULIC SYSTEM...3435
HYDRAULIC/HYDROSTATIC SCHEMATICS...3437
TROUBLESHOOTING...3463
HYDRAULIC SYSTEM INFORMATION...3464
Tighten Procedures...3464
LIFT CYLINDER(S)...3465
Checking The Lift Cylinder...3465
Removal And Installation...3465
TILT CYLINDER...3467
Checking The Tilt Cylinder...3467
Rod End Seal...3468
HYDRAULIC CYLINDER...3469
Lift Cylinder Identification...3469
Tilt Cylinder Identification...3470
Disassembly...3471
Assembly...3473
MAIN RELIEF VALVE...3476
Checking The Main Relief Valve...3476
Checking The Main Relief Valve Without Auxiliaries...3477
Removal And Installation...3478
DUAL PRESSURE MAIN RELIEF VALVE (S/N 512811001 & Above) W/ Select Valve (JEM)...3479
Checking The Low Setting...3479
Checking The High Setting...3480
Adjusting The Low Setting...3482
Adjusting The High Setting...3483
HYDRAULIC CONTROL VALVE...3484
Removal And Installation...3484
SELECT VALVE (S/N 512811001 & Above) W/SelectValve (JEM)...3486
Checking The Relief Valve...3486
Removal And Installation...3488
Disassembly And Assembly...3489
Solenoid Testing...3490
HYDRAULIC FILTER HOUSING...3491
Removal And Installation...3491
HYDRAULIC PUMP...3492
Checking The Output Of The Pump...3492
Removal And Installation...3493
HYDRAULIC FLUID RESERVOIR...3494
Removal And Installation...3494
LOCK VALVE (S/N 5103)...3495
Removal And Installation...3495
BUCKET POSITION VALVE (S/N 5102) & (S/N 5103)...3496
Removal And Installation...3496
FRONT AUXILIARY CONTROL VALVE (Apitech)...3497
Removal And Installation...3497
CONTROL PEDALS...3498
Removal And Installation...3498
Pedal Adjustment...3498
PEDAL INTERLOCK LINKAGE...3499
Removal And Installation...3499
Pedal Interlock Linkage Adjustment...3500
HYDROSTATIC SYSTEM...3501
TROUBLESHOOTING...3503
HYDROSTATIC SYSTEM INFORMATION...3504
Replenishing Valve Function...3504
Tow Valves...3504
FRONT PANEL...3505
Removal And Installation...3505
STEERING LEVERS...3507
Disassembly And Assembly...3507
Neutral Pre–Adjustment Checks...3509
Adjusting Lever Freeplay...3510
Adjusting The Wheel RPM Forward Compared To Reverse Travel...3511
Adjusting The Steering Neutral Setting...3513
Adjusting The Wheel RPM Left Compared To Right Side...3514
Hydrostatic Pump Neutral Adjustment...3515
HYDROSTATIC MOTOR...3517
Removal And Installation...3517
HYDROSTATIC CHARGE OIL FILTER...3519
Removal And Installation...3519
COLD OIL BY–PASS VALVE...3521
Removal And Installation...3521
HYDROSTATIC PUMP...3523
Removal And Installation...3523
Replenishing/High Pressure Relief Valve...3525
DRIVE BELT SHIELD...3526
Removal And Installation...3526
DRIVE BELT ...3527
Replacing The Drive Belt...3527
SPRING LOADED TENSIONER PULLEY...3528
Parts Identification...3528
Disassembly...3529
Assembly...3530
Adjusting The Drive Belt...3532
FIXED TENSIONER PULLEY...3533
Removal And Installation...3533
Disassembly...3534
Assembly...3536
Checking Pulley End Play...3540
Adjusting The Drive Belt...3541
OIL COOLER...3542
Removal And Installation...3542
DRIVE SYSTEM...3543
PARKING BRAKE PEDAL...3545
Adjustment...3545
PARKING BRAKE...3546
Removal And Installation...3546
Brake Block And Pads...3548
Brake Discs...3549
FRONT CHAINCASE COVER...3550
Removal And Installation...3550
REAR CHAINCASE COVER...3550
Removal And Installation...3550
AXLE SEAL...3551
Removal And Installation...3551
AXLE, SPROCKET AND BEARINGS...3553
Removal And Installation...3553
REDUCTION GEARCASE...3557
Reduction Gearcase Seal...3557
Removal And Installation...3558
Checking Reduction Gearcase...3559
Disassembly...3559
Assembly...3564
DRIVE CHAIN...3568
Removal And Installation...3568
CHAINCASE FLUID...3569
Removing The Fluid From The Chaincase...3569
MAIN FRAME...3571
OPERATOR CAB GAS CYLINDER...3573
Removal And Installation...3573
Disassembly And Assembly...3574
OPERATOR CAB...3575
Removal And Installation...3575
BOB–TACH...3577
Removal And Installation...3577
Bob–Tach Lever And Wedge...3579
Bob–Tach Stops...3580
LIFT ARMS...3581
Removal And Installation...3581
REAR GRILL...3582
Removal And Installation...3582
REAR DOOR...3583
Removal And Installation...3583
Hood Removal And Installation...3584
Bumper Removal And Installation...3584
Door Latch Removal And Installation...3584
Door Latch And Catch Adjustment...3584
FUEL TANK...3585
Removal And Installation...3585
Inlet Screen...3586
ELECTRICAL SYSTEM...3587
ELECTRICAL SCHEMATICS...3589
TROUBLESHOOTING...3621
ELECTRICAL SYSTEM INFORMATION...3622
Description...3622
Fuse Location...3622
BATTERY...3623
Removal And Installation...3623
Servicing The Electrical System...3624
Using A Booster Battery (Jump Starting)...3625
ALTERNATOR...3626
Alternator Output Test...3626
Rectifier (Diode) Test...3626
Alternator Regulator Test...3627
Removal And Installation...3628
Disassembly ...3629
Stator Continuity Test...3629
Stator Ground Test...3629
Rotor Continuity Test...3630
Rotor Ground Test...3630
Rectifier Continuity (Diode) Test...3630
Assembly...3631
STARTER...3632
Checking The Starter...3632
Removal And Installation...3633
Parts Identification...3634
Disassembly And Assembly...3635
Cleaning And Inspection...3637
STANDARD INSTRUMENT PANEL...3638
Removal And Installation...3638
FRONT LIGHTS...3639
Removal And Installation...3639
STEERING LEVER CONTROL HANDLE (Early Series)...3640
Disassembly And Assembly...3640
ENGINE SERVICE...3641
TROUBLESHOOTING...3645
ENGINE SPEED CONTROL...3646
Removal And Installation...3646
ENGINE MUFFLER...3647
Removal And Installation...3647
AIR CLEANER HOUSING...3648
Removal And Installation...3648
COOLANT RECOVERY TANK...3649
Removal And Installation...3649
RADIATOR...3650
Removal And Installation...3650
FAN DRIVE TENSION PULLEY...3652
Removal And Installation...3652
FAN GEARBOX/BLOWER HOUSING...3653
Removal And Installation...3653
FAN GEARBOX...3657
Parts Identification...3657
Disassembly...3658
Assembly...3662
Checking Backlash...3667
ENGINE...3670
Removal And Installation...3670
FLYWHEEL...3677
Removal And Installation...3677
Flywheel Ring Gear...3677
BELT SHIELD...3678
Removal And Installation...3678
ENGINE MOUNTS...3679
Removal And Installation...3679
GLOW PLUGS...3680
Checking The Glow Plugs...3680
Removal And Installation...3680
VALVE CLEARANCE...3681
Adjustment...3681
ENGINE COMPRESSION...3681
Checking...3681
FUEL INJECTION PUMP...3682
Description...3682
Removal And Installation...3682
Timing The Injection Pump...3686
FUEL INJECTOR NOZZLES...3688
Checking...3689
Removal And Installation...3688
CYLINDER HEAD...3691
Removal And Installation...3691
Cylinder Head Surface Alignment...3692
Exhaust Manifold...3692
VALVES, VALVE SEAT AND GUIDE...3693
Removal...3693
Installation...3693
Reconditioning The Valve And Valve Seats...3693
Valve Seat Insert...3694
Valve Guide...3694
Valve Spring...3695
ROCKER ARM AND SHAFT...3696
Disassembly And Assembly...3696
Checking Rocker Arm And Push Rods...3696
PISTON AND CONNECTING ROD...3697
Removal...3697
Disassembly...3697
Checking...3698
Assembly...3701
Installation...3702
CYLINDER LINERS...3703
Checking The Cylinder Bore...3703
Removal...3703
Installation...3703
MAIN BEARINGS...3704
Description...3704
Removal...3704
Installation...3705
Crankshaft End Play...3706
CRANKSHAFT...3707
Removal And Installation...3707
Checking The Crankshaft...3707
CRANKSHAFT GEAR...3709
Removal And Installation...3709
TIMING GEARCASE COVER SEAL...3710
Removal And Installation...3710
TIMING GEARCASE COVER...3711
Removal And Installation...3711
IDLER GEAR AND HUB...3713
Checking...3713
Installation...3714
FUEL INJECTION PUMP IDLER GEAR...3715
Removal And Installation...3715
Bearing Installation...3715
CAMSHAFT GEAR...3716
Removal And Installation...3716
TIMING GEARCASE...3717
Removal And Installation...3717
CAMSHAFT...3718
Removal And Installation...3718
Checking...3718
Camshaft Bearings...3719
Tappets...3719
Tappet Installation...3720
OIL PAN...3721
Removal...3721
Installation...3721
OIL PUMP...3722
Removal And Installation...3722
Checking...3722
Gear Replacement...3723
Rotor Replacement...3724
Oil Pump Relief Valve...3724
Oil Filter Housing And Block...3724
WATER PUMP...3725
Removal And Installation...3725
Disassembly...3725
Assembly...3726
THERMOSTAT...3728
Removal And Installation...3728
Checking The Thermostat...3728
WATER JACKET TUBE...3729
Removal And Installation...3729
SYSTEM ANALYSIS...3731
BOSS® DIAGNOSTIC TOOL...3733
Procedure...3733
SENDER AND SENSOR...3733
Service Checks...3733
Component...3733
RPM SENSOR...3734
Adjustment...3734
SERVICE CODES ...3735
Chart...3735
TROUBLESHOOTING THE BOSS® & LCD DISPLAY...3737
BOSS® UNIT...3738
Removal And Installation...3738
BOSS® INSTRUMENT PANEL...3739
Removal And Installation...3739
SPECIFICATIONS...3741
LOADER SPECIFICATIONS...3743
Loader Dimensions...3743
Performance...3743
Controls...3743
Engine...3743
Hydraulic System...3744
Electrical...3744
Drive System...3744
Capacities...3744
Tires...3744
ENGINE SPECIFICATIONS...3745
Cylinder Head...3745
Valve, Valve Guide & Seat Insert...3745
Valve Springs...3745
Rocker Arm...3745
Tappets...3745
Piston, Pin & Rings...3746
Connecting Rod & Bearing...3746
Cylinder Liners...3746
Camshaft...3746
Crankshaft...3747
Idler Gear...3747
Oil Pump...3747
Fuel System...3747
TORQUE SPECIFICATIONS FOR LOADER...3748
TORQUE SPECIFICATIONS FOR BOLTS...3750
Torque For General SAE Bolts...3750
Torque For General Metric Bolts...3751
HYDRAULIC CONNECTION SPECIFICATIONS...3752
O–ring Face Seal Connection...3752
Straight Thread O–ring Fitting...3752
Tubelines And Hoses...3752
Flare Fitting...3752
O–ring Flare Fitting...3753
Port Seal Fitting...3755
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...3756
DECIMAL AND MILLIMETER EQUIVALENTS...3757
U.S. TO METRIC CONVERSION...3757
SERVICE MANUAL REVISIONS...3759
850–001...3759
850–002...3761
850–003...3763
850–004...3765
850–005...3767
850–006...3769
850–007...3771
850–008...3773
850–009...3775
850–010...3777
850–011...3779
850–012...3781
850–13...3783
850-14...3785
850-15...3787
6724012 (6-12) - 853; 853H Service Manual...3789
MAINTENANCE SAFETY...3791
CONTENTS...3793
FOREWORD...3794
SAFETY INSTRUCTIONS...3797
SERIAL NUMBER LOCATIONS...3799
LOADER SERIAL NUMBER...3799
ENGINE SERIAL NUMBER...3799
DELIVERY REPORT...3799
BOBCAT LOADER IDENTIFICATION...3800
OPTIONS AND ACCESSORIES...3801
PREVENTIVE MAINTENANCE...3803
SERVICE SCHEDULE...3805
LIFTING AND BLOCKING THE LOADER...3806
Procedure...3806
TRANSPORTING THE LOADER...3807
Procedure...3807
TOWING THE LOADER...3807
Procedure...3807
STOPPING THE BOBCAT LOADER...3807
LIFTING THE LOADER...3808
Four Point Lift...3808
Single Point Lift...3808
LIFT ARM SUPPORT DEVICE...3809
Engaging The Lift Arm Support Device...3809
Disengaging The Lift Arm Support Device...3809
OPERATOR CAB...3810
Description...3810
Raising The Operator Cab...3810
Lowering The Operator Cab...3811
Emergency Exit...3811
SEAT BAR RESTRAINT SYSTEM...3812
Description...3812
Seat Bar Inspection...3812
Seat Bar Maintenance...3812
AIR CLEANER SERVICE...3813
Replacing Filter Element...3813
FUEL SYSTEM...3815
Fuel Specifications...3815
Filling The Fuel Tank...3815
Fuel Filter...3815
Removing Air From The Fuel System...3816
ENGINE LUBRICATION SYSTEM...3817
Checking Engine Oil...3817
Replacing Oil And Filter...3817
ENGINE COOLING SYSTEM...3819
Cleaning The Cooling System...3819
Checking The Coolant Level...3819
Removing Coolant From The Cooling System...3820
Propylene Glycol...3820
ALTERNATOR BELT...3820
Adjusting The Alternator Belt...3820
USING A BOOSTER BATTERY (Jump Starting)...3821
Procedure...3821
HYDRAULIC/HYDROSTATIC SYSTEM...3822
Checking And Adding Fluid...3822
Replacing Hydraulic/Hydrostatic Filters...3822
Replacing Hydraulic Fluid...3823
Hydraulic Reservoir Breather Cap...3824
SPARK ARRESTOR MUFFLER...3825
Cleaning Procedure...3825
TIRE MAINTENANCE...3826
Wheel Nuts...3826
Tire Rotation...3826
Tire Mounting...3826
FINAL DRIVE TRANSMISSION (CHAINCASE)...3827
Checking And Adding Oil...3827
Removing Oil From The Chaincase...3827
FAN GEARBOX...3827
Checking And Maintaining...3827
LUBRICATING THE LOADER...3828
Procedure...3828
REMOTE START SWITCH...3830
Procedure...3830
HYDRAULIC SYSTEM...3833
HYDRAULIC / HYDROSTATIC SCHEMATICS...3835
TROUBLESHOOTING...3843
HYDRAULIC SYSTEM INFORMATION...3844
Flare Connections...3844
O–ring Face Seal Connection...3844
Straight Thread O–ring Fitting...3844
Tubelines And Hoses...3844
LIFT CYLINDER(S)...3845
Checking The Lift Cylinder...3845
Removal And Installation...3845
TILT CYLINDER...3847
Checking The Tilt Cylinder...3847
Removal And Installation...3847
Rod End Seal...3848
HYDRAULIC CYLINDER...3849
Lift Cylinder Identification...3849
Tilt Cylinder Identification...3850
Disassembly...3851
Assembly...3853
MAIN RELIEF VALVE...3859
Checking The Main Relief Valve...3859
Checking The Main Relief Valve Without Auxiliaries...3860
Removal And Installation...3861
DUAL PRESSURE MAIN RELIEF VALVE – 853H...3862
Checking The Low Setting...3862
Checking The High Setting...3863
Adjusting The Low Setting...3865
Adjusting The High Setting...3866
SELECT VALVE (G.E.M. Block) 853H...3867
Checking The Main Relief Valve...3867
HYDRAULIC CONTROL VALVE...3868
Removal And Installation...3868
Identification Chart...3870
Disassembly And Assembly...3871
Main Relief Valve...3872
Port Relief Valve...3872
Anti–Cavitation Valve...3873
Rubber Boot...3874
Lift Spool And Detent...3875
Tilt Spool And Centering Spring...3880
Auxiliary Spool...3881
Auxiliary Electric Solenoid...3882
H Port – Auxiliary Section...3883
Base End Restrictor...3883
Inspection...3883
Spool Seal Installation...3884
HYDRAULIC PUMP...3885
Checking The Output Of The Pump...3885
Removal And Installation...3886
Parts Identification...3887
Disassembly...3888
Inspection...3890
Assembly...3891
HYDRAULIC PUMP (Double Gear) 853H...3893
Checking The Output Of The Pump...3893
Removal And Installation...3894
Parts Identification...3895
Disassembly...3896
Inspection...3900
Assembly...3901
BUCKET POSITION VALVE (Optional)...3904
Removal And Installation...3904
HYDRAULIC FLUID RESERVOIR...3905
Removal And Installation...3905
HYDROSTATIC FILTER HOUSING...3906
Removal And Installation...3906
HYDRAULIC FILTER HOUSING...3907
Removal And Installation...3907
CONTROL PEDALS...3908
Removal And Installation...3908
Pedal Adjustment...3908
PEDAL INTERLOCK LINKAGE...3909
Removal And Installation...3909
Pedal Interlock Linkage Adjustment...3910
HYDROSTATIC SYSTEM...3911
TROUBLESHOOTING...3913
HYDROSTATIC SYSTEM INFORMATION...3914
Replenishing Valve Function...3914
FRONT PANEL...3915
Removal And Installation...3915
STEERING LEVERS...3917
Disassembly And Assembly...3917
Pre–Adjustment Checks...3919
Adjusting Lever Freeplay...3920
Adjusting The Wheel RPM Forward Compared To Reverse Travel...3921
Adjusting The Steering Neutral Setting...3923
Adjusting The Wheel RPM Left Compared To Right Side...3924
HYDROSTATIC MOTOR...3925
Removal And Installation...3925
Parts Identification...3926
Disassembly...3927
Inspection...3932
Assembly...3933
Timing The Hydrostatic Motor...3936
HYDROSTATIC PUMP...3937
Removal And Installation...3937
Replenishing/High Pressure Relief Valve...3939
Parts Identification...3940
Hydraulic Pump Removal...3945
Hydrostatic Pump Separation...3945
Charge Pump Disassembly...3946
Disassembly...3947
Inspection...3956
Assembly...3958
Charge Pump Assembly...3967
Hydrostatic Pump Connection...3968
Hydraulic Pump Installation...3969
Hydrostatic Pump Neutral Adjustment...3970
DRIVE BELT SHIELD...3972
Removal And Installation...3972
DRIVE BELT...3973
Adjusting The Drive Belt...3973
Replacing The Drive Belt...3974
DRIVE BELT TENSIONER PULLEY...3975
Removal And Installation...3975
Disassembly...3976
Assembly...3978
Checking Pulley End Play...3982
OIL COOLER...3983
Removal And Installation...3983
DRIVE SYSTEM...3985
PARKING BRAKE PEDAL...3987
Removal And Installation...3987
Disassembly And Assembly...3988
PARKING BRAKE DISC...3989
Removal And Installation...3989
FRONT CHAINCASE COVER...3991
Removal And Installation...3991
REAR CHAINCASE COVER...3991
Removal And Installation...3991
AXLE SEAL...3992
Removal And Installation...3992
AXLE, SPROCKET AND BEARINGS...3994
Removal And Installation...3994
REDUCTION GEARCASE...3998
Reduction Gearcase Seal...3998
Removal And Installation...3999
Checking Reduction Gearcase...4000
Disassembly...4000
Assembly...4005
DRIVE CHAIN...4009
Removal And Installation...4009
CHAINCASE FLUID...4010
Removing The Fluid From The Chaincase...4010
MAIN FRAME...4011
SEAT BAR...4013
Removal And Installation...4013
Assembly...4015
Compressing The Gas Cylinder...4016
OPERATOR CAB GAS CYLINDER...4017
Removal And Installation...4017
Disassembly And Assembly...4018
OPERATOR CAB...4019
Removal And Installation...4019
OPERATOR SEAT...4021
Removal And Installation...4021
BOB–TACH...4022
Removal And Installation...4022
Bob–Tach Lever And Wedge...4024
Bob–Tach Stops...4025
LIFT ARMS...4026
Removal And Installation...4026
REAR GRILL...4027
Removal And Installation...4027
REAR DOOR...4028
Removal And Installation...4028
Hood Removal And Installation...4029
Bumper Removal And Installation...4029
Door Latch Removal And Installation...4029
Door Latch And Catch Adjustment...4029
FUEL TANK...4030
Removal And Installation...4030
Inlet Screen...4031
ELECTRICAL SYSTEM...4033
ELECTRICAL SCHEMATICS...4035
TROUBLESHOOTING...4087
ELECTRICAL SYSTEM INFORMATION...4088
Description...4088
Fuse Location (Standard & BOSS® Option)...4088
BATTERY...4089
Removal And Installation...4089
ALTERNATOR...4090
Alternator Output Test...4090
Rectifier (Diode) Test...4090
Alternator Regulator Test...4091
Removal And Installation...4092
Disassembly And Inspection...4093
Stator Continuity Test...4093
Stator Ground Test...4093
Rotor Continuity Test...4094
Rotor Ground Test...4094
Rectifier Continuity (Diode) Test...4094
Assembly...4095
STARTER...4096
Removal And Installation...4096
Checking The Starter...4097
Parts Identification...4098
Disassembly And Assembly...4099
Cleaning And Inspection...4101
STANDARD INSTRUMENT PANEL...4102
Removal And Installation...4102
FRONT LIGHTS...4103
Removal And Installation...4103
RELAY SWITCHES...4104
Location...4104
ENGINE SERVICE...4105
TROUBLESHOOTING...4107
ENGINE SPEED CONTROL...4108
Removal And Installation...4108
Disassembly...4108
RADIATOR...4109
Removal And Installation...4109
COOLANT RECOVERY TANK...4111
Removal And Installation...4111
ENGINE MUFFLER...4112
Removal And Installation...4112
AIR CLEANER HOUSING...4113
Removal And Installation...4113
BLOWER HOUSING/FAN GEARBOX...4114
Removal And Installation...4114
FAN DRIVE TENSION PULLEY...4116
Removal And Installation...4116
BLOWER FAN...4117
Removal And Installation...4117
FAN GEARBOX...4118
Parts Identification...4118
Disassembly...4119
Assembly...4124
Checking Backlash...4129
ENGINE...4132
Removal And Installation...4132
Engine Mount Replacement...4139
FLYWHEEL...4140
Removal And Installation...4140
Flywheel Ring Gear...4140
BELT SHIELD...4141
Removal And Installation...4141
VALVE CLEARANCE...4142
Adjustment...4142
ENGINE COMPRESSION...4142
Checking...4142
GLOW PLUGS...4143
Removal And Installation...4143
Checking The Glow Plugs...4143
FUEL INJECTION PUMP...4144
Description...4144
Removal And Installation...4144
Timing The Injection Pump...4148
FUEL INJECTOR NOZZLES...4150
Removal And Installation...4150
Checking...4151
CYLINDER HEAD...4153
Removal And Installation...4153
Cylinder Head Surface Alignment...4154
Exhaust Manifold...4154
VALVES, VALVE SEAT AND GUIDE...4155
Removal...4155
Installation...4155
Reconditioning The Valve And Valve Seats...4155
Valve Seat Insert...4156
Valve Guide...4156
Valve Spring...4157
ROCKER ARM AND SHAFT...4158
Disassembly And Assembly...4158
Checking Rocker Arm And Push Rods...4158
PISTON AND CONNECTING ROD...4159
Removal...4159
Disassembly...4159
Checking...4160
Assembly...4163
Installation...4164
CYLINDER LINERS...4165
Checking The Cylinder Bore...4165
Removal...4165
Installation...4165
MAIN BEARINGS...4166
Description...4166
Removal...4166
Installation...4167
Crankshaft End Play...4168
CRANKSHAFT...4169
Removal And Installation...4169
Checking Tuffriding (Soft Nitriding) Coating...4169
Checking the Crankshaft...4169
CRANKSHAFT GEAR...4171
Removal And Installation...4171
TIMING GEARCASE COVER SEAL...4172
Removal And Installation...4172
TIMING GEARCASE COVER...4173
Removal And Installation...4173
IDLER GEAR AND HUB...4175
Removal...4175
Checking...4175
Installation...4176
FUEL INJECTION PUMP IDLER GEAR...4177
Removal And Installation...4177
Bearing Installation...4177
CAMSHAFT GEAR...4178
Removal And Installation...4178
TIMING GEARCASE...4179
Removal And Installation...4179
CAMSHAFT...4180
Removal And Installation...4180
Checking...4180
Camshaft Bearings...4181
Tappets...4181
Tappet Installation...4182
OIL PAN...4183
Removal...4183
Installation...4183
OIL PUMP...4184
Removal And Installation...4184
Checking...4184
Gear Replacement...4185
Rotor Replacement...4186
Oil Pump Relief Valve...4186
Oil Filter Housing And Block...4186
WATER PUMP...4187
Removal And Installation...4187
Disassembly...4187
Assembly...4188
THERMOSTAT...4190
Removal And Installation...4190
Checking The Thermostat...4190
WATER JACKET TUBE...4191
Removal And Installation...4191
SYSTEMS ANALYSIS...4193
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...4195
Inspecting The BICS System Controller (Engine STOPPED – Key ON)...4195
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)...4195
Inspecting The Traction Lock (Engine RUNNING)...4195
Inspecting The Lift Arm By–Pass Control...4195
Maintenance...4195
Troubleshooting Chart...4196
Troubleshooting Guide...4197
BICS SYSTEM CONTROLLER...4197
TRACTION LOCK...4198
SEAT SENSOR...4199
SEAT BAR SENSOR...4200
LIFT LOCK BY–PASS VALVE...4201
BICS™ SYSTEM CONTROLLER...4202
Removal And Installation...4202
Controller Test...4203
SEAT BAR SENSOR...4204
Removal And Installation...4204
Seat Bar Sensor Test...4205
SEAT SENSOR...4206
Removal And Installation...4206
Seat Sensor Test...4207
TRACTION LOCK...4208
Removal And Installation...4208
LIFT LOCK BY–PASS VALVE...4209
Removal And Installation...4209
Disassembly And Assembly...4210
TILT LOCK VALVE...4211
Removal And Installation...4211
Disassembly And Assembly...4212
BOSS® DIAGNOSTIC TOOL...4213
Procedure...4213
SENDER AND SENSOR...4213
Service Checks...4213
Component...4213
RPM SENSOR...4213
Adjustment...4213
MONITOR SERVICE CODES...4214
TROUBLESHOOTING THE BOSS® & LCD DISPLAY...4217
OPERATION SENSING SYSTEM UNIT...4218
Removal And Installation...4218
BOSS® INSTRUMENT PANEL...4219
Removal And Installation...4219
PWM MODULE...4220
Description...4220
PWM TROUBLESHOOTING...4221
Conditions...4221
Chart...4222
PWM CONTROL HANDLE...4223
Handle Testing...4223
PWM ELECTRIC SOLENOID...4223
Solenoid Coil Testing...4223
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE...4224
Controls Identification Chart...4224
SPECIFICATIONS...4225
LOADER SPECIFICATIONS...4227
LOADER DIMENSIONS...4227
OPERATION & PERFORMANCE...4227
ENGINE...4227
HYDRAULIC SYSTEM...4228
ELECTRICAL...4228
DRIVE SYSTEM...4228
CAPACITIES...4228
TIRES...4228
VIBRATION DATA...4228
ENGINE SPECIFICATIONS...4229
Cylinder Head...4229
Valve, Valve Guide & Seat Insert...4229
Valve Springs...4229
Rocker Arm...4229
Tappets...4229
Piston, Pin & Rings...4230
Connecting Rod & Bearing...4230
Cylinder Liners...4230
Camshaft...4230
Crankshaft...4231
Idler Gear...4231
Oil Pump...4231
Fuel System...4231
Torque For General Metric Bolts...4232
TORQUE SPECIFICATIONS FOR LOADER...4233
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...4235
STANDARD TORQUE SPECIFICATIONS FOR BOLTS...4236
DECIMAL AND MILLIMETER EQUIVALENTS...4237
U.S. TO METRIC CONVERSION...4237
SERVICE MANUAL REVISIONS...4239
850–001...4239
850–002...4241
850–003...4243
850–004...4245
850–005...4247
850-006...4249
