Complete repair service manual with electrical wiring diagrams for Bobcat Loaders 825, 843, 843B, 853, 853H, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Bobcat Loaders 825, 843, 843B, 853, 853H workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6549634 (11-98) - 825 Operation & Maintenance Manual.pdf
6549635 (11-98) - 825 Operation & Maintenance Manual.pdf
6549899 (6-12) - 825 Service Manual.pdf
6549899 (12-83) - 825 Service Manual.pdf
6556864 (12-82) - 843 Operator's Manual.pdf
6566091 (6-12) - 843, 843B Service Manual.pdf
6566091 (12-85) - 843, 843B Service Manual.pdf
6566408 (11-82) - 843 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
6720755 (6-12) - 853, 853H Service Manual.pdf
6720755 (6-99) - 853, 853H Service Manual.pdf
6722406 (6-97) - 853, 853H Operation & Maintenance Manual.pdf
6722906 (2-94) - 853 Operation & Maintenance Manual.pdf
6722906 (6-00) - 853, 853H Operation & Maintenance Manual.pdf
6724012 (4-95) - 853, 853H Service Manual.pdf
6724012 (6-12) - 853, 853H Service Manual.pdf
6724034 (6-00) - 853, 853H Operation & Maintenance Manual.pdf

Total Pages: 4,132 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

...
CONTENTS OF TABLES
FOREWORD . . ii
SAFETY INSTRUCTIONS . . v
SERIAL NUMBER LOCATIONS . . vii
DELIVERY REPORT . . vii
BOBCAT LOADER IDENTIFICATION . . viii
PREVENTIVE MAINTENANCE . . 1–1
HYDRAULIC SYSTEM . . 2–1
HYDROSTATIC SYSTEM . . 3–1
DRIVE SYSTEM . . 4–1
MAIN FRAME . . 5–1
ELECTRICAL SYSTEM . . 6–1
ENGINE SERVICE . . 7–1
SYSTEM ANALYSIS . . 8–1
SPECIFICATIONS . . 9–1

6549634 (11-98) - 825 Operation & Maintenance Manual............1
  OPERATOR SAFETY WARNINGS............3
  FOREWORD............5
    CONTENTS............5
    825 BOBCAT LOADER PICTORIAL NOMENCLATURE............6
    DECAL LOCATIONS & SAFETY SIGNS............7
  OPERATING INSTRUCTIONS............8
    OPERATING INSTRUCTIONS............9
    SAFETY............9
    MOUNTING AND DISMOUNTING............9
    DASH PANEL............10
    LIFT, TILT AND AUXILIARY CONTROLS............10
    DRIVE CONTROLS............11
      Steering Controls............11
      Range Control............11
      Throttle Control............11
    PRE-STARTING INSPECTION............12
    STARTING PROCEDURE............12
    NORMAL STARTING CONDITIONS............12
    COLD WEATHE STARTING CONDITIONS............12
    STOPPING THE ENGINE............13
    BOB-TACH OPERATION............13
      Installing Attachment............13
      To Remove Attachment............14
    FILLING BUCKET FROM A PILE............14
    OPERATION HINTS............14
    DIGGING WITH A BUCKET............15
    LEVELING AND BACKFILLING............15
    DUMPING THE BUCKET............15
    TOWING............16
    TRANSPORTING BY TRAILER............16
  SERVICE INSTRUCTIONS............17
    SERVICE & MAINTENANCE............18
    MAINTENANCE SAFETY............19
    SERVICING INSTRUCTIONS............21
    SERVICE SCHEDULE............21
    REAR GRILL............22
    TILTING THE ROPS............22
    ENGINE MAINTENANCE............22
      Engine Oil............22
      Specifications............22
    CHANGING OIL AND FILTER............23
    ENGINE AIR INLET SYSTEM (AIR CLEANER)............24
    ENGINE COOLING SYSTEM............25
    FAN BELT ADJUSTMENT............25
    FLUSHING THE COOLING SYSTEM............26
    FUEL SYSTEM............26
      Safety Precautions............26
    FUEL SPECIFICATIONS............26
      Condensation In The Fuel Tank............26
    TO SERVICE THE FUEL SYSTEM............27
    VENTING THE FUEL SYSTEM............27
    ELECTRICAL SYSTEM MAINTENANCE............28
      Electrical System............28
    HYDRAULIC SYSTEM............29
      Hydraulic / Hydrostatic Transmission Fluid............29
    CHECKING AND ADDING HYDRAULIC FLUID............29
    HYDRAULIC FLUID FILTERS............29
      To Replace The Suction (25 Micron) Filter ............30
      To Replace The Hydrostatic Transmission Filter............30
    DRAINING THE FLUID RESERVOIR............30
    LEAKS............31
    QUICK COUPLERS............31
    HYDRAULIC CYLINDER MAINTENANCE............31
    OIL COOLER............31
    CARE OF THE HYDROSTSATIC TRANSMISSION............32
      Loader Start-Up............32
      Cold Weather Start-Up............32
    FINAL DRIVE CHAIN............32
    TIRES............33
    TIRE MAINTENANCE............33
    TIRE ROTATION............33
    TIRE REPLACEMENT............33
    LUBRICATION............33
    WHEEL TORQUING............34
    BOB-TACH............34
    TECHNICAL DATA............34
    CAPACITIES............34
    ADJUSTMENTS............34
    LOADER SPECIFICATIONS............34
  TROUBLESHOOTING............35
    TROUBLESHOOTING THE ENGINE............37
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM............39
    TROUBLESHOOTING THE HYDRAULIC SYSTEM............40
  MAJOR PARTS............41
    MAIN FRAME PARTS............43
    HYDRAULIC SYSTEM............44
    ENGINE PARTS............45
    ELECTRICAL SYSTEM............46
    HYDROSTATIC SYSTEM............47
    DRIVE SYSTEM............48
  LOADER SPECIFICATIONS............49
    OPERATIONAL SPECIFICATIONS............49
    ENGINE............49
    HYDRULIC SYSTEM............49
    ELECTRICAL............49
    CAPACITIES............49
    HYDRAULIC SYSTEM............49
    HYDROSTATIC DRIVE SYSTEM............49
    ELECTRICAL SYSTEM............49
  WARRANTY............51
6549635 (11-98) - 825 Operation & Maintenance Manual............53
  OPERATOR SAFETY WARNINGS............55
  FOREWORD............57
    CONTENTS............57
    REFERENCE INFORMATION............57
    825 BOBCAT LOADER IDENTIFICATION............58
    SAFETY INSTRUCTIONS............59
      SAFETY IS YOUR RESPONSIBILITY............59
      BEFORE OPERATING THE BOBCAT LOADER............59
  OPERATING INSTRUCTIONS............61
    OPERATING INSTRUCTIONS............63
    SAFTY SIGNS (DECAL) LOCATION............65
    CONTROLS............66
    DASH PANEL............66
    THROTTLE CONTROL............67
    STOPPING THE ENGINE............67
    PARKING BRAKE............67
    SPEED-RANGE CONTROL............67
    STEERING CONTROLS............68
    HYDRAULIC CONTROLS............69
      Foot Pedal (Hydraulic)............69
      Lift Arm Operation............69
      Tilt Operation............69
      Auxiliary Pedal............70
    BEFORE YOU START THE ENGINE............70
    STARTING THE ENGINE............71
      Normal Starting Condition............72
      Making Cold Temperature Starting Easier............72
      Cold Weather Starting Procedure............73
    BOBCAT LOADER OPERATION............73
      Bucket Size............74
      Installation Of Attachment............74
      Removal Of The Attachment............74
    OPERATION OF THE BOBCAT LOADER............75
    OPERATING PROCEDURE............75
      Filling The Bucket............76
      To Empty The Bucket............76
      Digging Into The Ground............77
      Making The Ground Level............77
      Filling A Hole............77
    TO PULL THE LOADER............78
    STOPPING THE BOBCAT LOADER............78
    TRANSPORTING THE BOBCAT LOADER............78
    LIFT ARM STOP............79
    LIFTING THE OPERATOR GUARD............80
  PREVENTIVE MAINTENANCE............81
    MAINTENANCE SAFETY............82
    SERVICE SCHEDULE............83
    ENGINE SERVICE............84
    AIR CLEANER SERVICE............84
    FUEL SYSTEM............85
    FUEL SYSTEM SERVICE............85
    FUEL FILTERS............85
    REMOVING THE AIR FROM THE FUEL SYSTEM............86
    ENGINE LUBRICTION SYSTEM............87
    REPLACEMENT OF THE ENGINE OIL AND FILTER............87
    ENGINE COOLING SYSTEM............88
      Coolant level............88
      Removing Coolant From The Cooling System............88
    ALTERNATOR BELT............88
    ELECTRICAL SYSTEM............89
    USING AN EXTRA BATTERY (JUMP STARTING)............91
    TO INSTALL NEW BATTERIES............92
    HYDRAULIC/HYDROSTATIC SYSTEM............93
    HYDRAULIC/HYDROSTATIC FLUID RESERVOIR............93
      Checking And Adding Hydraulic Fluid............95
      Removing Hydraulic Fluid............95
    REPLACEMENT OF THE HYDRAULIC FILTERS............96
    OIL COOLER............96
    FINAL DRIVE CHAIN............97
    TIRE MAINTENANCE............97
      Tire Rotation............97
    LUBRICATION OF THE BOBCAT LOADER............98
    BOB-TACH............98
    SPARK ARRESTOR MUFFLER............99
    SERIAL NUMBER............99
    DELIVERY REPORT............99
  TROUBLESHOOTING............101
    TROUBLESHOOTING THE ENGINE............103
    TROUBLESHOOTING THE DRIVE SYSTEM............104
    TROUBLESHOOTING THE HYDRAULIC SYSTEM............104
  MAJOR PARTS............105
    MAIN FRAME............107
    FUEL SYSTEM............108
    DRIVE TRAIN............109
    BRAKES............110
    HYDRAULIC CIRCUITRY............111
    HYDROSTATIC CIRCUITRY............113
    STEERING LEVERS............114
    ELECTRICAL SYSTEM............115
    POWER UNIT............116
    DECALS............117
  DECALS............119
    WARNING - 6563484............121
    WARNING - 6561380............122
    IMPORTANT - 6560573............123
  GENERAL INFORMATION............125
    LOADER SPECIFICATIONS............127
    OPERATION & PERFORMANCE............127
    ENGINE............127
    LOADER HYDRAULICS............128
    ELECTRICAL............128
    DRIVE SYSTEM............128
    CAPACITIES............128
    TIRES............128
    ADDITIONAL PUBLICATIONS............129
  WARRANTY............131
6549899 (12-83) - 825 Service Manual............133
  MAINTENANCE SAFETY............135
  CONTENTS............137
    FOREWORD............137
  PREVENTIVE MAINTENANCE............139
    INTRODUCTION............141
      Symbols............141
      Serial Number Identification............141
      Loader Serial Number............141
      Engine Serial Number............142
      Pre-Delivery Inspection............142
      30 Hour Inspection............142
    SERVICE SCHEDULE............143
    REAR GRILL............144
    TILTING THE OPERATOR GUARD............144
      ROPS Tilt Motor............145
    ENGINE MAINTENANCE............145
      Engine Oil............145
      Specifications............145
    ENGINE OIL AND FILTER REPLACEMENT............147
    ENGINE AIR INLET SYSTEM (AIR CLEANER)............148
    ENGINE COOLING SYSTEM............149
    FAN BELT ADJUSTMENT............149
    FLUSHING THE COOLING SYSTEM............149
    FUEL SYSTEM............150
    FUEL SPECIFICATIONS............150
      Water In The Fuel Tank............150
    TO SERVICE THE FUEL SYSTEM............151
    REMOVE THE AIR FROM THE FUEL SYSTEM............151
    ELECTRICAL SYSTEM MAINTENANCE............152
      Electrical System............152
    HYDRAULIC SYSTEM............153
      Hydraulic/Hydrostatic Transmission Fluid............153
    CHECKING AND ADDING HYDRAULIC FLUID............153
    HYDRAULIC FLUID FILTERS............153
      Replacement Of The Suction (25 Micron) Filter ............154
      Replacement Of The Return Line Filter (10 Micron)............154
    DRAINING THE FLUID RESERVOIR............154
    LEAKS............155
    OIL COOLER............155
    CARE OF THE HYDROSTATIC TRANSMISSION............155
      Loader Start–Up............156
      Cold Weather Start–Up............156
    FINAL DRIVE CHAIN............156
    TIRES............156
    TIRE MAINTENANCE............157
    TIRE ROTATION............157
    TIRE REPLACEMENT............157
    LUBRICATION............157
    WHEEL MOUNTING NUTS............157
    BOB–TACH............158
    PARK BRAKE............158
  HYDRAULIC SYSTEM............159
    HYDRAULIC / HYDROSTATIC SCHEMATICS............161
    HYDRAULIC SYSTEM............171
    TUBELINES, HOSES, FITTINGS............171
      37° Flare Connection............171
      Straight Thread O–Ring Fitting (Elbows, Adapter, Etc.)............172
      Pipe Thread Fittings............172
      Tubelines And Hoses............172
    HYDRAULIC SYSTEM TROUBLESHOOTING............172
    GEAR PUMP............174
      Testing............174
      Removal............174
    DISASSEMBLY OF GEAR PUMP............175
    TO INSPECT PARTS FOR WEAR............175
      General............175
      Gear Assembly............175
      Front And Back Plates............175
      Body............176
      Assembly Of Gear Pump............176
    CONTROL VALVE............176
      Relief Valve Check............176
      Internal Leaks............177
      Control Valve Repair............177
        Removal............177
        Disassembly............177
    LIFT VALVE SPOOL (Float Detent)............178
       Repair Of The Float Detent Of The Lift Spool............178
      To Assemble The Detent Assembly............178
      Inspection, Repair And Assembly Of Control Valve............178
    CONTROL PEDALS............179
      Adjustment............179
      Removal Of Pedal Assembly............180
    HYDRAULIC CYLINDERS............180
      Checking For Internal Leak (Lift Cylinder)............180
      Removal Of Lift Cylinder............180
      Removal Of Tilt Cylinder............180
    HYDRAULIC CYLINDER REPAIR............180
      To Disassemble A Hydraulic Lift Or Tilt Cylinder............181
      To Replace The Cylinder Seals............181
      To Assemble The Hydraulic Cylinder............181
    OIL COOLER............182
      Cleaning Of Grill............182
      Removal Of Oil Cooler............182
      By–Pass Valve............182
      Cooler By-Pass Hose............182
  HYDROSTATIC SYSTEM............183
    HYDROSTATIC DRIVE SYSTEM............185
      Description............185
    HYDROSTATIC TRANSMISSION TROUBLESHOOTING............185
    CONTROL LINKAGE............190
      Adjustment Of Steering Linkage............190
    ADJUSTMENT OF SPEED RANGE LINKAGE............190
    STEERING CONTROLLINKAGE............191
      Removal............191
    CHECKING HYDROSTATIC SYSTEM............192
      Test Kit............192
      Charge Pressure Check............194
      Charge Pump Inlet Pressure............194
    CHECKING RELIEF VALVES............195
      Charge Relief Valve............195
      Filter Relief Valve............195
      Charge Inlet Relief Valve............195
      High Pressure Relief Valve............195
    MICRON FINAL FILTER ELEMENT REPLACEMENT............196
    TEMPERATURE AND PRESSURE SWITCHES............196
    REMOVAL OF HYDROSTATIC PUMP ASSEMBLY............197
    INSTALLING HYDROSTATIC PUMP............197
    REMOVAL OF HYDROSTATIC MOTOR............198
    INSTALLING HYDROSTATICMOTOR............199
      New Hydrostatic Pump & Motor............199
    HYDROSTATIC PUMP OR MOTOR DISASSEMBLY ............201
    INSPECT PARTS FOR WEAR............202
    TO ASSEMBLE PUMP OR MOTOR............202
    STARTING PROCEDURE, AFTER REPAIR............203
  FINAL DRIVE SYSTEM............205
    FINAL DRIVE SYSTEM............207
      Description............207
    REMOVAL OF REDUCTION HOUSING............207
    DISASSEMBLY OF REDUCTION HOUSING ............207
      Removal Of The Intermediate Gear (6)............207
      Removal Of Input Drive Gear (7)............208
      Removal Of Output Gear (14)............208
    ASSEMBLY OF REDUCTION HOUSING............208
      Installing The Output Shaft And Gear............208
      Installing Input Shaft And Gear............208
      Installing Intermediate Gear............208
      Drive Chain Adjustment (Internal Adjustment Type)............208
      Drive Chain Adjustment (External Adjustment Type)............209
      Drive Chain Idler Removal (Internal Adjustment Type)............209
      To Disassemble The Idler Gear (Internal)............210
      Drive Chain Idler Removal (External Adjustment Type)............210
    REMOVAL OF DRIVE CHAIN............211
    INSTALLING DRIVE CHAIN............211
    REMOVAL OF AXLE............212
      Removal Of Rear Axle............212
      Removal Of Front Axle............212
      Installation Of The Axle............213
    AXLE BEARING AND SEAL REPLACEMENT............213
    NSTALLATION OF AXLES PROCKET............214
    PARK BRAKE REMOVAL............214
  MAIN FRAME............215
    MAIN FRAME............217
      Description ............217
    REMOVAL OF ROPS............217
    PIVOT PIN AND BUSHING REPLACEMENT ............217
    BOB–TACH REMOVAL............217
    LIFT ARMS REMOVAL............218
    FUEL TANK REMOVAL............218
      Removing Fuel Tank On Loader S/N 16999 & Below ............218
      Removing Fuel Tank On Loader S/N 17001 & Above............218
    ELECTRIC MOTOR FOR ROPS (Cab Tilt – S/N 19126 & Below)............218
      Removal Of Tilt Mechanism............219
    MECHANICAL TILT FOR THE ROPS (S/N 19127 & Above)............219
  ELECTRICAL SYSTEM............221
    ELECTRICAL SCHEMATICS............225
    ELECTRICAL CIRCUITRY............229
    PROBLEM ANALYSIS............229
    FAN BELT............231
    TO CHECK ALTERNATOR OUTPUT............231
    TO CHECK THE REGULATOR............231
    ALTERNATOR SERVICE............232
      Removal (ROPS Must Be Tilted)............232
      Disassembly............232
      To Check Rotor............232
      To Check Stator ............232
      To Check Diode Trio............233
      To Check Rectifier............233
      Assembly............233
    STARTER SERVICE............234
      To Check The Starter............234
      To Remove Starter............234
      Disassembly And Inspection............234
      Assembly............234
  ENGINE SERVICE............235
    INTRODUCTION............237
      Engine Parts............237
      Engine Number Location............237
    STARTING A NEW OR RECONDITIONED ENGINE............237
    ENGINE OVERHAUL............237
      Engine Removal............237
      Cylinder Head Maintenance............238
      To Remove The Valves............239
      Combustion Chamber Inserts............239
      Reconditioning Cylinder Heads............240
      Cleaning............240
      Inspection............240
      Reconditioning Of Valves AndValve Seats............241
      Valve Seat Inserts............241
      To Install Inserts............241
       To Disassemble The Rocker Shaft Assembly............242
       To Assemble The Rocker Shaft Assembly............243
      Push Rods............243
      To Install The Valves............243
    INSTALLING CYLINDER HEAD............244
      Cylinder Head Gasket............244
       To Install The Cylinder Head............244
    CONNECTING RODS AND PISTONS............245
      To Remove Pistons And Connecting Rods............245
      To Remove Pistons And Rings From The Connecting Rods............246
      Inspection............246
      To Install The Pistons To The Connecting Rods............246
      Installing The Piston Rings............247
      To Install Rings............247
      To Install Piston And Connecting Rod Assemblies............248
      Installing New Pistons............248
      Cylinder Liners............249
      To Install New Cylinder Liners............249
    CRANKSHAFT AND MAIN BEARINGS............249
      Description............249
      To Install Main Bearings And Thrust Washers............250
      To Install Thrust Washers............250
      To Remove The Crankshaft............251
      To Reinstall The Crankshaft............252
      Crankshaft Rear End Oil Seal............253
    FLYWHEEL AND FLYWHEEL HOUSING............253
      To Remove The Flywheel............253
      To Replace The Flywheel Ring Gear............253
      To Reinstall The Flywheel............254
      To Install The Flywheel Housing............254
    TIMING CASE AND DRIVE............254
      To Remove The Timing Case Cover............254
      Replacement Of The Crankshaft Front Oil Seal............255
      To Install The Timing Case Cover............255
      To Remove The Idler Gear And Hub............255
      To Install The Idler Gear And Hub............255
      To Remove The Camshaft Gear............256
      To Install The Camshaft Gear............256
      To Remove The Fuel Pump Gear............256
      To Install The Fuel Pump Gear............256
      To Remove The Fuel Pump Drive Hub............257
      To Install The Fuel Pump Drive Hub............257
       To Remove The Timing CaseBack Plate............257
      To Install The Timing Case Back Plate............258
      To Remove The Camshaft And Tappets............258
      To Install The Tappets And Camshaft............258
      Timing Marks............259
      To Reset The Engine To The Original Timing............259
      Timing Pin............260
      Check Valve Timing............260
      Adjusting Valve Clearance............261
      Valve Adjustment Sequence............261
    LUBRICATION SYSTEM............261
      The Lubricating Oil Pump............261
      To Remove The Sump............261
      To Install The Oil Pan............261
      To Remove The Oil Pump............262
      To Dismantle The Oil Pump............262
      Inspection............262
      To Assemble The Oil Pump............263
      To Install The Oil Pump............263
      Oil Pressure Relief Valve............263
      To Dismantle The Oil Pressure Relief Valve............264
      To Assemble The Oil Pressure Relief Valve............264
    COOLING SYSTEM............264
      Fan Belt............264
      Adjustment Of Fan Belt............264
      Water Pump............265
      Remove The Water Pump............265
      To Disassemble The Water Pump............265
      Inspection............265
      To Assemble The Water Pump............266
      To Install The Water Pump............266
      Thermostat............266
      To Remove The Thermostat............266
       To Test The Thermostat............267
      Replacement Of The Thermostat............267
    FUEL SYSTEM............267
      To Test Fuel Lift Pump............267
      To Remove The Lift Pump............267
      Fuel Injection Pump............268
      To Remove The Fuel Injection Pump............268
      To Install The Fuel Injection Pump............268
      Checking Fuel Injection Pump Timing............268
      Timing The fuel Injection Pump (Using Timing Tool MS 67123)............269
      Checking The Timing Mark On The Flange Of The Injection Pump............271
      Injector Problems............272
      Testing For Faulty Injector............272
      Injector Removal............272
      Injector Installation............272
      Fuel Pipes (High Pressure)............272
      Using C.A.V. Thermostart Units............273
      Charging The Fuel System............274
  SPECIFICATIONS............275
    SPECIFICATIONS............277
      Cylinder Block............277
      Cylinder Liner (Cast Iron)............277
      Pistons............277
      Piston Rings............277
      Piston Pin Bushing............277
      Connecting Rod............277
      Connecting Rod Alignment............278
      Crankshaft............278
      Crankshaft Thrust Washers............278
      Main Bearings............278
      Connecting Rod Bearings............278
      Camshaft............279
      Camshaft Thrust Plates............279
      Cylinder Head............279
      Combustion Chamber Inserts............279
      Valve Guides (Inlet)............279
      Valve Guides (Exhaust)............279
      Valves (Inlet)............280
      Valves (Exhaust)............280
      Inner Valve Springs............280
      Outer Valve Springs............280
      Rocker Levers............280
      Valve Clearance............280
      Rocker Shaft............280
      Push Rods............280
      Lifters............280
    TIMING GEARS............281
      Injector Pump Gear............281
      Crankshaft Gear............281
      Timing Gear Backlash............281
    LUBRICATION SYSTEM............281
      Lubricating Oil Pump............281
      Pump Clearances............281
      Lubricating Oil Pump Drive Gear............281
      Relief Valve (Lube Oil)............281
      Lubricating Oil Filter............281
    COOLING SYSTEM............281
      Thermostat............281
    FUEL SYSTEM............281
      Fuel Lift Pump............282
      Final Fuel Filter............282
      Fuel Injection Pump............282
      Injectors............282
      Starting Aid............282
    SERVICE WEAR LIMITS............282
    DE–RATING FOR ALTITUDE............283
    TORQUE SPECIFICATIONS............283
      Hydrostatic Pump and Motor............283
      High Pressure Relief Valves............283
      Loader Torque Specs............283
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS............284
    DECIMAL AND MILLIMETER EQUIVALENTS............285
    U.S. TO METRIC CONVERSION............285
    SPECIAL TOOLS............286
    825 LOADER SPECIFICATIONS............287
      SPECIFICATIONS............287
      ENGINE............287
      LOADER HYDRAULICS............288
      ELECTRICAL............288
      DRIVE SYSTEM............288
      CAPACITIES............288
      TIRES............288
  ALPHABETICAL INDEX............289
  SERVICE BULLETINS............293
    825-001............293
    825-002............295
    825-003............297
    825-004............299
    825-005............301
  SERVICE MANUAL REVISIONS............293
    825-1............303
    825-2............305
    825-3............307
6549899 (6-12) - 825 Service Manual............309
  MAINTENANCE SAFETY............311
  CONTENTS............313
    FOREWORD............313
  PREVENTIVE MAINTENANCE............315
    INTRODUCTION............317
      Symbols............317
      Serial Number Identification............317
      Loader Serial Number............317
      Engine Serial Number............318
      Pre-Delivery Inspection............318
      30 Hour Inspection............318
    SERVICE SCHEDULE............319
    REAR GRILL............320
    TILTING THE OPERATOR GUARD............320
      ROPS Tilt Motor............321
    ENGINE MAINTENANCE............321
      Engine Oil............321
      Specifications............321
    ENGINE OIL AND FILTER REPLACEMENT............323
    ENGINE AIR INLET SYSTEM (AIR CLEANER)............324
    ENGINE COOLING SYSTEM............325
    FAN BELT ADJUSTMENT............325
    FLUSHING THE COOLING SYSTEM............325
    FUEL SYSTEM............326
    FUEL SPECIFICATIONS............326
      Water In The Fuel Tank............326
    TO SERVICE THE FUEL SYSTEM............327
    REMOVE THE AIR FROM THE FUEL SYSTEM............327
    ELECTRICAL SYSTEM MAINTENANCE............328
      Electrical System............328
    HYDRAULIC SYSTEM............329
      Hydraulic/Hydrostatic Transmission Fluid............329
    CHECKING AND ADDING HYDRAULIC FLUID............329
    HYDRAULIC FLUID FILTERS............329
      Replacement Of The Suction (25 Micron) Filter ............330
      Replacement Of The Return Line Filter (10 Micron)............330
    DRAINING THE FLUID RESERVOIR............330
    LEAKS............331
    OIL COOLER............331
    CARE OF THE HYDROSTATIC TRANSMISSION............331
      Loader Start–Up............332
      Cold Weather Start–Up............332
    FINAL DRIVE CHAIN............332
    TIRES............332
    TIRE MAINTENANCE............333
    TIRE ROTATION............333
    TIRE REPLACEMENT............333
    LUBRICATION............333
    WHEEL MOUNTING NUTS............333
    BOB–TACH............334
    PARK BRAKE............334
  HYDRAULIC SYSTEM............335
    HYDRAULIC / HYDROSTATIC SCHEMATICS............337
    HYDRAULIC SYSTEM............347
    TUBELINES, HOSES, FITTINGS............347
      37° Flare Connection............347
      Straight Thread O–Ring Fitting (Elbows, Adapter, Etc.)............348
      Pipe Thread Fittings............348
      Tubelines And Hoses............348
    HYDRAULIC SYSTEM TROUBLESHOOTING............348
    GEAR PUMP............350
      Testing............350
      Removal............350
    DISASSEMBLY OF GEAR PUMP............351
    TO INSPECT PARTS FOR WEAR............351
      General............351
      Gear Assembly............351
      Front And Back Plates............351
      Body............352
      Assembly Of Gear Pump............352
    CONTROL VALVE............352
      Relief Valve Check............352
      Internal Leaks............353
      Control Valve Repair............353
        Removal............353
        Disassembly............353
    LIFT VALVE SPOOL (Float Detent)............354
       Repair Of The Float Detent Of The Lift Spool............354
      To Assemble The Detent Assembly............354
      Inspection, Repair And Assembly Of Control Valve............354
    CONTROL PEDALS............355
      Adjustment............355
      Removal Of Pedal Assembly............356
    HYDRAULIC CYLINDERS............356
      Checking For Internal Leak (Lift Cylinder)............356
      Removal Of Lift Cylinder............356
      Removal Of Tilt Cylinder............356
    HYDRAULIC CYLINDER REPAIR............356
      To Disassemble A Hydraulic Lift Or Tilt Cylinder............357
      To Replace The Cylinder Seals............357
      To Assemble The Hydraulic Cylinder............357
    OIL COOLER............358
      Cleaning Of Grill............358
      Removal Of Oil Cooler............358
      By–Pass Valve............358
      Cooler By-Pass Hose............358
  HYDROSTATIC SYSTEM............359
    HYDROSTATIC DRIVE SYSTEM............361
      Description............361
    HYDROSTATIC TRANSMISSION TROUBLESHOOTING............361
    CONTROL LINKAGE............366
      Adjustment Of Steering Linkage............366
    ADJUSTMENT OF SPEED RANGE LINKAGE............366
    STEERING CONTROLLINKAGE............367
      Removal............367
    CHECKING HYDROSTATIC SYSTEM............368
      Test Kit............368
      Charge Pressure Check............370
      Charge Pump Inlet Pressure............370
    CHECKING RELIEF VALVES............371
      Charge Relief Valve............371
      Filter Relief Valve............371
      Charge Inlet Relief Valve............371
      High Pressure Relief Valve............371
    MICRON FINAL FILTER ELEMENT REPLACEMENT............372
    TEMPERATURE AND PRESSURE SWITCHES............372
    REMOVAL OF HYDROSTATIC PUMP ASSEMBLY............373
    INSTALLING HYDROSTATIC PUMP............373
    REMOVAL OF HYDROSTATIC MOTOR............374
    INSTALLING HYDROSTATICMOTOR............375
      New Hydrostatic Pump & Motor............375
    HYDROSTATIC PUMP OR MOTOR DISASSEMBLY ............377
    INSPECT PARTS FOR WEAR............378
    TO ASSEMBLE PUMP OR MOTOR............378
    STARTING PROCEDURE, AFTER REPAIR............379
  FINAL DRIVE SYSTEM............381
    FINAL DRIVE SYSTEM............383
      Description............383
    REMOVAL OF REDUCTION HOUSING............383
    DISASSEMBLY OF REDUCTION HOUSING ............383
      Removal Of The Intermediate Gear (6)............383
      Removal Of Input Drive Gear (7)............384
      Removal Of Output Gear (14)............384
    ASSEMBLY OF REDUCTION HOUSING............384
      Installing The Output Shaft And Gear............384
      Installing Input Shaft And Gear............384
      Installing Intermediate Gear............384
      Drive Chain Adjustment (Internal Adjustment Type)............384
      Drive Chain Adjustment (External Adjustment Type)............385
      Drive Chain Idler Removal (Internal Adjustment Type)............385
      To Disassemble The Idler Gear (Internal)............386
      Drive Chain Idler Removal (External Adjustment Type)............386
    REMOVAL OF DRIVE CHAIN............387
    INSTALLING DRIVE CHAIN............387
    REMOVAL OF AXLE............388
      Removal Of Rear Axle............388
      Removal Of Front Axle............388
      Installation Of The Axle............389
    AXLE BEARING AND SEAL REPLACEMENT............389
    NSTALLATION OF AXLES PROCKET............390
    PARK BRAKE REMOVAL............390
  MAIN FRAME............391
    MAIN FRAME............393
      Description ............393
    REMOVAL OF ROPS............393
    PIVOT PIN AND BUSHING REPLACEMENT ............393
    BOB–TACH REMOVAL............393
    LIFT ARMS REMOVAL............394
    FUEL TANK REMOVAL............394
      Removing Fuel Tank On Loader S/N 16999 & Below ............394
      Removing Fuel Tank On Loader S/N 17001 & Above............394
    ELECTRIC MOTOR FOR ROPS (Cab Tilt – S/N 19126 & Below)............394
      Removal Of Tilt Mechanism............395
    MECHANICAL TILT FOR THE ROPS (S/N 19127 & Above)............395
  ELECTRICAL SYSTEM............397
    ELECTRICAL SCHEMATICS............401
    ELECTRICAL CIRCUITRY............405
    PROBLEM ANALYSIS............405
    FAN BELT............407
    TO CHECK ALTERNATOR OUTPUT............407
    TO CHECK THE REGULATOR............407
    ALTERNATOR SERVICE............408
      Removal (ROPS Must Be Tilted)............408
      Disassembly............408
      To Check Rotor............408
      To Check Stator ............408
      To Check Diode Trio............409
      To Check Rectifier............409
      Assembly............409
    STARTER SERVICE............410
      To Check The Starter............410
      To Remove Starter............410
      Disassembly And Inspection............410
      Assembly............410
  ENGINE SERVICE............411
    INTRODUCTION............413
      Engine Parts............413
      Engine Number Location............413
    STARTING A NEW OR RECONDITIONED ENGINE............413
    ENGINE OVERHAUL............413
      Engine Removal............413
      Cylinder Head Maintenance............414
      To Remove The Valves............415
      Combustion Chamber Inserts............415
      Reconditioning Cylinder Heads............416
      Cleaning............416
      Inspection............416
      Reconditioning Of Valves AndValve Seats............417
      Valve Seat Inserts............417
      To Install Inserts............417
       To Disassemble The Rocker Shaft Assembly............418
       To Assemble The Rocker Shaft Assembly............419
      Push Rods............419
      To Install The Valves............419
    INSTALLING CYLINDER HEAD............420
      Cylinder Head Gasket............420
       To Install The Cylinder Head............420
    CONNECTING RODS AND PISTONS............421
      To Remove Pistons And Connecting Rods............421
      To Remove Pistons And Rings From The Connecting Rods............422
      Inspection............422
      To Install The Pistons To The Connecting Rods............422
      Installing The Piston Rings............423
      To Install Rings............423
      To Install Piston And Connecting Rod Assemblies............424
      Installing New Pistons............424
      Cylinder Liners............425
      To Install New Cylinder Liners............425
    CRANKSHAFT AND MAIN BEARINGS............425
      Description............425
      To Install Main Bearings And Thrust Washers............426
      To Install Thrust Washers............426
      To Remove The Crankshaft............427
      To Reinstall The Crankshaft............428
      Crankshaft Rear End Oil Seal............429
    FLYWHEEL AND FLYWHEEL HOUSING............429
      To Remove The Flywheel............429
      To Replace The Flywheel Ring Gear............429
      To Reinstall The Flywheel............430
      To Install The Flywheel Housing............430
    TIMING CASE AND DRIVE............430
      To Remove The Timing Case Cover............430
      Replacement Of The Crankshaft Front Oil Seal............431
      To Install The Timing Case Cover............431
      To Remove The Idler Gear And Hub............431
      To Install The Idler Gear And Hub............431
      To Remove The Camshaft Gear............432
      To Install The Camshaft Gear............432
      To Remove The Fuel Pump Gear............432
      To Install The Fuel Pump Gear............432
      To Remove The Fuel Pump Drive Hub............433
      To Install The Fuel Pump Drive Hub............433
       To Remove The Timing CaseBack Plate............433
      To Install The Timing Case Back Plate............434
      To Remove The Camshaft And Tappets............434
      To Install The Tappets And Camshaft............434
      Timing Marks............435
      To Reset The Engine To The Original Timing............435
      Timing Pin............436
      Check Valve Timing............436
      Adjusting Valve Clearance............437
      Valve Adjustment Sequence............437
    LUBRICATION SYSTEM............437
      The Lubricating Oil Pump............437
      To Remove The Sump............437
      To Install The Oil Pan............437
      To Remove The Oil Pump............438
      To Dismantle The Oil Pump............438
      Inspection............438
      To Assemble The Oil Pump............439
      To Install The Oil Pump............439
      Oil Pressure Relief Valve............439
      To Dismantle The Oil Pressure Relief Valve............440
      To Assemble The Oil Pressure Relief Valve............440
    COOLING SYSTEM............440
      Fan Belt............440
      Adjustment Of Fan Belt............440
      Water Pump............441
      Remove The Water Pump............441
      To Disassemble The Water Pump............441
      Inspection............441
      To Assemble The Water Pump............442
      To Install The Water Pump............442
      Thermostat............442
      To Remove The Thermostat............442
       To Test The Thermostat............443
      Replacement Of The Thermostat............443
    FUEL SYSTEM............443
      To Test Fuel Lift Pump............443
      To Remove The Lift Pump............443
      Fuel Injection Pump............444
      To Remove The Fuel Injection Pump............444
      To Install The Fuel Injection Pump............444
      Checking Fuel Injection Pump Timing............444
      Timing The fuel Injection Pump (Using Timing Tool MS 67123)............445
      Checking The Timing Mark On The Flange Of The Injection Pump............447
      Injector Problems............448
      Testing For Faulty Injector............448
      Injector Removal............448
      Injector Installation............448
      Fuel Pipes (High Pressure)............448
      Using C.A.V. Thermostart Units............449
      Charging The Fuel System............450
  SPECIFICATIONS............451
    SPECIFICATIONS............453
      Cylinder Block............453
      Cylinder Liner (Cast Iron)............453
      Pistons............453
      Piston Rings............453
      Piston Pin Bushing............453
      Connecting Rod............453
      Connecting Rod Alignment............454
      Crankshaft............454
      Crankshaft Thrust Washers............454
      Main Bearings............454
      Connecting Rod Bearings............454
      Camshaft............455
      Camshaft Thrust Plates............455
      Cylinder Head............455
      Combustion Chamber Inserts............455
      Valve Guides (Inlet)............455
      Valve Guides (Exhaust)............455
      Valves (Inlet)............456
      Valves (Exhaust)............456
      Inner Valve Springs............456
      Outer Valve Springs............456
      Rocker Levers............456
      Valve Clearance............456
      Rocker Shaft............456
      Push Rods............456
      Lifters............456
    TIMING GEARS............457
      Injector Pump Gear............457
      Crankshaft Gear............457
      Timing Gear Backlash............457
    LUBRICATION SYSTEM............457
      Lubricating Oil Pump............457
      Pump Clearances............457
      Lubricating Oil Pump Drive Gear............457
      Relief Valve (Lube Oil)............457
      Lubricating Oil Filter............457
    COOLING SYSTEM............457
      Thermostat............457
    FUEL SYSTEM............457
      Fuel Lift Pump............458
      Final Fuel Filter............458
      Fuel Injection Pump............458
      Injectors............458
      Starting Aid............458
    SERVICE WEAR LIMITS............458
    DE–RATING FOR ALTITUDE............459
    TORQUE SPECIFICATIONS............459
      Hydrostatic Pump and Motor............459
      High Pressure Relief Valves............459
      Loader Torque Specs............459
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS............460
    DECIMAL AND MILLIMETER EQUIVALENTS............461
    U.S. TO METRIC CONVERSION............461
    SPECIAL TOOLS............462
    825 LOADER SPECIFICATIONS............463
      SPECIFICATIONS............463
      ENGINE............463
      LOADER HYDRAULICS............464
      ELECTRICAL............464
      DRIVE SYSTEM............464
      CAPACITIES............464
      TIRES............464
  ALPHABETICAL INDEX............465
  SERVICE BULLETINS............469
    825-001............469
    825-002............471
    825-003............473
    825-004............475
    825-005............477
  SERVICE MANUAL REVISIONS............469
    825-1............479
    825-2............481
    825-3............483
    825-4............485
6556864 (12-82) - 843 Operator's Manual............487
  WARNINGS............489
  SAFETY INSTRUCTIONS............491
    SAFETY IS YOUR RESPONSIBILITY............491
    BEFORE YOU OPERATE THE BOBCAT LOADER............491
  FOREWORD............493
    CONTENTS............493
    843 BOBCAT LOADER IDENTIFICATION............494
  OPERATING INSTRUCTIONS............495
    OPERATING  INSTRUCTIONS............497
    CONTROLS............498
    SAFETY SIGNS (DECALS) LOCATION............499
    DASH PANEL............500
    THROTTLE CONTROL............500
    STOPPING THE ENGINE............500
    PARKING BRAKE............500
    STEERING LEVERS............501
    HYDRAULIC CONTROLS............502
      Foot Pedals (Hydraulic)............502
      Lift Arm Operation............502
      Float Position............502
      Tilt (Bucket) Operation............502
      Auxiliary Lever............503
    BEFORE YOU START THE ENGINE............503
    STARTING THE ENGINE............504
      Normal Starting Condition............505
      Making Cold Temperature Starting Easier............505
      Cold Weather Starting Condition............506
    BOBCAT LOADER OPERATION............506
      Bucket Size............506
      Installation Of Attachments............507
      Removal Of Attachments............507
    OPERATING PROCEDURE............508
      Filling The Bucket............509
      To Empty The Bucket............509
      Digging Into The Ground............510
      Making The Ground Level............510
      Filling A Hole............510
    STOPPING THE BOBCAT LOADER............511
    TRANSPORTING THE BOBCAT LOADER............511
    LIFT ARM STOP............512
    LIFTING THE OPERATOR GUARD............513
    LOWERING THE OPERATOR GUARD............513
  PREVENTIVE MAINTENANCE............515
    WARNINGS............517
    SERVICE SCHEDULE............519
    ENGINE SERVICE............520
    ADJUSTING DOOR LATCH............520
    AIR CLEANER SERVICE............520
    FUEL SYSTEM............521
    FUEL SYSTEM SERVICE............521
    FUEL FILTER............522
    REMOVING THE AIR FROM THE FUEL SYSTEM............522
    ENGINE LUBRICATION SYSTEM............523
    REPLACEMENT OF ENGINE OIL AND FILTER............523
    ENGINE COOLING SYSTEM............524
      Coolant Level............524
      Removing Coolant From The Cooling System............524
    ALTERNATOR BELT............524
    ELECTRICAL SYSTEM............524
    USING AN EXTRA BATTERY............527
    HYDRAULIC SYSTEM............529
    HYDRAULIC/HYDROSTATIC FLUID RESERVOIR............529
      Checking And Adding Hydraulic Fluid............531
      Removing The Hydraulic Fluid............531
    REPLACEMENT OF HYDRAULIC FILTER............531
    FINAL DRIVE TRANSMISSION (CHAINCASE)............532
    TO DRAIN CHAINCASE FLUID............532
    TIRE MAINTENANCE............532
      Tire Rotation............533
    LUBRICATION OF THE BOBCAT LOADER............533
    SPARK ARRESTOR MUFFLER............534
    OPERATOR GUARD............534
    BOB-TACH............534
    PIVOT PINS............535
    AUXILIARY CONTROL LOCKBOLT............535
    BRAKE PEDAL ADJUSTMENT............535
    LOADER SERIAL NUMBER............536
    DELIVERY REPORT............536
    THIRTY HOUR INSPECTION............536
  TROUBLESHOOTING............537
    TROUBLESHOOTING THE ENGINE............539
    TROUBLESHOOTING THE DRIVE SYSTEM............540
    TROUBLESHOOTING THE HYDRAULIC SYSTEM............541
  MAJOR PARTS............543
    MAIN FRAME............545
    OPERATOR GUARD ELECTRICAL............546
    ENGINE ELECTRICAL............547
    HYDRAULIC SYSTEM............548
    CONTROL PEDALS............549
    DRIVE SYSTEM............550
    HYDROSTATIC SYSTEM............551
    HAND CONTROLS............552
    SEAT & FUEL SYSTEM............553
    ENGINE & ATTACHING PARTS............554
    DECALS............556
  DECALS............557
    WARNING - 6563484............559
    SERVICE SCHEDULE - 6561387............560
    WARNING - 6563380............562
    WARNING - 6561380............563
    IMPORTANT - 6560573............564
  GENERAL INFORMATION............565
    LOADER SPECIFICATIONS............567
    SPECIFICATIONS............567
    ENGINE............567
    LOADER HYDRAULICS............568
    ELECTRICAL............568
    DRIVE SYSTEM............568
    CAPACITIES............568
    TIRES............568
    ADDITIONAL PUBLICATIONS............569
6566091 (12-85) - 843, 843B Service Manual............573
  MAINTENANCE SAFETY............575
  CONTENTS............577
    FOREWORD............579
    SAFETY INSTRUCTIONS............581
    FIRE PREVENTION............582
    SERIAL NUMBER LOCATIONS............583
    LOADER SERIAL NUMBER............583
    ENGINE SERIAL NUMBER............583
    DELIVERY REPORT............583
    BOBCAT LOADER IDENTIFICATION............584
  PREVENTIVE MAINTENANCE............585
    SERVICE SCHEDULE............587
    LIFTING AND BLOCKING THE LOADER............588
      Procedure............588
    TRANSPORTING THE BOBCAT LOADER............589
      Procedure............589
    LIFT ARM STOP............590
      Procedure............590
    OPERATOR CAB............591
      Seat Bar System............591
      Seat Bar Inspection............591
      Seat Bar Maintenance............592
      Raising The Operator Cab............593
      Lowering The Operator Cab............593
    USING AN EXTRA BATTERY (JUMP STARTING)............594
      Procedure............594
    REMOTE START SWITCH............595
      Procedure............595
  HYDRAULIC SYSTEM............597
    HYDRAULIC / HYDROSTATIC SCHEMATICS............599
    TROUBLESHOOTING............651
    HYDRAULIC SYSTEM INFORMATION............652
      Flare Connections............652
      Straight Thread O-Ring Fitting............652
      Tubelines And Hoses............652
    LIFT CYLINDER............653
      Checking The Lift Cylinder(s)............653
      Removal And Installation............653
    TILT CYLINDERS............655
      Checking The Tilt Cylinder............655
      Removal And Installation............655
      Rod End Seal............656
    TILT CYLINDER (CESSNA)............657
      Disassembly............657
      Assembly............659
    HYDRAULIC CYLINDER REPAIR............663
      Disassembly............663
      Assembly............665
    HYDRAULIC CONTROL VALVE (CESSNA)............668
      Checking The Main Relief Valve............668
      Main Relief Valve Removal And Installation............669
      Removal And Installation............669
      Disassembly............671
      Inlet Section............672
      Tilt Section............673
      Lift Section............675
      Auxiliary Section............677
      Valve Spool Bolt............678
      Assembly............679
    HYDRAULIC CONTROL VALVE (MELROE)............680
      Checking The Main Relief Valve............680
      Main Relief Valve Removal And Installation............681
      Removal And Installation............681
      Disassembly And Assembly............683
      Detent Assembly............685
      Centering Mechanism............688
    HYDRAULIC PUMP (SINGLE STAGE)............689
      Checking The Output Of The Hydraulic Pump............689
      Removal And Installation............690
      Disassembly And Assembly............690
      Inspection............692
    HYDRAULIC PUMP (DOUBLE STAGE)............693
      Removal And Installation............694
      Disassembly And Assembly............696
      Inspection............698
    BUCKET POSITION VALVE (S/N 15001 & ABOVE)............699
      Removal And Installation............699
      Disassembly And Assembly............699
    PORT BLOCK (S/N 14999 & BELOW)............701
      40 Micron Filter (Bronze)............701
      Neutral By-Pass Valve............702
      Removal And Installation............702
    PORT BLOCK (S/N 15001 & ABOVE)............705
      Removal And Installation............705
      Charge By-Pass............706
      Cold Oil By-Pass............706
    HYDRAULIC FLUID FILTER HOUSING (S/N 15001 & ABOVE)............707
      Removal And Installation............707
      By-Pass Valve............707
    HYDRAULIC/HYDROSTATIC RESERVOIR (S/N 21514 & BELOW)............708
      Removal And Installation............708
    HYDRAULIC CONTROL PEDALS (S/N 14999 & BELOW)............710
      Removal And Installation............710
      Adjustment............710
    HYDRAULIC CONTROL PEDALS (S/N 15001 & ABOVE)............711
      Removal And Installation............711
      Adjustment............711
    PEDAL LOCK LINKAGE............712
      Adjustment............712
  HYDROSTATIC SYSTEM............713
    TROUBLESHOOTING............715
    HYDROSTATIC SYSTEM INFORMATION............716
      High Pressure Relief/Replenishing Valves Function............716
    FRONT AND SIDE PANELS (S/N 19999 & BELOW)............717
      Removal And Installation............717
    STEERING LEVERS (S/N 16191 & BELOW)............718
      Removal And Installation............718
      Repairing The Steering Levers............719
      Steering Linkage Adjustment............720
      Removal And Installation............721
      RepairingThe Pintle Lever............722
    FRONT AND SIDE PANEL (ONE PIECE) (S/N 20001 & ABOVE) & 843B............723
      Removal And Installation............723
    STEERING LEVERS - 843-(S/N 16192 THRU 25999), 843-(STARTING WITH S/N 34222) & 843B............726
      Removal And Installation............726
      Repairing The Steering Levers............727
    STEERING LINKAGE 843-(S/N 16192 THRU 25999), 843-(STARTING WITH S/N 34222) & 843B............728
      Steering Linkage Adjustment............728
      Removal And Installation............729
      Repairing The Pintle Lever............730
    STEERING LINKAGE (S/N 26000 THRU 29869)............731
      Description............731
      Neutral Adjustment............731
      Steering Lever Centering Spring Mechanism............733
      Removal And Installation (Creep Mechanism)............734
    SERVO CONTROL............737
      Removal And Installation............737
      Disassembly And Assembly............738
    PINTLE LEVER ARMS (S/N 26000 - 29869)............739
      Removal And Installation............739
    STEERING LINKAGE (S/N 29870 - 31863)............741
      Description............741
      Neutral Adjustment............741
      Steering Lever Centering Spring Mechanism............743
      Creep Centering Spring Mechanism............743
      Pintle Arm............743
    STEERING LINKAGE (S/N 31864-34221)............744
      Hydrostatic Pump Centering Spring Adjustment............745
      Servo Control Unit Adjustment............746
      Steering Lever Centering Spring Adjustment............747
      Wheel RPM Adjustment (Left To Right)............748
    HYDROSTATIC MOTOR............750
      Removal And Installation............750
      Disassembly And Assembly............751
      Inspection............755
      Timing The Hydrostatic Motor............756
      High Pressure Hose Routing............756
    HYDROSTATIC PUMPS............757
      Checking The High Pressure Relief/Replenishing Valve............757
      Checking Charge Pressure............758
      Removal And Installation............758
      Disassembly And Assembly............759
      Rear Pump............761
      Front Pump............761
      Inspection............764
      Tow Valves............765
      Hydrostatic Pump Rear Mount (S/N 21574 & Above)............766
    HYDROSTATIC FLUID FILTER HOUSING............767
      Removal And Installation............767
  DRIVE SYSTEM............769
    PARKING BRAKE............771
      Adjustment............771
      Removal And Installation............771
      Block And Pucks............772
    AXLES, SEALS AND BEARINGS............774
      Removal............774
      Installation............775
    FINAL DRIVE CHAIN............778
      Removal............778
      Installation............778
    REDUCTION GEARCASE............780
      Removal And Installation............780
      Checking Reduction Gearcase............781
      Disassembly And Assembly............781
      Installation............786
      Reduction Gearcase Seal............787
  MAIN FRAME............789
    OPERATOR CAB (S/N 19999 & BELOW)............791
      Removal And Installation............791
    OPERATOR CAB (S/N 20001 & ABOVE)............793
      Removal And Installation............793
    OPERATOR CAB GAS CYLINDER............796
      Removal And Installation............796
    REAR DOOR............797
      Door Latch Adjustment............797
      Removal And Installation............798
    LIFT ARMS............799
      Removal And Installation............799
    BOB-TACH............801
      Removal And Installation............801
      Tilt Cylinder Rod End Seal............802
      Disassembly And Assembly............803
    FUEL TANK (S/N 19999 & BELOW)............805
      Removal And Installation............805
    FUEL TANK (S/N 20001 & ABOVE)............806
      Removal And Installation............806
      Fuel Tank Sender Switch............807
  ELECTRICAL SYSTEM............809
    ELECTRICAL SCHEMATICS............812
    ELECTRICAL SYSTEM INFORMATION............839
      Description............839
    TROUBLESHOOTING............839
    BATTERY............840
      Checking The Battery............840
      Removal And Installation............840
    ALTERNATOR............841
      Alternator Belt Adjustment............841
      Checking The Alternator Wire Harness............842
      Checking Alternator Output............842
      Checking Alternator Regulator............842
      Removal And Installation............843
      Disassembly And Assembly............844
    MELROE ALTERNATOR............846
      Checking The Alternator Output............846
      Checking The Alternator Regulator............847
      Removal And Installation............848
      Disassembly And Assembly............849
    MANDO ALTERNATOR............851
    STARTER............852
      Checking The Starter............852
      Removal And Installation............852
      Disassembly And Assembly............854
      Cleaning And Inspection............854
      Replacing The Brushes............855
  ENGINE SERVICE............857
    ENGINE SERVICE (PERKINS ENGINE)............859
      TROUBLESHOOTING............861
      VALVE CLEARANCE............862
        Adjustment............862
      ENGINE COMPRESSION............863
        Checking............863
      FUEL FILTER............864
        Removal And Installation............864
        Water Trap............864
      FUEL LIFT PUMP............865
        Checking............865
        Removal And Installation............865
      REMOVING AIR FROM FUEL SYSTEM............866
        Procedure............866
      FUEL INJECTION PUMP............867
        Removal And Installation............867
      ENGINE TIMING TO INJECTION PUMP (USING DIAL INDICATOR)............868
        Procedure............868
      EMGINE TIMING TO INJECTOR PUMP (USING TIMING TOOL)............869
        Procedure............869
      CHECKING TIMING MARK ON INJECTION PUMP FLANGE............870
        Procedure............870
      FUEL INJECTOR NOZZLES............871
        Removal And Installation............871
        Checking............872
      ENGINE............873
        Removal And Installation............873
      RADIATOR............877
        Removal And Installation............877
      OIL COOLER............878
        Removal And Installation............878
      ENGINE MUFFLER............879
        Removal And Installation............879
      ENGINE BLOWER HOUSING............880
        Removal And Installation............880
      ENGINE FLYWHEEL & U-JOINT............881
        Removal And Installation............881
        Flywheel Ring Gear............881
      CYLINDER HEAD............882
        Removing The Cylinder Head............882
        Cylinder Head Surface Alignment............882
        Installing The Cylinder Head............883
      VALVES............884
        Removal Of The Valves............884
        Installing The Valves............884
        Reconditioning The Valves And Valve Seats............884
        Installing Valve Guides............885
        Changing The Valve Springs............886
      COMBUSTION CHAMBER INSERTS............887
        Removal And Installation............887
      ROCKER ARMS............888
        Disassembly............888
        Assembly............888
      PISTON AND CONNECTING RODS............889
        Removal............889
        Disassembly............890
        Inspection............890
        Installation............891
      CYLINDER LINERS............892
        Checking............892
        Removal And Installation............892
      MAIN BEARINGS............893
        Removal............893
        Installation............894
        Crankshaft End Play............894
      CRANKSHAFT............895
        Removal............895
        Checking............895
        Installation............896
      REAR MAIN OIL SEAL............897
        Removal And Installation............897
      TIMING CASE COVER............898
        Removal And Installation............898
      IDLER GEAR AND HUB............899
        Removal............899
        Installation............899
      CAMSHAFT GEAR............901
        Removal............901
        Installation............901
      FUEL INJECTION PUMP DRIVE GEAR............902
        Removal And Installation............902
      CRANKSHAFT GEAR............902
        Removal............902
      TIMING CASE............903
        Removal And Installation............903
      CAMSHAFT AND TAPPETS............904
        Removal............904
        Inspection............905
        Installation............905
      LUBRICATION SYSTEM............906
        Description............906
      OIL PUMP............907
        Removal And Installation............907
        Disassembly And Assembly............907
        Checking............907
      WATER PUMP............909
        Removal And Installation............909
        Disassembly............909
        Checking............910
        Assembly............910
      THERMOSTAT............911
        Removal............911
        Testing The Thermostat............911
        Installation............911
    ENGINE SERVICE (PERKINS ENGINE - 200 SERIES)............913
      TROUBLESHOOTING............915
      VALVE CLEARANCE............916
        Adjustment............916
      ENGINE COMPRESSION............917
        Checking............917
      FUEL FILTER (S/N 13315 & BELOW)............918
        Removal And Installation............918
        Water Trap............918
      FUEL FILTER (S/M 13316 & ABOVE)............918
        Removal And Installation............918
      REMOVING AIR FROM THE FUEL SYSTEM (S/N 13315 & BELOW)............919
        Procedure............919
      REMOVING AIR FROM THE FUEL SYSTEM (S/N 13316 & ABOVE)............920
        Procedure............920
      FUEL INJECTION PUMP............921
        Removal And Installation............921
        Maximum Speed Setting............922
      TIMING THE FUEL INJECTION PUMP............923
        Procedure............923
      FUEL INJECTOR NOZZLES............925
        Removal And Installation............925
        Checking............926
      GLOW PLUGS............927
        Checking............927
      ENGINE............928
        Removal And Installation............928
      RADIATOR............931
        Removal And Installation............931
      OIL COOLER............933
        Removal And Installation............933
      ENGINE MUFFLER............934
        Removal And Installation............934
      ENGINE BLOWER HOUSING............935
        Removal And Installation............935
      ENGINE FLYWHEEL & U-JOINT............936
        Removal And Installation............936
        Flywheel Ring Gear............936
      CYLINDER HEAD............937
        Removing The Cylinder Head............937
        Cylinder Head Surface Alignment............937
        Installing The Cylinder Head............938
      VALVES............939
        Removing The Valves............939
        Installing The Valves............939
        Reconditioning The Valves And Valve Seats............939
        Installing The Valve Guides............940
        Checking The Valve Springs............941
      CONBUSTION CHAMBER INSERTS............942
        Removal And Installation............942
      ROCKER ARMS............943
        Disassembly............943
        Assembly............943
      PISTON AND CONNECTING RODS............944
        Removal............944
        Disassembly............945
        Inspection............945
        Installation............946
      CYLINDER LINERS............947
        Checking............947
        Removal And Installation............947
      MAIN BEARINGS............948
        Removal............948
        Installation............949
        Crankshaft End Play............949
      CRANKSHAFT............950
        Removal............950
        Installation............951
      REAR MAIN OIL SEAL............952
        Removal And Installation............952
      TIMING CASE COVER............953
        Removal And Installation............953
        Front Seal............954
      IDLER GEAR AND HUB............955
        Removal............955
        Installation............956
      CAMSHAFT GEAR............957
        Removal............957
        Installation............957
      FUEL INJECTION PUMP DRIVE GEAR............958
        Removal And Installation............958
      CRANKSHAFT GEAR............958
        Removal............958
      TIMING CASE............959
        Removal And Installation............959
      CAMSHAFT AND TAPPETS............960
        Removal............960
        Inspection............961
        Installation............961
      LUBRICATION SYSTEM............962
        Description............962
      OIL PUMP............963
        Removal And Installation............963
        Inspection............964
      OIL FILTER ADAPTER HOUSING............965
        Removal And Installation............965
      WATER PUMP............966
        Removal And Installation............966
        Disassembly............966
        Checking............967
        Assembly............967
      THERMOSTAT............968
        Removal............968
        Testing The Thermostat............968
        Installation............968
    ENGINE SERVICE (ISUZU ENGINE)............969
      TROUBLESHOOTING............971
      VALVE CLEARANCE............972
        Adjustment............972
      ENGINE COMPRESSION............973
        Checking............973
      FUEL FILTER............974
        Water Trap............974
        Fuel Filter Element............974
      REMOVING AIR FROM FUEL SYSTEM............975
        Procedure............975
      FUEL INJECTION PUMP............976
        Removal And Installation............976
      ENGINE TIMING TO INJECTION PUMP............979
        Procedure............979
      FUEL INJECTOR NOZZLES............981
        Removal And Installation............981
        Checking............982
      GLOW PLUGS............984
        Removal And Installation............984
      ENGINE OIL AND FILTER............985
        Removal And Installation............985
      ENGINE............987
        Removal And Installation............987
      RADIATOR............992
        Removal And Installation............992
      OIL COOLER............994
        Removal And Installation............994
      ENGINE MUFFLER............995
        Removal And Installation............995
      ENGINE FLYWHEEL & U-JOINT............996
        Removal And Installation............996
        Flywheel Ring Gear............996
      ENGINE BLOWER HOUSING............997
        Removal And Installation............997
      ENGINE MOUNTS............998
        Removal And Installation............998
      CYLINDER HEAD............999
        Removal And Installation............999
        Cylinder Head Surface Alignment............1000
        Exhaust Manifold............1000
      VALVES............1001
        Removal And Installation............1001
        Reconditioning The Valves And Valve Seats............1001
        Valve Seat Insert............1002
        Valve Guides............1002
        Valve Springs............1003
      ROCKER ARMS............1004
        Disassembly And Assembly............1004
        Push Rods............1004
      PISTON AND CONNECTING ROD............1005
        Removal............1005
        Disassembly............1005
        Inspection............1006
        Assembly............1009
        Installation............1010
      CYLINDER LINERS............1011
        Checking............1011
        Removal............1011
        Installation............1011
      MAIN BEARINGS............1012
        Removal............1012
        Installation............1013
        Crankshaft End Play............1014
      CRANKSHAFT............1015
        Removal............1015
        Checking Tuffriding (Soft Nitriding) Coating............1015
        Checking............1015
        Crankshaft Gear............1017
        Removal And Installation............1017
        Installation............1017
      TIMING CASE COVER SEAL............1018
        Removal And Installation............1018
      TIMING CASE COVER............1019
        Removal And Installation............1019
      IDLER GEAR AND HUB............1021
        Removal And Installation............1021
        Checking............1021
      FUEL INJECTION PUMP IDLER GEAR............1023
        Removal And Installation............1023
        Bearing Installation............1023
      CAMSHAFT GEAR............1024
        Removal And Installation............1024
      TIMING CASE............1025
        Removal And Installation............1025
      CAMSHAFT............1026
        Removal And Installation............1026
        Checking............1026
        Camshaft Bearing............1027
        Tappets............1027
        Installation............1028
      OIL PAN............1029
        Removal............1029
        Installation............1029
      OIL PUMP............1030
        Removal And Installation............1030
        Checking............1030
        Gear Replacement............1031
        Rotor Replacement............1032
        Oil Pump Relief Valve............1032
      WATER PUMP............1033
        Removal And Installation............1033
        Disassembly............1033
        Assembly............1034
      THERMOSTAT............1036
        Removal And Installation............1036
        Inspection............1036
      WATER JACKET TUBE............1037
        Removal And Installation............1037
  TECHNICAL DATA............1039
    GENERAL SPECIFICATIONS............1041
      TORQUE SPECIFICATIONS............1043
        Seat Bar, Fuel Tank & Panel Group............1043
        Steering Levers, Linkage & Pedal Group............1044
        Brakem Axle & Chaincase Group............1045
        Operator Guard, Lift Arm & Main Frame Group............1046
        Hydraulic/Hydrostatic Group............1047
        Engine Group (Perkins)............1048
        Engine Group (200 Series Perkins)............1050
        Engine Group (Isuzu)............1052
      HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS............1054
      DECIMAL AND MILLIMETER EQUIVALENTS............1055
      U.S. TO METRIC CONVERSION............1055
      STANDARD TORQUE SPECIFICATIONS FOR BOLTS............1056
    TECHNICAL DATA (PERKINS ENGINE)............1057
      LOADER SPECIFICATIONS............1059
        Specifications............1059
        Engine............1059
        Loader Hydraulics............1060
        Electrical............1060
        Drive System............1060
        Capacities............1060
        Tires............1060
      ENGINE SPECIFICATIONS............1061
        Cylinder Head Dimensions............1061
        Piston And Connecting Rod Dimensions............1062
        Cylinder Block And Liner Dimensions............1063
        crankshaft And Main Bearings Dimensions............1063
        Timing Case, Camshaft And Drive Dimensions............1064
        Oil Pump Dimensions............1065
        Cooling System and Wster Pump Dimensions............1066
        Fuel System Specifications............1066
        De-Rating For Altitude............1067
        Engine Torque............1067
        Grinding Specifications For Crankshaft............1068
    TECHNICAL DATA (PERKINS ENGINE - 200 SERIES)............1069
      LOADER SPECIFICATIONS............1071
        Specifications............1071
        Engine............1071
        Loader Hydraulics............1072
        Electrical............1072
        Drive System............1072
        Capacities............1072
        Tires............1072
      ENGINE SPECIFICATIONS............1073
        Cylinder Head Dimensions............1073
        Pistons And Connecting Rod Dimensions............1073
        Cylinder Block And Liner Dimensions............1074
        Crankshaft And Main Bearing Dimensions............1074
        Timing Case, Camshaft And Drive Dimensions............1075
        Oil Pump Dimensions............1075
        Cooling System And Water Pump Dimensions............1075
        Fuel System Specifications............1076
        De-Rating For Altitude............1076
        Engine Torques............1076
        Grinding Specifications For Crankshaft............1077
    TECHNICAL DATA (iSUZU ENGINE)............1079
      LOADER SPECIFICATIONS............1081
        Operation And Performance............1081
        Engine............1081
        Loader Hydraulics............1082
        Electrical............1082
        Drive System............1082
        Capacities............1082
        Tires............1082
      ENGINE SPECIFICATIONS............1083
        Cylinder Head............1083
        Valve, Vale Guide And Seat Insert............1083
        Valve Springs............1083
        Rocker Arm............1083
        Tappets............1084
        Piston, Pin And Rings............1084
        Connecting Rod & Bearing............1084
        Cylinder Liners............1084
        Camshaft............1084
        Crankshaft............1085
        Idler Gear............1085
        Oil Pump............1085
        Fuel System............1085
        Engine Torque............1086
  SERVICE MANUAL REVISIONS............1087
    843-1............1087
    843-2............1089
    843-3............1091
    843-4............1093
    843-5............1095
    843-6............1097
    843-7............1099
    843-8............1101
    843-9............1103
    843-10............1105
    843-11............1107
    843-12............1109
    843-13............1111
    843-14............1113
    843-15............1115
    843-16............1117
6566091 (6-12) - 843, 843B Service Manual............1118
  MAINTENANCE SAFETY............1120
  CONTENTS............1122
    FOREWORD............1124
    SAFETY INSTRUCTIONS............1126
    FIRE PREVENTION............1127
    SERIAL NUMBER LOCATIONS............1128
    LOADER SERIAL NUMBER............1128
    ENGINE SERIAL NUMBER............1128
    DELIVERY REPORT............1128
    BOBCAT LOADER IDENTIFICATION............1129
  PREVENTIVE MAINTENANCE............1130
    SERVICE SCHEDULE............1132
    LIFTING AND BLOCKING THE LOADER............1133
      Procedure............1133
    TRANSPORTING THE BOBCAT LOADER............1134
      Procedure............1134
    LIFT ARM STOP............1135
      Procedure............1135
    OPERATOR CAB............1136
      Seat Bar System............1136
      Seat Bar Inspection............1136
      Seat Bar Maintenance............1137
      Raising The Operator Cab............1138
      Lowering The Operator Cab............1138
    USING AN EXTRA BATTERY (JUMP STARTING)............1139
      Procedure............1139
    REMOTE START SWITCH............1140
      Procedure............1140
  HYDRAULIC SYSTEM............1142
    HYDRAULIC / HYDROSTATIC SCHEMATICS............1144
    TROUBLESHOOTING............1196
    HYDRAULIC SYSTEM INFORMATION............1197
      Flare Connections............1197
      Straight Thread O-Ring Fitting............1197
      Tubelines And Hoses............1197
    LIFT CYLINDER............1198
      Checking The Lift Cylinder(s)............1198
      Removal And Installation............1198
    TILT CYLINDERS............1200
      Checking The Tilt Cylinder............1200
      Removal And Installation............1200
      Rod End Seal............1201
    TILT CYLINDER (CESSNA)............1202
      Disassembly............1202
      Assembly............1204
    HYDRAULIC CYLINDER REPAIR............1208
      Disassembly............1208
      Assembly............1210
    HYDRAULIC CONTROL VALVE (CESSNA)............1213
      Checking The Main Relief Valve............1213
      Main Relief Valve Removal And Installation............1214
      Removal And Installation............1214
      Disassembly............1216
      Inlet Section............1217
      Tilt Section............1218
      Lift Section............1220
      Auxiliary Section............1222
      Valve Spool Bolt............1223
      Assembly............1224
    HYDRAULIC CONTROL VALVE (MELROE)............1225
      Checking The Main Relief Valve............1225
      Main Relief Valve Removal And Installation............1226
      Removal And Installation............1226
      Disassembly And Assembly............1228
      Detent Assembly............1230
      Centering Mechanism............1233
    HYDRAULIC PUMP (SINGLE STAGE)............1234
      Checking The Output Of The Hydraulic Pump............1234
      Removal And Installation............1235
      Disassembly And Assembly............1235
      Inspection............1237
    HYDRAULIC PUMP (DOUBLE STAGE)............1238
      Removal And Installation............1239
      Disassembly And Assembly............1241
      Inspection............1243
    BUCKET POSITION VALVE (S/N 15001 & ABOVE)............1244
      Removal And Installation............1244
      Disassembly And Assembly............1244
    PORT BLOCK (S/N 14999 & BELOW)............1246
      40 Micron Filter (Bronze)............1246
      Neutral By-Pass Valve............1247
      Removal And Installation............1247
    PORT BLOCK (S/N 15001 & ABOVE)............1250
      Removal And Installation............1250
      Charge By-Pass............1251
      Cold Oil By-Pass............1251
    HYDRAULIC FLUID FILTER HOUSING (S/N 15001 & ABOVE)............1252
      Removal And Installation............1252
      By-Pass Valve............1252
    HYDRAULIC/HYDROSTATIC RESERVOIR (S/N 21514 & BELOW)............1253
      Removal And Installation............1253
    HYDRAULIC CONTROL PEDALS (S/N 14999 & BELOW)............1255
      Removal And Installation............1255
      Adjustment............1255
    HYDRAULIC CONTROL PEDALS (S/N 15001 & ABOVE)............1256
      Removal And Installation............1256
      Adjustment............1256
    PEDAL LOCK LINKAGE............1257
      Adjustment............1257
  HYDROSTATIC SYSTEM............1258
    TROUBLESHOOTING............1260
    HYDROSTATIC SYSTEM INFORMATION............1261
      High Pressure Relief/Replenishing Valves Function............1261
    FRONT AND SIDE PANELS (S/N 19999 & BELOW)............1262
      Removal And Installation............1262
    STEERING LEVERS (S/N 16191 & BELOW)............1263
      Removal And Installation............1263
      Repairing The Steering Levers............1264
      Steering Linkage Adjustment............1265
      Removal And Installation............1266
      RepairingThe Pintle Lever............1267
    FRONT AND SIDE PANEL (ONE PIECE) (S/N 20001 & ABOVE) & 843B............1268
      Removal And Installation............1268
    STEERING LEVERS - 843-(S/N 16192 THRU 25999), 843-(STARTING WITH S/N 34222) & 843B............1271
      Removal And Installation............1271
      Repairing The Steering Levers............1272
    STEERING LINKAGE 843-(S/N 16192 THRU 25999), 843-(STARTING WITH S/N 34222) & 843B............1273
      Steering Linkage Adjustment............1273
      Removal And Installation............1274
      Repairing The Pintle Lever............1275
    STEERING LINKAGE (S/N 26000 THRU 29869)............1276
      Description............1276
      Neutral Adjustment............1276
      Steering Lever Centering Spring Mechanism............1278
      Removal And Installation (Creep Mechanism)............1279
    SERVO CONTROL............1282
      Removal And Installation............1282
      Disassembly And Assembly............1283
    PINTLE LEVER ARMS (S/N 26000 - 29869)............1284
      Removal And Installation............1284
    STEERING LINKAGE (S/N 29870 - 31863)............1286
      Description............1286
      Neutral Adjustment............1286
      Steering Lever Centering Spring Mechanism............1288
      Creep Centering Spring Mechanism............1288
      Pintle Arm............1288
    STEERING LINKAGE (S/N 31864-34221)............1289
      Hydrostatic Pump Centering Spring Adjustment............1290
      Servo Control Unit Adjustment............1291
      Steering Lever Centering Spring Adjustment............1292
      Wheel RPM Adjustment (Left To Right)............1293
    HYDROSTATIC MOTOR............1295
      Removal And Installation............1295
      Disassembly And Assembly............1296
      Inspection............1300
      Timing The Hydrostatic Motor............1301
      High Pressure Hose Routing............1301
    HYDROSTATIC PUMPS............1302
      Checking The High Pressure Relief/Replenishing Valve............1302
      Checking Charge Pressure............1303
      Removal And Installation............1303
      Disassembly And Assembly............1304
      Rear Pump............1306
      Front Pump............1306
      Inspection............1309
      Tow Valves............1310
      Hydrostatic Pump Rear Mount (S/N 21574 & Above)............1311
    HYDROSTATIC FLUID FILTER HOUSING............1312
      Removal And Installation............1312
  DRIVE SYSTEM............1314
    PARKING BRAKE............1316
      Adjustment............1316
      Removal And Installation............1316
      Block And Pucks............1317
    AXLES, SEALS AND BEARINGS............1319
      Removal............1319
      Installation............1320
    FINAL DRIVE CHAIN............1323
      Removal............1323
      Installation............1323
    REDUCTION GEARCASE............1325
      Removal And Installation............1325
      Checking Reduction Gearcase............1326
      Disassembly And Assembly............1326
      Installation............1331
      Reduction Gearcase Seal............1332
  MAIN FRAME............1334
    OPERATOR CAB (S/N 19999 & BELOW)............1336
      Removal And Installation............1336
    OPERATOR CAB (S/N 20001 & ABOVE)............1338
      Removal And Installation............1338
    OPERATOR CAB GAS CYLINDER............1341
      Removal And Installation............1341
    REAR DOOR............1342
      Door Latch Adjustment............1342
      Removal And Installation............1343
    LIFT ARMS............1344
      Removal And Installation............1344
    BOB-TACH............1346
      Removal And Installation............1346
      Tilt Cylinder Rod End Seal............1347
      Disassembly And Assembly............1348
    FUEL TANK (S/N 19999 & BELOW)............1350
      Removal And Installation............1350
    FUEL TANK (S/N 20001 & ABOVE)............1351
      Removal And Installation............1351
      Fuel Tank Sender Switch............1352
  ELECTRICAL SYSTEM............1354
    ELECTRICAL SCHEMATICS............1357
    ELECTRICAL SYSTEM INFORMATION............1384
      Description............1384
    TROUBLESHOOTING............1384
    BATTERY............1385
      Checking The Battery............1385
      Removal And Installation............1385
    ALTERNATOR............1386
      Alternator Belt Adjustment............1386
      Checking The Alternator Wire Harness............1387
      Checking Alternator Output............1387
      Checking Alternator Regulator............1387
      Removal And Installation............1388
      Disassembly And Assembly............1389
    MELROE ALTERNATOR............1391
      Checking The Alternator Output............1391
      Checking The Alternator Regulator............1392
      Removal And Installation............1393
      Disassembly And Assembly............1394
    MANDO ALTERNATOR............1396
    STARTER............1397
      Checking The Starter............1397
      Removal And Installation............1397
      Disassembly And Assembly............1399
      Cleaning And Inspection............1399
      Replacing The Brushes............1400
  ENGINE SERVICE............1402
    ENGINE SERVICE (PERKINS ENGINE)............1404
      TROUBLESHOOTING............1406
      VALVE CLEARANCE............1407
        Adjustment............1407
      ENGINE COMPRESSION............1408
        Checking............1408
      FUEL FILTER............1409
        Removal And Installation............1409
        Water Trap............1409
      FUEL LIFT PUMP............1410
        Checking............1410
        Removal And Installation............1410
      REMOVING AIR FROM FUEL SYSTEM............1411
        Procedure............1411
      FUEL INJECTION PUMP............1412
        Removal And Installation............1412
      ENGINE TIMING TO INJECTION PUMP (USING DIAL INDICATOR)............1413
        Procedure............1413
      EMGINE TIMING TO INJECTOR PUMP (USING TIMING TOOL)............1414
        Procedure............1414
      CHECKING TIMING MARK ON INJECTION PUMP FLANGE............1415
        Procedure............1415
      FUEL INJECTOR NOZZLES............1416
        Removal And Installation............1416
        Checking............1417
      ENGINE............1418
        Removal And Installation............1418
      RADIATOR............1422
        Removal And Installation............1422
      OIL COOLER............1423
        Removal And Installation............1423
      ENGINE MUFFLER............1424
        Removal And Installation............1424
      ENGINE BLOWER HOUSING............1425
        Removal And Installation............1425
      ENGINE FLYWHEEL & U-JOINT............1426
        Removal And Installation............1426
        Flywheel Ring Gear............1426
      CYLINDER HEAD............1427
        Removing The Cylinder Head............1427
        Cylinder Head Surface Alignment............1427
        Installing The Cylinder Head............1428
      VALVES............1429
        Removal Of The Valves............1429
        Installing The Valves............1429
        Reconditioning The Valves And Valve Seats............1429
        Installing Valve Guides............1430
        Changing The Valve Springs............1431
      COMBUSTION CHAMBER INSERTS............1432
        Removal And Installation............1432
      ROCKER ARMS............1433
        Disassembly............1433
        Assembly............1433
      PISTON AND CONNECTING RODS............1434
        Removal............1434
        Disassembly............1435
        Inspection............1435
        Installation............1436
      CYLINDER LINERS............1437
        Checking............1437
        Removal And Installation............1437
      MAIN BEARINGS............1438
        Removal............1438
        Installation............1439
        Crankshaft End Play............1439
      CRANKSHAFT............1440
        Removal............1440
        Checking............1440
        Installation............1441
      REAR MAIN OIL SEAL............1442
        Removal And Installation............1442
      TIMING CASE COVER............1443
        Removal And Installation............1443
      IDLER GEAR AND HUB............1444
        Removal............1444
        Installation............1444
      CAMSHAFT GEAR............1446
        Removal............1446
        Installation............1446
      FUEL INJECTION PUMP DRIVE GEAR............1447
        Removal And Installation............1447
      CRANKSHAFT GEAR............1447
        Removal............1447
      TIMING CASE............1448
        Removal And Installation............1448
      CAMSHAFT AND TAPPETS............1449
        Removal............1449
        Inspection............1450
        Installation............1450
      LUBRICATION SYSTEM............1451
        Description............1451
      OIL PUMP............1452
        Removal And Installation............1452
        Disassembly And Assembly............1452
        Checking............1452
      WATER PUMP............1454
        Removal And Installation............1454
        Disassembly............1454
        Checking............1455
        Assembly............1455
      THERMOSTAT............1456
        Removal............1456
        Testing The Thermostat............1456
        Installation............1456
    ENGINE SERVICE (PERKINS ENGINE - 200 SERIES)............1458
      TROUBLESHOOTING............1460
      VALVE CLEARANCE............1461
        Adjustment............1461
      ENGINE COMPRESSION............1462
        Checking............1462
      FUEL FILTER (S/N 13315 & BELOW)............1463
        Removal And Installation............1463
        Water Trap............1463
      FUEL FILTER (S/M 13316 & ABOVE)............1463
        Removal And Installation............1463
      REMOVING AIR FROM THE FUEL SYSTEM (S/N 13315 & BELOW)............1464
        Procedure............1464
      REMOVING AIR FROM THE FUEL SYSTEM (S/N 13316 & ABOVE)............1465
        Procedure............1465
      FUEL INJECTION PUMP............1466
        Removal And Installation............1466
        Maximum Speed Setting............1467
      TIMING THE FUEL INJECTION PUMP............1468
        Procedure............1468
      FUEL INJECTOR NOZZLES............1470
        Removal And Installation............1470
        Checking............1471
      GLOW PLUGS............1472
        Checking............1472
      ENGINE............1473
        Removal And Installation............1473
      RADIATOR............1476
        Removal And Installation............1476
      OIL COOLER............1478
        Removal And Installation............1478
      ENGINE MUFFLER............1479
        Removal And Installation............1479
      ENGINE BLOWER HOUSING............1480
        Removal And Installation............1480
      ENGINE FLYWHEEL & U-JOINT............1481
        Removal And Installation............1481
        Flywheel Ring Gear............1481
      CYLINDER HEAD............1482
        Removing The Cylinder Head............1482
        Cylinder Head Surface Alignment............1482
        Installing The Cylinder Head............1483
      VALVES............1484
        Removing The Valves............1484
        Installing The Valves............1484
        Reconditioning The Valves And Valve Seats............1484
        Installing The Valve Guides............1485
        Checking The Valve Springs............1486
      CONBUSTION CHAMBER INSERTS............1487
        Removal And Installation............1487
      ROCKER ARMS............1488
        Disassembly............1488
        Assembly............1488
      PISTON AND CONNECTING RODS............1489
        Removal............1489
        Disassembly............1490
        Inspection............1490
        Installation............1491
      CYLINDER LINERS............1492
        Checking............1492
        Removal And Installation............1492
      MAIN BEARINGS............1493
        Removal............1493
        Installation............1494
        Crankshaft End Play............1494
      CRANKSHAFT............1495
        Removal............1495
        Installation............1496
      REAR MAIN OIL SEAL............1497
        Removal And Installation............1497
      TIMING CASE COVER............1498
        Removal And Installation............1498
        Front Seal............1499
      IDLER GEAR AND HUB............1500
        Removal............1500
        Installation............1501
      CAMSHAFT GEAR............1502
        Removal............1502
        Installation............1502
      FUEL INJECTION PUMP DRIVE GEAR............1503
        Removal And Installation............1503
      CRANKSHAFT GEAR............1503
        Removal............1503
      TIMING CASE............1504
        Removal And Installation............1504
      CAMSHAFT AND TAPPETS............1505
        Removal............1505
        Inspection............1506
        Installation............1506
      LUBRICATION SYSTEM............1507
        Description............1507
      OIL PUMP............1508
        Removal And Installation............1508
        Inspection............1509
      OIL FILTER ADAPTER HOUSING............1510
        Removal And Installation............1510
      WATER PUMP............1511
        Removal And Installation............1511
        Disassembly............1511
        Checking............1512
        Assembly............1512
      THERMOSTAT............1513
        Removal............1513
        Testing The Thermostat............1513
        Installation............1513
    ENGINE SERVICE (ISUZU ENGINE)............1514
      TROUBLESHOOTING............1516
      VALVE CLEARANCE............1517
        Adjustment............1517
      ENGINE COMPRESSION............1518
        Checking............1518
      FUEL FILTER............1519
        Water Trap............1519
        Fuel Filter Element............1519
      REMOVING AIR FROM FUEL SYSTEM............1520
        Procedure............1520
      FUEL INJECTION PUMP............1521
        Removal And Installation............1521
      ENGINE TIMING TO INJECTION PUMP............1524
        Procedure............1524
      FUEL INJECTOR NOZZLES............1526
        Removal And Installation............1526
        Checking............1527
      GLOW PLUGS............1529
        Removal And Installation............1529
      ENGINE OIL AND FILTER............1530
        Removal And Installation............1530
      ENGINE............1532
        Removal And Installation............1532
      RADIATOR............1537
        Removal And Installation............1537
      OIL COOLER............1539
        Removal And Installation............1539
      ENGINE MUFFLER............1540
        Removal And Installation............1540
      ENGINE FLYWHEEL & U-JOINT............1541
        Removal And Installation............1541
        Flywheel Ring Gear............1541
      ENGINE BLOWER HOUSING............1542
        Removal And Installation............1542
      ENGINE MOUNTS............1543
        Removal And Installation............1543
      CYLINDER HEAD............1544
        Removal And Installation............1544
        Cylinder Head Surface Alignment............1545
        Exhaust Manifold............1545
      VALVES............1546
        Removal And Installation............1546
        Reconditioning The Valves And Valve Seats............1546
        Valve Seat Insert............1547
        Valve Guides............1547
        Valve Springs............1548
      ROCKER ARMS............1549
        Disassembly And Assembly............1549
        Push Rods............1549
      PISTON AND CONNECTING ROD............1550
        Removal............1550
        Disassembly............1550
        Inspection............1551
        Assembly............1554
        Installation............1555
      CYLINDER LINERS............1556
        Checking............1556
        Removal............1556
        Installation............1556
      MAIN BEARINGS............1557
        Removal............1557
        Installation............1558
        Crankshaft End Play............1559
      CRANKSHAFT............1560
        Removal............1560
        Checking Tuffriding (Soft Nitriding) Coating............1560
        Checking............1560
        Crankshaft Gear............1562
        Removal And Installation............1562
        Installation............1562
      TIMING CASE COVER SEAL............1563
        Removal And Installation............1563
      TIMING CASE COVER............1564
        Removal And Installation............1564
      IDLER GEAR AND HUB............1566
        Removal And Installation............1566
        Checking............1566
      FUEL INJECTION PUMP IDLER GEAR............1568
        Removal And Installation............1568
        Bearing Installation............1568
      CAMSHAFT GEAR............1569
        Removal And Installation............1569
      TIMING CASE............1570
        Removal And Installation............1570
      CAMSHAFT............1571
        Removal And Installation............1571
        Checking............1571
        Camshaft Bearing............1572
        Tappets............1572
        Installation............1573
      OIL PAN............1574
        Removal............1574
        Installation............1574
      OIL PUMP............1575
        Removal And Installation............1575
        Checking............1575
        Gear Replacement............1576
        Rotor Replacement............1577
        Oil Pump Relief Valve............1577
      WATER PUMP............1578
        Removal And Installation............1578
        Disassembly............1578
        Assembly............1579
      THERMOSTAT............1581
        Removal And Installation............1581
        Inspection............1581
      WATER JACKET TUBE............1582
        Removal And Installation............1582
  TECHNICAL DATA............1584
    GENERAL SPECIFICATIONS............1586
      TORQUE SPECIFICATIONS............1588
        Seat Bar, Fuel Tank & Panel Group............1588
        Steering Levers, Linkage & Pedal Group............1589
        Brakem Axle & Chaincase Group............1590
        Operator Guard, Lift Arm & Main Frame Group............1591
        Hydraulic/Hydrostatic Group............1592
        Engine Group (Perkins)............1593
        Engine Group (200 Series Perkins)............1595
        Engine Group (Isuzu)............1597
      HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS............1599
      DECIMAL AND MILLIMETER EQUIVALENTS............1600
      U.S. TO METRIC CONVERSION............1600
      STANDARD TORQUE SPECIFICATIONS FOR BOLTS............1601
    TECHNICAL DATA (PERKINS ENGINE)............1602
      LOADER SPECIFICATIONS............1604
        Specifications............1604
        Engine............1604
        Loader Hydraulics............1605
        Electrical............1605
        Drive System............1605
        Capacities............1605
        Tires............1605
      ENGINE SPECIFICATIONS............1606
        Cylinder Head Dimensions............1606
        Piston And Connecting Rod Dimensions............1607
        Cylinder Block And Liner Dimensions............1608
        crankshaft And Main Bearings Dimensions............1608
        Timing Case, Camshaft And Drive Dimensions............1609
        Oil Pump Dimensions............1610
        Cooling System and Wster Pump Dimensions............1611
        Fuel System Specifications............1611
        De-Rating For Altitude............1612
        Engine Torque............1612
        Grinding Specifications For Crankshaft............1613
    TECHNICAL DATA (PERKINS ENGINE - 200 SERIES)............1614
      LOADER SPECIFICATIONS............1616
        Specifications............1616
        Engine............1616
        Loader Hydraulics............1617
        Electrical............1617
        Drive System............1617
        Capacities............1617
        Tires............1617
      ENGINE SPECIFICATIONS............1618
        Cylinder Head Dimensions............1618
        Pistons And Connecting Rod Dimensions............1618
        Cylinder Block And Liner Dimensions............1619
        Crankshaft And Main Bearing Dimensions............1619
        Timing Case, Camshaft And Drive Dimensions............1620
        Oil Pump Dimensions............1620
        Cooling System And Water Pump Dimensions............1620
        Fuel System Specifications............1621
        De-Rating For Altitude............1621
        Engine Torques............1621
        Grinding Specifications For Crankshaft............1622
    TECHNICAL DATA (iSUZU ENGINE)............1624
      LOADER SPECIFICATIONS............1626
        Operation And Performance............1626
        Engine............1626
        Loader Hydraulics............1627
        Electrical............1627
        Drive System............1627
        Capacities............1627
        Tires............1627
      ENGINE SPECIFICATIONS............1628
        Cylinder Head............1628
        Valve, Vale Guide And Seat Insert............1628
        Valve Springs............1628
        Rocker Arm............1628
        Tappets............1629
        Piston, Pin And Rings............1629
        Connecting Rod & Bearing............1629
        Cylinder Liners............1629
        Camshaft............1629
        Crankshaft............1630
        Idler Gear............1630
        Oil Pump............1630
        Fuel System............1630
        Engine Torque............1631
  SERVICE MANUAL REVISIONS............1632
    843-1............1632
    843-2............1634
    843-3............1636
    843-4............1638
    843-5............1640
    843-6............1642
    843-7............1644
    843-8............1646
    843-9............1648
    843-10............1650
    843-11............1652
    843-12............1654
    843-13............1656
    843-14............1658
    843-15............1660
    843-16............1662
    843-17............1664
6566408 (11-82) - 843 Operation & Maintenance Manual............1666
  WARNINGS............1668
  SAFETY INSTRUCTIONS............1670
  FOREWORD............1672
    CONTENTS............1672
    REFERENCE INFORMATION............1672
    843 BOBCAT LOADER IDENTIFICATION............1673
  OPERATING INSTRUCTIONS............1674
    OPERATING INSTRUCTIONS............1676
    CONTROLS............1677
    DECAL LOCATIONS............1678
    DASH PANEL............1679
    THROTTLE CONTROL............1679
    STOPPING THE ENGINE............1679
    PARKING BRAKE............1679
    STEERING LEVERS............1680
    HYDRAULIC CONTROLS............1681
      Foot Pedals (Hydraulic)............1681
      Lift Arm Operation............1681
      Float Position............1681
      Tilt (Bucket) Operation............1681
      Auxiliary Lever............1682
    BEFORE YOU START THE ENGINE............1682
    STARTING THE ENGINE............1683
      Normal Starting Condition............1684
      Making Cold Temperature Starting Easier............1684
      Cold Weather Starting Condition............1685
    BOBCAT LOADER OPERATION............1685
      Bucket Size............1685
      Installation Of Attachments............1686
      Removal Of Attachments............1686
    OPERATING PROCEDURE............1687
      Filling The Bucket............1688
      To Empty The Bucket............1688
      Digging Into The Ground............1689
      Making The Ground Level............1689
      Filling A Hole............1689
    STOPPING THE BOBCAT LOADER............1690
    TRANSPORTING THE BOBCAT LOADER............1690
    LIFT ARM STOP............1691
    LIFTING THE OPERATOR GUARD............1692
    LOWERING THE OPERATOR GUARD............1692
  PREVENTIVE MAINTENANCE............1694
    WARNINGS............1695
    SERVICE SCHEDULE............1696
    ENGINE SERVICE............1697
    ADJUSTING THE DOOR LATCH............1697
    AIR CLEANER SERVICE............1697
    FUEL SYSTEM............1698
    FUEL SYSTEM SERVICE............1698
    FUEL FILTER............1699
    REMOVING AIR FROM THE FUEL SYSTEM............1699
    ENGINE LUBRICATION SYSTEM............1700
    REPLACEMENT OF ENGINE OIL AND FILTER............1700
    ENGINE COOLING SYSTEM............1701
      Coolant Level............1701
    REMOVING COOLANT FROM THE COOLING SYSTEM............1701
    ALTERNATOR BELT............1702
    ELECTRICAL SYSTEM............1702
    USING AN EXTRA BATTERY (JUMP STARTING)............1705
    TO INSTALL A NEW BATTERY............1706
    SPARK ARRESTOR MUFFLER............1707
    HYDRAULIC SYSTEM............1707
    REPLACEMENT OF THE HYDRAULIC FILTER............1709
    HYDRAULIC/HYDROSTATIC FLUID RESERVOIR............1709
      Removing The Hydraulic/Hydrostatic Fluid............1709
    FINAL DRIVE TRANSMISSION (CHAINCASE)............1710
    TIRE MAINTENANCE............1710
      Tire Rotation............1710
      Wheel Nuts............1710
    LUBRICATION OF THE BOBCAT LOADER............1711
    ROLL OVER PROTECTION STRUCTURE (ROPS & FOPS)............1711
    BOB-TACH............1712
    PIVOT PINS............1712
    AUXILIARY CONTROL LOCKBOLT............1712
    BRAKE PEDAL ADJUSTMENT............1713
    SERIAL NUMBER IDENTIFICATION............1713
    DELIVERY REPORT............1713
  MAJOR PARTS............1714
    MAIN FRAME............1716
    OPERATOR GUARD ELECTRICAL............1717
    ENGINE ELECTRICAL............1718
    HYDRAULIC SYSTEM............1719
    DRIVE SYSTEM............1720
    CONTROL PEDALS............1721
    HYDROSTATIC SYSTEM............1722
    HAND CONTROLS............1723
    SEAT & FUEL SYSTEM............1724
    ENGINE & ATTACHING PARTS............1725
    DECALS............1727
  DECALS............1728
    WARNING - 6563484............1730
    SERVICE SCHEDULE - 6561387............1731
    WARNING - 6563380............1733
    WARNING - 6561380............1734
    IMPORTANT - 6560573............1735
  GENERAL INFORMATION............1736
    LOADER SPECIFICATIONS............1738
    OPERATION & PERFORMANCE............1738
    ENGINE............1738
    LOADER HYDRAULICS............1739
    ELECTRICAL............1739
    DRIVE SYSTEM............1739
    CAPACITIES............1739
    TIRES............1739
    ADDITIONAL PUBLICATIONS............1740
  WARRANTY............1742
6566611 (1-84) - 843 Operator's Manual............1744
  WARNINGS............1746
  FOREWORD............1748
    CONTENTS............1748
    SAFETY INSTRUCTIONS............1750
      SAFETY IS YOUR RESPONSIBILITY............1750
      BEFORE YOU OPERATE THE BOBCAT LOADER............1750
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR............1751
    FIRE PREVENTION............1751
    SERIAL NUMBER LOCATIONS............1752
    DELIVERY REPORT............1752
    843 BOBCAT LOADER IDENTIFICATION............1753
  OPERATING INSTRUCTIONS............1754
    OPERATING INSTRUCTIONS............1756
    CONTROLS............1757
    SAFETY SIGNS (DECALS)............1758
    DASH PANEL............1760
    THROTTLE CONTROL............1760
    TO STOP THE ENGINE............1760
    PARKING BRAKE............1760
    STEERING LEVERS............1761
    HYDRAULIC CONTROLS............1762
      Foot Pedal (Hydraulic)............1762
      Lift Arm Operation............1762
      Tilt (Bucket) Operation............1762
      Auxiliary Lever Operation............1762
    BEFORE YOU START THE ENGINE............1763
    STARTING THE ENGINE............1764
      Normal Starting Condition............1765
      Cold Temperature Starting Condition............1766
    ATTACHMENTS AND BUCKETS............1766
      Installation Of Attachments............1767
      Installation Of Bucket............1767
      Removal Of The Bucket............1768
    OPERATING PROCEDURES............1768
      Filling A Bucket............1769
      To Empty The Bucket............1769
      Digging Into The Ground............1770
      Filling A Hole............1771
    PARKING THE BOBCAT LOADER............1771
    TRANSPORTING THE BOBCAT LOADER............1771
    LIFTING THE BOBCAT LOADER............1772
  PREVENTIVE MAINTENANCE............1774
    WARNINGS............1775
    SERVICE SCHEDULE............1776
    LIFT ARM STOP............1777
    LIFTING THE OPERATOR CAB............1777
    LOWERING THE OPERATOR CAB............1778
    ROLL OVER & FALLING OBJECT PROTECTION STRUCTURE (ROPS & FOPS)............1778
    ENGINE SERVICE............1779
    ADJUSTING THE REAR DOOR LATCH............1779
    AIR CLEANER SERVICE............1779
    FUEL SYSTEM............1780
    FUEL SYSTEM SERVICE............1780
    FUEL FILTER............1781
    REMOVING AIR FROM THE FUEL SYSTEM............1781
    ENGINE LUBRICATION SYSTEM............1782
    REPLACEMENT OF ENGINE OIL AND FILTER............1782
    ENGINE COOLING SYSTEM............1783
      Coolant Level............1783
    REMOVING COOLANT FROM THE COOLING SYSTEM............1783
    BELT ADJUSTMENT............1784
    ELECTRICAL SYSTEM............1784
    USING AN EXTRA BATTERY (JUMP STARTING)............1787
    INSTALLING A NEW BATTERY............1788
    SPARK ARRESTOR MUFFLER............1789
    HYDRAULIC/HYDROSTATIC SYSTEM............1791
    REPLACEMENT OF THE HYDRAULIC FILTER............1791
    REPLACMENT OF THE HYDROSTATIC FILTER............1792
    HYDRAULIC/HYDROSTATIC FLUID RESERVOIR............1792
      Checking And Adding Fluid............1792
      Removing The Hydraulic/Hydrostatic Fluid............1792
    FINAL DRIVE TRANSMISSION............1793
      Chaincase............1793
      Reduction Gearcase............1793
    TIRE MAINTENANCE............1793
      Tire Rotation............1793
      Wheel Nuts............1794
    LUBRICATION OF THE BOBCAT LOADER............1794
    BOB-TACH............1795
    PIVOT PINS............1795
    BRAKE PEDAL ADJUSTMENT............1796
    AUXILIARY LOCKBOLT............1796
  TROUBLESHOOTING............1798
    TROUBLESHOOTING THE HYDRAULIC SYSTEM............1800
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM............1801
    TROUBLESHOOTING THE ENGINE............1802
  MAJOR PARTS............1804
    MAIN FRAME............1806
    OPERATOR GUARD ELECTRICAL............1807
    ENGINE ELECTRICAL............1808
    HYDRAULIC SYSTEM............1809
    DRIVE SYSTEM............1810
    CONTROL PEDALS............1811
    HYDROSTATIC SYSTEM............1812
    HAND CONTROLS............1813
    SEAT & FRAME SYSTEM............1814
    ENGINE & ATTACHING PARTS............1815
  WARNING SIGNS............1818
    WARNING - 6565980............1820
    SERVICE SCHEDULE - 6567875............1821
    WARNING - 6563380............1823
    WARNING - 6561380............1824
    IMPORTANT - 6560573............1825
  GENERAL INFORMATION............1826
    LOADER SPECIFICATIONS............1828
    OPERATION & PERFORMANCE............1828
    ENGINE............1828
    LOADER HYDRAULICS............1829
    ELECTRICAL............1829
    DRIVE SYSTEM............1829
    CAPACITIES............1829
    TIRES............1829
    ADDITIONAL PUBLICATIONS............1830
  WARRANTY............1832
6566894 (4-97) - 843 Operation & Maintenance Manual............1834
  OPERATOR SAFETY WARNINGS............1836
  CONTENTS............1838
  FOREWORD............1840
    SERIAL NUMBER LOCATIONS............1842
    LOADER SERIAL NUMBER............1842
    ENGINE SERIAL NUMBER............1842
    DELIVERY REPORT............1842
    BOBCAT LOADER IDENTIFICATION............1843
  SAFETY............1844
    SAFETY INSTRUCTIONS............1846
      Safety Is The Operator's Responsibility............1846
      Before Operating The Bobcat Loader............1847
      Safe Operation Needs A Qualified Operator............1847
    FIRE PREVENTION............1848
  OPERATING INSTRUCTIONS............1850
    OPERATING INSTRUCTIONS............1852
    GETTING ON AND OFF THE LOADER............1852
    SAFETY SIGNS (DECALS)............1853
    LEARNING THE CONTROLS............1853
    DASH PANEL............1856
    THROTTLE CONTROL............1856
    PARKING BRAKE............1856
    STEERING LEVERS............1857
    HYDRAULIC CONTROLS............1858
      Left Foot Pedal / Lift Arm Operation............1858
      Left Foot Pedal / Float Position For the Lift Arms............1858
      Right Foot Pedal / Tilt (Bucket) Operation............1858
      Right Lever / Auxiliary Operation............1859
    BEFORE STARTING THE ENGINE............1859
    STARTING THE ENGINE............1861
      Cold Temperature Starting............1862
    ATTACHMENTS & BUCKETS............1863
      Bucket Or Fork Installation............1864
      Bucket Or Fork Removal............1864
    OPERATING PROCEDURES............1865
      Filling The Bucket............1866
      Emptying The Bucket............1866
      Digging Into The Ground............1867
      Leveling The Ground (Using Float Position For The Lift Arms)............1867
      Backfilling............1868
    PARKING THE LOADER............1868
    TOWING THE LOADER............1868
    TRANSPORTING THE LOADER............1868
    LIFTING THE LOADER............1869
  PREVENTIVE MAINTENANCE............1870
    MAINTENANCE SAFETY............1872
    SERVICE SCHEDULE............1874
    LIFT ARM STOP............1875
    OPERATOR CAB............1875
      Raising The Operator Cab............1876
      Lowering The Operator Cab............1876
    SEAT BAR SYSTEM............1876
      Inspection Of The Seat Bar System............1877
      Service Of The Seat Bar System............1877
    REAR DOOR............1877
      Door Latch Adjustment............1878
    AIR CLEANER............1878
    FUEL SYSTEM............1879
      Filling The Fuel Tank............1879
      Fuel Filter............1880
      Removing Air From The Fuel System............1881
    ENGINE LUBRICATION SYSTEM............1882
      Engine Oil And Filter Replacement............1882
    COOLING SYSTEM............1883
      Coolant Level............1883
      Coolant Replacement............1883
      Cooling System Maintenance............1883
    ALTERNATOR BELT ADJUSTMENT............1884
    ELECTRICAL SYSTEM............1887
      Electrical System Service............1887
      Using An Extra Battery (Jump Starting)............1887
      Battery Replacement............1889
    HYDRAULIC / HYDROSTATIC SYSTEM............1889
      Hydraulic / Hydrostatic Fluid Reservoir............1889
      Checking And Adding Fluid............1889
      Hydraulic Fluid Replacement............1891
      Hydraulic (10 Micron) Filter Replacement............1891
      Hydrostatic (#3 Element) Filter Replacement............1892
    SPARK ARRESTOR MUFFLER............1893
    FINAL DRIVE TRANSMISSION (CHAINCASE)............1893
      Chaincase Fluid Level............1893
    TIRE MAINTENANCE............1894
      Tire Rotation............1894
      Wheel Nuts............1894
    LOADER LUBRICATION............1895
    BOB-TACH............1896
    PIVOT PINS............1896
    BRAKE PEDAL ADJUSTMENT............1896
  TROUBLESHOOTING............1898
    TROUBLESHOOTING THE ENGINE............1900
    TROUBLESHOOTING THE DRIVE SYSTEM............1901
    TROUBLESHOOTING THE HYDRAULIC SYSTEM............1902
  MAJOR PARTS............1904
    MAIN FRAME............1906
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM............1907
    DRIVE SYSTEM............1908
    HYDRAULIC SYSTEM............1909
    HYDROSTATIC SYSTEM............1910
    HAND CONTROLS AND CONTROL PEDALS............1911
    OPERATOR CAB ELECTRICAL SYSTEM............1912
    ENGINE ELECTRICAL............1913
    ENGINE & ATTACHING PARTS............1914
  SAFETY SIGNS............1916
    WARNING - 6565980............1918
    SERVICE SCHEDULE - 6567875............1919
    WARNING - 6568692............1921
    WARNING - 6568691............1922
    IMPORTANT - 6560573............1923
  SPECIFICATIONS............1924
    OPERATION AND PERFORMANCE............1926
    ENGINE............1926
    HYDRAULIC SYSTEM............1927
    ELECTRICAL............1927
    DRIVE SYSTEM............1927
    CAPACITIES............1927
    TIRES............1927
  WARRANTY............1928
6570536 (3-97) - 843 Operation & Maintenance Manual............1930
  OPERATOR SAFETY WARNINGS............1932
  FOREWORD............1934
    CONTENTS............1934
    REFERENCE INFORMATION............1934
    SAFETY INSTRUCTIONS............1936
      SAFETY IS THE OPERATOR'S RESPONSIBILITY............1936
      BEFORE OPERATING THE BOBCAT LOADER............1936
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR............1937
    FIRE PREVENTION............1937
    SERIAL NUMBER LOCATIONS............1938
      Loader Serial Number............1938
      Engine Serial Number............1938
    DELIVERY REPORT............1938
    BOBCAT SKID STEER LOADER IDENTIFICATION............1939
    SAFETY SIGNS (DECALS)............1940
  OPERATING INSTRUCTIONS............1942
    INSTRUMENT PANEL............1944
    LEARNING THE CONTROLS............1945
    THROTTLE CONTROL............1945
    STOPPING THE ENGINE............1945
    STEERING LEVERS............1946
    HYDRAULIC CONTROLS............1947
      Foot Pedals............1947
      Lift Arm Operation............1947
      Tilt Operation (Bucket)............1947
      Auxiliary Lever Operation............1947
      High Horse Power Hydraulics (Optional)............1947
    BEFORE STARTING THE ENGINE............1948
    SEAT BAR RESTRAINT SYSTEM............1949
    OPERATING INSTRUCTIONS............1951
    GETTING ON AND OFF THE LOADER............1951
    GETTING READY FOR OPERATION............1951
    STARTING THE ENGINE............1953
      Normal Starting Condition............1953
      Cold Starting Condition............1954
      Warming The Hydrostatic Transmission............1954
    ATTACHMENTS & BUCKETS............1955
      Installation And Removal............1956
    OPERATING PROCEDURE............1957
      Filling The Bucket............1958
      Emptying The Bucket............1958
      Digging Into The Ground............1958
      Leveling The Ground............1959
      Backfilling............1959
    PARKING THE BOBCAT LOADER............1960
    TRANSPORTING THE BOBCAT LOADER............1960
    LIFTING THE LOADER............1961
    TOWING THE LOADER............1961
  PREVENTIVE MAINTENANCE............1962
    MAINTENANCE SAFETY............1963
    SERVICE SCHEDULE............1964
    LIFT ARM SUPPORT DEVICE............1965
    OPERATOR CAB............1966
      Raising The Operator Cab............1966
      Lowering The Operator Cab............1966
    SEAT BAR SYSTEM............1967
      Seat Bar Inspection............1967
      Seat Bar Maintenance............1967
    REAR DOOR............1968
      Adjustment............1968
    AIR CLEANER SERVICE............1969
    FUEL SYSTEM............1970
      Fuel Specifications............1970
      Filling The Fuel Tank............1970
      Fuel Filter............1970
      Removing Air From The Fuel System............1971
    ENGINE LUBRICATION SYSTEM............1972
      Replacing Engine Oil And Filter............1972
    COOLING SYSTEM............1974
      Coolant Removal............1974
      Cleaning............1974
    ALTERNATOR BELT ADJUSTMENT............1976
    ELECTRICAL SYSTEM............1977
      Electrical System Service............1977
      Using An Extra Battery (Jump Starting)............1977
      Battery Replacement............1978
      Operator Cab Wiring Diagram............1979
      Engine Wiring Diagram............1981
    HYDRAULIC / HYDROSTATIC SYSTEM............1983
      Checking And Adding Fluid............1983
      Hydraulic Filter Replacement............1983
      Hydrostatic Filter Replacement............1983
      Hydraulic Fluid Replacement............1984
      Hydraulic / Hydrostatic Flow Chart............1985
    SPARK ARRESTOR MUFFLER............1989
    FINAL DRIVE TRANSMISSION (CHAINCASE)............1990
    TIRE MAINTENANCE............1990
      Tire Rotation............1990
      Tire Installation On Rim............1990
      Tire Pressure............1990
      Wheel Nuts............1990
    LOADER LUBRICATION............1991
    BOB-TACH............1992
    PIVOT PINS............1992
    BRAKE PEDAL ADJUSTMENT............1992
  TROUBLESHOOTING............1994
    TROUBLESHOOTING THE ENGINE............1996
    TROUBLESHOOTING THE DRIVE SYSTEM............1997
    TROUBLESHOOTING THE HYDRAULIC SYSTEM............1998
  MAJOR PARTS............2000
    MAIN FRAME............2002
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM............2003
    DRIVE SYSTEM............2004
    HYDRAULIC SYSTEM............2005
    HYDROSTATIC SYSTEM............2006
    HAND CONTROLS  AND CONTROL PEDALS............2008
    OPERATOR CAB ELECTRICAL SYSTEM............2009
    ENGINE ELECTRICAL............2011
    ENGINE & ATTACHING PARTS............2012
  SAFETY SIGNS............2014
    WARNING - 6565980............2016
    SERVIC SCHEDULE - 6567875............2017
    WARNING - 6575855............2019
    WARNING - 6575854............2020
    IMPORTANT - 6560573............2021
    DANGER - 6575694............2021
  SPECIFICATIONS............2022
    843............2024
      OPERATION & PERFORMANCE............2024
      ENGINE............2024
      HYDRAULIC SYSTEM............2025
      ELECTRICAL............2025
      DRIVE SYSTEM............2025
      CAPACITIES............2025
      TIRES............2025
    843 HIGH HORSE POWER HYDRULICS............2026
      OPERATION AND PERFORMANCE............2026
      ENGINE............2026
      HYDRAULIC SYSTEM............2027
      ELECTRICAL............2027
      DRIVE SYSTEM............2027
      CAPACITIES............2027
      TIRES............2027
  WARRANTY............2028
6720547 (7-97) - 843B Operation & Maintenance Manual............2030
  OPERATOR SAFETY WARNINGS............2032
  CONTENTS............2034
    REFERENCE INFORMATION............2034
  FOREWORD............2036
    SERIAL NUMBER LOCATIONS............2038
      LOADER SERIAL NUMBER............2038
      ENGINE SERIAL NUMBER............2038
    DELIVERY REPORT............2038
    BOBCAT LOADER IDENTIFICATION............2039
    OPTIONS AND ACCESSORIES............2040
  SAFETY............2042
    SAFETY INSTRUCTIONS............2044
      SAFETY IS THE OPERATOR’S RESPONSIBILITY............2044
      BEFORE OPERATING THE BOBCAT LOADER............2045
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR*............2045
    FIRE PREVENTION............2046
    MACHINE SIGNS (DECALS)............2047
  OPERATING INSTRUCTIONS............2050
    INSTRUMENT PANEL............2052
    THROTTLE CONTROL............2052
    PARKING BRAKE............2053
    STEERING LEVERS............2054
    HYDRAULIC CONTROLS............2055
      Foot Pedals............2055
      Lift Arm Operation............2055
      Tilt Operation (Bucket)............2055
      Auxiliary Lever Operation (Opt.)............2055
    DAILY INSPECTION............2056
    SEAT BAR RESTRAINT SYSTEM............2057
    GETTING READY FOR OPERATION............2058
    STARTING THE ENGINE............2060
      Normal Starting Condition............2060
      Cold Temperature Starting Condition............2061
      Warming The Hydraulic/Hydrostatic System............2062
    STOPPING THE ENGINE............2062
    ATTACHMENTS AND BUCKETS............2063
      Removal And Installation............2064
    OPERATING PROCEDURE............2066
      Filling The Bucket............2067
      Emptying The Bucket............2067
      Digging Into The Ground............2068
      Leveling The Ground (Using Lift Arms In Float Position)............2069
      Backfilling............2069
    PARKING THE BOBCAT LOADER............2070
    TRANSPORTING THE BOBCAT LOADER............2070
    LIFTING THE LOADER............2071
    TOWING THE LOADER............2071
  PREVENTIVE MAINTENANCE............2072
    MAINTENANCE SAFETY............2073
    SERVICE SCHEDULE............2074
    LIFT ARM SUPPORT DEVICE............2075
    OPERATOR CAB............2075
      Raising The Operator Cab............2076
      Lowering The Operator Cab............2076
    SEAT BAR SYSTEM............2077
      Seat Bar Inspection............2077
      Seat Bar Maintenance............2077
    REAR DOOR............2078
      Adjustment............2078
    AIR CLEANER SERVICE............2079
    FUEL SYSTEM............2080
      Fuel Specifications............2080
      Filling The Fuel Tank............2080
      Fuel Filter............2080
      Removing Air From The Fuel System............2081
    ENGINE LUBRICATION SYSTEM............2082
      Replacing Oil And Filter............2082
    COOLING SYSTEM............2084
      Checking The Coolant Level............2084
      Removing Coolant From The Cooling System............2084
      Cleaning The Cooling System............2085
    ALTERNATOR BELT............2086
      Adjusting The Alternator Belt............2086
    ELECTRICAL SYSTEM............2087
      Description............2087
      Electrical System Service............2087
      Using A Booster Battery (Jump Starting)............2087
      Battery Removal And Installation............2088
    HYDRAULIC/HYDROSTATIC SYSTEM............2089
      Checking And Adding Fluid............2089
      Hydraulic Filter Replacement............2089
      Hydrostatic Filter Replacement............2089
      Hydraulic Fluid Replacement............2090
    SPARK ARRESTOR MUFFLER............2091
    TIRE MAINTENANCE............2092
      Wheel Nuts............2092
      Tire Rotation............2092
      Tire Inflation............2092
    FINAL DRIVE TRANSMISSION (CHAINCASE)............2093
      Checking And Adding Oil............2093
    LUBRICATION OF THE BOBCAT LOADER............2094
    BOB–TACH............2095
    PIVOT PINS............2095
    PARKING BRAKE ADJUSTMENT............2095
  TROUBLESHOOTING............2096
    TROUBLESHOOTING THE ENGINE............2098
    TROUBLESHOOTING THE DRIVE SYSTEM............2099
    TROUBLESHOOTING THE HYDRAULIC SYSTEM............2100
  SPECIFICATIONS............2102
    SPECIFICATIONS............2104
    PERFORMANCE............2104
    ENGINE............2104
    HYDRAULIC SYSTEM............2105
    ELECTRICAL............2105
    DRIVE SYSTEM............2105
    CAPACITIES............2105
    TIRES............2105
    ADDITIONAL PUBLICATIONS............2106
  WARRANTY............2108
6720755 (6-12) - 853, 853H Service Manual............2110
  MAINTENANCE SAFETY............2112
  ALPHABETICAL INDEX............2114
  CONTENTS............2116
    FOREWORD............2117
    SAFETY INSTRUCTIONS............2120
    SERIAL NUMBER LOCATIONS............2122
    LOADER SERIAL NUMBER............2122
    ENGINE SERIAL NUMBER............2122
    DELIVERY REPORT............2122
    BOBCAT LOADER IDENTIFICATION............2123
  PREVENTIVE MAINTENANCE............2124
    SERVICE SCHEDULE............2126
    LIFTING AND BLOCKING THE LOADER............2127
      Procedure............2127
    TRANSPORTING THE LOADER............2128
      Procedure............2128
    TOWING THE LOADER............2128
      Procedure............2128
    LIFTING THE LOADER............2129
      Four Point Lift............2129
      Single Point Lift............2129
    LIFT ARM SUPPORT DEVICE............2130
      Engaging The Lift Arm Support Device............2130
      Disengaging The Lift Arm Support Device............2131
    OPERATOR CAB............2132
      Description............2132
      Raising The Operator Cab............2132
      Lowering The Operator Cab............2133
      Emergency Exit............2133
    SEAT BAR RESTRAINT SYSTEM............2134
      Description............2134
      Inspecting The Seat Bar............2134
      Maintaining The Seat Bar............2134
    AIR CLEANER SERVICE............2135
      Replacing Filter Element............2135
    FUEL SYSTEM............2137
      Fuel Specifications............2137
      Filling The Fuel Tank............2137
      Fuel Filter............2137
      Removing Air From The Fuel System............2138
    ENGINE LUBRICATION SYSTEM............2139
      Checking Engine Oil............2139
      Replacing Oil And Filter............2139
    ENGINE COOLING SYSTEM............2141
      Checking The Coolant Level............2141
      Cleaning The Cooling System............2141
      Replacing The Coolant............2142
    ALTERNATOR BELT............2143
      Adjusting The Alternator Belt............2143
    HYDRAULIC/HYDROSTATIC SYSTEM............2144
      Checking And Adding Fluid............2144
      Replacing Hydraulic/Hydrostatic Filters............2144
      Replacing The Hydraulic Fluid............2145
      Hydraulic Reservoir Breather Cap............2146
    SPARK ARRESTOR MUFFLER............2147
      Cleaning Procedure............2147
    TIRE MAINTENANCE............2148
      Wheel Nuts............2148
      Tire Rotation............2148
      Tire Mounting............2148
    FINAL DRIVE TRANSMISSION (CHAINCASE)............2149
      Checking And Adding Oil............2149
    FAN GEARBOX............2149
      Checking And Maintaining............2149
    LUBRICATING THE LOADER............2150
      Procedure............2150
    REMOTE START SWITCH............2152
      Procedure............2152
  HYDRAULIC SYSTEM............2154
    HYDRAULIC/HYDROSTATIC SCHEMATICS............2156
    TROUBLESHOOTING............2182
    HYDRAULIC SYSTEM INFORMATION............2183
      Tighten Procedures............2183
    LIFT CYLINDER(S)............2184
      Checking The Lift Cylinder............2184
      Removal And Installation............2184
    TILT CYLINDER............2186
      Checking The Tilt Cylinder............2186
        Rod End Seal............2187
        HYDRAULIC CYLINDER............2188
        Lift Cylinder Identification............2188
        Tilt Cylinder Identification............2189
        Disassembly............2190
        Assembly............2192
    MAIN RELIEF VALVE............2195
      Checking The Main Relief Valve............2195
      Checking The Main Relief Valve Without Auxiliaries............2196
      Removal And Installation............2197
    DUAL PRESSURE MAIN RELIEF VALVE (S/N 512811001 & Above) W/ Select Valve (JEM)............2198
      Checking The Low Setting............2198
      Checking The High Setting............2199
      Adjusting The Low Setting............2201
      Adjusting The High Setting............2202
    HYDRAULIC CONTROL VALVE............2203
      Removal And Installation............2203
    SELECT VALVE (S/N 512811001 & Above) W/SelectValve (JEM)............2205
      Checking The Relief Valve............2205
      Removal And Installation............2207
      Disassembly And Assembly............2208
      Solenoid Testing............2209
    HYDRAULIC FILTER HOUSING............2210
      Removal And Installation............2210
    HYDRAULIC PUMP............2211
      Checking The Output Of The Pump............2211
      Removal And Installation............2212
    HYDRAULIC FLUID RESERVOIR............2213
      Removal And Installation............2213
    LOCK VALVE (S/N 5103)............2214
      Removal And Installation............2214
    BUCKET POSITION VALVE (S/N 5102) & (S/N 5103)............2215
      Removal And Installation............2215
    FRONT AUXILIARY CONTROL VALVE (Apitech)............2216
      Removal And Installation............2216
    CONTROL PEDALS............2217
      Removal And Installation............2217
      Pedal Adjustment............2217
    PEDAL INTERLOCK LINKAGE............2218
      Removal And Installation............2218
      Pedal Interlock Linkage Adjustment............2219
  HYDROSTATIC SYSTEM............2220
    TROUBLESHOOTING............2222
    HYDROSTATIC SYSTEM INFORMATION............2223
      Replenishing Valve Function............2223
      Tow Valves............2223
    FRONT PANEL............2224
      Removal And Installation............2224
    STEERING LEVERS............2226
      Disassembly And Assembly............2226
      Neutral Pre–Adjustment Checks............2228
      Adjusting Lever Freeplay............2229
      Adjusting The Wheel RPM Forward Compared To Reverse Travel............2230
      Adjusting The Steering Neutral Setting............2232
      Adjusting The Wheel RPM Left Compared To Right Side............2233
      Hydrostatic Pump Neutral Adjustment............2234
    HYDROSTATIC MOTOR............2236
      Removal And Installation............2236
    HYDROSTATIC CHARGE OIL FILTER............2238
      Removal And Installation............2238
    COLD OIL BY–PASS VALVE............2240
      Removal And Installation............2240
    HYDROSTATIC PUMP............2242
      Removal And Installation............2242
      Replenishing/High Pressure Relief Valve............2244
    DRIVE BELT SHIELD............2245
      Removal And Installation............2245
    DRIVE BELT ............2246
      Replacing The Drive Belt............2246
    SPRING LOADED TENSIONER PULLEY............2247
      Parts Identification............2247
      Disassembly............2248
      Assembly............2249
      Adjusting The Drive Belt............2251
    FIXED TENSIONER PULLEY............2252
      Removal And Installation............2252
      Disassembly............2253
      Assembly............2255
      Checking Pulley End Play............2259
      Adjusting The Drive Belt............2260
    OIL COOLER............2261
      Removal And Installation............2261
  DRIVE SYSTEM............2262
    PARKING BRAKE PEDAL............2264
      Adjustment............2264
    PARKING BRAKE............2265
      Removal And Installation............2265
      Brake Block And Pads............2267
      Brake Discs............2268
    FRONT CHAINCASE COVER............2269
      Removal And Installation............2269
    REAR CHAINCASE COVER............2269
      Removal And Installation............2269
    AXLE SEAL............2270
      Removal And Installation............2270
    AXLE, SPROCKET AND BEARINGS............2272
      Removal And Installation............2272
    REDUCTION GEARCASE............2276
      Reduction Gearcase Seal............2276
      Removal And Installation............2277
      Checking Reduction Gearcase............2278
      Disassembly............2278
      Assembly............2283
    DRIVE CHAIN............2287
      Removal And Installation............2287
    CHAINCASE FLUID............2288
      Removing The Fluid From The Chaincase............2288
  MAIN FRAME............2290
    OPERATOR CAB GAS CYLINDER............2292
      Removal And Installation............2292
      Disassembly And Assembly............2293
    OPERATOR CAB............2294
      Removal And Installation............2294
      BOB–TACH............2296
      Removal And Installation............2296
      Bob–Tach Lever And Wedge............2298
      Bob–Tach Stops............2299
    LIFT ARMS............2300
      Removal And Installation............2300
    REAR GRILL............2301
      Removal And Installation............2301
    REAR DOOR............2302
      Removal And Installation............2302
      Hood Removal And Installation............2303
      Bumper Removal And Installation............2303
      Door Latch Removal And Installation............2303
      Door Latch And Catch Adjustment............2303
    FUEL TANK............2304
      Removal And Installation............2304
      Inlet Screen............2305
  ELECTRICAL SYSTEM............2306
    ELECTRICAL SCHEMATICS............2308
    TROUBLESHOOTING............2340
    ELECTRICAL SYSTEM INFORMATION............2341
      Description............2341
      Fuse Location............2341
    BATTERY............2342
      Removal And Installation............2342
      Servicing The Electrical System............2343
      Using A Booster Battery (Jump Starting)............2344
    ALTERNATOR............2345
      Alternator Output Test............2345
      Rectifier (Diode) Test............2345
      Alternator Regulator Test............2346
      Removal And Installation............2347
      Disassembly ............2348
      Stator Continuity Test............2348
      Stator Ground Test............2348
      Rotor Continuity Test............2349
      Rotor Ground Test............2349
      Rectifier Continuity (Diode) Test............2349
      Assembly............2350
    STARTER............2351
      Checking The Starter............2351
      Removal And Installation............2352
      Parts Identification............2353
      Disassembly And Assembly............2354
      Cleaning And Inspection............2356
    STANDARD INSTRUMENT PANEL............2357
      Removal And Installation............2357
    FRONT LIGHTS............2358
      Removal And Installation............2358
    STEERING LEVER CONTROL HANDLE (Early Series)............2359
      Disassembly And Assembly............2359
  ENGINE SERVICE............2360
    TROUBLESHOOTING............2364
    ENGINE SPEED CONTROL............2365
      Removal And Installation............2365
    ENGINE MUFFLER............2366
      Removal And Installation............2366
    AIR CLEANER HOUSING............2367
      Removal And Installation............2367
    COOLANT RECOVERY TANK............2368
      Removal And Installation............2368
    RADIATOR............2369
      Removal And Installation............2369
    FAN DRIVE TENSION PULLEY............2371
      Removal And Installation............2371
    FAN GEARBOX/BLOWER HOUSING............2372
      Removal And Installation............2372
    FAN GEARBOX............2376
      Parts Identification............2376
      Disassembly............2377
      Assembly............2381
      Checking Backlash............2386
    ENGINE............2389
      Removal And Installation............2389
    FLYWHEEL............2396
      Removal And Installation............2396
      Flywheel Ring Gear............2396
    BELT SHIELD............2397
      Removal And Installation............2397
    ENGINE MOUNTS............2398
      Removal And Installation............2398
    GLOW PLUGS............2399
      Checking The Glow Plugs............2399
      Removal And Installation............2399
    VALVE CLEARANCE............2400
      Adjustment............2400
    ENGINE COMPRESSION............2400
      Checking............2400
    FUEL INJECTION PUMP............2401
      Description............2401
      Removal And Installation............2401
      Timing The Injection Pump............2405
    FUEL INJECTOR NOZZLES............2407
      Checking............2408
      Removal And Installation............2407
    CYLINDER HEAD............2410
      Removal And Installation............2410
      Cylinder Head Surface Alignment............2411
      Exhaust Manifold............2411
    VALVES, VALVE SEAT AND GUIDE............2412
      Removal............2412
      Installation............2412
      Reconditioning The Valve And Valve Seats............2412
      Valve Seat Insert............2413
      Valve Guide............2413
      Valve Spring............2414
    ROCKER ARM AND SHAFT............2415
      Disassembly And Assembly............2415
      Checking Rocker Arm And Push Rods............2415
    PISTON AND CONNECTING ROD............2416
      Removal............2416
      Disassembly............2416
      Checking............2417
      Assembly............2420
      Installation............2421
    CYLINDER LINERS............2422
      Checking The Cylinder Bore............2422
      Removal............2422
      Installation............2422
    MAIN BEARINGS............2423
      Description............2423
      Removal............2423
      Installation............2424
      Crankshaft End Play............2425
    CRANKSHAFT............2426
      Removal And Installation............2426
      Checking The Crankshaft............2426
    CRANKSHAFT GEAR............2428
      Removal And Installation............2428
    TIMING GEARCASE COVER SEAL............2429
      Removal And Installation............2429
    TIMING GEARCASE COVER............2430
      Removal And Installation............2430
    IDLER GEAR AND HUB............2432
      Checking............2432
      Installation............2433
    FUEL INJECTION PUMP IDLER GEAR............2434
      Removal And Installation............2434
      Bearing Installation............2434
    CAMSHAFT GEAR............2435
      Removal And Installation............2435
    TIMING GEARCASE............2436
      Removal And Installation............2436
    CAMSHAFT............2437
      Removal And Installation............2437
      Checking............2437
      Camshaft Bearings............2438
      Tappets............2438
      Tappet Installation............2439
    OIL PAN............2440
      Removal............2440
      Installation............2440
    OIL PUMP............2441
      Removal And Installation............2441
      Checking............2441
      Gear Replacement............2442
      Rotor Replacement............2443
      Oil Pump Relief Valve............2443
      Oil Filter Housing And Block............2443
    WATER PUMP............2444
      Removal And Installation............2444
      Disassembly............2444
      Assembly............2445
    THERMOSTAT............2447
      Removal And Installation............2447
      Checking The Thermostat............2447
    WATER JACKET TUBE............2448
      Removal And Installation............2448
  SYSTEM ANALYSIS............2450
    BOSS® DIAGNOSTIC TOOL............2452
      Procedure............2452
    SENDER AND SENSOR............2452
      Service Checks............2452
      Component............2452
    RPM SENSOR............2453
      Adjustment............2453
    SERVICE CODES ............2454
      Chart............2454
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY............2456
    BOSS® UNIT............2457
      Removal And Installation............2457
    BOSS® INSTRUMENT PANEL............2458
      Removal And Installation............2458
  SPECIFICATIONS............2460
    LOADER SPECIFICATIONS............2462
      Loader Dimensions............2462
      Performance............2462
      Controls............2462
      Engine............2462
      Hydraulic System............2463
      Electrical............2463
      Drive System............2463
      Capacities............2463
      Tires............2463
    ENGINE SPECIFICATIONS............2464
      Cylinder Head............2464
      Valve, Valve Guide & Seat Insert............2464
      Valve Springs............2464
      Rocker Arm............2464
      Tappets............2464
      Piston, Pin & Rings............2465
      Connecting Rod & Bearing............2465
      Cylinder Liners............2465
      Camshaft............2465
      Crankshaft............2466
      Idler Gear............2466
      Oil Pump............2466
      Fuel System............2466
    TORQUE SPECIFICATIONS FOR LOADER............2467
    TORQUE SPECIFICATIONS FOR BOLTS............2469
      Torque For General SAE Bolts............2469
      Torque For General Metric Bolts............2470
    HYDRAULIC CONNECTION SPECIFICATIONS............2471
      O–ring Face Seal Connection............2471
      Straight Thread O–ring Fitting............2471
      Tubelines And Hoses............2471
      Flare Fitting............2471
      O–ring Flare Fitting............2472
      Port Seal Fitting............2474
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS............2475
    DECIMAL AND MILLIMETER EQUIVALENTS............2476
    U.S. TO METRIC CONVERSION............2476
  SERVICE MANUAL REVISIONS............2478
    850–001............2478
    850–002............2480
    850–003............2482
    850–004............2484
    850–005............2486
    850–006............2488
    850–007............2490
    850–008............2492
    850–009............2494
    850–010............2496
    850–011............2498
    850–012............2500
    850–13............2502
    850-14............2504
    850-15............2506
6720755 (6-99) - 853, 853H Service Manual............2508
  MAINTENANCE SAFETY............2510
  ALPHABETICAL INDEX............2512
  CONTENTS............2514
    FOREWORD............2515
    SAFETY INSTRUCTIONS............2518
    SERIAL NUMBER LOCATIONS............2520
    LOADER SERIAL NUMBER............2520
    ENGINE SERIAL NUMBER............2520
    DELIVERY REPORT............2520
    BOBCAT LOADER IDENTIFICATION............2521
  PREVENTIVE MAINTENANCE............2522
    SERVICE SCHEDULE............2524
    LIFTING AND BLOCKING THE LOADER............2525
      Procedure............2525
    TRANSPORTING THE LOADER............2526
      Procedure............2526
    TOWING THE LOADER............2526
      Procedure............2526
    LIFTING THE LOADER............2527
      Four Point Lift............2527
      Single Point Lift............2527
    LIFT ARM SUPPORT DEVICE............2528
      Engaging The Lift Arm Support Device............2528
      Disengaging The Lift Arm Support Device............2529
    OPERATOR CAB............2530
      Description............2530
      Raising The Operator Cab............2530
      Lowering The Operator Cab............2531
      Emergency Exit............2531
    SEAT BAR RESTRAINT SYSTEM............2532
      Description............2532
      Inspecting The Seat Bar............2532
      Maintaining The Seat Bar............2532
    AIR CLEANER SERVICE............2533
      Replacing Filter Element............2533
    FUEL SYSTEM............2535
      Fuel Specifications............2535
      Filling The Fuel Tank............2535
      Fuel Filter............2535
      Removing Air From The Fuel System............2536
    ENGINE LUBRICATION SYSTEM............2537
      Checking Engine Oil............2537
      Replacing Oil And Filter............2537
    ENGINE COOLING SYSTEM............2539
      Checking The Coolant Level............2539
      Cleaning The Cooling System............2539
      Replacing The Coolant............2540
    ALTERNATOR BELT............2541
      Adjusting The Alternator Belt............2541
    HYDRAULIC/HYDROSTATIC SYSTEM............2542
      Checking And Adding Fluid............2542
      Replacing Hydraulic/Hydrostatic Filters............2542
      Replacing The Hydraulic Fluid............2543
      Hydraulic Reservoir Breather Cap............2544
    SPARK ARRESTOR MUFFLER............2545
      Cleaning Procedure............2545
    TIRE MAINTENANCE............2546
      Wheel Nuts............2546
      Tire Rotation............2546
      Tire Mounting............2546
    FINAL DRIVE TRANSMISSION (CHAINCASE)............2547
      Checking And Adding Oil............2547
    FAN GEARBOX............2547
      Checking And Maintaining............2547
    LUBRICATING THE LOADER............2548
      Procedure............2548
    REMOTE START SWITCH............2550
      Procedure............2550
  HYDRAULIC SYSTEM............2552
    HYDRAULIC/HYDROSTATIC SCHEMATICS............2554
    TROUBLESHOOTING............2580
    HYDRAULIC SYSTEM INFORMATION............2581
      Tighten Procedures............2581
    LIFT CYLINDER(S)............2582
      Checking The Lift Cylinder............2582
      Removal And Installation............2582
    TILT CYLINDER............2584
      Checking The Tilt Cylinder............2584
        Rod End Seal............2585
        HYDRAULIC CYLINDER............2586
        Lift Cylinder Identification............2586
        Tilt Cylinder Identification............2587
        Disassembly............2588
        Assembly............2590
    MAIN RELIEF VALVE............2593
      Checking The Main Relief Valve............2593
      Checking The Main Relief Valve Without Auxiliaries............2594
      Removal And Installation............2595
    DUAL PRESSURE MAIN RELIEF VALVE (S/N 512811001 & Above) W/ Select Valve (JEM)............2596
      Checking The Low Setting............2596
      Checking The High Setting............2597
      Adjusting The Low Setting............2599
      Adjusting The High Setting............2600
    HYDRAULIC CONTROL VALVE............2601
      Removal And Installation............2601
    SELECT VALVE (S/N 512811001 & Above) W/SelectValve (JEM)............2603
      Checking The Relief Valve............2603
      Removal And Installation............2605
      Disassembly And Assembly............2606
      Solenoid Testing............2607
    HYDRAULIC FILTER HOUSING............2608
      Removal And Installation............2608
    HYDRAULIC PUMP............2609
      Checking The Output Of The Pump............2609
      Removal And Installation............2610
    HYDRAULIC FLUID RESERVOIR............2611
      Removal And Installation............2611
    LOCK VALVE (S/N 5103)............2612
      Removal And Installation............2612
    BUCKET POSITION VALVE (S/N 5102) & (S/N 5103)............2613
      Removal And Installation............2613
    FRONT AUXILIARY CONTROL VALVE (Apitech)............2614
      Removal And Installation............2614
    CONTROL PEDALS............2615
      Removal And Installation............2615
      Pedal Adjustment............2615
    PEDAL INTERLOCK LINKAGE............2616
      Removal And Installation............2616
      Pedal Interlock Linkage Adjustment............2617
  HYDROSTATIC SYSTEM............2618
    TROUBLESHOOTING............2620
    HYDROSTATIC SYSTEM INFORMATION............2621
      Replenishing Valve Function............2621
      Tow Valves............2621
    FRONT PANEL............2622
      Removal And Installation............2622
    STEERING LEVERS............2624
      Disassembly And Assembly............2624
      Neutral Pre–Adjustment Checks............2626
      Adjusting Lever Freeplay............2627
      Adjusting The Wheel RPM Forward Compared To Reverse Travel............2628
      Adjusting The Steering Neutral Setting............2630
      Adjusting The Wheel RPM Left Compared To Right Side............2631
      Hydrostatic Pump Neutral Adjustment............2632
    HYDROSTATIC MOTOR............2634
      Removal And Installation............2634
    HYDROSTATIC CHARGE OIL FILTER............2636
      Removal And Installation............2636
    COLD OIL BY–PASS VALVE............2638
      Removal And Installation............2638
    HYDROSTATIC PUMP............2640
      Removal And Installation............2640
      Replenishing/High Pressure Relief Valve............2642
    DRIVE BELT SHIELD............2643
      Removal And Installation............2643
    DRIVE BELT ............2644
      Replacing The Drive Belt............2644
    SPRING LOADED TENSIONER PULLEY............2645
      Parts Identification............2645
      Disassembly............2646
      Assembly............2647
      Adjusting The Drive Belt............2649
    FIXED TENSIONER PULLEY............2650
      Removal And Installation............2650
      Disassembly............2651
      Assembly............2653
      Checking Pulley End Play............2657
      Adjusting The Drive Belt............2658
    OIL COOLER............2659
      Removal And Installation............2659
  DRIVE SYSTEM............2660
    PARKING BRAKE PEDAL............2662
      Adjustment............2662
    PARKING BRAKE............2663
      Removal And Installation............2663
      Brake Block And Pads............2665
      Brake Discs............2666
    FRONT CHAINCASE COVER............2667
      Removal And Installation............2667
    REAR CHAINCASE COVER............2667
      Removal And Installation............2667
    AXLE SEAL............2668
      Removal And Installation............2668
    AXLE, SPROCKET AND BEARINGS............2670
      Removal And Installation............2670
    REDUCTION GEARCASE............2674
      Reduction Gearcase Seal............2674
      Removal And Installation............2675
      Checking Reduction Gearcase............2676
      Disassembly............2676
      Assembly............2681
    DRIVE CHAIN............2685
      Removal And Installation............2685
    CHAINCASE FLUID............2686
      Removing The Fluid From The Chaincase............2686
  MAIN FRAME............2688
    OPERATOR CAB GAS CYLINDER............2690
      Removal And Installation............2690
      Disassembly And Assembly............2691
    OPERATOR CAB............2692
      Removal And Installation............2692
      BOB–TACH............2694
      Removal And Installation............2694
      Bob–Tach Lever And Wedge............2696
      Bob–Tach Stops............2697
    LIFT ARMS............2698
      Removal And Installation............2698
    REAR GRILL............2699
      Removal And Installation............2699
    REAR DOOR............2700
      Removal And Installation............2700
      Hood Removal And Installation............2701
      Bumper Removal And Installation............2701
      Door Latch Removal And Installation............2701
      Door Latch And Catch Adjustment............2701
    FUEL TANK............2702
      Removal And Installation............2702
      Inlet Screen............2703
  ELECTRICAL SYSTEM............2704
    ELECTRICAL SCHEMATICS............2706
    TROUBLESHOOTING............2738
    ELECTRICAL SYSTEM INFORMATION............2739
      Description............2739
      Fuse Location............2739
    BATTERY............2740
      Removal And Installation............2740
      Servicing The Electrical System............2741
      Using A Booster Battery (Jump Starting)............2742
    ALTERNATOR............2743
      Alternator Output Test............2743
      Rectifier (Diode) Test............2743
      Alternator Regulator Test............2744
      Removal And Installation............2745
      Disassembly ............2746
      Stator Continuity Test............2746
      Stator Ground Test............2746
      Rotor Continuity Test............2747
      Rotor Ground Test............2747
      Rectifier Continuity (Diode) Test............2747
      Assembly............2748
    STARTER............2749
      Checking The Starter............2749
      Removal And Installation............2750
      Parts Identification............2751
      Disassembly And Assembly............2752
      Cleaning And Inspection............2754
    STANDARD INSTRUMENT PANEL............2755
      Removal And Installation............2755
    FRONT LIGHTS............2756
      Removal And Installation............2756
    STEERING LEVER CONTROL HANDLE (Early Series)............2757
      Disassembly And Assembly............2757
  ENGINE SERVICE............2758
    TROUBLESHOOTING............2762
    ENGINE SPEED CONTROL............2763
      Removal And Installation............2763
    ENGINE MUFFLER............2764
      Removal And Installation............2764
    AIR CLEANER HOUSING............2765
      Removal And Installation............2765
    COOLANT RECOVERY TANK............2766
      Removal And Installation............2766
    RADIATOR............2767
      Removal And Installation............2767
    FAN DRIVE TENSION PULLEY............2769
      Removal And Installation............2769
    FAN GEARBOX/BLOWER HOUSING............2770
      Removal And Installation............2770
    FAN GEARBOX............2774
      Parts Identification............2774
      Disassembly............2775
      Assembly............2779
      Checking Backlash............2784
    ENGINE............2787
      Removal And Installation............2787
    FLYWHEEL............2794
      Removal And Installation............2794
      Flywheel Ring Gear............2794
    BELT SHIELD............2795
      Removal And Installation............2795
    ENGINE MOUNTS............2796
      Removal And Installation............2796
    GLOW PLUGS............2797
      Checking The Glow Plugs............2797
      Removal And Installation............2797
    VALVE CLEARANCE............2798
      Adjustment............2798
    ENGINE COMPRESSION............2798
      Checking............2798
    FUEL INJECTION PUMP............2799
      Description............2799
      Removal And Installation............2799
      Timing The Injection Pump............2803
    FUEL INJECTOR NOZZLES............2805
      Checking............2806
      Removal And Installation............2805
    CYLINDER HEAD............2808
      Removal And Installation............2808
      Cylinder Head Surface Alignment............2809
      Exhaust Manifold............2809
    VALVES, VALVE SEAT AND GUIDE............2810
      Removal............2810
      Installation............2810
      Reconditioning The Valve And Valve Seats............2810
      Valve Seat Insert............2811
      Valve Guide............2811
      Valve Spring............2812
    ROCKER ARM AND SHAFT............2813
      Disassembly And Assembly............2813
      Checking Rocker Arm And Push Rods............2813
    PISTON AND CONNECTING ROD............2814
      Removal............2814
      Disassembly............2814
      Checking............2815
      Assembly............2818
      Installation............2819
    CYLINDER LINERS............2820
      Checking The Cylinder Bore............2820
      Removal............2820
      Installation............2820
    MAIN BEARINGS............2821
      Description............2821
      Removal............2821
      Installation............2822
      Crankshaft End Play............2823
    CRANKSHAFT............2824
      Removal And Installation............2824
      Checking The Crankshaft............2824
    CRANKSHAFT GEAR............2826
      Removal And Installation............2826
    TIMING GEARCASE COVER SEAL............2827
      Removal And Installation............2827
    TIMING GEARCASE COVER............2828
      Removal And Installation............2828
    IDLER GEAR AND HUB............2830
      Checking............2830
      Installation............2831
    FUEL INJECTION PUMP IDLER GEAR............2832
      Removal And Installation............2832
      Bearing Installation............2832
    CAMSHAFT GEAR............2833
      Removal And Installation............2833
    TIMING GEARCASE............2834
      Removal And Installation............2834
    CAMSHAFT............2835
      Removal And Installation............2835
      Checking............2835
      Camshaft Bearings............2836
      Tappets............2836
      Tappet Installation............2837
    OIL PAN............2838
      Removal............2838
      Installation............2838
    OIL PUMP............2839
      Removal And Installation............2839
      Checking............2839
      Gear Replacement............2840
      Rotor Replacement............2841
      Oil Pump Relief Valve............2841
      Oil Filter Housing And Block............2841
    WATER PUMP............2842
      Removal And Installation............2842
      Disassembly............2842
      Assembly............2843
    THERMOSTAT............2845
      Removal And Installation............2845
      Checking The Thermostat............2845
    WATER JACKET TUBE............2846
      Removal And Installation............2846
  SYSTEM ANALYSIS............2848
    BOSS® DIAGNOSTIC TOOL............2850
      Procedure............2850
    SENDER AND SENSOR............2850
      Service Checks............2850
      Component............2850
    RPM SENSOR............2851
      Adjustment............2851
    SERVICE CODES ............2852
      Chart............2852
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY............2854
    BOSS® UNIT............2855
      Removal And Installation............2855
    BOSS® INSTRUMENT PANEL............2856
      Removal And Installation............2856
  SPECIFICATIONS............2858
    LOADER SPECIFICATIONS............2860
      Loader Dimensions............2860
      Performance............2860
      Controls............2860
      Engine............2860
      Hydraulic System............2861
      Electrical............2861
      Drive System............2861
      Capacities............2861
      Tires............2861
    ENGINE SPECIFICATIONS............2862
      Cylinder Head............2862
      Valve, Valve Guide & Seat Insert............2862
      Valve Springs............2862
      Rocker Arm............2862
      Tappets............2862
      Piston, Pin & Rings............2863
      Connecting Rod & Bearing............2863
      Cylinder Liners............2863
      Camshaft............2863
      Crankshaft............2864
      Idler Gear............2864
      Oil Pump............2864
      Fuel System............2864
    TORQUE SPECIFICATIONS FOR LOADER............2865
    TORQUE SPECIFICATIONS FOR BOLTS............2867
      Torque For General SAE Bolts............2867
      Torque For General Metric Bolts............2868
    HYDRAULIC CONNECTION SPECIFICATIONS............2869
      O–ring Face Seal Connection............2869
      Straight Thread O–ring Fitting............2869
      Tubelines And Hoses............2869
      Flare Fitting............2869
      O–ring Flare Fitting............2870
      Port Seal Fitting............2872
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS............2873
    DECIMAL AND MILLIMETER EQUIVALENTS............2874
    U.S. TO METRIC CONVERSION............2874
  SERVICE MANUAL REVISIONS............2876
    850–001............2876
    850–002............2878
    850–003............2880
    850–004............2882
    850–005............2884
    850–006............2886
    850–007............2888
    850–008............2890
    850–009............2892
    850–010............2894
    850–011............2896
    850–012............2898
    850–13............2900
    850-14............2902
6722406 (6-97) - 853, 853H Operation & Maintenance Manual............2904
  OPERATOR SAFETY WARNINGS............2906
  CONTENTS............2908
    REFERENCE INFORMATION............2908
    MELROE COMPANY IS ISO 9001 CERTIFIED............2909
    REGULAR MAINTENANCE ITEMS............2909
  FOREWORD............2910
    SERIAL NUMBER LOCATIONS............2912
    LOADER SERIAL NUMBER............2912
    ENGINE SERIAL NUMBER............2912
    DELIVERY REPORT............2912
    BOBCAT SKID STEER LOADER IDENTIFICATION............2913
    OPTIONS AND ACCESSORIES............2914
  SAFETY............2916
    SAFETY INSTRUCTIONS............2918
      SAFETY IS THE OPERATOR’S RESPONSIBILITY............2918
      BEFORE OPERATING THE BOBCAT LOADER............2919
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR*............2919
    FIRE PREVENTION............2920
    MACHINE SIGNS (DECALS)............2921
  OPERATING INSTRUCTIONS............2924
    MONITOR SERVICE CODES............2925
    INSTRUMENT PANEL............2926
    ENGINE SPEED CONTROL............2928
    PARKING BRAKE............2928
    STEERING LEVERS............2929
    HYDRAULIC CONTROLS............2930
      Foot Pedals............2930
        Lift Arm Operation............2930
        Tilt Operation (Bucket)............2930
        Bucket Position Valve Operation............2930
      Auxiliary Hydraulics Operation ............2931
      Auxiliary Hydraulics Operation – 853H Plus (5103)............2932
    DAILY INSPECTION............2934
    SEAT BAR RESTRAINT SYSTEM............2935
    GETTING READY FOR OPERATION............2936
    STARTING THE ENGINE............2937
      Normal Starting Condition – 853 Plus (5102), 853H Plus (5103)............2938
      Cold Temperature Starting Condition – 853 Plus (5102), 853H (5103)............2939
      Normal Starting Condition – 853 Base (5101)............2940
      Cold Temperature Starting Condition – 853 Base (5101)............2941
    STOPPING THE ENGINE............2941
    ATTACHMENTS AND BUCKETS............2942
      Installation And Removal............2943
    OPERATING PROCEDURES............2944
      Filling The Bucket............2945
      Emptying The Bucket............2945
      Digging Into The Ground............2946
      Leveling The Ground (Using Lift Arms In Float Position)............2946
      Backfilling............2947
    PARKING THE BOBCAT LOADER............2947
    TRANSPORTING THE BOBCAT LOADER............2947
    LIFTING THE LOADER............2948
      Four Point Lift............2948
      Single Point Lift............2948
  PREVENTIVE MAINTENANCE............2950
    MAINTENANCE SAFETY............2951
    SERVICE SCHEDULE............2952
    LIFT ARM SUPPORT DEVICE............2953
      To Engage Lift Arm Support Device............2953
      To Disengage Lift Arm Support Device............2953
    OPERATOR CAB............2954
      Raising The Operator Cab............2954
      Lowering The Operator Cab............2954
      Emergency Exit............2955
    SEAT BAR RESTRAINT SYSTEM............2956
      Seat Bar Inspection............2956
      Seat Bar Maintenance............2956
    REAR DOOR............2957
      Adjustment............2957
    REAR GRILL............2957
    AIR CLEANER SERVICE............2958
      853 Plus (5102), 853H Plus (5103)............2958
      853 Base (5101)............2959
    FUEL SYSTEM............2960
      Fuel Specifications............2960
      Filling The Fuel Tank............2960
      Fuel Filter............2960
      Removing Air From The Fuel System............2961
    ENGINE LUBRICATION SYSTEM............2962
      Checking Engine Oil............2962
      Replacing Oil And Filter............2962
    COOLING SYSTEM............2964
      Cleaning The Cooling System............2964
      Checking The Coolant Level............2964
      Removing Coolant From The Cooling System............2965
    ALTERNATOR BELT............2966
      Adjusting The Alternator Belt............2966
    ELECTRICAL SYSTEM............2967
      Description............2967
      Electrical System Service............2967
      Fuses............2967
      Using A Booster Battery (Jump Starting)............2968
      Battery Removal And Installation............2969
    HYDRAULIC/HYDROSTATIC SYSTEM............2970
      Checking And Adding Fluid............2970
      Hydraulic/Hydrostatic Filter Replacement............2970
      Hydraulic Fluid Replacement............2971
      Hydraulic Reservoir Breather Cap............2971
    SPARK ARRESTOR MUFFLER............2972
    TIRE MAINTENANCE............2973
      Wheel Nuts............2973
      Tire Rotation............2973
      Tire Mounting............2973
    FINAL DRIVE TRANSMISSION (CHAINCASE)............2974
      Checking And Adding Oil............2974
    FAN GEARBOX............2974
    DRIVE BELT ............2975
      Adjustment............2975
      Drive Belt Replacement............2975
    LUBRICATION OF THE BOBCAT LOADER............2976
    PIVOT PINS............2977
    BOB–TACH............2978
    PARKING BRAKE PEDAL............2978
      Adjustment............2978
  SYSTEMS ANALYSIS............2980
    MONITOR SERVICE CODES............2981
    SERVICE CODES............2982
  MACHINE SIGN TRANSLATIONS............2984
    IMPORTANT - 6560573............2986
    WARNING - 6579511............2987
    WARNING - 6579510............2988
    SERVICE SCHEDULE - 6708212............2989
    WARNING - 6579528............2991
    WARNING - 6577754............2991
    DANGER - 6722302............2991
    DANGER - 6702301............2991
  SPECIFICATIONS............2992
    853 Base (5101) & 853 Plus (5102)............2994
      LOADER DIMENSIONS............2994
      OPERATION & PERFORMANCE............2994
      ENGINE............2994
      HYDRAULIC SYSTEM............2995
      ELECTRICAL............2995
      DRIVE SYSTEM............2995
      CAPACITIES............2995
      TIRES............2995
    853H Plus (5103)............2996
      LOADER DIMENSIONS............2996
      OPERATION & PERFORMANCE............2996
      ENGINE............2996
      HYDRAULIC SYSTEM............2997
      ELECTRICAL............2997
      DRIVE SYSTEM............2997
      CAPACITIES............2997
      TIRES............2997
    MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES............2998
    ADDITIONAL PUBLICATIONS............3001
  WARRANTY............3002
6722906 (2-94) - 853 Operation & Maintenance Manual............3003
6722906 (6-00) - 853, 853H Operation & Maintenance Manual............3102
  OPERATOR SAFETY WARNINGS............3104
  CONTENTS............3106
    REFERENCE INFORMATION............3106
    BOBCAT COMPANY IS ISO 9001 CERTIFIED............3107
    REGULAR MAINTENANCE ITEMS............3107
  FOREWORD............3108
    SERIAL NUMBER LOCATIONS............3110
    LOADER SERIAL NUMBER............3110
    ENGINE SERIAL NUMBER............3110
    DELIVERY REPORT............3110
    BOBCAT SKID STEER LOADER IDENTIFICATION............3111
  SAFETY............3112
    SAFETY INSTRUCTIONS............3114
      SAFETY IS THE OPERATOR’S RESPONSIBILITY............3114
      BEFORE OPERATING THE BOBCAT LOADER............3115
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR *............3115
    FIRE PREVENTION............3116
    MACHINE SIGNS (DECALS)............3117
  OPERATING INSTRUCTIONS............3120
    INSTRUMENT PANEL............3122
      Standard............3122
      Optional BOSS®............3123
    ENGINE SPEED CONTROL............3124
    PARKING BRAKE............3124
    STEERING LEVERS............3125
    HYDRAULIC CONTROLS............3126
      Foot Pedals............3126
        Lift Arm Operation............3126
        Tilt Operation (Bucket)............3126
        Bucket Position Valve Operation (Optional)............3126
      Auxiliary Hydraulics Operation (Optional)............3127
      Auxiliary Hydraulics Operation (With OptionalBOSS®)............3128
      Auxiliary Hydraulics Operation – 853H (Optional)............3129
    DAILY INSPECTION............3131
    SEAT BAR RESTRAINT SYSTEM............3132
    GETTING READY FOR OPERATION............3133
    STARTING THE ENGINE............3134
      Normal Starting Condition – (Standard)............3135
      Cold Temperature Starting Condition – (Standard)............3136
      Normal Starting Condition – (Optional)............3137
      Warming The Hydraulic/Hydrostatic System............3136
      Normal Starting Condition – (Optional)............3137
      Cold Temperature Starting Condition (Optional)............3138
    STOPPING THE ENGINE............3138
    ATTACHMENTS AND BUCKETS............3139
      Installation And Removal............3140
    OPERATING PROCEDURES............3141
      Filling The Bucket............3142
      Emptying The Bucket............3142
      Digging Into The Ground............3143
      Leveling The Ground (Using Lift Arms In Float Position)............3143
      Backfilling............3144
    PARKING THE BOBCAT LOADER............3144
    TRANSPORTING THE BOBCAT LOADER............3144
    LIFTING THE LOADER............3145
      Four Point Lift............3145
      Single Point Lift............3145
  PREVENTIVE MAINTENANCE............3146
    MAINTENANCE SAFETY............3147
    SERVICE SCHEDULE............3148
    LIFT ARM SUPPORT DEVICE............3149
      To Engage Lift Arm Support Device............3149
      To Disengage Lift Arm Support Device............3149
    OPERATOR CAB............3150
      Raising The Operator Cab............3150
      Lowering The Operator Cab............3150
      Emergency Exit............3151
    SEAT BAR RESTRAINT SYSTEM............3152
      Seat Bar Inspection............3152
      Seat Bar Maintenance............3152
    REAR DOOR............3153
      Adjustment............3153
    REAR GRILL............3153
    AIR CLEANER SERVICE............3154
      Standard............3154
      Optional............3154
      Servicing The Air Cleaner ............3155
    FUEL SYSTEM............3156
      Fuel Specifications............3156
      Filling The Fuel Tank............3156
      Fuel Filter............3156
      Removing Air From The Fuel System............3157
    ENGINE LUBRICATION SYSTEM............3158
      Checking Engine Oil............3158
      Replacing Oil And Filter............3158
    COOLING SYSTEM............3160
      Cleaning The Cooling System............3160
      Checking The Coolant Level............3160
      Removing Coolant From The Cooling System............3161
      Propylene Glycol............3161
    ALTERNATOR BELT............3162
      Adjusting The Alternator Belt............3162
    ELECTRICAL SYSTEM............3163
      Description............3163
      Servicing The Electrical System............3163
      Fuse Location – 853 (Optional) & 853H (Option)............3163
      Fuse Location – 853 (Standard)............3163
      Using A Booster Battery (Jump Starting)............3164
      Battery Removal And Installation............3165
    HYDRAULIC/HYDROSTATIC SYSTEM............3166
      Checking And Adding Fluid............3166
      Hydraulic/Hydrostatic Filter Replacement............3166
      Hydraulic Fluid Replacement............3167
      Hydraulic Reservoir Breather Cap............3167
    SPARK ARRESTOR MUFFLER............3168
    TIRE MAINTENANCE............3169
      Wheel Nuts............3169
      Tire Rotation............3169
      Tire Mounting............3169
    FINAL DRIVE TRANSMISSION (CHAINCASE)............3170
      Checking And Adding Oil............3170
    FAN GEARBOX............3170
    DRIVE BELT ............3171
      Adjustment............3171
      Drive Belt Replacement............3171
    LUBRICATION OF THE BOBCAT LOADER............3172
    PIVOT PINS............3173
    BOB–TACH............3174
    PARKING BRAKE PEDAL............3174
      Adjustment............3174
  SYSTEMS ANALYSIS............3176
    SERVICE CODES............3178
  MACHINE SIGN TRANSLATIONS............3180
    IMPORTANT - 6560573............3182
    WARNING - 6579511............3183
    SERVICE SCHEDULE - 6708212............3184
    WARNING - 6579510............3186
    WARNING - 6579639............3187
    WARNING - 6577754............3187
    DANGER - 6702302............3187
    DANGER - 6702301............3187
  SPECIFICATIONS............3188
    LOADER DIMENSIONS............3190
    OPERATION & PERFORMANCE............3190
    ENGINE............3190
    HYDRAULIC SYSTEM............3191
    ELECTRICAL............3191
    DRIVE SYSTEM............3191
    CAPACITIES............3191
    TIRES............3191
    BOBCAT COMPANY APPROVED ATTACHMENTS & ACCESSORIES............3192
    ATTACHMENTS & ACCESSORIES............3195
    ADDITIONAL PUBLICATIONS............3196
  WARRANTY............3198
6724012 (4-95) - 853, 853H Service Manual............3200
  MAINTENANCE SAFETY............3202
  CONTENTS............3204
    FOREWORD............3205
    SAFETY INSTRUCTIONS............3208
    SERIAL NUMBER LOCATIONS............3210
    LOADER SERIAL NUMBER............3210
    ENGINE SERIAL NUMBER............3210
    DELIVERY REPORT............3210
    BOBCAT LOADER IDENTIFICATION............3211
    OPTIONS AND ACCESSORIES............3212
  PREVENTIVE MAINTENANCE............3214
    SERVICE SCHEDULE............3216
    LIFTING AND BLOCKING THE LOADER............3217
      Procedure............3217
    TRANSPORTING THE LOADER............3218
      Procedure............3218
    TOWING THE LOADER............3218
      Procedure............3218
    STOPPING THE BOBCAT LOADER............3218
    LIFTING THE LOADER............3219
      Four Point Lift............3219
      Single Point Lift............3219
    LIFT ARM SUPPORT DEVICE............3220
      Engaging The Lift Arm Support Device............3220
      Disengaging The Lift Arm Support Device............3220
    OPERATOR CAB............3221
      Description............3221
      Raising The Operator Cab............3221
      Lowering The Operator Cab............3222
      Emergency Exit............3222
    SEAT BAR RESTRAINT SYSTEM............3223
      Description............3223
      Seat Bar Inspection............3223
      Seat Bar Maintenance............3223
    AIR CLEANER SERVICE............3224
      Replacing Filter Element............3224
    FUEL SYSTEM............3226
      Fuel Specifications............3226
      Filling The Fuel Tank............3226
      Fuel Filter............3226
      Removing Air From The Fuel System............3227
    ENGINE LUBRICATION SYSTEM............3228
      Checking Engine Oil............3228
      Replacing Oil And Filter............3228
    ENGINE COOLING SYSTEM............3230
      Cleaning The Cooling System............3230
      Checking The Coolant Level............3230
      Removing Coolant From The Cooling System............3231
      Propylene Glycol............3231
    ALTERNATOR BELT............3231
      Adjusting The Alternator Belt............3231
    USING A BOOSTER BATTERY (Jump Starting)............3232
      Procedure............3232
    HYDRAULIC/HYDROSTATIC SYSTEM............3233
      Checking And Adding Fluid............3233
      Replacing Hydraulic/Hydrostatic Filters............3233
      Replacing Hydraulic Fluid............3234
      Hydraulic Reservoir Breather Cap............3235
    SPARK ARRESTOR MUFFLER............3236
      Cleaning Procedure............3236
    TIRE MAINTENANCE............3237
      Wheel Nuts............3237
      Tire Rotation............3237
      Tire Mounting............3237
    FINAL DRIVE TRANSMISSION (CHAINCASE)............3238
      Checking And Adding Oil............3238
      Removing Oil From The Chaincase............3238
    FAN GEARBOX............3238
      Checking And Maintaining............3238
    LUBRICATING THE LOADER............3239
      Procedure............3239
    REMOTE START SWITCH............3241
      Procedure............3241
  HYDRAULIC SYSTEM............3244
    HYDRAULIC / HYDROSTATIC SCHEMATICS............3246
    TROUBLESHOOTING............3254
    HYDRAULIC SYSTEM INFORMATION............3255
      Flare Connections............3255
      O–ring Face Seal Connection............3255
      Straight Thread O–ring Fitting............3255
      Tubelines And Hoses............3255
    LIFT CYLINDER(S)............3256
      Checking The Lift Cylinder............3256
      Removal And Installation............3256
    TILT CYLINDER............3258
      Checking The Tilt Cylinder............3258
      Removal And Installation............3258
      Rod End Seal............3259
    HYDRAULIC CYLINDER............3260
      Lift Cylinder Identification............3260
      Tilt Cylinder Identification............3261
      Disassembly............3262
      Assembly............3264
    MAIN RELIEF VALVE............3270
      Checking The Main Relief Valve............3270
      Checking The Main Relief Valve Without Auxiliaries............3271
      Removal And Installation............3272
    DUAL PRESSURE MAIN RELIEF VALVE – 853H............3273
      Checking The Low Setting............3273
      Checking The High Setting............3274
      Adjusting The Low Setting............3276
      Adjusting The High Setting............3277
    SELECT VALVE (G.E.M. Block) 853H............3278
      Checking The Main Relief Valve............3278
    HYDRAULIC CONTROL VALVE............3279
      Removal And Installation............3279
      Identification Chart............3281
      Disassembly And Assembly............3282
      Main Relief Valve............3283
      Port Relief Valve............3283
      Anti–Cavitation Valve............3284
      Rubber Boot............3285
      Lift Spool And Detent............3286
      Tilt Spool And Centering Spring............3291
      Auxiliary Spool............3292
      Auxiliary Electric Solenoid............3293
      H Port – Auxiliary Section............3294
      Base End Restrictor............3294
      Inspection............3294
      Spool Seal Installation............3295
    HYDRAULIC PUMP............3296
      Checking The Output Of The Pump............3296
      Removal And Installation............3297
      Parts Identification............3298
      Disassembly............3299
      Inspection............3301
      Assembly............3302
    HYDRAULIC PUMP (Double Gear) 853H............3304
      Checking The Output Of The Pump............3304
      Removal And Installation............3305
      Parts Identification............3306
      Disassembly............3307
      Inspection............3311
      Assembly............3312
    BUCKET POSITION VALVE (Optional)............3315
      Removal And Installation............3315
    HYDRAULIC FLUID RESERVOIR............3316
      Removal And Installation............3316
    HYDROSTATIC FILTER HOUSING............3317
      Removal And Installation............3317
    HYDRAULIC FILTER HOUSING............3318
      Removal And Installation............3318
    CONTROL PEDALS............3319
      Removal And Installation............3319
      Pedal Adjustment............3319
    PEDAL INTERLOCK LINKAGE............3320
      Removal And Installation............3320
      Pedal Interlock Linkage Adjustment............3321
  HYDROSTATIC SYSTEM............3322
    TROUBLESHOOTING............3324
    HYDROSTATIC SYSTEM INFORMATION............3325
      Replenishing Valve Function............3325
    FRONT PANEL............3326
      Removal And Installation............3326
    STEERING LEVERS............3328
      Disassembly And Assembly............3328
      Pre–Adjustment Checks............3330
      Adjusting Lever Freeplay............3331
      Adjusting The Wheel RPM Forward Compared To Reverse Travel............3332
      Adjusting The Steering Neutral Setting............3334
      Adjusting The Wheel RPM Left Compared To Right Side............3335
    HYDROSTATIC MOTOR............3336
      Removal And Installation............3336
      Parts Identification............3337
      Disassembly............3338
      Inspection............3343
      Assembly............3344
      Timing The Hydrostatic Motor............3347
    HYDROSTATIC PUMP............3348
      Removal And Installation............3348
      Replenishing/High Pressure Relief Valve............3350
      Parts Identification............3351
      Hydraulic Pump Removal............3356
      Hydrostatic Pump Separation............3356
      Charge Pump Disassembly............3357
      Disassembly............3358
      Inspection............3367
      Assembly............3369
      Charge Pump Assembly............3378
      Hydrostatic Pump Connection............3379
      Hydraulic Pump Installation............3380
      Hydrostatic Pump Neutral Adjustment............3381
    DRIVE BELT SHIELD............3383
      Removal And Installation............3383
    DRIVE BELT............3384
      Adjusting The Drive Belt............3384
      Replacing The Drive Belt............3385
    DRIVE BELT TENSIONER PULLEY............3386
      Removal And Installation............3386
      Disassembly............3387
      Assembly............3389
      Checking Pulley End Play............3393
    OIL COOLER............3394
      Removal And Installation............3394
  DRIVE SYSTEM............3396
    PARKING BRAKE PEDAL............3398
      Removal And Installation............3398
      Disassembly And Assembly............3399
    PARKING BRAKE DISC............3400
      Removal And Installation............3400
    FRONT CHAINCASE COVER............3402
      Removal And Installation............3402
    REAR CHAINCASE COVER............3402
      Removal And Installation............3402
    AXLE SEAL............3403
      Removal And Installation............3403
    AXLE, SPROCKET AND BEARINGS............3405
      Removal And Installation............3405
    REDUCTION GEARCASE............3409
      Reduction Gearcase Seal............3409
      Removal And Installation............3410
      Checking Reduction Gearcase............3411
      Disassembly............3411
      Assembly............3416
    DRIVE CHAIN............3420
      Removal And Installation............3420
    CHAINCASE FLUID............3421
      Removing The Fluid From The Chaincase............3421
  MAIN FRAME............3422
    SEAT BAR............3424
      Removal And Installation............3424
      Assembly............3426
      Compressing The Gas Cylinder............3427
    OPERATOR CAB GAS CYLINDER............3428
      Removal And Installation............3428
      Disassembly And Assembly............3429
    OPERATOR CAB............3430
      Removal And Installation............3430
    OPERATOR SEAT............3432
      Removal And Installation............3432
    BOB–TACH............3433
      Removal And Installation............3433
      Bob–Tach Lever And Wedge............3435
      Bob–Tach Stops............3436
    LIFT ARMS............3437
      Removal And Installation............3437
    REAR GRILL............3438
      Removal And Installation............3438
    REAR DOOR............3439
      Removal And Installation............3439
      Hood Removal And Installation............3440
      Bumper Removal And Installation............3440
      Door Latch Removal And Installation............3440
      Door Latch And Catch Adjustment............3440
    FUEL TANK............3441
      Removal And Installation............3441
      Inlet Screen............3442
  ELECTRICAL SYSTEM............3444
    ELECTRICAL SCHEMATICS............3446
    TROUBLESHOOTING............3498
    ELECTRICAL SYSTEM INFORMATION............3499
      Description............3499
      Fuse Location (Standard & BOSS® Option)............3499
    BATTERY............3500
      Removal And Installation............3500
    ALTERNATOR............3501
      Alternator Output Test............3501
      Rectifier (Diode) Test............3501
      Alternator Regulator Test............3502
      Removal And Installation............3503
      Disassembly And Inspection............3504
      Stator Continuity Test............3504
      Stator Ground Test............3504
      Rotor Continuity Test............3505
      Rotor Ground Test............3505
      Rectifier Continuity (Diode) Test............3505
      Assembly............3506
    STARTER............3507
      Removal And Installation............3507
      Checking The Starter............3508
      Parts Identification............3509
      Disassembly And Assembly............3510
      Cleaning And Inspection............3512
    STANDARD INSTRUMENT PANEL............3513
      Removal And Installation............3513
    FRONT LIGHTS............3514
      Removal And Installation............3514
    RELAY SWITCHES............3515
      Location............3515
  ENGINE SERVICE............3516
    TROUBLESHOOTING............3518
    ENGINE SPEED CONTROL............3519
      Removal And Installation............3519
      Disassembly............3519
    RADIATOR............3520
      Removal And Installation............3520
    COOLANT RECOVERY TANK............3522
      Removal And Installation............3522
    ENGINE MUFFLER............3523
      Removal And Installation............3523
    AIR CLEANER HOUSING............3524
      Removal And Installation............3524
    BLOWER HOUSING/FAN GEARBOX............3525
      Removal And Installation............3525
    FAN DRIVE TENSION PULLEY............3527
      Removal And Installation............3527
    BLOWER FAN............3528
      Removal And Installation............3528
    FAN GEARBOX............3529
      Parts Identification............3529
      Disassembly............3530
      Assembly............3535
      Checking Backlash............3540
    ENGINE............3543
      Removal And Installation............3543
      Engine Mount Replacement............3550
    FLYWHEEL............3551
      Removal And Installation............3551
      Flywheel Ring Gear............3551
    BELT SHIELD............3552
      Removal And Installation............3552
    VALVE CLEARANCE............3553
      Adjustment............3553
    ENGINE COMPRESSION............3553
      Checking............3553
    GLOW PLUGS............3554
      Removal And Installation............3554
      Checking The Glow Plugs............3554
    FUEL INJECTION PUMP............3555
      Description............3555
      Removal And Installation............3555
      Timing The Injection Pump............3559
    FUEL INJECTOR NOZZLES............3561
      Removal And Installation............3561
      Checking............3562
    CYLINDER HEAD............3564
      Removal And Installation............3564
      Cylinder Head Surface Alignment............3565
      Exhaust Manifold............3565
    VALVES, VALVE SEAT AND GUIDE............3566
      Removal............3566
      Installation............3566
      Reconditioning The Valve And Valve Seats............3566
      Valve Seat Insert............3567
      Valve Guide............3567
      Valve Spring............3568
    ROCKER ARM AND SHAFT............3569
      Disassembly And Assembly............3569
      Checking Rocker Arm And Push Rods............3569
    PISTON AND CONNECTING ROD............3570
      Removal............3570
      Disassembly............3570
      Checking............3571
      Assembly............3574
      Installation............3575
    CYLINDER LINERS............3576
      Checking The Cylinder Bore............3576
      Removal............3576
      Installation............3576
    MAIN BEARINGS............3577
      Description............3577
      Removal............3577
      Installation............3578
      Crankshaft End Play............3579
    CRANKSHAFT............3580
      Removal And Installation............3580
      Checking Tuffriding (Soft Nitriding) Coating............3580
      Checking the Crankshaft............3580
    CRANKSHAFT GEAR............3582
      Removal And Installation............3582
    TIMING GEARCASE COVER SEAL............3583
      Removal And Installation............3583
    TIMING GEARCASE COVER............3584
      Removal And Installation............3584
    IDLER GEAR AND HUB............3586
      Removal............3586
      Checking............3586
      Installation............3587
    FUEL INJECTION PUMP IDLER GEAR............3588
      Removal And Installation............3588
      Bearing Installation............3588
    CAMSHAFT GEAR............3589
      Removal And Installation............3589
    TIMING GEARCASE............3590
      Removal And Installation............3590
    CAMSHAFT............3591
      Removal And Installation............3591
      Checking............3591
      Camshaft Bearings............3592
      Tappets............3592
      Tappet Installation............3593
    OIL PAN............3594
      Removal............3594
      Installation............3594
    OIL PUMP............3595
      Removal And Installation............3595
      Checking............3595
      Gear Replacement............3596
      Rotor Replacement............3597
      Oil Pump Relief Valve............3597
      Oil Filter Housing And Block............3597
    WATER PUMP............3598
      Removal And Installation............3598
      Disassembly............3598
      Assembly............3599
    THERMOSTAT............3601
      Removal And Installation............3601
      Checking The Thermostat............3601
    WATER JACKET TUBE............3602
      Removal And Installation............3602
  SYSTEMS ANALYSIS............3604
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............3606
      Inspecting The BICS System Controller (Engine STOPPED – Key ON)............3606
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)............3606
      Inspecting The Traction Lock (Engine RUNNING)............3606
      Inspecting The Lift Arm By–Pass Control............3606
      Maintenance............3606
      Troubleshooting Chart............3607
      Troubleshooting Guide............3608
        BICS SYSTEM CONTROLLER............3608
        TRACTION LOCK............3609
        SEAT SENSOR............3610
        SEAT BAR SENSOR............3611
        LIFT LOCK BY–PASS VALVE............3612
    BICS™ SYSTEM CONTROLLER............3613
      Removal And Installation............3613
      Controller Test............3614
    SEAT BAR SENSOR............3615
      Removal And Installation............3615
      Seat Bar Sensor Test............3616
    SEAT SENSOR............3617
      Removal And Installation............3617
      Seat Sensor Test............3618
    TRACTION LOCK............3619
      Removal And Installation............3619
    LIFT LOCK BY–PASS VALVE............3620
      Removal And Installation............3620
      Disassembly And Assembly............3621
    TILT LOCK VALVE............3622
      Removal And Installation............3622
      Disassembly And Assembly............3623
    BOSS® DIAGNOSTIC TOOL............3624
      Procedure............3624
    SENDER AND SENSOR............3624
      Service Checks............3624
      Component............3624
    RPM SENSOR............3624
      Adjustment............3624
    MONITOR SERVICE CODES............3625
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY............3628
    OPERATION SENSING SYSTEM UNIT............3629
      Removal And Installation............3629
    BOSS® INSTRUMENT PANEL............3630
      Removal And Installation............3630
    PWM MODULE............3631
      Description............3631
    PWM TROUBLESHOOTING............3632
      Conditions............3632
      Chart............3633
    PWM CONTROL HANDLE............3634
      Handle Testing............3634
    PWM ELECTRIC SOLENOID............3634
      Solenoid Coil Testing............3634
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE............3635
      Controls Identification Chart............3635
  SPECIFICATIONS............3636
    LOADER SPECIFICATIONS............3638
      LOADER DIMENSIONS............3638
      OPERATION & PERFORMANCE............3638
      ENGINE............3638
      HYDRAULIC SYSTEM............3639
      ELECTRICAL............3639
      DRIVE SYSTEM............3639
      CAPACITIES............3639
      TIRES............3639
      VIBRATION DATA............3639
    ENGINE SPECIFICATIONS............3640
      Cylinder Head............3640
      Valve, Valve Guide & Seat Insert............3640
      Valve Springs............3640
      Rocker Arm............3640
      Tappets............3640
      Piston, Pin & Rings............3641
      Connecting Rod & Bearing............3641
      Cylinder Liners............3641
      Camshaft............3641
      Crankshaft............3642
      Idler Gear............3642
      Oil Pump............3642
      Fuel System............3642
      Torque For General Metric Bolts............3643
    TORQUE SPECIFICATIONS FOR LOADER............3644
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS............3646
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS............3647
    DECIMAL AND MILLIMETER EQUIVALENTS............3648
    U.S. TO METRIC CONVERSION............3648
  SERVICE MANUAL REVISIONS............3650
    850–001............3650
    850–002............3652
    850–003............3654
    850–004............3656
    850–005............3658
6724012 (6-12) - 853, 853H Service Manual............3660
  MAINTENANCE SAFETY............3662
  CONTENTS............3664
    FOREWORD............3665
    SAFETY INSTRUCTIONS............3668
    SERIAL NUMBER LOCATIONS............3670
    LOADER SERIAL NUMBER............3670
    ENGINE SERIAL NUMBER............3670
    DELIVERY REPORT............3670
    BOBCAT LOADER IDENTIFICATION............3671
    OPTIONS AND ACCESSORIES............3672
  PREVENTIVE MAINTENANCE............3674
    SERVICE SCHEDULE............3676
    LIFTING AND BLOCKING THE LOADER............3677
      Procedure............3677
    TRANSPORTING THE LOADER............3678
      Procedure............3678
    TOWING THE LOADER............3678
      Procedure............3678
    STOPPING THE BOBCAT LOADER............3678
    LIFTING THE LOADER............3679
      Four Point Lift............3679
      Single Point Lift............3679
    LIFT ARM SUPPORT DEVICE............3680
      Engaging The Lift Arm Support Device............3680
      Disengaging The Lift Arm Support Device............3680
    OPERATOR CAB............3681
      Description............3681
      Raising The Operator Cab............3681
      Lowering The Operator Cab............3682
      Emergency Exit............3682
    SEAT BAR RESTRAINT SYSTEM............3683
      Description............3683
      Seat Bar Inspection............3683
      Seat Bar Maintenance............3683
    AIR CLEANER SERVICE............3684
      Replacing Filter Element............3684
    FUEL SYSTEM............3686
      Fuel Specifications............3686
      Filling The Fuel Tank............3686
      Fuel Filter............3686
      Removing Air From The Fuel System............3687
    ENGINE LUBRICATION SYSTEM............3688
      Checking Engine Oil............3688
      Replacing Oil And Filter............3688
    ENGINE COOLING SYSTEM............3690
      Cleaning The Cooling System............3690
      Checking The Coolant Level............3690
      Removing Coolant From The Cooling System............3691
      Propylene Glycol............3691
    ALTERNATOR BELT............3691
      Adjusting The Alternator Belt............3691
    USING A BOOSTER BATTERY (Jump Starting)............3692
      Procedure............3692
    HYDRAULIC/HYDROSTATIC SYSTEM............3693
      Checking And Adding Fluid............3693
      Replacing Hydraulic/Hydrostatic Filters............3693
      Replacing Hydraulic Fluid............3694
      Hydraulic Reservoir Breather Cap............3695
    SPARK ARRESTOR MUFFLER............3696
      Cleaning Procedure............3696
    TIRE MAINTENANCE............3697
      Wheel Nuts............3697
      Tire Rotation............3697
      Tire Mounting............3697
    FINAL DRIVE TRANSMISSION (CHAINCASE)............3698
      Checking And Adding Oil............3698
      Removing Oil From The Chaincase............3698
    FAN GEARBOX............3698
      Checking And Maintaining............3698
    LUBRICATING THE LOADER............3699
      Procedure............3699
    REMOTE START SWITCH............3701
      Procedure............3701
  HYDRAULIC SYSTEM............3704
    HYDRAULIC / HYDROSTATIC SCHEMATICS............3706
    TROUBLESHOOTING............3714
    HYDRAULIC SYSTEM INFORMATION............3715
      Flare Connections............3715
      O–ring Face Seal Connection............3715
      Straight Thread O–ring Fitting............3715
      Tubelines And Hoses............3715
    LIFT CYLINDER(S)............3716
      Checking The Lift Cylinder............3716
      Removal And Installation............3716
    TILT CYLINDER............3718
      Checking The Tilt Cylinder............3718
      Removal And Installation............3718
      Rod End Seal............3719
    HYDRAULIC CYLINDER............3720
      Lift Cylinder Identification............3720
      Tilt Cylinder Identification............3721
      Disassembly............3722
      Assembly............3724
    MAIN RELIEF VALVE............3730
      Checking The Main Relief Valve............3730
      Checking The Main Relief Valve Without Auxiliaries............3731
      Removal And Installation............3732
    DUAL PRESSURE MAIN RELIEF VALVE – 853H............3733
      Checking The Low Setting............3733
      Checking The High Setting............3734
      Adjusting The Low Setting............3736
      Adjusting The High Setting............3737
    SELECT VALVE (G.E.M. Block) 853H............3738
      Checking The Main Relief Valve............3738
    HYDRAULIC CONTROL VALVE............3739
      Removal And Installation............3739
      Identification Chart............3741
      Disassembly And Assembly............3742
      Main Relief Valve............3743
      Port Relief Valve............3743
      Anti–Cavitation Valve............3744
      Rubber Boot............3745
      Lift Spool And Detent............3746
      Tilt Spool And Centering Spring............3751
      Auxiliary Spool............3752
      Auxiliary Electric Solenoid............3753
      H Port – Auxiliary Section............3754
      Base End Restrictor............3754
      Inspection............3754
      Spool Seal Installation............3755
    HYDRAULIC PUMP............3756
      Checking The Output Of The Pump............3756
      Removal And Installation............3757
      Parts Identification............3758
      Disassembly............3759
      Inspection............3761
      Assembly............3762
    HYDRAULIC PUMP (Double Gear) 853H............3764
      Checking The Output Of The Pump............3764
      Removal And Installation............3765
      Parts Identification............3766
      Disassembly............3767
      Inspection............3771
      Assembly............3772
    BUCKET POSITION VALVE (Optional)............3775
      Removal And Installation............3775
    HYDRAULIC FLUID RESERVOIR............3776
      Removal And Installation............3776
    HYDROSTATIC FILTER HOUSING............3777
      Removal And Installation............3777
    HYDRAULIC FILTER HOUSING............3778
      Removal And Installation............3778
    CONTROL PEDALS............3779
      Removal And Installation............3779
      Pedal Adjustment............3779
    PEDAL INTERLOCK LINKAGE............3780
      Removal And Installation............3780
      Pedal Interlock Linkage Adjustment............3781
  HYDROSTATIC SYSTEM............3782
    TROUBLESHOOTING............3784
    HYDROSTATIC SYSTEM INFORMATION............3785
      Replenishing Valve Function............3785
    FRONT PANEL............3786
      Removal And Installation............3786
    STEERING LEVERS............3788
      Disassembly And Assembly............3788
      Pre–Adjustment Checks............3790
      Adjusting Lever Freeplay............3791
      Adjusting The Wheel RPM Forward Compared To Reverse Travel............3792
      Adjusting The Steering Neutral Setting............3794
      Adjusting The Wheel RPM Left Compared To Right Side............3795
    HYDROSTATIC MOTOR............3796
      Removal And Installation............3796
      Parts Identification............3797
      Disassembly............3798
      Inspection............3803
      Assembly............3804
      Timing The Hydrostatic Motor............3807
    HYDROSTATIC PUMP............3808
      Removal And Installation............3808
      Replenishing/High Pressure Relief Valve............3810
      Parts Identification............3811
      Hydraulic Pump Removal............3816
      Hydrostatic Pump Separation............3816
      Charge Pump Disassembly............3817
      Disassembly............3818
      Inspection............3827
      Assembly............3829
      Charge Pump Assembly............3838
      Hydrostatic Pump Connection............3839
      Hydraulic Pump Installation............3840
      Hydrostatic Pump Neutral Adjustment............3841
    DRIVE BELT SHIELD............3843
      Removal And Installation............3843
    DRIVE BELT............3844
      Adjusting The Drive Belt............3844
      Replacing The Drive Belt............3845
    DRIVE BELT TENSIONER PULLEY............3846
      Removal And Installation............3846
      Disassembly............3847
      Assembly............3849
      Checking Pulley End Play............3853
    OIL COOLER............3854
      Removal And Installation............3854
  DRIVE SYSTEM............3856
    PARKING BRAKE PEDAL............3858
      Removal And Installation............3858
      Disassembly And Assembly............3859
    PARKING BRAKE DISC............3860
      Removal And Installation............3860
    FRONT CHAINCASE COVER............3862
      Removal And Installation............3862
    REAR CHAINCASE COVER............3862
      Removal And Installation............3862
    AXLE SEAL............3863
      Removal And Installation............3863
    AXLE, SPROCKET AND BEARINGS............3865
      Removal And Installation............3865
    REDUCTION GEARCASE............3869
      Reduction Gearcase Seal............3869
      Removal And Installation............3870
      Checking Reduction Gearcase............3871
      Disassembly............3871
      Assembly............3876
    DRIVE CHAIN............3880
      Removal And Installation............3880
    CHAINCASE FLUID............3881
      Removing The Fluid From The Chaincase............3881
  MAIN FRAME............3882
    SEAT BAR............3884
      Removal And Installation............3884
      Assembly............3886
      Compressing The Gas Cylinder............3887
    OPERATOR CAB GAS CYLINDER............3888
      Removal And Installation............3888
      Disassembly And Assembly............3889
    OPERATOR CAB............3890
      Removal And Installation............3890
    OPERATOR SEAT............3892
      Removal And Installation............3892
    BOB–TACH............3893
      Removal And Installation............3893
      Bob–Tach Lever And Wedge............3895
      Bob–Tach Stops............3896
    LIFT ARMS............3897
      Removal And Installation............3897
    REAR GRILL............3898
      Removal And Installation............3898
    REAR DOOR............3899
      Removal And Installation............3899
      Hood Removal And Installation............3900
      Bumper Removal And Installation............3900
      Door Latch Removal And Installation............3900
      Door Latch And Catch Adjustment............3900
    FUEL TANK............3901
      Removal And Installation............3901
      Inlet Screen............3902
  ELECTRICAL SYSTEM............3904
    ELECTRICAL SCHEMATICS............3906
    TROUBLESHOOTING............3958
    ELECTRICAL SYSTEM INFORMATION............3959
      Description............3959
      Fuse Location (Standard & BOSS® Option)............3959
    BATTERY............3960
      Removal And Installation............3960
    ALTERNATOR............3961
      Alternator Output Test............3961
      Rectifier (Diode) Test............3961
      Alternator Regulator Test............3962
      Removal And Installation............3963
      Disassembly And Inspection............3964
      Stator Continuity Test............3964
      Stator Ground Test............3964
      Rotor Continuity Test............3965
      Rotor Ground Test............3965
      Rectifier Continuity (Diode) Test............3965
      Assembly............3966
    STARTER............3967
      Removal And Installation............3967
      Checking The Starter............3968
      Parts Identification............3969
      Disassembly And Assembly............3970
      Cleaning And Inspection............3972
    STANDARD INSTRUMENT PANEL............3973
      Removal And Installation............3973
    FRONT LIGHTS............3974
      Removal And Installation............3974
    RELAY SWITCHES............3975
      Location............3975
  ENGINE SERVICE............3976
    TROUBLESHOOTING............3978
    ENGINE SPEED CONTROL............3979
      Removal And Installation............3979
      Disassembly............3979
    RADIATOR............3980
      Removal And Installation............3980
    COOLANT RECOVERY TANK............3982
      Removal And Installation............3982
    ENGINE MUFFLER............3983
      Removal And Installation............3983
    AIR CLEANER HOUSING............3984
      Removal And Installation............3984
    BLOWER HOUSING/FAN GEARBOX............3985
      Removal And Installation............3985
    FAN DRIVE TENSION PULLEY............3987
      Removal And Installation............3987
    BLOWER FAN............3988
      Removal And Installation............3988
    FAN GEARBOX............3989
      Parts Identification............3989
      Disassembly............3990
      Assembly............3995
      Checking Backlash............4000
    ENGINE............4003
      Removal And Installation............4003
      Engine Mount Replacement............4010
    FLYWHEEL............4011
      Removal And Installation............4011
      Flywheel Ring Gear............4011
    BELT SHIELD............4012
      Removal And Installation............4012
    VALVE CLEARANCE............4013
      Adjustment............4013
    ENGINE COMPRESSION............4013
      Checking............4013
    GLOW PLUGS............4014
      Removal And Installation............4014
      Checking The Glow Plugs............4014
    FUEL INJECTION PUMP............4015
      Description............4015
      Removal And Installation............4015
      Timing The Injection Pump............4019
    FUEL INJECTOR NOZZLES............4021
      Removal And Installation............4021
      Checking............4022
    CYLINDER HEAD............4024
      Removal And Installation............4024
      Cylinder Head Surface Alignment............4025
      Exhaust Manifold............4025
    VALVES, VALVE SEAT AND GUIDE............4026
      Removal............4026
      Installation............4026
      Reconditioning The Valve And Valve Seats............4026
      Valve Seat Insert............4027
      Valve Guide............4027
      Valve Spring............4028
    ROCKER ARM AND SHAFT............4029
      Disassembly And Assembly............4029
      Checking Rocker Arm And Push Rods............4029
    PISTON AND CONNECTING ROD............4030
      Removal............4030
      Disassembly............4030
      Checking............4031
      Assembly............4034
      Installation............4035
    CYLINDER LINERS............4036
      Checking The Cylinder Bore............4036
      Removal............4036
      Installation............4036
    MAIN BEARINGS............4037
      Description............4037
      Removal............4037
      Installation............4038
      Crankshaft End Play............4039
    CRANKSHAFT............4040
      Removal And Installation............4040
      Checking Tuffriding (Soft Nitriding) Coating............4040
      Checking the Crankshaft............4040
    CRANKSHAFT GEAR............4042
      Removal And Installation............4042
    TIMING GEARCASE COVER SEAL............4043
      Removal And Installation............4043
    TIMING GEARCASE COVER............4044
      Removal And Installation............4044
    IDLER GEAR AND HUB............4046
      Removal............4046
      Checking............4046
      Installation............4047
    FUEL INJECTION PUMP IDLER GEAR............4048
      Removal And Installation............4048
      Bearing Installation............4048
    CAMSHAFT GEAR............4049
      Removal And Installation............4049
    TIMING GEARCASE............4050
      Removal And Installation............4050
    CAMSHAFT............4051
      Removal And Installation............4051
      Checking............4051
      Camshaft Bearings............4052
      Tappets............4052
      Tappet Installation............4053
    OIL PAN............4054
      Removal............4054
      Installation............4054
    OIL PUMP............4055
      Removal And Installation............4055
      Checking............4055
      Gear Replacement............4056
      Rotor Replacement............4057
      Oil Pump Relief Valve............4057
      Oil Filter Housing And Block............4057
    WATER PUMP............4058
      Removal And Installation............4058
      Disassembly............4058
      Assembly............4059
    THERMOSTAT............4061
      Removal And Installation............4061
      Checking The Thermostat............4061
    WATER JACKET TUBE............4062
      Removal And Installation............4062
  SYSTEMS ANALYSIS............4064
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............4066
      Inspecting The BICS System Controller (Engine STOPPED – Key ON)............4066
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)............4066
      Inspecting The Traction Lock (Engine RUNNING)............4066
      Inspecting The Lift Arm By–Pass Control............4066
      Maintenance............4066
      Troubleshooting Chart............4067
      Troubleshooting Guide............4068
        BICS SYSTEM CONTROLLER............4068
        TRACTION LOCK............4069
        SEAT SENSOR............4070
        SEAT BAR SENSOR............4071
        LIFT LOCK BY–PASS VALVE............4072
    BICS™ SYSTEM CONTROLLER............4073
      Removal And Installation............4073
      Controller Test............4074
    SEAT BAR SENSOR............4075
      Removal And Installation............4075
      Seat Bar Sensor Test............4076
    SEAT SENSOR............4077
      Removal And Installation............4077
      Seat Sensor Test............4078
    TRACTION LOCK............4079
      Removal And Installation............4079
    LIFT LOCK BY–PASS VALVE............4080
      Removal And Installation............4080
      Disassembly And Assembly............4081
    TILT LOCK VALVE............4082
      Removal And Installation............4082
      Disassembly And Assembly............4083
    BOSS® DIAGNOSTIC TOOL............4084
      Procedure............4084
    SENDER AND SENSOR............4084
      Service Checks............4084
      Component............4084
    RPM SENSOR............4084
      Adjustment............4084
    MONITOR SERVICE CODES............4085
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY............4088
    OPERATION SENSING SYSTEM UNIT............4089
      Removal And Installation............4089
    BOSS® INSTRUMENT PANEL............4090
      Removal And Installation............4090
    PWM MODULE............4091
      Description............4091
    PWM TROUBLESHOOTING............4092
      Conditions............4092
      Chart............4093
    PWM CONTROL HANDLE............4094
      Handle Testing............4094
    PWM ELECTRIC SOLENOID............4094
      Solenoid Coil Testing............4094
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE............4095
      Controls Identification Chart............4095
  SPECIFICATIONS............4096
    LOADER SPECIFICATIONS............4098
      LOADER DIMENSIONS............4098
      OPERATION & PERFORMANCE............4098
      ENGINE............4098
      HYDRAULIC SYSTEM............4099
      ELECTRICAL............4099
      DRIVE SYSTEM............4099
      CAPACITIES............4099
      TIRES............4099
      VIBRATION DATA............4099
    ENGINE SPECIFICATIONS............4100
      Cylinder Head............4100
      Valve, Valve Guide & Seat Insert............4100
      Valve Springs............4100
      Rocker Arm............4100
      Tappets............4100
      Piston, Pin & Rings............4101
      Connecting Rod & Bearing............4101
      Cylinder Liners............4101
      Camshaft............4101
      Crankshaft............4102
      Idler Gear............4102
      Oil Pump............4102
      Fuel System............4102
      Torque For General Metric Bolts............4103
    TORQUE SPECIFICATIONS FOR LOADER............4104
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS............4106
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS............4107
    DECIMAL AND MILLIMETER EQUIVALENTS............4108
    U.S. TO METRIC CONVERSION............4108
  SERVICE MANUAL REVISIONS............4110
    850–001............4110
    850–002............4112
    850–003............4114
    850–004............4116
    850–005............4118
    850-006............4120
6724034 (6-00) - 853, 853H Operation & Maintenance Manual............4122
  OPERATOR SAFETY WARNINGS............4124
  CONTENTS............4126
  FOREWORD............4128
    BOBCAT COMPANY IS ISO 9001 CERTIFIED............4130
    REGULAR MAINTENANCE ITEMS............4130
    MOTOR OIL............4130
    SERIAL NUMBER LOCATIONS............4132
    LOADER SERIAL NUMBER............4132
    ENGINE SERIAL NUMBER............4132
    DELIVERY REPORT............4132
    BOBCAT LOADER IDENTIFICATION............4133
    OPTIONS AND ACCESSORIES............4134
      Tires............4134
      Operator Cab............4134
      Hydraulics............4134
      Other............4134
      Instrumentation............4134
  SAFETY............4136
    SAFETY INSTRUCTIONS FOR BOBCAT SKID-STEER LOADERS AND ATTACHMENTS............4138
      SAFETY IS THE OPERATOR’S RESPONSIBILITY............4138
    BEFORE OPERATING THE BOBCAT LOADER............4139
    SAFE OPERATION NEEDS A QUALIFIED OPERATOR*............4139
    FIRE PREVENTION............4140
    MACHINE SIGNS (DECALS)............4141
  OPERATING INSTRUCTIONS............4144
    INSTRUMENT PANELS............4146
      Standard............4146
      Boss® Option............4147
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............4149
      Description............4149
      Lift Arm By-Pass Control............4150
      Traction Lock Override............4150
      Seat Sensor Override (If Equipped)............4150
    ENGINE SPEED CONTROL............4151
      Operation............4151
    PARKING BRAKE............4151
      Operation............4151
    STEERING LEVERS............4153
      Operation............4153
    STOPPING THE BOBCAT LOADER............4153
      Procedure............4153
    SEAT BAR RESTRAINT SYSTEM............4154
    HYDRAULIC CONTROLS............4156
      Foot Pedals............4156
      Lift Arm Operation............4156
      Lift Arm Float Position............4156
      Tilt Operation............4156
      Bucket Position Valve Operation (Optional)............4156
      Auxiliary Hydraulics (Optional)............4157
      Auxiliary Hydraulic Button............4158
      Front Auxiliary Control (Optional)............4159
      Rear Auxiliary Control (Optional)............4159
      Front Auxiliary Hydraulics Continuous Operation (Detent)............4159
      Attachment Functions Control............4160
    AUXILIARY HIGH HORSEPOWER HYDRAULICS OPERATION............4161
      Secondary Front Auxiliary Hydraulics (853H Only)............4162
    DAILY INSPECTION............4163
    GETTING READY FOR OPERATION............4164
    STARTING THE ENGINE............4166
      Normal Starting Condition (Standard)............4166
      Cold Temperature Starting Condition (Standard)............4168
      Normal Starting Condition (BOSS® Option)............4169
      Cold Temperature Starting Condition (BOSS® Option)............4170
      Warming The Hydraulic/Hydrostatic System............4170
    STOPPING THE ENGINE............4170
    ATTACHMENTS AND BUCKETS............4171
      Choosing The Correct Bucket............4171
      Installing And Removal............4172
    OPERATING PROCEDURE............4174
      Filling The Bucket............4175
      Emptying the Bucket............4175
      Digging Into The Ground............4176
      Leveling The Ground (Using Lift Arms In Float Position)............4176
      Backfilling............4177
    PARKING THE BOBCAT LOADER............4177
    STOPPING THE BOBCAT LOADER............4177
    TRANSPORTING THE BOBCAT LOADER............4178
      Loading Onto Transport Vehicle............4178
      Fastening To Transport Vehicle............4178
    TOWING THE LOADER............4179
    STOPPING THE BOBCAT LOADER............4179
    LIFTING THE LOADER............4180
      Four Point Lift............4180
      Single Point Lift............4180
  PREVENTIVE MAINTENANCE............4182
    MAINTENANCE SAFETY............4184
    SERVICE SCHEDULE............4186
      Chart............4186
    LIFT ARM SUPPORT DEVICE............4187
      Engaging The Lift Arm Support Device............4187
      Disengaging The Lift Arm Support Device............4188
    OPERATOR CAB............4189
      Raising The Operator Cab............4189
      Lowering The Operator Cab............4190
      Emergency Exit............4191
    SEAT BAR RESTRAINT SYSTEM............4192
      Inspecting The Seat Bar............4192
      Maintaining The Seat Bar............4192
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............4193
      Inspecting The BICS™ Controller (Engine Stopped - Key ON)............4193
      Inspecting The Seat and Seat Bar Sensors (Engine RUNNING)............4193
      Inspecting The Traction Lock (Engine RUNNING)............4193
      Inspecting The Lift Arm By-Pass Control............4193
      Maintenance............4194
    REAR DOOR............4195
      Opening The Rear Door............4195
      Adjusting The Rear Door............4195
    REAR GRILL............4196
    AIR CLEANER SERVICE............4197
    FUEL SYSTEM............4199
      Fuel Specifications............4199
      Filling The Fuel Tank............4199
      Fuel Filter............4200
      Removing Air From The Fuel System............4201
    ENGINE LUBRICATION SYSTEM............4202
      Checking Engine Oil............4202
      Oil Chart............4202
      Replacment Of Oil And Filter............4202
    COOLING SYSTEM............4204
      Cleaning The Cooling System............4204
      Checking The Coolant Level............4204
      Removing Coolant From The Cooling System............4205
      Propylene Glycol............4205
    ALTERNATOR BELT............4205
      Adjusting The Alternator Belt............4205
    ELECTRICAL SYSTEM............4206
      Description............4206
      Servicing The Electrical System............4206
      Fuse Location - (Standard & BOSS® Option)............4206
      Using A Booster Battery (Jump Starting)............4207
      Removing And Installing The Battery............4208
    HYDRAULIC / HYDROSTATIC SYSTEM............4209
      Checking And Adding Fluid............4209
      Hydraulic/Hydrostatic Filter Replacement............4209
      Hydraulic Fluid Replacement............4210
      Hydraulic Reservoir Breather Cap............4212
    SPARK ARRESTOR MUFFLER............4213
      Maintenance............4213
    TIRE MAINTENANCE............4214
      Wheel Nuts............4214
      Tire Rotation............4214
      Tire Mounting............4214
    FINAL DRIVE TRANSMISSION (CHAINCASE)............4215
      Checking And Adding Oil............4215
      Removing Oil From The Chaincase............4215
    FAN GEARBOX............4216
      Checking And Maintaining............4216
    DRIVE BELT............4216
      Adjusting The Drive Belt............4216
      Replacing The Drive Belt............4217
    LUBRICATING THE BOBCAT LOADER............4218
    PIVOT PINS............4219
    BOB-TACH............4220
  SYSTEM SETUP & ANALYSIS............4222
    SERVICE CODES............4224
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............4226
      Troubleshooting Chart............4226
    ADVANCED HAND CONTROLS (AHC)............4227
      Troubleshooting Chart............4227
  MACHINE SIGN TRANSLATIONS............4228
    IMPORTANT (6560573)............4230
    WARNING (6579511)............4231
    SERVICE SCHEDULE (6708212)............4232
    WARNING (6579510)............4234
    DANGER (6579528)............4235
    WARNING (6577754)............4235
    WARNING (6579639)............4236
    WARNING (6579509)............4236
  SPECIFICATIONS............4238
    LOADER SPECIFICATIONS............4240
      Machine Dimensions............4240
      Performance............4241
      Controls............4241
      Engine............4241
      Hydraulic System............4242
      Electrical............4242
      Drive System............4243
      Capacities............4243
      Tires............4243
      Floor Pressure............4243
    MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES - For use on 853 Bobcat Loaders............4244
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS............4247
  WARRANTY............4248

Bobcat Loaders 825, 843, 843B, 853, 853H Repair Service Manuals + Operation & Maintenance Manuals