Loader Bobcat 853, 853H. Manual — part 48

RED = RED

RNG = ORANGE

BLK = BLACK

LBL = LIGHT BLUE

DBL = DARK BLUE

LGN = LIGHT GREEN

DGN = DARK GREEN

YEL = YELLOW

PNK = PINK
BRN = BROWN

TAN = TAN

PUR = PURPLE

WHT = WHITE

GRY = GREY

C

21

6

C

12

4

C

11

6

C

11

5

C

20

1

C

11

4

RED/WHT

C

10

8

RED/WHT

TO OPTIONS

TO OPTIONS

C

10

5

RNG

A

B

A

B

E

H

D

K

F

J

G

A

C

B

A

B

A

B

B

A

A B

5 OHM

RESISTOR

FILTER

AIR

LEVEL

COOLANT

TEMPERATURE

OIL

HYDRAULIC

PRESSURE

PRE-FILTER

PRESSURE

OIL

HYDRAULIC

PRESSURE

RETURN FILTER

C120

BLK

YEL/LBL

A

B

B
A

TRANSDUCER HARNESS - 6704345

C

12

3

PRESSURE

CHARGE

HYDRAULIC

RNG

RED

TO OPTIONS

C

10

6

RNG/DGN

RNG

LIGHT

WORK

RIGHT

LIGHT

WORK

LEFT

REAR LIGHT HARNESS - 6704232

TAILLIGHT

RIGHT

TAILLIGHT

LEFT

BL

K

D

BL

/W

H

T

BL

K

PN

K

PN

K

B

LK

B

LK

ALARM

BACKUP

RNG/DGN

RNG

D

C

D

C

E

E

RED/WHT

EN

G

IN

E

FU

SE

R

ED

/W

H

T

AC

C

ES

SO

R

Y

FU

SE

R

E

D

/W

H

T

DIODE

D

1

*

LBL/BLK

BL

K

R

N

G

BL

K

BL

K

C122

C110

RED/WHT

RNG

BLK

6660316 WAS 6651570

VACUUM SWITCH

RED

R

ED

LBL

/W

H

T

BL

K

PU

R

/L

BL

LG

N

/R

ED

LG

N

/PN

K

R

N

G

D

G

N

/Y

EL

LG

N

/D

BL

RED

F

D
C

RED

A

B

E

PNK

DBL/WHT

BLK

B

F

A

ENGINE HARNESS (BOSS) - 6704234

A

1

E

1

F

1

#

#

#

A

2

A

3

K

2

F

1

*

*

*

*

F

2

E

2

F

3

#

#

#

K

1

J

2

J

3

J

1

G

3

G

2

F

2

*

*

*

*

*

*

*

PIN NUMBER = 18 PIN CONNECTOR

#

A

1

B

3

H

3

H

1

E

3

E

2

D

2

D

1

*

*

*

*

*

*

*

*

E

3

#

D

2

D

3

C

1

D

1

#

#

#

#

B

1

B

2

E

1

F

3

*

*

*

*

B

3

B

2

B

1

A

3

A

2

C

2

#

#

#

#

#

#

C

1

D

3

C

2

*

*

*

C

3

*

PIN NUMBER = 30 PIN CONNECTOR

C

3

G

1

*

*

*

H

2

#

(MAGNETIC PICKUP)

ENGINE RPM

TO OPTIONS

HERE OR

HARNESS (IF EQUIPPED)

HOURMETER AND

AUXILIARY

30

86

WHT/BLK

R

N

G

/D

B

L

YEL

/D

G

N

6651664

RED

EXC

PUR

LGN/WHT

C118

LGN

COOLANT

ENGINE

PRESSURE

ENGINE OIL

LEVEL

FUEL

SOLENOID

FUEL SHUTOFF

BOSS

PLUGS

GLOW

R

N

G

C121

B

LK

h

RNG

BLK

FOR DRAWING CLARITY

BODIES NOT SHOWN

SOME CONNECTOR

C

12

8

87A

87

WHT/LGN

WHT

85

30

86

RED

BLK

RED

LBL/RNG

LBL/BLK

87A

87

85

BLK

PNK

DBL/WHT

BLK

85

86

30

87A

87

RED

RED

B

ALTERNATOR

S

G

RED

RED

BATTERY

STARTER

B

S

M

GLOW PLUG RELAY

WHT/LGN

B

A

B

A

CONNECTORS

LETTER ACROSS

WIRES CONNECT BY

SHUTDOWN RELAY

STARTER RELAY

F

A
B

HR

D

BL

/YE

L

YE

L/

D

B

L

BL

K

YE

L/

BR

N

BL

K

Y

EL

/L

B

L

BL

K

PU

R

BL

K

BL

K

Y

EL

/L

B

L

P

U

R

/R

ED

BL

K

BL

K

YE

L/

R

E

D

R

N

G

/W

H

T

R

N

G

/W

H

T

W

H

T/

R

N

G

PU

R

/W

H

T

PU

R

/R

ED

R

N

G

R

N

G

BL

K

BL

K

RNG

BLK

RNG

RNG

PUR/RED
PUR/WHT
PNK

DBL/WHT

WHT

BLK

C119

853 BOSS - WIRING SCHEMATIC

V-0803

(Printed January 2005)

S/N 512811001 - 14999

V-0803 (12-12-05)

RED

C

20

3

RED/WHT

TAIL

REAR WORK

HEADLIGHT

WARNING

B2

B1

(IF EQUIPPED)

LIGHT SWITCH

TO ENGINE

CAB HARNESS (BOSS) - 6705136

BLK

RNG/DBL

RNG/DBL

RED/WHT

MODE LIGHT

DETENT LIGHT

EQUIPPED)

(IF

LAMP

FLASHER

RIGHT

EQUIPPED)

(IF

LAMP

FLASHER

LEFT

EQUIPPED)

(IF

HEADLIGHT

RIGHT

EQUIPPED)

(IF

HEADLIGHT

LEFT

BR

N

D

B

L

BL

K

START

RUN

OFF

ACC

A

B

F

E

C

D

(IF EQUIPPED)

AUXILIARY HYDRAULIC SWITCH

LGN/DBL

DGN/YEL

RNG

LGN/PNK

RED

LGN/RED

LCD DISPLAY MONITOR

B

R

N

ST

RNG

RNG

BLK

PNK
RED/WHT

RNG

WHT

BLK

D

B

L

BR

N

BR

N

DGN/WHT
DGN/WHT

DIAGNOSTIC PORT

BLK

PUR/WHT

PUR/RED

BLK

RNG

PUR/WHT

PUR/RED

B
C
A
E
D

1

2
3
4

BOSS DISPLAY

PUR/RED

BLK

BRN

FLASHER

(FRONT WIPER)

TO OPTIONS

C

20

4

RED/WHT

SO

I

B

IGNITION SWITCH

RED/WHT

BLK

DBL/WHT

RNG

PUR/WHT

1

2

ATTACHMENT

HERE OR TO

C

46

0

ATTACHMENT

HERE OR TO

C

46

0

C

44

1

C

45

7

REAR AUX.

TURN

SIGNAL

B
A
C

DGN
BRN
YEL

RNG

YEL/LGN
YEL/RED

WHT

RNG/WHT

HORN

SKI CONTROL

B
A

C

A

B

B

A

ATTACHMENT

TO

RNG/DBL

LEFT HANDLE (IF EQUIPPED)

C

40

3

DBL

C

44

0

C

44

1

C

44

0

C

45

7

REAR AUX.

SIGNAL

TURN

C

A

B

YEL

BRN

DGN

RNG

YEL/RED

YEL/LGN

YEL

C120

WITH FRONT AUXILIARY VALVE

C

45

9

C

45

8

DGN

DBL

C

40

3

LGN

B
F
E
A

LEFT HANDLE (IF EQUIPPED)

RIGHT HANDLE (IF EQUIPPED)

RNG/DBL

DGN

ATTACHMENT

TO

ATTACHMENT

TO

AUX.

FRONT

C

B
A

A
B

A
B

B
A

C

A

B

D

C

SKI CONTROL

HORN

SKI CONTROL

WATER KIT

DETENT

RNG/WHT

DGN/RED

DGN/LGN

RNG/WHT

RNG

YEL

WHT

F

E

B

D

A

K

J

G

H

C

C

41

4

C

41

5

HORN

D

G

N

/R

ED

DGN

RNG

DGN/RED

RNG

A

DGN/LGN

C

YEL

YEL/WHT

BASE SOLENOID

REAR AUXILIARY

ROD SOLENOID

REAR AUXILIARY

B
A

B
A

B
A

A

B

BLK

BLK

C

41

0

C

41

1

A

B

A

B

A

B

A

B

R

N

G

LG

N

/D

BL

LG

N

/R

ED

LG

N

/PN

K

D

G

N

/YE

L

LG

N

/R

ED

LG

N

/PN

K

LG

N

/D

BL

R

N

G

R

N

G

F

F

E

E

D

D

YEL
YEL/WHT

RNG

B

D

G

N

/L

G

N

D

G

N

R

N

G

CONTROLS HARNESS - 6705283

BASE SOLENOID

FRONT AUXILIARY

ROD SOLENOID

FRONT AUXILIARY

CONTROLS MODULE

B

A

C

B

A

C

H

A

B

E

F

G

C

K

J

D

H

A

B

E

F

G

C

A
B

RNG

BL

K

RNG/DBL

C408

C407

D

C

B

DGN/LGN

DGN/RED

BLK

BLK

R

N

G

BL

K

J

K

B

A

A

C120

WITHOUT FRONT AUXILIARY VALVE

C

45

9

C

45

8

DGN

LGN

B
F
E
A

RIGHT HANDLE (IF EQUIPPED)

DGN

ATTACHMENT

TO

AUX.

FRONT

C

B
A

A
B

D

C

SKI CONTROL

WATER KIT

DETENT

DGN/RED

DGN/LGN

RNG/WHT

RNG

YEL

B

F

A

K

J

G

H

E

D

C

D

B

E

C

A

F

D

B

E

C

A

F

J

H

K

C

E

G

A

B

D F

J

H

K

C

E

G

A

F

D

B

C

41

4

C

41

5

C

41

3

HORN

LBL

/R

ED

LBL/RED

RELIEF SOLENOID

HIGH PRESSURE

YE

L

YE

L

D

G

N

/L

G

N

CONTROLS HARNESS - 6702999

D

G

N

/R

ED

DGN

RNG

DGN/RED

RNG

A

DGN/LGN

C

B
A

A

B

BLK

A

B

A

B

A

B

A

B

R

N

G

LG

N

/D

B

L

LG

N

/R

E

D

LG

N

/PN

K

D

G

N

/YEL

LG

N

/R

E

D

LG

N

/PN

K

LG

N

/D

B

L

R

N

G

R

N

G

YEL
YEL/WHT

RNG

B

D

G

N

/L

G

N

D

G

N

R

N

G

BASE SOLENOID

FRONT AUXILIARY

ROD SOLENOID

FRONT AUXILIARY

CONTROLS MODULE

ATTACHMENT

TO

A
B

RNG

BL

K

RNG/DBL

C408

C407

C

B

DGN/LGN

DGN/RED

BLK

BLK

R

N

G

B

LK

B

A

A

1.

Alternator belt is loose or damaged.

2.

Battery connections are dirty or loose.

3.

Battery is damaged.

4.

The cable & wire connection are not making a good contact.

5.

The alternator is damaged.

6.

The engine is locked.

7.

The starter is damaged.

8.

The wiring or the solenoid is damaged.

9.

Check the fuses.

PROBLEM

CAUSE

Battery will not take a charge.

2, 3, 4

Alternator will not charge.

1, 4

Starter will not turn the engine.

2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE

TROUBLESHOOTING

Chart

The following troubleshooting chart is provided for
assistance in locating and correcting problems. Many of
the recommended procedures must be done by
authorized Bobcat Service Personnel only.

Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manuals, Handbook
and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing.
Check for correct function after adjustments,
repairs or service. Untrained operators and
failure to follow instructions can cause injury
or death.

W–2003–0199

853, 853H Loader

–6–5–

Service Manual

ELECTRICAL SYSTEM INFORMATION

Description

The loader has a 12 volt, negative ground alternator
charging system. The electrical system is protected by
fuses. The fuses will protect the electrical system when
there is an electrical overload. The reason for the
overload must be found before starting the engine again.

Fuse Location

The electrical system for the (S/N 5102), (S/N 5103) and
earlier model 853 loaders are protected by two fuses
(Item 1) [A] installed in the wiring harness located in the
engine compartment.

The electrical system for the (S/N 5101) and (S/N 11010
& Below) loaders are protected by two fuses (Item 1) [B]
installed in the instrument panel.

A

P–00910

1

–6–6–

853, 853H Loader

Service Manual

B

B–12883

B–13752

1

1

(S/N 5101)

(S/N 11010 & Bel.)

BATTERY

Removal And Installation

Open the rear door.

Disconnect the negative(–) cable (Item 1) [A] from the
battery.

Disconnect the positive (+) cable (Item 1) [B] from the
battery.

Remove the nuts from the holddown clamp (Item 2) [B]
and remove the battery holddown clamp.

Remove the battery from the loader [C].

Batteries contain acid which burns eyes and
skin on contact. Wear goggles, protective
clothing and rubber gloves to keep acid off
body.

In case of acid contact, wash immediately with
water. In case of eye contact get prompt medical
attention and wash eye with clean, cool water
for at least 15 minutes.

If electrolyte is taken internally drink large
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention.

W–2065–1296

A

CD–15008

1

C

CD–15137

853, 853H Loader

–6–7–

Service Manual

B

CD–15136

2

1