Bobcat 450 453 Loader Service Manual 6724259 (6-12) – PDF DOWNLOAD

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Bobcat 450 453 Loader Service Manual 6724259 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 450 453 Loader Service Manual 6724259 (6-12) – PDF DOWNLOAD

Language : English
Pages : 354
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat 450 453 Loader Service Manual 6724259 (6-12) – PDF DOWNLOAD

(450–S/N 561711001 & Above)
(453–S/N 561811001 & Above)

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS:
Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual,
Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure
to follow instructions can cause injury or death.
The following publications provide information on the safe use and maintenance of the loader and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routin e
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your
Bobcat dealer for more information on translated versions.
• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.
• The Skid–Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.
• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

TABLE OF CONTENTS:

Bobcat 450 453 Loader Service Manual 6724259 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
SERIAL NUMBER LOCATIONS 13
LOADER SERIAL NUMBER 13
ENGINE SERIAL NUMBER 13
DELIVERY REPORT 13
BOBCAT SKID STEER LOADER IDENTIFICATION 14
OPTIONS AND ACCESSORIES 15
PREVENTIVE MAINTENANCE 17
SERVICE SCHEDULE 19
LIFTING AND BLOCKING THE LOADER 20
Procedure 20
TRANSPORTING THE LOADER 21
Procedure 21
LIFTING THE LOADER 22
Single Point Lift 22
TOWING THE LOADER 22
LIFT ARM SUPPORT DEVICE 23
Engaging The Lift Arm Support Device 23
Disengaging The Lift Arm Support Device 24
OPERATOR CAB 25
Description 25
Emergency Exit 25
Raising The Operator Cab 25
Lowering The Operator Cab 26
SEAT BAR RESTRAINT SYSTEM 27
Seat Bar Inspection 27
Seat Bar Maintenance 27
Foot Pedal Clean Out 27
AIR CLEANER SERVICE 28
450 Loader 28
453 Loader 29
FUEL SYSTEM 30
450 Loader 30
Fuel Specifications 30
Filling The Fuel Tank 30
Fuel Filter 30
453 Loader 31
Fuel Specifications 31
Filling the Fuel Tank 31
Fuel Filter 31
Removing Air From The Fuel System 32
ENGINE LUBRICATION SYSTEM 33
450 Loader 33
Replacing Oil And Filter 33
453 Loader 34
Replacing Oil And Filter 34
ENGINE COOLING SYSTEM 35
450 Loader 35
Cleaning The Cooling System 35
453 Loader 36
Checking The Coolant Level 36
Cleaning The Cooling System 36
Removing Coolant From The Cooling System 36
ALTERNATOR BELT ADJUSTMENT (453) 37
ELECTRICAL SYSTEM 37
Description 37
PIVOT PINS 37
SPARK ARRESTOR MUFFLER 38
Cleaning The Spark Arrestor Muffler 38
HYDRAULIC/HYDROSTATIC SYSTEM 39
Checking And Adding Fluid 39
Replacing The Hydraulic/Hydrostatic Filter Element 40
Removing The Hydraulic/Hydrostatic Fluid 40
FINAL DRIVE TRANSMISSION (CHAINCASE) 41
Checking And Adding Oil 41
AUXILIARY CONTROL LOCKBOLT 41
TIRE MAINTENANCE 41
Wheel Nuts 41
Tire Rotation 41
Tire Inflation 41
LUBRICATING THE LOADER 42
BOB–TACH 43
REMOTE START SWITCH 44
Procedure 45
HYDRAULIC SYSTEM 47
HYDRAULIC / HYDROSTATIC SCHEMATICS 49
TROUBLESHOOTING 53
HYDRAULIC SYSTEM INFORMATION 54
Tighten Procedures 54
LIFT CYLINDER(S) 55
Removal and Installation 55
Checking The Lift Cylinder For Internal Leakage 56
TILT CYLINDER 57
Removal And Installation 57
Checking The Tilt Cylinder For Internal Leakage 58
HYDRAULIC CYLINDERS 59
Disassembly And Assembly 59
Lift Cylinder Identification 61
LIFT ARM BY–PASS BLOCK 62
Removal And Installation 62
Disassembly And Assembly 63
HYDRAULIC CONTROL VALVE 65
Checking The Main Relief Valve 65
Main Relief Valve Removal And Installation 66
Main Relief Valve Adjustment 66
Removal And Installation 67
Identification Chart 68
Disassembly And Assembly 69
Load Check Valve 69
Main Relief Valve 69
Anti–Cavitation Valve 70
Rubber Boot 71
Lift Spool Detent 72
Tilt Centering Spring 76
Auxiliary Spool Detent 76
Spool Seal Installation 77
HYDRAULIC PUMP 78
Checking The Output Of The Hydraulic Pump 78
Removal And Installation 79
Disassembly And Assembly 81
Parts Identification 83
HYDRAULIC RESERVOIR 84
Removal And Installation 84
HYDRAULIC FILTER BLOCK 85
Removal And Installation 85
Disassembly And Assembly 85
450 Filter Block 85
453 Filter Block 86
PEDAL INTERLOCK LINKAGE 87
Removal And Installation 87
CONTROL PEDALS 87
Removal And Installation 87
Pedal Adjustment 87
HYDROSTATIC SYSTEM 89
TROUBLESHOOTING 91
HYDROSTATIC SYSTEM INFORMATION 92
Replenishing Valve Function 92
CONTROL SHIELD AND STEERING LEVER PANELS 93
Removal And Installation 93
STEERING LEVERS AND STEERING LEVER PANELS 94
Removal And Installation 94
STEERING LEVERS 94
Removal And Installation 94
Disassembly And Assembly 95
STEERING LINKAGE 96
Adjustment 96
Pintle Arm Removal And Installation 97
Pintle Arm Disassembly And Assembly 97
DRIVE BELT 98
Removal And Installation 98
450 Loader 98
453 Loader 98
HYDR0STATIC PUMP 99
Checking Charge Pressure 99
Removal And Installation 100
450 Loader 100
453 Loader 101
Parts Identification 103
Disassembly And Assembly 104
Inspection 107
TENSION PULLEY AND SPRING 110
Removal And Installation 110
HYDROSTATIC MOTOR 112
Removal And Installation 112
Parts Identification 113
Disassembly 114
Inspection 118
Assembly 119
DRIVE SYSTEM 123
PARKING BRAKE PEDAL 125
Removal And Installation 125
Disassembly And Assembly 125
CHAINCASE FLUID 126
Removing Oil From The Chaincase 126
CHAINCASE COVER 126
Removal And Installation 126
Disassembly And Assembly 126
PARKING BRAKE DISC 127
Removal And Installation 127
AXLE HUB 128
Removal And Installation 128
AXLE SEAL 129
Removal And Installation 129
AXLE, BEARINGS, AND SPROCKET 130
Removing The Axle 130
Removing And Installing The Axle Bearing 131
Removing The Bearing Races 132
Installing The Bearing Races 133
Installing The Inner Bearing And Axle Sprocket 133
DRIVE CHAINS 134
Removal And Installation 134
MAIN FRAME 135
SEAT BAR 137
Gas Spring Removal And Installation 137
Compressing The Gas Spring 138
Seat Bar Removal And Installation 139
Assembly 141
OPERATOR CAB 142
Removal And Installation 142
OPERATOR CAB GAS CYLINDER 144
Removal And Installation 144
OPERATOR SEAT 145
Removal And Installation 145
BOB–TACH 147
Removal 147
Installation 148
Seal Removal And Installation 149
Lever And Wedge Removal 149
Lever And Wedge Installation 151
LIFT ARMS 153
Removal And Installation 153
FUEL TANK 156
Removal And Installation 156
REAR WINDOW 157
Removal And Installation 157
REAR DOOR 158
Exhaust Pipe Removal And Installation 158
Removal And Installation 158
ELECTRICAL SYSTEM 159
ELECTRICAL SCHEMATICS 161
TROUBLESHOOTING 185
Chart 185
ELECTRICAL SYSTEM INFORMATION 186
Description 186
Fuse Location 186
Relay Switches Location – 453 Only 186
BATTERY 187
Removal And Installation 187
Maintenance 188
ALTERNATOR (450) 189
Checking The Alternator Circuit (450) 189
Replacing The Stator 190
ALTERNATOR (453) 191
Removal And Installation 191
Adjusting The Alternator Belt 191
Alternator Output Test 192
Alternator Regulator Test 193
Disassembly and Inspection – Parts Identification 194
Stator Continuity Test 194
Stator Ground Test 194
Rotor Continuity Test 195
Rotor Ground Test 195
Rectifier Continuity (Diode) Test 195
Assembly 196
STARTER (453) 197
Removal And Installation 197
Checking The Starter 197
Parts Identification 198
Disassembly, Assembly And Inspection 199
STARTER (450) 202
Checking The Starter 202
Removal And Installation 202
Disassembly, Assembly And Inspection 203
INSTRUMENT PANEL 205
Removal And Installation 205
FRONT LIGHTS (OPTIONAL) 206
Removal And Installation 206
REAR LIGHT (OPTIONAL) 207
Removal And Installation 207
ENGINE SERVICE 209
ENGINE SERVICE (450) 211
TROUBLESHOOTING 213
IGNITION SYSTEM 215
Spark Plugs 215
Ignition Module Air Gap 215
Testing Ignition Module Primary 216
Testing Ignition Module Secondary 216
Valve & Tappet Clearance 217
Compression Test 217
CARBURETOR AND GOVERNOR 218
Carburetor Adjustment On The Engine 218
Main Fuel Adjustment 218
Idle Fuel Adjustment 218
Idle Speed Setting 219
Shutdown Control Solenoid 219
Governor And Adjustment 220
Disassembly And Assembly 220
ENGINE 224
Removal And Installation 224
Muffler Removal And Installation 227
Intake Manifold Removal And Installation 228
Breather and Valve Cover Removal And Installation 229
Fuel Pump Removal And Installation 229
ENGINE DISASSEMBLY 230
Flywheel Removal And Installation 230
Stator Removal and Installation 230
Cylinder Head Removal 231
Cylinder Barrel Removal 232
Cylinder Barrel Inspection And Resizing 233
Valve Removal And Installation 234
Valve Guide Removal And Installation 234
Valve Seat Insert Removal 235
Valve Seat Insert Installation 235
Valve Details 236
Piston And Piston Rings 237
Closure Plate 239
Crankcase Halves 239
Camshaft Removal 240
Crankshaft Removal 240
Connecting Rod Removal 241
Governor Gear And Cross Shaft Removal 242
Oil Pickup Removal 242
OIl Pump Removal 243
ENGINE ASSEMBLY 244
Oil Pump Installation 244
Cross Shaft And Governor Shaft Installation 246
Connecting Rod Installation 247
Crankshaft And Bearing Installation 247
Tappets And Camshaft Installation 249
Sealing The Crankcase 250
Recommended Sealants 251
Installing Camshaft Bore Plug 251
Installing Crankcase Halves 252
Front And Rear Seal Installation 252
Filter Adapter Installation 253
Installing Oil Pressure Relief Valve And Closure Plate 253
Piston Installation 254
Setting Valve To Tappet Clearance 255
Cylinder Head Installation 256
ENGINE SERVICE 453 (KUBOTA) 257
TROUBLESHOOTING 259
FUEL SYSTEM 261
Replacing The Fuel Filter 261
Removing The Air From The Fuel System 261
Fuel Injection Pump 262
Checking The Injection Pump 262
Removing The Injection Pump 263
Installing The Injection Pump 264
Timing The Injection Pump 264
Fuel Injector Nozzles 265
Removing The Fuel Injector Nozzle 265
Checking Fuel Injector Nozzles 266
Installing The Fuel Injector Nozzle 266
Checking Glow Plugs 267
Engine Compression Test 267
OIL COOLER & SHROUDING 268
Removal And Installation 268
RADIATOR 268
Removal And Installation 268
ENGINE SPEED CONTROL 269
Adjustment 269
Removal And Installation 269
ENGINE 270
Removal And Installation 270
FLYWHEEL 275
Removal And Installation 275
FAN 276
Removal And Installation 276
CYLINDER HEAD 277
Removing The Cylinder Head 277
Disassembly Of The Cylinder Head 279
Servicing The Cylinder Head 280
Assembly Of The Cylinder Head 282
Installing The Cylinder Head 282
REPAIRING THE ENGINE 284
Removing The Gearcase 284
Removing The Timing Gear, Camshaft & Oil Pump 286
Removing Pistons & Crankshaft 288
Servicing The Timing Gear And Camshaft 290
Servicing The Connecting Rods And Pistons 292
Servicing The Crankshaft 293
Servicing The Cylinder Liners 295
Servicing The Oil Pump 296
Servicing The Water Pump 296
ASSEMBLY OF THE ENGINE 297
Installing The Crankshaft 297
Installing The Pistons 297
Installing The Camshaft And Timing Gears 298
Installing The Gearcase Cover 300
SYSTEMS ANALYSIS 301
BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM) 303
Inspecting The BICS™ System Controller (Engine STOPPED – Key ON) 303
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING) 303
Inspecting The Traction Lock (Engine Running) 303
Inspecting The Lift Arm By–Pass Control 303
Maintenance 303
Troubleshoot Chart 304
Troubleshooting Guide 305
BICS CONTROLLER 305
TRACTION LOCK 306
SEAT SENSOR 307
SEAT BAR SENSOR 308
LIFT LOCK BYPASS VALVE 309
BICS™ SYSTEM CONTROLLER 310
Removal And Installation 310
Controller Test 311
SEAT BAR SENSOR 312
Removal And Installation 312
Seat Bar Sensor Test 313
SEAT SENSOR 314
Removal And Installation 314
Seat Sensor Test 315
TRACTION LOCK 316
Removal And Installation 316
LIFT ARM BY–PASS BLOCK 317
Removal And Installation 317
LIFT AND TILT LOCK BY–PASS VALVE 318
Disassembly And Assembly 318
SPECIFICATIONS 321
450 LOADER SPECIFICATIONS 323
PERFORMANCE 323
CONTROLS 323
ENGINE 323
HYDRAULIC SYSTEM 324
ELECTRICAL 324
DRIVE SYSTEM 324
CAPACITIES 324
TIRES 324
ENGINE SPECIFICATIONS – 450 (KOHLER) 325
Engine (General) 325
Cylinder Bore 325
Crankshaft 325
Camshaft 325
Connecting Rod 325
Piston, Pin & Rings 325
Valves, Guides & Tappet 325
Oil Pump 326
Engine Torque 326
453 LOADER SPECIFICATIONS 327
PERFORMANCE 327
CONTROLS 327
ENGINE 327
HYDRAULIC SYSTEM 328
ELECTRICAL 328
DRIVE SYSTEM 328
CAPACITIES 328
TIRES 328
ENGINE SPECIFICATIONS – 453 (KUBOTA) 329
Fuel Injector Nozzles 329
Fuel Injection Pump 329
Cylinder Head 329
Valves 329
Valve Springs 329
Rocker Arms 329
Camshaft 329
Cylinders 330
Piston Rings 330
Pistons 330
Crankshaft 330
Oil Pump 330
Thermostat 330
Crankshaft Re–Grind Data 331
Engine Torque 332
TORQUE SPECIFICATIONS FOR BOLTS 333
Torque For General SAE Bolts 333
Torque For General Metric Bolts 334
HYDRAULIC CONNECTION SPECIFICATIONS 335
O–ring Face Seal Connection 335
Straight Thread O–ring Fitting 335
Tubelines And Hoses 335
Flare Fitting 335
O–ring Flare Fitting 336
Port Seal Fitting 338
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 339
Specifications 339
DECIMAL AND MILLIMETER EQUIVALENTS 340
U S TO METRIC CONVERSION 340
GLOSSARY OF HYDRAULIC SYMBOLS 341
SERVICE MANUAL REVISIONS 343
450/453-1 343
450/453-2 345
450/453-3 347
450/453-4 349
450/453-5 351
450/453-6 353

IMAGES PREVIEW OF THE MANUAL:

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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