Bobcat 453 Loader Service Manual 6900363 (6-12) – PDF DOWNLOAD

Description

Bobcat 453 Loader Service Manual 6900363 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 453 Loader Service Manual 6900363 (6-12) – PDF DOWNLOAD

Language : English
Pages : 296
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat 453 Loader Service Manual 6900363 (6-12) – PDF DOWNLOAD

S/N 515011001 & Above
S/N 515111001 & 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:

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 routine 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 Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and
correct service procedures for Bobcat Skid–Steer loaders.
• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

TABLE OF CONTENTS:

Bobcat 453 Loader Service Manual 6900363 (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
PREVENTIVE MAINTENANCE 15
SERVICE SCHEDULE 17
LIFTING AND BLOCKING THE LOADER 18
Procedure 18
TRANSPORTING THE LOADER 19
Procedure 19
TOWING THE LOADER 20
Procedure 20
LIFT ARM SUPPORT DEVICE 21
Engaging The Lift Arm Support Device 21
Disengaging The Lift Arm Support Device 22
OPERATOR CAB 23
Description 23
Raising The Operator Cab 23
Lowering The Operator Cab 24
Emergency Exit 25
SEAT BAR RESTRAINT SYSTEM 26
Description 26
Inspectng The Seat Bar 26
Maintaining The Seat Bar 26
AIR CLEANER SERVICE 27
Replacing Filter Element 27
FUEL SYSTEM 28
Fuel Specifications 28
Filling The Fuel Tank 28
Fuel Filter 29
Removing Air From The Fuel System 30
ENGINE LUBRICATION SYSTEM 31
Checking Engine Oil 31
Oil Chart 31
Replacing Oil and Filter 31
ENGINE COOLING SYSTEM 32
Checking The Coolant Level 32
Cleaning The Cooling System 32
Replacing the Coolant 32
ALTERNATOR BELT 33
Adjusting The Alternator Belt 33
HYDRAULIC/HYDROSTATIC SYSTEM 34
Checking And Adding Fluid 34
Hydraulic/Hydrostatic Filter Replacement 35
Replacing The Hydraulic/Hydrostatic Fluid 35
SPARK ARRESTOR MUFFLER 36
Cleaning Procedure 36
TIRE MAINTENANCE 37
Wheel Nuts 37
Tire Rotation 37
Tire Inflation 37
FINAL DRIVE TRANSMISSION (CHAINCASE) 38
Checking And Adding Oil 38
AUXILIARY CONTROL LOCKBOLT 38
LUBRICATING THE LOADER 39
Procedure 39
PIVOT PINS 41
BOB–TACH 41
Inspection And Maintenance 41
REMOTE START SWITCH 42
Procedure 42
HYDRAULIC SYSTEM 45
HYDRAULIC SYSTEM INFORMATION 47
HYDRAULIC / HYDROSTATIC SCHEMATICS 51
TROUBLESHOOTING 59
Chart 59
LIFT CYLINDER(S) 60
Checking The Lift Cylinders 60
Removal And Installation 61
TILT CYLINDER 63
Checking The Tilt Cylinder 63
Removal And Installation 64
HYDRAULIC CYLINDERS 65
Lift Cylinder Parts Identification 65
Tilt Cylinder Parts Identification 65
Disassembly And Assembly 66
BICS™ BLOCK VALVE 68
Removal And Installation 68
Disassembly And Assembly 69
MAIN RELIEF VALVE 72
Checking The Main Relief Valve 72
Checking The Main Relief Valve With Auxiliaries 73
Removal And Installation 74
Main Relief Valve Adjustment 74
HYDRAULIC CONTROL VALVE 75
Removal And Installation 75
Identification Chart 76
Disassembly And Assembly 77
Load Check Valve 77
Main Relief Valve 77
Anti–Cavitation Valve 78
Rubber Boot 78
Lift Spool Detent 79
Tilt Centering Spring 83
Auxiliary Spool Detent 83
Spool Seal Installation 84
HYDRAULIC PUMP 85
Checking The Output Of The Hydraulic Pump 85
Removal And Installation 86
Parts Identification 88
Disassembly And Assembly 89
HYDRAULIC RESERVOIR 91
Removal And Installation 91
HYDRAULIC FILTER BLOCK 92
Removal And Installation 92
Block Disassembly And Assembly 93
PEDAL INTERLOCK LINKAGE 94
Removal And Installation 94
CONTROL PEDALS 94
Removal and Installation 94
Pedal Adjustment 94
HYDROSTATIC SYSTEM 95
TROUBLESHOOTING 97
Chart 97
HYDROSTATIC SYSTEM INFORMATION 98
Replenishing Valve Function 98
CONTROL SHIELD AND STEERING LEVER PANELS 99
Removal And Installation 99
STEERING LEVERS 100
Removal And Installation 100
Disassembly And Assembly 101
STEERING LINKAGE 102
Adjustment 102
Pintle Arm Removal And Installation 103
Pintle Arm Disassembly And Assembly 103
HYDROSTATIC MOTOR 104
Removal And Installation 104
Parts Identification 105
Disassembly 106
Inspection 110
Assembly 111
DRIVE BELT 115
Removal And Installation 115
CHARGE PRESSURE 116
Checking 116
HYDROSTATIC PUMP 117
Parts Identification 117
Removal And Installation 118
Disassembly And Assembly 120
Inspection 123
TENSION PULLEY AND SPRING 126
Removal And Installation 126
DRIVE SYSTEM 129
PARKING BRAKE PEDAL 131
Removal And Installation 131
Disassembly And Assembly 131
CHAINCASE FLUID 132
Removing Oil From The Chaincase 132
CHAINCASE COVER 132
Removal And Installation 132
Disassembly And Assembly 132
PARKING BRAKE DISC 133
Removal And Installation 133
AXLE HUB 134
Removal And Installation 134
AXLE SEAL 135
Removal And Installation 135
AXLE, BEARINGS, AND SPROCKET 136
Removing The Axle 136
Removing And Installing The Axle Bearing 137
Removing The Bearing Races 138
Installing The Bearing Races 139
Installing The Inner Bearing And Axle Sprocket 139
DRIVE CHAIN 140
Removal And Installation 140
MAIN FRAME 141
SEAT BAR 143
Removal And Installation 143
Assembly 146
OPERATOR CAB 147
Removal And Installation 147
OPERATOR CAB GAS CYLINDER 149
Removal And Installation 149
OPERATOR SEAT 150
Removal And Installation 150
BOB–TACH 152
Removal 152
Installation 153
Seal Removal And Installation 154
Lever And Wedge Removal 154
Lever And Wedge Installation 156
LIFT ARMS 158
Removal And Installation 158
FUEL TANK 161
Removal And Installation 161
REAR WINDOW 162
Removal And Installation 162
REAR DOOR 163
Exhaust Pipe Removal And Installation 163
Removal And Installation 163
ELECTRICAL SYSTEM 165
ELECTRICAL SCHEMATICS 167
TROUBLESHOOTING 171
Chart 171
ELECTRICAL SYSTEM INFORMATION 172
Description 172
Fuse Location 172
Relay Switches Location 172
BATTERY 173
Removal And Installation 173
Servicing The Electrical System 174
Using A Booster Battery (Jump Starting) 175
ALTERNATOR 176
Removal And Installation 176
Adjusting The Alternator Belt 176
Alternator Belt Removal And Installation 177
Description 179
Tests 179
Alternator Output Test 179
Full Field Test 180
Alternator Regulator Test 180
Alternator Regulator Test With Voltmeter 180
STARTER 181
Removal And Installation 181
Checking The Starter In The Loader 181
Parts Identification 182
Disassembly 183
Inspection And Repair 188
No Load Test 191
Assembly 192
INSTRUMENT PANEL 199
Removal And Installation 199
FRONT LIGHTS (OPTIONAL) 200
Removal And Installation 200
REAR LIGHT (OPTIONAL) 201
Removal And Installation 201
ENGINE SERVICE 203
TROUBLESHOOTING 205
Chart 205
ENGINE SPEED CONTROL 207
Adjustment 207
Removal And Installation 207
RADIATOR 208
Removal And Installation 208
RADIATOR MOUNTING BRACKET 208
Removal And Installation 208
FAN 209
Removal And Installation 209
FLYWHEEL 210
Removal And Installation 210
ENGINE MOUNTING BRACKET 210
Removal And Installation 210
VALVE CLEARANCE 211
Ajustment 211
FUEL INJECTION PUMP 212
Checking The Injection Pump 212
Removal 213
Installation 214
Timing Procedure 214
FUEL INJECTOR NOZZLES 215
Checking 215
Removal 216
Installation 216
GLOW PLUGS 217
Checking 217
ENGINE COMPRESSION TEST 217
Procedure 217
ENGINE 218
Removal And Installation 218
CYLINDER HEAD 224
Removal And Installation 224
Inspection 225
Top Clearance 225
ROCKER ARM AND SHAFT 226
Checking 226
VALVE AND VALVE SPRINGS 227
Valve Removal 227
Checking Valve Spring 227
VALVE GUIDE, VALVE AND VALVE SEAT 228
Checking The Valve Guide 228
Reconditioning The Valve And Valve Seat 229
TIMING GEARCASE COVER 230
Removal And Installation 230
IDLER GEAR AND CAMSHAFT 232
Removal And Installation 232
Servicing The Idler Gear And Shaft 234
TIMING GEARS 234
Checking Backlash 234
FUEL CAMSHAFT 235
Removal And Installation 235
Governor 235
CRANKSHAFT GEAR 236
Removal And Installation 236
OIL PUMP 236
Removal And Installation 236
Oil Pump Service 236
Checking Engine Oil Pressure 237
Relief Valve 237
PISTON AND CONNECTING ROD 238
Removal And Installation 238
Servicing The Piston And Connecting Rod 239
Connecting Rod Alignment 241
CRANKSHAFT AND BEARINGS 242
Removal And Installation 242
Inspection Of Crankshaft And Bearings 243
CYLINDER BORE 246
Inspection 246
HYDRAULIC OIL COOLER AND SHROUDING 247
Removal And Installation 247
THERMOSTAT 248
Removal And Installation 248
WATER PUMP 249
Removal And Installation 249
Disassembly And Assembly 249
SYSTEMS ANALYSIS 251
BICS™ (With Press To Operate Button) 253
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 253
Inspecting The Seat Bar Sensor (Engine RUNNING) 253
Inspecting The Traction Lock (Engine RUNNING) 253
Inspecting The Lift Arm By–Pass Control 253
Troubleshooting Chart 254
Inspecting The BICSTM Controller (Engine STOPPED – Key ON) 255
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING) 255
Inspecting The Traction Lock (Engine Running) 255
Inspecting The Lift Arm By–Pass Control 255
Maintenance 255
Troubleshoot Chart 256
BICS™ SYSTEM CONTROLLER 257
Troubleshooting Guide 257
Removal And Installation 258
SEAT BAR SENSOR 259
Troubleshooting Guide 259
Seat Bar Sensor Test 260
Removal And Installation 261
BICS™ Controller Seat Bar Sensor Circuit Test 262
SEAT SENSOR 263
Troubleshooting Guide 263
Seat Sensor Test 264
Removal And Installation 265
BICS™ Controller Seat Sensor Circuit Test 266
TRACTION LOCK 267
Troubleshooting Guide 267
Removal And Installation 268
SPECIFICATIONS 269
SKID STEER LOADER SPECIFICATIONS 271
PERFORMANCE 271
CONTROLS 271
ENGINE 271
HYDRAULIC SYSTEM 272
ELECTRICAL 272
DRIVE SYSTEM 272
CAPACITIES 272
TIRES 272
FLOOR PRESSURE 272
ENGINE SPECIFICATIONS 273
Engine 273
Fuel Injector Nozzles 273
Fuel Injection Pump 273
Cylinder Head 273
Valves 273
Valve Springs 273
Rocker Arms 273
Camshaft 274
Cylinders 274
Piston Rings 274
Pistons 274
Crankshaft 274
Oil Pump 275
Thermostat 275
ENGINE BOLT TORQUE 276
Re–Grinding The Crankshaft 277
TORQUE SPECIFICATIONS FOR BOLTS 278
Torque For General SAE Bolts 278
Torque For General Metric Bolts 279
HYDRAULIC CONNECTION SPECIFICATIONS 280
O–ring Face Seal Connection 280
Straight Thread O–ring Fitting 280
Tubelines And Hoses 280
Flare Fitting 280
O–ring Flare Fitting 281
Port Seal Fitting 283
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 284
Specifications 284
DECIMAL AND MILLIMETER EQUIVALENTS 285
U S TO METRIC CONVERSION 285
SERVICE MANUAL REVISIONS 287
453-1 287
453-2 289
453-3 291
453-4 293
453-5 295

IMAGES PREVIEW OF THE MANUAL:

Questions? Email us: [email protected]

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V