Bobcat 520 530 533 Loader Service Manual 6556407 (6-12) – PDF DOWNLOAD
FILE DETAILS:
Bobcat 520 530 533 Loader Service Manual 6556407 (6-12) – PDF DOWNLOAD
Language : English
Pages : 174
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat 520 530 533 Loader Service Manual 6556407 (6-12) – PDF DOWNLOAD
FORWARD:
This manual gives instructions for:
1. Correct service and adjustment of the Bobcat Loader.
2. Overhaul instructions of the engine, loader hydraulic/hydrostatic system and
mai nframe parts.
See the Owner’s Manual for operating instructions (Starting Procedure, Regular Checks,
Basic Maintenance, etc. ).
Make a complete inspection of these items after completion of service or repair:
1. Check the hydraulic fluid level, engine oil level, fuel supply, and coolant level.
2. Look for any sign of fuel, oil or hydraulic fluid leaks.
3. Complete lubrication of the machine.
4. Check the battery condition, electrolyte level and cables.
5. Check the air cleaner system for damage or leaks. Check the element and replace if
necessary.
6. Check the electrical system.
7. Check the warni ng lamps.
8. Check the tires for wear and correct pressure.
9. Check the Bob-Tach attachment for condition. Check the wedges for damage or
wear.
10. Check ali safety items for condition (Operator Enclosure, Seat Belt, Safety Treads,
Lamps, Parking B rake, etc. ).
11. Make a visual inspection for loose or broken parts or connections.
12. Operate the loader, and check operation of drive system and hydraulic system.
Tel1 the owner if any of the above items are in need of repair.
TABLE OF CONTENTS:
Bobcat 520 530 533 Loader Service Manual 6556407 (6-12) – PDF DOWNLOAD
MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 5
SAFETY INSTRUCTIONS 7
PREVENTIVE MAINTENANCE 9
INTRODUCTION 11
Symbols 11
Serial Number Identification 11
Loader Serial Number 11
Engine Serial Number 11
Pre-Delivery Inspection 12
30 Hour Inspection 12
PREVENTIVE MAINTENANCE 13
SERVICE SCHEDULE 13
ENGINE SERVICE 14
AIR CLEANER SYSTEM 14
FUEL SYSTEM 15
FUEL SYSTEM SERVICE 15
FUEL FILTER 15
ENGINE LUBRICATION SYSTEM 16
CHANGING ENGINE OIL AND FILTER (520/530) 16
CHANGING OIL AND FILTER (533) 17
ENGINE COOLING SYSTEM (520/530) 18
ENGINE COOLING SYSTEM (533) 18
ELECTRICAL SYSTEM 19
HYDRAULIC SYSTEM 20
HYDRAULIC / HYDROSTATIC FLUID 20
Checking And Adding Fluid 20
Hydraulic / Hydrostatic Fluid Replacement 21
HYDRAULIC FILTER REPLACEMENT 21
FINAL DRIVE TRANSMISSION (CHAINCASE) 21
TIRE MAINTENANCE 22
Tire Rotation 22
LUBRICATION OF LOADER 22
BOB-TACH 23
PIVOT PINS 23
FUEL INJECTION PUMP RESERVOIR (533) 24
HYDRAULIC SYSTEM 25
HYDRAULIC / HYDROSTATIC SCHEMATICS 27
HYDRAULIC CIRCUIT 47
GENERAL INFORMATION 47
Keeping Parts And Work Area Clean 47
37° Flare Connections 47
Straight Thread O-Ring Connections 48
Tubelines And Hoses 48
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM 48
HYDRAULIC PUMP 49
Checking Output Of The Pump 49
PROBLEM ANALYSIS 51
CHECKING RELIEF VALVE 52
To Check Release Pressure 52
Relief Valve Removal And Replacement 52
CHECKING OUTPUT OF VANE PUMP 52
VANE PUMP REPAIR 53
Removal 53
Disassembly 53
Inspection 53
Assembly 53
Pump Istallation 54
CHECKING CONTROL VALVE AND CYLINDERS 54
To Check Lift Cylinders 54
To Check Tilt Cylinders 54
HYDRAULIC CYLINDER REPAIR 54
Removal And Installation 54
Disassembly And Repair 54
CONTROL VALVE REPAIR 55
Removal 55
Disassembly And Inspection 55
Assembly Of Valve 56
ADJUSTMENT OF PEDAL LINKAGE 57
HYDRAULIC HOSES 57
Hydraullic Hose Protection 57
QUICK COUPLERS 58
Restriction In The Quick-Couplers 58
HYDROSTATIC SYSTEM 59
HYDROSTATIC CIRCUIT 61
TROUBLESHOOTING CHART 61
REPLENISHING VALVE 64
Checking The Replenishing Valves 64
BY-PASS VALVE REPAIR 64
REMOVAL AND INSTALLATION OF PUMP ASSEMBLY 64
REPAIR OF HYDROSTATIC PUMP ASSEMBLY 65
Pump Disassembly 65
Assembly 66
HYDROSTATIC MOTOR REMOVAL AND INSTALLATION 67
Installation 67
HYDROSTATIC MOTOR REPAIR 67
Disassembly And Inspection 67
Assembly 68
STEERING LINKAGE 71
Adjustment (Old Style Linkage) 71
Adjustment (New Style Linkage) 71
DRIVE SYSTEM 73
DRIVE CHAINS 75
Chain Replacement 75
AXLES AND BEARINGS 75
Removal Procedure For All Four Axles 75
Assembly And Installation 76
BRAKE PAD REPLACEMENT 77
MAIN FRAME 79
REMOVAL OF ROPS (OPERATOR GUARD) 81
REPLACEMENT OF PIVOT PINS 81
Bushing Replacement 82
BOB-TACH 83
To Check The Wedges 83
Removal Of Bob-Tach 85
Bob-Tach Over Center Stop 85
REMOVAL OF FUEL TANK AND HYDRAULIC RESERVOIR 86
ELECTRICAL SYSTEM 87
ELECTRICAL CIRCUITRY 89
PROBLEM ANALYSIS CHARTS 89
CHECKS AND REPAIRS OF THE ELECTRICAL SYSTEM (520/530) 96
Checking A C Voltage 96
Alternator Repair 96
Replacement Of The Stator 96
STARTER 96
To Check The Starter 96
Removal Of Starter 96
Disassembly And Repair 97
CHECKS AND REPAIRS OF THE ELECTRICAL SYSTEM (533) 97
To Check The Wiring 97
To Check The Generator Output 98
To Check The Regulator 98
To Check The Engine Pre-Heat 98
GENERATOR SERVICE 99
Removal Of The Generator 99
Disassembly 99
STARTER 101
Checking The Starter 101
CHECKING ELECTRICAL WIRING 102
STARTER SUPPORT BRACKET 102
ENGINE SERVICE (520/530) 103
TROUBLESHOOTING THE ENGINE 105
CHECKS AND ADJUSTMENTS 106
Oil Pressure 106
Valve Clearance 106
Compression 106
Adjustment Of The Carburetor 106
Throttle And Govenor Linkage 106
Ignition System Adjustment 107
CARBURETOR REPAIR 107
Removal 107
Disassembly And Inspection 108
Assembly 108
REPAIR OF THE GOVENOR 108
Removal 108
Installation 109
ENGINE 109
Removal And Installation Of The Engine 109
REPAIR OF THE ENGINE 109
Flywheel 109
Repair Of The Valves And Guides 110
TIMING COVER, TIMING GEARS, CAMSHAFT 110
Timing Cover 110
Timing Gears 110
Camshaft And Tappets 111
OIL PUMP AND RELIEF VALVE 111
Adjust Gear Clearance For Engine Oil Pump 111
PISTONS, RODS, CRANKSHAFT 112
CYLINDER HEADS 113
INTAKE AND EXHAUST MANIFOLD 113
ENGINE HEAT SHIELD 113
ENGINE SERVICE (533) 115
ENGINE OVERHAUL 117
DISASSEMBLY OF ENGINE 117
CLEANING AND INSPECTION 119
DISASSEMBLY AND ASSEMBLY OF ROCKER SHAFT 119
Disassembly 119
DISASSEMBLY OF THE CYLINDER HEAD 120
Inspection 120
Inspection Of The Combustion Chambers 120
Inspection Or The Valves And Valve Guides 121
Inspection And Correction Of The Valve Seats 121
Inspection Of The Valve Springs 122
Inspection Of The Push-Rods And Tappets 122
Installation Of The Hot Plugs 122
Assembly Of The Valve System 123
CYLINDER BLOCK 123
Inspection Of The Cylinder Block For Cracks 123
Distortion Of The Cylinder Block Upper Surface 123
Correction Of Cylinder Bores 123
PISTONS AND PISTON RING ASSEMBLIES 124
Disassembly 124
Inspection Of Pistons 124
Inspection Of Piston Ring Clearance 124
Assembly Of Piston And Connecting Rods 124
Connecting Rods 125
Clearance Between The Small-End Bushing And Piston Pin 125
Clearance Between The Big-End Bearing And Crankpin 125
Connecting Rod Bearings 125
Connecting Rod Bearing Oil Clearance 126
CRANKSHAFT BEARINGS 126
Crankshaft 126
FLYWHEEL AND RING GEAR 127
CAMSHAFT 127
TIMING GEAR 127
MANIFOLD ASSEMBLY 127
ASSEMBLY OF ENGINE 127
Special Cautions 127
Assembly 128
Method Of Adjustment 130
DISASSEMBLY, INSPECTION AND ASSEMBLY OF THE OIL PUMP 131
Inspection 131
DISASSEMBLY, INSPECTION AND ASSEMBLY OF THE OIL FILTER ASSEMBLY 131
Disassembly And Assembly 131
Inspection 132
WATER PUMP 132
Disassembly Of Water Pump 132
Inspection 132
Assembly 132
INJECTION NOZZLES 133
Disassembly Of The Nozzle Holder Assembly 134
Inspection Of The Nozzle Holder Assemblies 134
Assembling The Nozzle 134
INJECTION PUMP 134
Removal Of Pump 134
To Remove The Pump Drive Gear 135
To Install The Pump Drive Gear 135
Installation And Timing Of Injection Pump 135
TECHNICAL DATA 137
FUEL SPECIFICATIONS 139
LUBRICANTS 139
Gasoline Engine (520/530) 139
Diesel Engine (533) 139
Hydraulic System 139
Chaincase 139
LOADER SPECIFICATIONS (520/530) 140
Operating Specifications 140
Engine 140
Electrical 140
Hydraulics System 140
Power Train 140
Capacities 140
Tires 140
LOADER SPECIFICATIONS (533) 141
Operating 141
Engine 141
Electrical 141
Hydraulic System 141
Power Train 141
Capacities 141
Tires 141
LOADER TORQUE SPECIFICATIONS 142
GASOLINE ENGINE TORQUE SPECIFICATIONS (520/530) 142
DIESEL ENGINE TORQUE SPECIFICATIONS (533) 142
HYDROSTATIC PUMP TORQUE SPECIFICATIONS 142
HYDRAULIC MOTOR TORQUE SPECIFICATIONS 142
HYDRAULIC / HYDROSTATIC SYSTEM 142
SEAL INSTALLING TOOLS 143
FITS, CLEARANCE, ADJUSTMENTS (520/530) 143
Engine 143
Cylinder Bore 143
Crankshaft 143
Connecting Rod 143
Piston, Pin & Rings 143
Valves, Guides, Tappets 143
FITS, CLEARANCE, ADJUSTMENTS (533) 144
Valves 144
Glow Plugs 144
Starting Motor 144
Generator 144
Oil Pump 144
DIMENSIONAL SPECIFICATIONS 144
Cylinder Head 144
Cylinder Block 145
Piston Rings 145
Connecting Rods 145
Crankshaft 146
Camshaft 146
Timing Gears 146
Manifolds 147
Oil Pump 147
GENERAL tORQUE SPECIFICATIONS 147
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 148
DECIMALS AND MILLIMETER EQUIVALENTS 149
U S TO METRIC CONVERSION 149
ALPHABETICAL INDEX 151
SERVICE BULLETINS 155
530-001 155
530-002 157
530-003 159
530-004 161
530-005 163
530-006 165
530-007 167
530-008 169
SERVICE MANUAL REVISIONS 171
530-009 171
530-10 173
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