Bobcat 553 Loader Service Manual 6724024 (6-12) – PDF DOWNLOAD

Description

Bobcat 553 Loader Service Manual 6724024 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 553 Loader Service Manual 6724024 (6-12) – PDF DOWNLOAD

Language : English
Pages : 298
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 553 Loader Service Manual 6724024 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
SAFETY INSTRUCTIONS 9
SERIAL NUMBER LOCATIONS 11
LOADER SERIAL NUMBER 11
ENGINE SERIAL NUMBER 11
DELIVERY REPORT 11
553 BOBCAT LOADER IDENTIFICATION 12
OPTIONS AND ACCESSORIES 13
PREVENTIVE MAINTENANCE 15
SERVICE SCHEDULE 17
LIFTING AND BLOCKING THE LOADER 18
Procedure 18
TRANSPORTING THE LOADER 19
Procedure 19
LIFTING THE LOADER 20
Single Point Lift 20
TOWING THE LOADER 20
Procedure 20
STOPPING THE BOBCAT LOADER 20
LIFT ARM SUPPORT DEVICE 21
Installing And Removing Lift Arm Support Device 21
OPERATOR CAB 21
Description 21
Emergency Exit 22
Raising The Operator Cab 22
Lowering The Operator Cab 22
SEAT BAR RESTRAINT SYSTEM 23
Description 23
Seat Bar Inspection 23
Seat Bar Maintenance 23
AIR CLEANER SERVICE 24
Replacing Filter Element 24
FUEL SYSTEM 26
Fuel Specifications 26
Filling The Fuel Tank 26
Fuel Filter 26
Removing Air From The Fuel System 27
ENGINE LUBRICATION SYSTEM 28
Checking Engine Oil 28
Replacing Oil And Filter 28
ENGINE COOLING SYSTEM 30
Checking The Coolant Level 30
Propylene Glycol 30
Cleaning The Cooling System 30
Removing Coolant From The Cooling System 30
ALTERNATOR BELT 32
Adjusting The Alternator Belt 32
USING A BOOSTER BATTERY (Jump Starting) 33
Procedure 33
HYDRAULIC/HYDROSTATIC SYSTEM 34
Checking And Adding Fluid 34
Replacing Hydraulic/Hydrostatic Filter 35
Replacing The Hydraulic Fluid 35
SPARK ARRESTOR MUFFLER 36
Cleaning Procedure 36
TIRE MAINTENANCE 37
Wheel Nuts 37
Tire Rotation 37
Tire Mounting 37
FINAL DRIVE TRANSMISSION (CHAINCASE) 38
Checking And Adding Oil 38
Removing Oil From The Chaincase 38
LUBRICATION OF THE LOADER 39
Procedure 39
REMOTE START SWITCH 41
Procedure 41
HYDRAULIC SYSTEM 43
HYDRAULIC / HYDROSTATIC SCHEMATICS 45
TROUBLESHOOTING 49
HYDRAULIC SYSTEM INFORMATION 50
Flare Connections 50
O–ring Face Seal Connection 50
Straight Thread O–ring Fitting 50
Tubelines and Hoses 50
LIFT CYLINDER(S) 51
Removal and Installation 51
Checking The Lift Cylinder(s) For Internal Leakage 51
TILT CYLINDER 52
Removal And Installation 52
Checking The Tilt Cylinder For Internal Leakage 53
HYDRAULIC CYLINDER IDENTIFICATION 54
Lift Cylinder Components 54
Tilt Cylinder Components 55
HYDRAULIC CYLINDER 56
Disassembly 56
Assembly 58
HYDRAULIC CONTROL VALVE 64
Removal And Installation 64
Checking The Main Relief Valve 67
Main Relief Valve Removal And Installation 68
Main Relief Valve Adjustment 68
Identification Chart 69
Disassembly And Assembly 70
Load Check Valve 70
Main Relief Valve 71
Anti–Cavitation Valve 72
Rubber Boot 73
Lift Spool Detent 74
Tilt Centering Spring 78
Auxiliary Spool Detent 78
One Way Restrictors 79
Inspection 79
Spool Seal Installation 80
HYDRAULIC PUMP 81
Removal And Installation 81
Checking The Output Of The Hydraulic Pump 82
Main Relief Valve Adjustment 83
Parts Identification 84
Disassembly and Assembly 85
Inspection 86
HYDRAULIC FILTER HOUSING 87
Removal And Installation 87
HYDRAULIC FLUID RESERVOIR 88
Removal And Installation 88
CONTROL PEDALS 89
Removal And Installation 89
Pedal Adjustment 89
PEDAL INTERLOCK LINKAGE 90
Removal And Installation 90
Adjustment 91
CROSSMEMBER LINKAGE 92
Removal And Installation 92
HYDROSTATIC SYSTEM 93
TROUBLESHOOTING 95
HYDROSTATIC SYSTEM INFORMATION 96
Replenishing Valve Function 96
CONTROL PANEL 97
Removal And Installation 97
STEERING LEVERS 98
Removal And Installation 98
Disassembly And Assembly 99
STEERING LINKAGE 100
Removal And Installation 100
Pintle Lever Disassembly And Assembly 102
Steering Neutral Adjustment 103
HYDR0STATIC PUMP 105
Checking Charge Pressure 105
Removal And Installation 106
Drive Coupler Removal And Installation 109
Parts Identification 110
Disassembly and Assembly 111
Inspection 115
PORT BLOCK 118
Removal And Installation 118
Oil Cooler Bypass Valve 118
Hydraulic Oil Temperature Switch 118
Charge Pressure Bypass Valve 118
HYDROSTATIC DRIVE MOTOR 119
Removal And Installation 119
Parts Identification 121
Disassembly And Assembly 122
Inspection 129
Timing The Hydrostatic Motor 130
DRIVE SYSTEM 131
PARKING BRAKE 133
Removal And Installation 133
Disassembly And Assembly 133
PARKING BRAKE DISC 134
Removal And Installation 134
Brake Disc Guide Removal And Installation 135
CHAINCASE FLUID 136
Removing Oil From The Chaincase 136
CHAINCASE COVERS 136
Front Cover Removal And Installation 136
Rear Cover Removal And Installation 136
AXLE SEAL 137
Removal And Installation 137
AXLE, BEARINGS, AND SPROCKET 139
Removal And Installation 139
DRIVE CHAIN 143
Removal 143
MAIN FRAME 145
SEAT BAR 147
Removal And Installation 147
Assembly 149
Compressing The Gas Cylinder 150
OPERATOR CAB GAS CYLINDER 151
Removal And Installation 151
Disassembly And Assembly 151
OPERATOR CAB 152
Removal And Installation 152
OPERATOR SEAT 155
Removal And Installation 155
BOB–TACH 156
Removal And Installation 156
Bob–Tach Lever And Wedge 158
LIFT ARMS 160
Removal And Installation 160
REAR GRILL 163
Removal And Installation 163
FUEL TANK 164
Removal And Installation 164
Fuel Level Sender 164
REAR DOOR 165
Removal And Installation 165
Door Handle Adjustment 166
ELECTRICAL SYSTEM 167
ELECTRICAL SCHEMATICS 169
TROUBLESHOOTING 191
ELECTRICAL SYSTEM INFORMATION 192
Description 192
Fuse Location 192
Relay Switches Location 192
Removing And Installing The Battery 193
ALTERNATOR 194
Alternator Belt Shield Removal And Installation 194
Removal And Installation 195
Adjusting The Alternator Belt 195
Alternator Output Test 196
Rectifier (Diode) Test 196
Alternator Regulator Test 197
Disassembly And Inspection – Parts Identification 198
Stator Continuity Test 198
Stator Ground Test 198
Rotor Continuity Test 199
Rotor Ground Test 199
Rectifier Continuity (Diode) Test 199
Assembly 200
STARTER 201
Removal And Installation 201
Checking The Starter 201
Disassembly And Assembly 202
Parts Identification 202
Cleaning And Inspection 203
Replacing The Brushes 203
INSTRUMENT PANEL 204
Removal And Installation 204
FRONT LIGHTS 205
Removal And Installation 205
ENGINE SERVICE 207
TROUBLESHOOTING 210
ENGINE SPEED CONTROL 212
Removal And Installation 212
Disassembly 212
Linkage Bar Removal And Installation 213
RADIATOR 214
Removal And Installation 214
ENGINE MUFFLER 216
Removal And Installation 216
AIR CLEANER 216
Removal And Installation 216
FUEL FILTER 217
Removal And Installation 217
ENGINE 218
Removal And Installation 218
U–JOINT COUPLER 222
Removal And Installation 222
Disassemly And Assembly 222
FLYWHEEL 223
Removal And Installation 223
Flywheel Ring Gear 223
BLOWER FAN HOUSING 224
Removal And Installation 224
ENGINE COMPRESSION 225
Checking 225
GLOW PLUGS 226
Checking 226
Removal And Installation 227
FUEL INJECTION PUMP 228
Checking The Injection Pump 228
Removal And Installation 229
Timing The Injection Pump 232
FUEL INJECTOR NOZZLES 234
Removal 234
Installation 234
Checking Fuel Injector Nozzles 235
CYLINDER HEAD 236
Removal 236
Installation 238
Disassembly 240
Assembly 240
Servicing The Cylinder Head 241
TIMING GEARCASE COVER 244
Removal 244
Installation 246
TIMING GEARS AND CAMSHAFT 247
Removal 247
Installation 250
Servicing The Timing Gear And The Camshaft 251
OIL PUMP 253
Removal And Installation 253
Servicing The Oil Pump 253
WATER PUMP 254
Removal And Installation 254
PISTONS AND CRANKSHAFT 255
Piston And Camshaft Removal 255
Piston Installation 256
Servicing The Pistons And Connecting Rods 257
Crankshaft Installation 259
Servicing The Crankshaft 259
Servicing The Cylinder Liners 261
BICS™ SYSTEM 263
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 265
Inspecting The BICS System Controller (Engine STOPPED – Key ON) 265
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING) 265
Inspecting The Traction Lock (Engine RUNNING) 265
Inspecting The Lift Arm By–Pass Control 265
Maintenance 265
Troubleshooting Chart 266
TROUBLESHOOTING GUIDE 267
BICS CONTROLLER 267
TRACTION LOCK 268
SEAT SENSOR 269
SEAT BAR SENSOR 270
LIFT LOCK BYPASS VALVE 271
BICS™ SYSTEM CONTROLLER 272
Removal And Installation 272
Controller Test 273
SEAT BAR SENSOR 274
Removal And Installation 274
Seat Bar Sensor Test 275
SEAT SENSOR 276
Removal And Installation 276
Seat Sensor Test 277
TRACTION LOCK 278
Removal And Installation 278
LIFT LOCK BYPASS VALVE 279
Removal And Installation 279
Disassembly And Assembly 280
TILT LOCK VALVE 281
Removal And Installation 281
Disassembly And Assembly 282
SPECIFICATIONS 283
LOADER SPECIFICATIONS 285
LOADER DIMENSIONS 285
OPERATIONS & PERFORMANCE 285
ENGINE 285
HYDRAULIC SYSTEM 286
ELECTRICAL 286
DRIVE SYSTEM 286
CAPACITIES 286
TIRES 286
VIBRATION DATA 286
ENGINE SPECIFICATIONS 287
Fuel Injection Nozzles 287
Fuel Injection Pump 287
Cylinder Head 287
Valves 287
Valve Springs 287
Rocker Arms 287
Camshaft 287
Cylinders 288
Piston Rings 288
Pistons 288
Crankshaft 288
Oil Pump 288
Thermostat 288
Grinding Specifications for the Crankshaft 289
TORQUE SPECIFICATIONS FOR LOADER 290
Specifications 290
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 291
Specifications 291
METRIC TORQUE SPECIFICATIONS FOR BOLTS 292
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 293
DECIMAL AND MILLIMETER EQUIVALENTS 294
U S TO METRIC CONVERSION 294
SERVICE MANUAL REVISIONS 295
553-1 295
553-2 297

DESCRIPTION:

Bobcat 553 Loader Service Manual 6724024 (6-12) – PDF DOWNLOAD

S/N 513011001 & Above
Europe Only – S/N 513031001 & 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 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 English edition or a combination English, French, German, Italian,
Dutch & Spanish edition.
• 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 versions.

IMAGES PREVIEW OF THE MANUAL:

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PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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