Bobcat 553 Loader Service Manual 6900450 (6-12) – PDF DOWNLOAD

Description

Bobcat 553 Loader Service Manual 6900450 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 553 Loader Service Manual 6900450 (6-12) – PDF DOWNLOAD

Language : English
Pages : 368
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 553 Loader Service Manual 6900450 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 9
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
TOWING THE LOADER 19
Procedure 19
STOPPING THE BOBCAT LOADER 20
LIFT ARM SUPPORT DEVICE 21
Engaging The Lift Arm Support Device 21
Disengaging The Lift Arm Support Device 22
OPERATOR CAB 23
Raising The Operator Cab 23
Lowering The Operator Cab 23
Emergency Exit 24
SEAT BAR RESTRAINT SYSTEM 25
Description 25
Seat Bar Inspection 25
Seat Bar Maintenance 25
AIR CLEANER SERVICE 26
Replacing Filter Element 26
FUEL SYSTEM 27
Fuel Specifications 27
Filling The Fuel Tank 27
Fuel Filter 27
Removing Air From The Fuel System 28
ENGINE LUBRICATION SYSTEM 29
Checking Engine Oil 29
Oil Chart 29
Replacing Oil And Filter 29
ENGINE COOLING SYSTEM 31
Cleaning The Cooling System 31
Replacing The Coolant 32
ALTERNATOR BELT 33
Adjusting The Alternator Belt 33
HYDRAULIC/HYDROSTATIC SYSTEM 34
Description 34
Checking And Adding Fluid 34
Replacing The Hydraulic/Hydrostatic Filter 35
Replacing 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
LUBRICATING THE BOBCAT LOADER 39
Procedure 39
PIVOT PINS 40
BOB–TACH 41
Inspection And Maintenance 41
AUXILIARY CONTROL LOCKBOLT 42
Removal 42
U–JOINT LUBRICATION 42
Procedure 42
REMOTE START SWITCH 43
Procedure 43
HYDRAULIC SYSTEM 45
HYDRAULIC / HYDROSTATIC SCHEMATICS 47
GLOSSARY OF HYDRAULIC / HYDROSTATIC SYMBOLS 51
TROUBLESHOOTING 55
HYDRAULIC SYSTEM INFORMATION 56
Tighten Procedures 56
LIFT CYLINDERS 57
Checking The Lift Cylinder(s) 57
Removal And Installation 58
TILT CYLINDER 60
Checking The Tilt Cylinder 60
Removal And Installation 61
HYDRAULIC CYLINDER 63
Lift Cylinder Identification 63
Tilt Cylinder Identification 64
Disassembly And Assembly 65
MAIN RELIEF VALVE 67
Checking The Main Relief Valve Without Auxiliaries 67
Checking The Main Relief Valve With Auxiliaries 68
Removal And Installation 69
Adjustment 69
HYDRAULIC CONTROL VALVE 70
Removal And Installation 70
Identification Chart 73
Disassembly and Assembly 74
Load Check Valve 74
Main Relief Valve 75
Anti–Cavitation Check Valve 76
Rubber Boot 77
Lift Spool Detent 78
Tilt Centering Spring 82
One Way Restrictors 83
Inspection 83
Spool Seal Installation 84
HYDRAULIC PUMP 85
Checking The Output Of The Hydraulic Pump 85
Removal And Installation 87
Parts Identification 88
Disassembly And Assembly 89
Inspection 90
HYDRAULIC FLUID RESERVOIR 91
Removal And Installation 91
LIFT LOCK BY–PASS VALVE 92
Removal And Installation 92
Disassembly and Assembly 93
TILT LOCK VALVE 94
Removal And Installation 94
Disassembly And Assembly 95
HYDRAULIC FILTER HOUSING 96
Removal And Installation 96
CONTROL PEDALS 97
Removal And Installation 97
Pedal Adjustment 97
PEDAL INTERLOCK LINKAGE 98
Removal And Installation 98
Adjustment 99
CROSSMEMBER LINKAGE 100
Removal And Installation 100
HYDROSTATIC SYSTEM 101
TROUBLESHOOTING 103
HYDROSTATIC SYSTEM INFORMATION 104
Replenishing Valve Function 104
CONTROL PANEL 105
Removal And Installation 105
STEERING LEVERS 106
Removal And Installation 106
Disassembly And Assembly 107
STEERING LINKAGE 108
Removal And Installation 108
Pintle Lever Disassembly And Assembly 110
Steering Neutral Adjustment 111
HYDROSTATIC MOTOR 113
Removal And Installation 113
Parts Identification 115
Disassembly And Assembly 116
Inspection 123
Timing The Hydrostatic Motor 124
HYDROSTATIC PUMP 125
Checking Charge Pressure 125
Removal And Installation 126
Drive Coupler Removal And Installation 129
Parts Identification 130
Disassembly And Assembly 131
Inspection 135
PORT BLOCK 138
Removal And Installation 138
Oil Cooler By–Pass Valve 138
Hydraulic Oil Temperature Switch 138
Charge Pressure By–Pass Valve 138
OIL COOLER 139
Removal and Installation 139
DRIVE SYSTEM 141
PARKING BRAKE 143
Removal And Installation 143
Disassembly And Assembly 143
PARKING BRAKE DISC 144
Removal and Installation 144
TRACTION LOCK GUIDES 145
Removal and Installation 145
CHAINCASE FLUID 146
Removing Oil From The Chaincase 146
CHAINCASE COVERS 146
Front Cover Removal And Installation 146
Rear Cover Removal And Installation 146
AXLE SEAL 147
Removal And Installation 147
AXLE, BEARINGS, AND SPROCKET 149
Removal And Installation 149
DRIVE CHAIN 153
Removal 153
MAIN FRAME 155
SEAT BAR 157
Removal And Installation 157
Assembling Components 160
Compression Spring Disassembly And Assembly 160
OPERATOR CAB GAS CYLINDER 161
Removal And Installation 161
Disassembly And Assembly 161
OPERATOR CAB 162
Removal And Installation 162
OPERATOR SEAT 165
Removal And Installation 165
REAR DOOR 166
Removal And Installation 166
Door Latch Adjustment 167
Striker Removal And Installation (S/N 516313551 & Above) & (S/N 516415035 & Above) 168
Striker Disassembly And Assembly (S/N 516313551 & Above) & (S/N 516415035 & Above) 168
Adjusting The Striker (S/N 516313551 & Above) & (S/N 516415035 & Above) 168
Latch Removal And Installation (S/N 516313551 & Above) & (S/N 516415035 & Above) 169
FUEL TANK 170
Removal And Installation 170
Fuel Level Sender 170
BOB–TACH 171
Removal And Installation 171
Bob–Tach Lever And Wedge 173
LIFT ARMS 175
Removal and Installation 175
REAR GRILL 179
Removal And Installation 179
ELECTRICAL SYSTEM 181
ELECTRICAL SCHEMATICS 183
TROUBLESHOOTING 215
ELECTRICAL SYSTEM INFORMATION 216
Description 216
Fuse Location 216
Relay Switches Location 216
BATTERY 217
Removal And Installation 217
USING A BOOSTER BATTERY (JUMP STARTING) 218
Procedure 218
ALTERNATOR 219
Removal And Installation 219
Adjusting The Alternator Belt 219
Description 220
Tests 220
Alternator Output Test 220
Full Field Test 221
Alternator Regulator Test 221
Alternator Regulator Test With Voltmeter 221
Parts Identification 222
Pulley Removal And Installation 223
Disassembly And Assembly 223
Rotor Continuity Test 226
Stator Continuity Test 227
Rectifier Continuity (Diode) Test 228
Brush Length 228
STARTER 229
Removal And Installation 229
Checking The Starter In The Loader 229
Parts Identification 230
Disassembly 231
Inspection And Repair 236
No Load Test 239
Assembly 240
INSTRUMENT PANEL 247
Removal And Installation 247
FRONT LIGHTS 248
Removal And Installation 248
ENGINE SERVICE 249
TROUBLESHOOTING 252
ENGINE SPEED CONTROL 254
Removal and Installation 254
Disassembly 254
Linkage Bar Removal And Installation 255
RADIATOR 256
Removal And Installation 256
ENGINE MUFFLER 258
Removal And Installation 258
AIR CLEANER 258
Removal And Installation 258
ENGINE 259
Removal And Installation 259
U–JOINT COUPLER 264
Removal And Installation 264
Disassembly and Assembly 264
RUBBER DRIVE COUPLER 265
Removal And Installation 265
Disassembly 265
Assembly 266
FLYWHEEL 268
Removal And Installation 268
FLYWHEEL HOUSING 269
Flywheel Ring Gear 269
Removal And Installation 269
ENGINE MOUNTING BRACKETS 269
Removal and Installation 269
BLOWER FAN HOUSING 270
Removal And Installation 270
ENGINE COMPRESSION 271
Checking 271
GLOW PLUGS 272
Checking 272
Removal And Installation 273
FUEL SHUT–OFF SOLENOID 274
Removal And Installation 274
FUEL LIFT PUMP 275
Removal And Installation 275
FUEL INJECTION PUMP 276
Checking The Injection Pump 276
Removal And Installation 277
Timing The Injection Pump 279
FUEL INJECTOR NOZZLES 280
Removal and Installation 280
Checking Fuel Injector Nozzles 281
THERMOSTAT 282
Removal And Installation 282
WATER PUMP 282
Removal And Installation 282
TIMING GEAR CASE COVER 283
Removal And Installation 283
OIL PUMP 285
Removal And Installation 285
CRANKSHAFT FRONT SEAL 287
Removal And Installation 287
ENGINE SPEED CONTROL PLATE 289
Removal And Installation 289
Governor Spring Removal 289
Start Spring Removal 289
Idle Limit And Fuel Limit Adjustment 290
EXHAUST MANIFOLD 290
Removal And Installation 290
VALVE COVER 291
Removal And Installation 291
ROCKER ARM 292
Removal And Installation 292
PUSH ROD 293
Removal And Installation 293
TAPPET 293
Removal And Installation 293
WATER FLANGE 294
Removal And Installation 294
CYLINDER HEAD 294
Removal 294
Installation 294
Checking Piston Top Clearance 295
Disassembly 296
Assembly 296
Servicing The Cylinder Head 297
Combustion Chamber Removal And Installation 299
IDLER GEAR 300
Removal And Installation 300
CAMSHAFT 301
Removal And Installation 301
FUEL CAMSHAFT 303
Removal And Installation 303
OIL PAN 305
Removal And Installation 305
GOVERNOR SHAFT 306
Removal And Installation 306
GOVERNOR FORK LEVER 309
Removal And Installation 309
PISTON 311
Removal And Installation 311
Checking The Piston And Connecting Rod 311
Connecting Rod Alignment 312
Piston Ring Gap 312
Piston Ring Installation 312
Connecting Rod Installation 313
Checking Engine Cylinder Bore 313
CRANKSHAFT 314
Removal And Installation 314
Checking Crankshaft Journal And Block Bearing 316
Checking The Crankshaft Journal And Main Bearing 317
Connecting Rod Journal 318
Checking The End Play Of The Crankshaft 319
Crankshaft Alignment 319
ENGINE TIMING 320
Installation 320
TIMING GEAR BACKLASH 320
Idler Gear And Crankshaft 320
Idler Gear And Camshaft Gear 321
Idler Gear And Fuel Camshaft Gear 321
Fuel Camshaft Gear And Governor Shaft Gear 321
SYSTEMS ANALYSIS 323
BICS™ – BOBCAT INTERLOCK CONTROL SYSTEM 325
BICS™ (With Press To Operate Button) 325
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 325
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 325
nspecting The Seat Bar Sensor (Engine RUNNING) 325
Inspecting The Traction Lock (Engine RUNNING) 325
Inspecting The Lift Arm By–Pass Control 325
Additional Inspection For Loaders With Advanced Hand Controls 325
Troubleshooting Chart 326
BICS™ (Without Press To Operate Button) 327
Inspecting The BICS Controller (Engine STOPPED –Key ON) 327
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED–Key ON) 327
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING) 327
nspecting The Traction Lock (Engine RUNNING) 327
Inspecting The Lift Arm By–Pass Control 327
Maintenance 328
Troubleshooting Chart 329
BICS™ SYSTEM CONTROLLER 330
Troubleshooting Guide 330
Removal And Installation 331
SEAT BAR SENSOR 332
Troubleshooting Guide 332
Seat Bar Sensor Test 333
Removal And Installation 334
BICS™ Controller Seat Bar Sensor Circuit Test 335
SEAT SENSOR 336
Troubleshooting Guide 336
Seat Sensor Test 337
Removal And Installation 338
BICS™ Controller Seat Sensor Circuit Test 339
TRACTION LOCK 340
Troubleshooting Guide 340
Removal and Installation 341
SPECIFICATIONS 343
LOADER SPECIFICATIONS 345
Loader Dimensions 345
Performance 345
Controls 345
Engine 345
Hydraulic System 346
Electrical 346
Drive System 346
Capacities 346
Tires 346
ENGINE SPECIFICATIONS 347
Engine Compression 347
Fuel Injection Nozzles 347
Fuel Injection Pump 347
Cylinder Head 347
Valves 347
Valve Springs 347
Rocker Arms 347
Camshaft 347
Cylinders 348
Piston Rings 348
Pistons 348
Crankshaft 348
Oil Pump 348
Thermostat 348
Grinding Specifications for the Crankshaft 349
TORQUE SPECIFICATIONS FOR LOADER 351
Specifications 351
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 352
Specifications 352
METRIC TORQUE SPECIFICATIONS FOR BOLTS 353
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 354
DECIMAL AND MILLIMETER EQUIVALENTS 355
U S TO METRIC CONVERSION 355
HYDRAULIC CONNECTION SPECIFICATIONS 356
O–ring Face Seal Connection 356
Straight Thread O–ring Fitting 356
Tubelines And Hoses 356
Flare Fitting 356
O–ring Flare Fitting 357
Port Seal Fitting 359
SERVICE MANUAL REVISIONS 361
553-1 361
553-2 363
553-3 365
553-4 367

DESCRIPTION:

Bobcat 553 Loader Service Manual 6900450 (6-12) – PDF DOWNLOAD

S/N 516311001 & Above
S/N 516411001 & Above

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.

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 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.

IMAGES PREVIEW OF THE MANUAL:

Customer Support: [email protected]

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V