Bobcat 553 Loader Service Manual 6901824 (6-12) – PDF DOWNLOAD

Description

Bobcat 553 Loader Service Manual 6901824 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 553 Loader Service Manual 6901824 (6-12) – PDF DOWNLOAD

Language : English
Pages : 410
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 553 Loader Service Manual 6901824 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
Fire Prevention 13
SERIAL NUMBER LOCATION 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
BOBCAT LOADER IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 21
Procedure 21
LIFT ARM SUPPORT DEVICE 23
Installing Lift Arm Support Device 23
Removing Lift Arm Support Device 24
OPERATOR CAB 27
Description 27
Raising The Operator Cab 27
Lowering The Operator Cab 28
Emergency Exit 28
TRANSPORTING THE BOBCAT LOADER 31
Procedure 31
Stopping The Bobcat Loader 31
TOWING THE LOADER 35
Procedure 35
REMOTE START 37
Procedure 37
SERVICE SCHEDULE 39
Chart 39
AIR CLEANER SERVICE 41
Replacing Filter Element 41
ENGINE COOLING SYSTEM 43
Cleaning The Cooling System 43
Checking The Coolant Level 44
Replacing The Coolant 44
FUEL SYSTEM 47
Fuel Specifications 47
Filling The Fuel Tank 47
Fuel Filter 48
Removing Air From The Fuel System 49
ENGINE LUBRICATION SYSTEM 51
Checking Engine Oil 51
Oil Chart 51
Replacing Oil And Filter 51
HYDRAULIC/HYDROSTATIC SYSTEM 53
Description 53
Checking And Adding Fluid 53
Replacing The Hydraulic/Hydrostatic Filter 54
Replacing Hydraulic Fluid 54
FINAL DRIVE TRANSMISSION (CHAINCASE) 57
Checking And Adding Oil 57
AUXILIARY CONTROL LOCKBOLT 59
Removal 59
BOB-TACH 61
Inspection And Maintenance 61
LUBRICATION OF THE BOBCAT LOADER 63
Procedure 63
TIRE MAINTENANCE 65
Wheel Nuts 65
Rotating 65
Mounting 65
SPARK ARRESTOR MUFFLER 67
Cleaning Procedure 67
PIVOT PINS 69
Procedure 69
SEAT BAR RESTRAINT SYSTEM 71
Description 71
Seat Bar Inspection 71
Seat Bar Maintenance 71
RUBBER COUPLER LUBRICATION 73
Procedure 73
HYDRAULIC SYSTEM 75
HYDRAULIC/HYDROSTATIC SCHEMATICS 77
HYDRAULIC SYSTEM INFORMATION 81
Tighten Procedures 85
Troubleshooting Chart 85
CYLINDER (LIFT) 87
Checking 87
Removal And Installation 88
Identification 91
Disassembly And Assembly 92
CYLINDER (TILT) 95
Checking 95
Removal And Installation 95
Identification 97
Disassembly And Assembly 98
MAIN RELIEF VALVE 101
Checking The Main Relief Valve Without Auxiliaries 101
Checking The Main Relief Valve With Auxiliaries 102
Removal and Installation 103
HYDRAULIC CONTROL VALVE 105
Removal And Installation 105
Identification Chart 108
Disassembly And Assembly 109
Load Check Valve 109
Main Releif Valve 110
Anti-Cavitation Check Valve 111
Port Relief Valve 112
Rubber Boot (Lift) 113
Rubber Boot (Tilt) 113
Rubber Boot (Aux ) 113
Lift Spool Detent 114
Tilt Centering Spring 118
Auxiliary Spool Detent 119
One Way Restrictors 119
Inspection 120
Spool Seal Installation 121
LIFT ARM BY-PASS CONTROL VALVE 123
Inspecting 123
Removal and Installation 123
Disassembly and Assembly 124
TILT LOCK VALVE 125
Removal And Installation 125
Disassembly and Assembly 126
HYDRAULIC PUMP 127
Check The Output Of The Hydraulic Pump 127
Removal And Installation 129
Identification 131
Disassembly And Assembly 132
Inspection 134
HYDRAULIC FILTER HOUSING 135
Removal and Installation 135
HYDRAULIC FLUID RESERVOIR 137
Removal and Installation 137
HYDROSTATIC SYSTEM 139
HYDROSTATIC SYSTEM INFORMATION 141
Troubleshooting Chart 141
Replenishing Valve Function 142
CONTROL PANEL 143
Removal and Installation 143
STEERING 145
Lever Removal and Installation 145
Lever Disassembly And Assembly 146
Linkage Removal And Installation 146
Pintle Lever Disassemby And Assembly 148
Linkage Neutral Adjustment 150
HYDROSTATIC MOTOR 153
Removal And Installation 153
Parts Identification 155
Disassembly And Assembly 156
Inspection 163
Timing The Hydrostatic Motor 165
PORT BLOCK 167
Removal And Installation 167
Oil Cooler By-Pass Valve 167
Hydraulic Oil Temperature Switch 167
Charge Pressure By-Pass Valve 168
HYDROSTATIC PUMP 169
Checking Charge Pressure 169
Removal And Installation 170
Drive Coupler Removal And Installation 173
Parts Identification 174
Disassembly And Assembly 175
Inspection 179
OIL COOLER 183
Removal and Installation 183
DRIVE SYSTEM 185
PARKING BRAKE 187
Disk Removal And Installation 187
Traction Lock Guides Removal And Installation 188
DRIVE COMPONENTS 189
Axle Seal Removal And Installation 189
Axle, Bearing, And Sprocket Removal And Installation 191
Chain Removal And Installation 195
CHAINCASE 197
Removing Oil From The Chaincase 197
Front Cover Removal And Installation 197
Rear Cover Removal And Installation 198
MAIN FRAME 199
SEAT BAR 201
Removal And Installation 201
Assembling Components 204
Compression Spring Disassembly And Assembly 204
OPERATOR CAB 205
Gas Cylinder Removal And Installation 205
Gas Cylinder Disassembly And Assembly 206
Removal And Installation 206
OPERATOR SEAT 211
Removal And Installation 211
Seat Belt Removal And Installation 211
BOB-TACH 213
Removal And Installation 213
Bob-Tach Lever And Wedge 215
LIFT ARM 217
Removal And Installation 217
REAR GRILL 221
Removal And Installation 221
REAR DOOR 223
Removal And Installation 223
Striker Removal and Installation 224
Striker Disassembly and Assembly 224
Adjusting The Striker 224
Latch Removal and Installation 225
FUEL TANK 227
Removal And Installation 227
Fuel Level Sender 227
CONTROL PEDALS 229
Removal And Installation 229
Pedal Adjustment 229
Pedal Interlock Linkage Removal And Installation 230
Pedal Interlock Linkage Adjustment 231
Crossbar Linkage Removal And Installation 231
ELECTRICAL SYSTEM 233
ELECTRICAL SCHEMATICS 235
ELECTRICAL SYSTEM INFORMATION 239
Troubleshooting 241
Description 242
Fuse Location 242
Relay Switches Location 243
BATTERY 245
Removal And Installation 245
Using A Booster Battery (Jump Starting) 246
ALTERNATOR 249
Removal And Installation 249
Adjusting The Alternator Belt 249
Description 250
Tests 250
Alternator Output Test 251
Full Field Test 251
Alternator Regulator Test 252
Alternator Regulator Test Using Voltmeter 252
Parts Identification 253
Pulley Removal And Installation 254
Disassembly And Assembly 255
Rotor Continuity Test 257
Stator Continuity Test 258
Rectifier Continuity (Diode) Test 259
Brush Length 259
STARTER 261
Removal And Installation 261
Checking The Starter In The Loader 262
Parts Identification 263
Disassembly 264
Inspection And Repair 269
No Load Test 273
Assembly 274
INSTRUMENT PANEL 281
Removal And Installation 281
LIGHTS 283
Front Removal And Installation 283
BICS™ SYSTEM CONTROLLER 285
Trouble Shooting Guide 285
Removal And Installation 286
BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON) 289
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 289
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 289
Inspecting The Seat Bar Sensor (Engine RUNNING) 289
Inspecting The Traction Lock (Engine RUNNING) 289
Inspecting The Lift Arm By-Pass Control 289
Additional Inspection For Loaders With Advanced Hand Controls 289
Troubleshooting Chart 290
SEAT BAR SENSOR 291
Troubleshooting Guide 291
Seat Bar Sensor Test 292
Removal And Installation 293
BICS™ Controller Seat Bar Sensor Circuit Test 295
TRACTION LOCK 297
Troubleshooting Guide 297
Removal And Installation 298
ENGINE SERVICE 301
TROUBLESHOOTING 303
Chart 303
ENGINE SPEED CONTROL 305
Removal And Installation 305
Disassembly 305
Linkage Bar Removal And Installation 306
ENGINE SPEED CONTROL PLATE 307
Removal And Installation 307
Governor Spring Removal 307
Start Spring Removal 307
Idle Limit And Fuel Limit Adjustment 308
MUFFLER 309
Removal And Installation 309
AIR CLEANER 311
Removal And Installation 311
RADIATOR 313
Removal And Installation 313
BLOWER FAN HOUSING 315
Removal And Installation 315
ENGINE COMPONENTS AND TESTING 317
Compression Checking 317
Glow Plugs Checking 318
Glow Plugs Removal And Installation 319
Fuel Shut-Off Solenoid, Removal And Installation 320
Fuel Lift Pump Removal And Installation 321
Fuel Injection Pump, Checking 321
Fuel Injection Pump Removal And Installation 322
Timing The Injection Pump 324
Fuel Injector Nozzles Removal And Installation 325
Checking Fuel Injector Nozzles 326
Engine Timing Installation 328
ENGINE 329
Removal And Installation 329
Engine Mounting Brackets Removal And Installation 333
FLYWHEEL 335
Removal And Installation 335
Flywheel Ring Gear 336
Housing Removal And Installation 336
RECONDITIONING THE ENGINE 337
Thermostat Removal And Installation 337
Water Pump Removal And Installation 337
Timing Gear Case Cover Removal And Installation 338
Oil Pump Removal And Installation 340
Crankshaft Front Seal Removal And Installation 342
Exhaust Manifold Removal And Installation 343
Valve Cover Removal And Installation 344
Rocker Arm Removal And Installation 345
Push Rod Removal And Installation 346
Tappet Removal And Installation 347
Cylinder Head Removal And Installation 347
Checking Piston Top Clearance 348
Disassembly 349
Assembly 349
Servicing The Cylinder Head 349
Combustion Chamber Removal And Installation 352
Idler Gear Removal And Installation 353
Camshaft Removal And Installation 354
Fuel Camshaft Removal And Installation 356
Oil Pan Removal And Installation 358
Governor Shaft Removal And Installation 359
Governor Fork Lever Removal And Installation 362
Piston Removal And Installation 363
Checking The Piston And Connecting Rod 364
Connecting Rod Alignment 365
Pison Ring Gap 365
Piston Ring Installation 366
Connecting Rod Installation 366
Checking Engine Cylinder Bore 367
Crankshaft Removal And Installation 367
Checking Crankshaft Journal And Block Bearing 370
Checking The Crankshaft Journal And Main Bearing 371
Connecting Rod Journal 372
Checking the End Play Of The Crankshaft 373
Crankshaft Alignment 373
Idler Gear And Crankshaft 374
Idler Gear And Crankshaft Gear 374
Idler Gear And Fuel Camshaft Gear 375
Fuel Camshaft Gear And Governor Shaft Gear 375
RUBBER DRIVE COUPLER 377
Removal And Installation 377
Disassembly 377
Assembly 378
WATER FLANGE 381
Removal And Installation 381
SPECIFICATIONS 383
LOADER SPECIFICATIONS 385
Machine Dimensions 385
Performance 386
Controls 386
Engine 386
Hydraulic System 387
Electrical 387
Drive System 388
Capacities 388
Tires 388
ENGINE SPECIFICATIONS 389
Engine Compression 389
Fuel Injection Nozzles 389
Fuel Injection Pump 389
Cylinder Head 389
Valves 389
Valve Springs 390
Rocker Arms 390
Camshaft 390
Cylinders 390
Piston Rings 391
Pistons 391
Crankshaft 391
Oil Pump 392
Thermostat 392
Crankshaft Re-Grind Data 393
TORQUE SPECIFICATIONS FOR BOLTS 395
Torque For General SAE Bolts 395
Torque For General Metric Bolts 396
HYDRAULIC CONNECTION SPECIFICATIONS 397
O-ring Face Seal Connection 397
Straight Thread O-ring Fitting 398
Tubelines And Hoses 398
Flare Fitting 398
O-ring Flare Fitting 399
Port Seal Fitting 401
HYDRAULIC FLUID SPECIFICATIONS 403
Specifications 403
CONVERSIONS 405
Decimal And Millimeter Equivalents 405
U S To Metric Conversion 405
SMR 407
553-1 407
553-2 409

DESCRIPTION:

Bobcat 553 Loader Service Manual 6901824 (6-12) – PDF DOWNLOAD

S/N 520311001 & Above
S/N 520411001 & 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 Bobcat machine and attachments:

IMAGES PREVIEW OF THE MANUAL:

Contact 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