Bobcat 553 Loader Service Manual 6903125 (6-12) – PDF DOWNLOAD

Description

Bobcat 553 Loader Service Manual 6903125 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 553 Loader Service Manual 6903125 (6-12) – PDF DOWNLOAD

Language : English
Pages : 411
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 553 Loader Service Manual 6903125 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
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 33
Procedure 33
REMOTE START 35
Procedure 35
SERVICE SCHEDULE 37
Chart 37
AIR CLEANER SERVICE 39
Replacing Filter Element 39
ENGINE COOLING SYSTEM 41
Cleaning The Cooling System 41
Checking The Coolant Level 42
Replacing The Coolant 42
FUEL SYSTEM 45
Fuel Specifications 45
Filling The Fuel Tank 45
Fuel Filter 46
Removing Air From The Fuel System 47
ENGINE LUBRICATION SYSTEM 49
Checking Engine Oil 49
Oil Chart 49
Replacing Oil And Filter 49
HYDRAULIC/HYDROSTATIC SYSTEM 51
Description 51
Checking And Adding Fluid 51
Replacing The Hydraulic/Hydrostatic Filter 52
Replacing Hydraulic Fluid 52
FINAL DRIVE TRANSMISSION (CHAINCASE) 55
Checking And Adding Oil 55
AUXILIARY CONTROL LOCKBOLT 57
Removal 57
BOB-TACH 59
Inspection And Maintenance 59
LUBRICATION OF THE BOBCAT LOADER 61
Procedure 61
TIRE MAINTENANCE 63
Wheel Nuts 63
Rotating 63
Mounting 63
SPARK ARRESTOR MUFFLER 65
Cleaning Procedure 65
PIVOT PINS 67
Procedure 67
SEAT BAR RESTRAINT SYSTEM 69
Description 69
Seat Bar Inspection 69
Seat Bar Maintenance 69
RUBBER COUPLER LUBRICATION 71
Procedure 71
HYDRAULIC SYSTEM 73
HYDRAULIC/HYDROSTATIC SCHEMATICS 75
HYDRAULIC SYSTEM INFORMATION 77
Tighten Procedures 81
Troubleshooting Chart 81
CYLINDER (LIFT) 83
Checking 83
Removal And Installation 84
Identification 87
Disassembly And Assembly 88
CYLINDER (TILT) 91
Checking 91
Removal And Installation 91
Identification 93
Disassembly And Assembly 94
MAIN RELIEF VALVE 97
Checking The Main Relief Valve Without Auxiliaries 97
Checking The Main Relief Valve With Auxiliaries 98
Removal and Installation 99
HYDRAULIC CONTROL VALVE 101
Removal And Installation 101
Identification Chart 104
Disassembly And Assembly 105
Load Check Valve 105
Main Releif Valve 106
Anti-Cavitation Check Valve 107
Port Relief Valve 108
Rubber Boot (Lift) 109
Rubber Boot (Tilt) 109
Rubber Boot (Aux ) 109
Lift Spool Detent 110
Tilt Centering Spring 114
Auxiliary Spool Detent 115
One Way Restrictors 115
Inspection 116
Spool Seal Installation 117
LIFT ARM BY-PASS CONTROL VALVE 119
Inspecting 119
Removal and Installation 119
Disassembly and Assembly 120
TILT LOCK VALVE 121
Removal And Installation 121
Disassembly and Assembly 122
HYDRAULIC PUMP 123
Check The Output Of The Hydraulic Pump 123
Removal And Installation 125
Identification 127
Disassembly And Assembly 128
Inspection 130
HYDRAULIC FILTER HOUSING 131
Removal and Installation 131
HYDRAULIC FLUID RESERVOIR 133
Removal and Installation 133
HYDROSTATIC SYSTEM 135
HYDROSTATIC SYSTEM INFORMATION 137
Troubleshooting Chart 137
Replenishing Valve Function 138
CONTROL PANEL 139
Removal and Installation 139
STEERING 141
Lever Removal and Installation 141
Lever Disassembly And Assembly 142
Linkage Removal And Installation 143
Pintle Lever Disassemby And Assembly 145
Linkage Neutral Adjustment 147
HYDROSTATIC MOTOR 151
Removal And Installation 151
Parts Identification 153
Disassembly And Assembly 154
Inspection 161
Timing The Hydrostatic Motor 163
PORT BLOCK 165
Removal And Installation 165
Oil Cooler By-Pass Valve 165
Hydraulic Oil Temperature Switch 165
Charge Pressure By-Pass Valve 166
HYDROSTATIC PUMP 167
Checking Charge Pressure 167
Removal And Installation 168
Drive Coupler Removal And Installation 171
Parts Identification 172
Disassembly And Assembly 173
Inspection 177
OIL COOLER 181
Removal and Installation 181
DRIVE SYSTEM 183
PARKING BRAKE 185
Disk Removal And Installation 185
Traction Lock Guides Removal And Installation 186
DRIVE COMPONENTS 187
Axle Seal Removal And Installation 187
Axle, Bearing, And Sprocket Removal And Installation 189
Chain Removal And Installation 193
CHAINCASE 195
Removing Oil From The Chaincase 195
Front Cover Removal And Installation 195
Rear Cover Removal And Installation 196
MAIN FRAME 197
SEAT BAR 199
Removal And Installation 199
Assembling Components 202
Compression Spring Disassembly And Assembly 202
OPERATOR CAB 203
Gas Cylinder Removal And Installation 203
Gas Cylinder Disassembly And Assembly 204
Removal And Installation 204
OPERATOR SEAT 209
Removal And Installation 209
Seat Belt Removal And Installation 209
BOB-TACH 211
Removal And Installation 211
Bob-Tach Lever And Wedge 213
LIFT ARM 215
Removal And Installation 215
REAR GRILL 219
Removal And Installation 219
REAR DOOR 221
Removal And Installation 221
Striker Removal and Installation 222
Striker Disassembly and Assembly 222
Adjusting The Striker 222
Latch Removal and Installation 223
FUEL TANK 225
Removal And Installation 225
Fuel Level Sender 225
CONTROL PEDALS 227
Removal And Installation 227
Pedal Adjustment 227
Pedal Interlock Linkage Removal And Installation 228
Pedal Interlock Linkage Adjustment 229
Crossbar Linkage Removal And Installation 229
ELECTRICAL SYSTEM 231
ELECTRICAL SCHEMATICS 235
ELECTRICAL SYSTEM INFORMATION 233
Troubleshooting 238
Description 239
Fuse Location 239
Relay Switches Location 240
BATTERY 242
Removal And Installation 242
Using A Booster Battery (Jump Starting) 243
ALTERNATOR 246
Removal And Installation 246
Adjusting The Alternator Belt 246
Description 247
Tests 247
Alternator Output Test 248
Full Field Test 248
Alternator Regulator Test 249
Alternator Regulator Test Using Voltmeter 249
Parts Identification 250
Pulley Removal And Installation 251
Disassembly And Assembly 252
Rotor Continuity Test 254
Stator Continuity Test 255
Rectifier Continuity (Diode) Test 256
Brush Length 256
STARTER 258
Removal And Installation 258
Checking The Starter In The Loader 259
Parts Identification 260
Disassembly 261
Inspection And Repair 266
No Load Test 270
Assembly 271
INSTRUMENT PANEL 278
Removal And Installation 278
LIGHTS 280
Front Removal And Installation 280
BICS™ SYSTEM CONTROLLER 282
Trouble Shooting Guide 282
Removal And Installation 283
BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON) 286
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 286
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 286
Inspecting The Seat Bar Sensor (Engine RUNNING) 286
Inspecting The Traction Lock (Engine RUNNING) 286
Inspecting The Lift Arm By-Pass Control 286
Additional Inspection For Loaders With Advanced Hand Controls 286
Troubleshooting Chart 287
SEAT BAR SENSOR 288
Troubleshooting Guide 288
Seat Bar Sensor Test 289
Removal And Installation 290
BICS™ Controller Seat Bar Sensor Circuit Test 292
TRACTION LOCK 294
Troubleshooting Guide 294
Removal And Installation 295
ENGINE SERVICE 298
TROUBLESHOOTING 302
Chart 302
ENGINE SPEED CONTROL 304
Removal And Installation 304
Disassembly 304
Linkage Bar Removal And Installation 305
ENGINE SPEED CONTROL PLATE 306
Removal And Installation 306
Governor Spring Removal 306
Start Spring Removal 306
Idle Limit And Fuel Limit Adjustment 307
MUFFLER 308
Removal And Installation 308
AIR CLEANER 310
Removal And Installation 310
RADIATOR 312
Removal And Installation 312
BLOWER FAN HOUSING 314
Removal And Installation 314
ENGINE COMPONENTS AND TESTING 316
Compression Checking 316
Glow Plugs Checking 316
Glow Plugs Removal And Installation 317
Fuel Shut-Off Solenoid, Removal And Installation 318
Fuel Lift Pump Removal And Installation 319
Fuel Injection Pump, Checking 319
Fuel Injection Pump Removal And Installation 320
Timing The Injection Pump 322
Fuel Injector Nozzles Removal And Installation 323
Checking Fuel Injector Nozzles 324
Breather Removal And Installation 326
Valve Clearance Adjustment 326
ENGINE 328
Removal And Installation 328
Engine Mounting Brackets Removal And Installation 332
FLYWHEEL 334
Removal And Installation 334
Flywheel Ring Gear 335
Housing Removal And Installation 335
RECONDITIONING THE ENGINE 336
Thermostat Removal And Installation 336
Water Pump Removal And Installation 337
Timing Gear Case Cover Removal And Installation 337
Oil Pump Removal And Installation 339
Checking Oil Pump 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 344
Push Rod Removal And Installation 346
Cylinder Head Removal 346
Cylinder Head Installation 347
Tappet Removal And Installation 347
Checking Piston Top Clearance 348
Cylinder Head Disassembly 349
Cylinder Head Assembly 349
Servicing The Cylinder Head 349
Cylinder Head Surface Flatness 350
Cylinder Head Flaw 350
Valve And Valve Guide Checking 351
Valve Guide Replacement 351
Reconditioning The Valve And Valve Seat 352
Correcting The Valve Seat 352
Valve Spring 353
Idler Gear Removal And Installation 354
Camshaft Removal And Installation 355
Camshaft Height 356
Camshaft Oil Clearance 356
Camshaft Alignment 357
Camshaft Gear Removal And Installation 357
Fuel Camshaft Removal And Installation 357
Engine Timing Gear Alignment 358
Governor Shaft Removal And Installation 359
Governor Fork Lever Removal And Installation 362
Oil Pan Removal And Installation 363
Piston Removal 365
Piston Pin Removal And Installation 366
Checking The Piston And Connecting Rod 366
Connecting Rod Alignment 367
Connecting Rod Bushing Removal And Installation 368
Piston Ring Gap 368
Checking Engine Cylinder Bore 369
Piston Ring Installation 369
Connecting Rod Installation 370
Piston Installation 370
Crankshaft End Play 371
Crankshaft Removal And Installation 371
Crankshaft Disassembly And Assembly 372
Checking Crankshaft Number One Journal And Block Bearing 373
Checking The Crankshaft Journals And Main Bearings 374
Connecting Rod Journal 376
Crankshaft Alignment 377
RUBBER DRIVE COUPLER 378
Removal And Installation 378
Disassembly 378
Assembly 379
WATER FLANGE 382
Removal And Installation 382
SPECIFICATIONS 384
LOADER SPECIFICATIONS 386
Machine Dimensions 386
Performance 387
Controls 387
Engine 387
Hydraulic System 388
Electrical 388
Drive System 389
Capacities 389
ENGINE SPECIFICATIONS – KUBOTA D1105-B 390
Engine Compression 390
Fuel Injection Nozzles 390
Fuel Injection Pump 390
Cylinder Head 390
Valves 390
Valve Springs 391
Rocker Arms 391
Camshaft 391
Cylinders 391
Piston Rings 392
Pistons 392
Crankshaft 392
Oil Pump 393
Thermostat 393
Crankshaft Re-Grind Data 394
TORQUE SPECIFICATIONS FOR BOLTS 396
Torque For General SAE Bolts 396
Torque For General Metric Bolts 397
HYDRAULIC CONNECTION SPECIFICATIONS 398
O-ring Face Seal Connection 398
Straight Thread O-ring Fitting 399
Tubelines And Hoses 399
Flare Fitting 399
O-ring Flare Fitting 400
Port Seal Fitting 402
HYDRAULIC FLUID SPECIFICATIONS 404
Specifications 404
CONVERSIONS 406
Decimal And Millimeter Equivalents 406
U S To Metric Conversion 406
SMR 408
Revision No: 553-1 408
Revision No: 553-2 410

DESCRIPTION:

Bobcat 553 Loader Service Manual 6903125 (6-12) – PDF DOWNLOAD

S/N 528011001 & Above
S/N 528111001 & 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.

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

IMAGES PREVIEW OF THE MANUAL:

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