Bobcat 553 Skid-Steer Loader Loader Service Manual 6904705 (10-12) – PDF DOWNLOAD

Description

Bobcat 553 Skid-Steer Loader Loader Service Manual 6904705 (10-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 553 Skid-Steer Loader Loader Service Manual 6904705 (10-12) – PDF DOWNLOAD

Language : English
Pages : 426
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 553 Skid-Steer Loader Loader Service Manual 6904705 (10-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
Fire Prevention 13
SERIAL NUMBER LOCATIONS 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
LOADER IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 21
Procedure 21
LIFT ARM SUPPORT DEVICE 23
Installing 23
Removing 24
OPERATOR CAB 27
Description 27
Raising 27
Lowering 28
TRANSPORTING LOADER ON A TRAILER 29
Loading And Unloading 29
Fastening 29
TOWING THE LOADER 31
Procedure 31
REMOTE START 33
Procedure 33
SERVICE SCHEDULE 35
Chart 35
AIR CLEANER SERVICE 37
Replacing Filter Elements 37
ENGINE COOLING SYSTEM 39
Cleaning 39
Checking 40
Removing And Replacing Coolant 40
FUEL SYSTEM 43
Fuel Specifications 43
Filling The Fuel Tank 43
Fuel Filter 44
Removing Air From The Fuel System 44
ENGINE LUBRICATION SYSTEM 45
Checking And Adding Engine Oil 45
Oil Chart 45
Removing And Replacing Oil And Filter 46
HYDRAULIC/HYDROSTATIC SYSTEM 47
Checking And Adding Fluid 47
Removing And Replacing The Hydraulic/Hydrostatic Filter 47
Removing And Replacing The Hydraulic/Hydrostatic Fluid 48
FINAL DRIVE TRANSMISSION (CHAINCASE) 49
Checking And Adding Oil 49
Removing Oil From Chaincase 49
AUXILIARY CONTROL LOCKBOLT 51
Procedure 51
BOB-TACH 53
Inspection And Maintenance 53
LUBRICATING THE BOBCAT 55
Lubrication Locations 55
TIRE MAINTENANCE 57
Wheel Nuts 57
Rotating 57
Mounting 58
SPARK ARRESTOR MUFFLER 59
Cleaning Procedure 59
PIVOT PINS 61
Inspection And Maintenance 61
SEAT BAR RESTRAINT SYSTEM 63
Inspection And Maintenance 63
RUBBER COUPLER LUBRICATION 65
Procedure 65
LOADER STORAGE AND RETURN TO SERVICE 67
Storage 67
Return to Service 67
STOPPING THE ENGINE AND LEAVING THE LOADER 69
Procedure 69
Emergency Exit 70
HYDRAULIC SYSTEM 71
HYDRAULIC/HYDROSTATIC SCHEMATICS 73
HYDRAULIC SYSTEM INFORMATION 75
Glossary Of Hydraulic / Hydrostatic Symbols 75
Troubleshooting Chart 79
CYLINDER (LIFT) 81
Testing 81
Removal And Installation 82
Parts Identification 85
Disassembly And Assembly 86
CYLINDER (TILT) 89
Testing 89
Removal And Installation 89
Parts Identification 91
Disassembly And Assembly 92
MAIN RELIEF VALVE 95
Description 95
Testing With Auxiliaries 95
Testing Without Auxiliaries 97
Removal and Installation 98
HYDRAULIC CONTROL VALVE 99
Description 99
BICS Valve Removal And Installation 99
Identification Chart 102
Disassembly And Assembly 103
Load Check Valve Removal And Installation 103
Main Relief Valve Removal And Installation 104
Anti-Cavitation Check Valve Removal And Installation 105
Port Relief Valve Removal And Installation 106
Rubber Boot (Lift) Removal And Installation 107
Rubber Boot (Tilt) Removal And Installation 107
Rubber Boot (Auxiliary) Removal And Installation 107
Lift Spool And Detent Removal And Installation 108
Tilt Spool Removal And Installation 112
Auxiliary Spool And Detent Removal And Installation 113
One Way Restrictors Removal And Installation 116
Spool Seal Installation 117
LIFT ARM BY-PASS CONTROL VALVE 119
Description 119
Testing 119
Removal And Installation 119
Disassembly And Assembly 120
TILT LOCK VALVE 121
Description 121
Testing 121
Removal And Installation 121
Disassembly And Assembly 122
HYDRAULIC PUMP 123
Description 123
Direct Pump Testing 123
Removal And Installation 124
Parts Identification 126
Disassembly And Assembly 127
HYDRAULIC/HYDROSTATIC FILTER 129
Description 129
Housing Removal And Installation 129
Housing Disassembly And Assembly 130
HYDRAULIC FLUID RESERVOIR 131
Description 131
Removal And Installation 131
Hydrauilc Fluid Screen 132
OIL COOLER 133
Description 133
Removal And Installation 133
HYDROSTATIC SYSTEM 135
HYDROSTATIC SYSTEM INFORMATION 137
Troubleshooting 137
Description 138
HYDROSTATIC MOTOR 139
Description 139
Removal And Installation 139
Parts Identification 141
Disassembly And Assembly 142
Timing 150
PORT BLOCK 151
Description 151
Removal And Installation 151
Oil Cooler By-Pass Valve Removal And Installation 151
Hydraulic Oil Temperature Switch Removal And Installation 151
Charge Pressure By-Pass Valve Removal And Installation 152
HYDROSTATIC PUMP 153
Description 153
Checking Charge Pressure 153
Removal And Installation 154
Drive Coupler Removal And Installation 157
Parts Identification 159
Disassembly And Assembly 160
Inspection 164
DRIVE SYSTEM 167
PARKING BRAKE 169
Description 169
Disk Removal And Installation 169
Traction Lock Guides Removal And Installation 170
DRIVE COMPONENTS 173
Description 173
Axle Seal Removal And Installation 173
Chain Removal And Installation 179
CHAINCASE 181
Description 181
Front Cover Removal And Installation 181
Rear Cover Removal And Installation 181
MAIN FRAME 183
SEAT BAR 185
Description 185
Removal And Installation 185
Disassembly And Assembly 188
Compression Spring Disassembly And Assembly 188
OPERATOR CAB 189
Gas Cylinder Removal And Installation 189
Gas Cylinder Disassembly And Assembly 190
Removal And Installation 190
OPERATOR SEAT 195
Removal And Installation 195
Seat Belt Removal And Installation 195
BOB-TACH 197
Description 197
Removal And Installation 197
Lever And Wedge Disassembly And Assembly 199
LIFT ARM 201
Removal And Installation 201
REAR GRILL 205
Removal And Installation 205
REAR DOOR 207
Removal And Installation 207
Striker Removal And Installation 208
Striker Disassembly And Assembly 208
Striker Adjustment 208
Latch Removal And Installation 209
FUEL TANK 211
Removal And Installation 211
Fuel Level Sender Removal And Installation 211
CONTROL PEDALS AND LINKAGES 213
Description 213
Removal And Installation 213
Pedal Adjustment 213
Pedal Interlock Linkage Removal And Installation 214
Pedal Interlock Linkage Adjustment 215
Crossbar Linkage Removal And Installation 215
CONTROL PANEL 217
Description 217
Removal And Installation 217
CONTROL LEVER 219
Description 219
Lever Removal And Installation 219
Lever Disassembly And Assembly 220
Linkage Removal And Installation 221
Pintle Lever Removal And Installation 223
Pintle Lever Disassemby And Assembly 223
WINDOW (REAR) 229
Removal 229
Installation 229
WINDOW (TOP) 231
Removal 231
Installation 231
WINDOW (SIDE) 233
Removal And Installation 233
WINDOW (FRONT DOOR) 235
Removal (Standard Window) 235
Installation (Standard Window) 235
Removal And Installation (Special Applications Window) 237
ELECTRICAL SYSTEM & ANALYSIS 239
ELECTRICAL SCHEMATICS 241
ELECTRICAL SYSTEM INFORMATION 245
Glossary Of Electrical Symbols 245
Description 249
Troubleshooting 250
Fuse And Relay Location And Identification 251
BATTERY 253
Removal And Installation 253
Using A Booster Battery (Jump Starting) 254
ALTERNATOR 257
Belt Adjustment 257
Charging System Inspection 257
Alternator Voltage Testing 258
Low Voltage Testing 259
High Voltage Testing 259
Removal And Installation 260
Parts Identification 261
STARTER 263
Testing 263
Removal And Installation 264
Parts Identification 265
INSTRUMENT PANELS 267
Left And Right Removal And Installation 267
LIGHTS 269
Front Removal And Installation 269
Rear Removal And Installation 270
Cab Light Removal And Installation 271
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) 273
Description 273
Inspecting The BICS System (Engine STOPPED – Key ON) 273
Inspecting The Seat Bar Sensor (Engine RUNNING) 273
Inspecting The Traction Lock (Engine RUNNING) 273
Inspecting The Lift Arm By-Pass Control 273
Troubleshooting Chart 274
Troubleshooting 275
Removal And Installation 276
SEAT BAR SENSOR 277
Description 277
Troubleshooting 277
Testing 278
Removal And Installation 279
Bobcat Interlock Control System (BICS) Circuit Test 281
TRACTION LOCK 283
Description 283
Troubleshooting 283
Removal And Installation 284
ENGINE SERVICE 287
ENGINE INFORMATION 291
Description 291
Specifications 292
Torque Values 296
Troubleshooting 297
Engine Removal And Installation 299
Engine Mount Replacement 304
Compression – Checking 305
ENGINE SPEED CONTROL 307
Removal And Installation 307
Linkage Bar Removal And Installation 308
ENGINE SPEED CONTROL PLATE 309
Removal And Installation 309
Governor Spring Removal 309
Start Spring Removal 309
Idle Limit And Fuel Limit Adjustment 310
MUFFLER 311
Removal And Installation 311
AIR CLEANER 313
Housing Removal And Installation 313
ENGINE COOLING SYSTEM 315
Cooling Fan Removal And Installation 315
Radiator Removal And Installation 316
Water Pump Removal And Installation 319
Thermostat Housing Removal And Installation 319
Thermostat Testing 320
LUBRICATION SYSTEM 321
Oil Pan Removal And Installation 321
Oil Pump Removal And Installation 321
Oil Pump Inspection 321
Engine Oil Pressure – Testing 322
FUEL SYSTEM 323
Fuel Camshaft Removal And Installation 323
Fuel Camshaft Governor Disassembly And Assembly 324
Fuel Shutoff Solenoid, Removal And Installation 329
Fuel Lift Pump Removal And Installation 329
Fuel Injection Pump, Checking 330
Fuel Injection Pump Removal And Installation 330
Injection Pump – Timing 333
Fuel Injector Removal And Installation 334
Fuel Injector Nozzle Pressure – Checking 336
Nozzle Spray Condition 337
Valve Seat Tightness 337
CYLINDER HEAD 339
Glow Plugs – Testing 339
Glow Plugs Removal And Installation 339
Closed Breather System – Checking 340
Valve Clearance Adjustment 341
Valve Timing – Checking 341
Exhaust Manifold Removal And Installation 342
Cylinder Head Removal And Installation 342
Cylinder Head Disassembly And Assembly 343
Cylinder Head – Servicing 344
Cylinder Head Top Clearance 345
Valve Guide And Valve Checking 346
Reconditioning The Valve And Valve Seat 348
Valve Springs 349
Valve Tappets 350
Rocker Arm And Shaft Removal And Installation 350
Rocker Arm And Shaft Disassembly And Assembly 350
Rocker Arm And Shaft – Checking 351
CRANKSHAFT AND PISTONS 353
Piston And Connecting Rod Removal And Installation 353
Piston And Connecting Rod – Servicing 354
Cylinder Bore Checking 358
Connecting Rod Alignment 358
Crankshaft And Bearing Removal And Installation 359
Crankshaft And Bearing – Servicing 360
CAMSHAFT AND TIMING GEARS 367
Timing Gearcase Cover Removal And Installation 367
Timing Gears Backlash – Checking 369
Idler Gear And Shaft Removal And Installation 370
Idler Gear And Shaft Servicing 370
Camshaft Removal And Installation 371
Camshaft Servicing 372
Camshaft Gear Removal And Installation 373
Engine Timing Gear Alignment 373
FLYWHEEL AND HOUSING 375
Flywheel Removal And Installation 375
Ring Gear Removal And Installation 375
Housing Removal And Installation 376
RUBBER DRIVE COUPLER 377
Removal And Installation 377
Disassembly And Assembly 377
WATER FLANGE 381
Removal And Installation 381
HEATER 383
HEATER SYSTEM 385
Description 385
REGULAR MAINTENANCE 387
Filter Element Removal And Installation 387
Heater Coil 387
TROUBLESHOOTING 389
Electric System 389
Heater Valve Not Opening Or Closing 389
Blower Motor Does Not Operate 389
Blower Motor Operates Normally, But Air Flow Is Insufficient 389
HEATER UNIT 391
Removal And Installation 391
HEATER COIL 393
Removal And Installation 393
HEATER FAN 395
Blower Removal And Installation 395
Disassembly And Assembly 395
HEATER MOTOR 397
Removal And Installation 397
RESISTOR 399
Removal And Installation 399
Checking 399
HEATER VALVE 401
Removal And Installation 401
HEATER SWITCH 403
Removal And Installation 403
Checking The Switch 404
SPECIFICATIONS 405
553 LOADER SPECIFICATIONS 407
Dimensions 407
Performance 408
Controls 408
Engine 408
Hydraulic System 409
Electrical 409
Drive System 410
Capacities 410
Tires 410
TORQUE SPECIFICATIONS FOR BOLTS 411
Torque For General SAE Bolts 411
Torque For General Metric Bolts 412
HYDRAULIC CONNECTION SPECIFICATIONS 413
O-ring Face Seal Connection 413
Straight Thread O-ring Fitting 414
Tubelines And Hoses 414
Flare Fitting 414
O-ring Flare Fitting 415
Port Seal Fitting 417
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 419
Specifications 419
CONVERSIONS 421
Decimal And Millimeter Equivalents 421
U S To Metric Conversion Chart 421
SMR 423
553-1 423
553-2 425

DESCRIPTION:

Bobcat 553 Skid-Steer Loader Loader Service Manual 6904705 (10-12) – PDF DOWNLOAD

S/N 539112001 & Above
S/N 539412001 & 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:

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