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Bobcat 553 Skid Steer Loader Service Repair Manual
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- Bobcat 553 Skid Steer Loader Service Repair Manual
- S/N 513011001 & Above
Europe Only – S/N 513031001 & Above
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Description
Bobcat 553 Skid Steer Loader Service Repair Manual
FILE DETAILS:
Bobcat 553 Skid Steer Loader Service Repair Manual
LANGUAGE:ENGLISH
PAGES:1892
DOWNLOADABLE:YES
FILE TYPE:PDF
BOBCAT 553 SKID STEER LOADER SERVICE REPAIR MANUAL:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat 553 Skid Steer Loader Service Repair Manual
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.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS (Including sidescreens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Melroe approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar and pedal interlocks must be correctly adjusted, clean and lubricated.
5. Machine signs must be legible and in the correct location.
6. Steering levers and foot pedals must return to neutral.
7. Check for correct funtion of the work lights.
8. The parking brake must function correctly
TABLE OF CONTENTS:
Bobcat 553 Skid Steer Loader Service Repair Manual
BOBCAT 553 SKID STEER LOADER S/N 513011001 & ABOVE EUROPE ONLY – S/N 513031001 & ABOVE............. 1 MAINTENANCE SAFETY.............................................................................. 3 CONTENTS........................................................................................ 5 FOREWORD........................................................................................ 7 SAFETY INSTRUCTIONS............................................................................. 9 SERIAL NUMBER LOCATIONS......................................................................... 11 553 BOBCAT LOADER IDENTIFICATION................................................................ 12 OPTIONS AND ACCESSORIES......................................................................... 13 PREVENTIVE MAINTENANCE.......................................................................... 25 HYDRAULIC SYSTEM................................................................................ 53 HYDROSTATIC SYSTEM.............................................................................. 101 DRIVE SYSTEM.................................................................................... 139 MAIN FRAME...................................................................................... 153 ELECTRICAL SYSTEM............................................................................... 175 ENGINE SERVICE.................................................................................. 215 BICS™ SYSTEM.................................................................................... 271 SPECIFICATIONS.................................................................................. 291 BOBCAT 553 SKID STEER LOADERS S/N 516311001 & ABOVE S/N 516411001 & ABOVE........................... 305 ALPHABETICAL INDEX.............................................................................. 308 CONTENTS........................................................................................ 310 PREVENTIVE MAINTENANCE.......................................................................... 316 HYDRAULIC SYSTEM................................................................................ 352 HYDROSTATIC SYSTEM.............................................................................. 400 DRIVE SYSTEM.................................................................................... 440 MAIN FRAME...................................................................................... 454 ELECTRICAL SYSTEM............................................................................... 480 ENGINE SERVICE.................................................................................. 543 SYSTEMS ANALYSIS................................................................................ 615 SPECIFICATIONS.................................................................................. 635 BOBCAT 553 SKID STEER LOADERS S/N 520311001 & ABOVE S/N 520411001 & ABOVE........................... 656 MAINTENANCE SAFETY.............................................................................. 658 ALPHABETICAL INDEX.............................................................................. 660 CONTENTS........................................................................................ 662 FOREWORD.................................................................................... 663 SAFETY INSTRUCTIONS......................................................................... 666 Fire Prevention......................................................................... 668 SERIAL NUMBER LOCATION...................................................................... 670 Loader Serial Number.................................................................... 670 Engine Serial Number.................................................................... 670 DELIVERY REPORT............................................................................. 671 BOBCAT LOADER IDENTIFICATION................................................................ 672 SAFETY AND MAINTENANCE.......................................................................... 674 LIFTING AND BLOCKING THE LOADER............................................................. 676 Procedure............................................................................... 676 LIFT ARM SUPPORT DEVICE..................................................................... 678 Installing Lift Arm Support Device...................................................... 678 Removing Lift Arm Support Device........................................................ 679 OPERATOR CAB................................................................................ 682 Description............................................................................. 682 Raising The Operator Cab................................................................ 682 Lowering The Operator Cab............................................................... 683 Emergency Exit.......................................................................... 683 TRANSPORTING THE BOBCAT LOADER.............................................................. 686 Procedure............................................................................... 686 Stopping The Bobcat Loader.............................................................. 686 TOWING THE LOADER........................................................................... 690 Procedure............................................................................... 690 REMOTE START................................................................................ 692 Procedure............................................................................... 692 SERVICE SCHEDULE............................................................................ 694 Chart................................................................................... 694 AIR CLEANER SERVICE......................................................................... 696 Replacing Filter Element................................................................ 696 ENGINE COOLING SYSTEM....................................................................... 698 Cleaning The Cooling System............................................................. 698 Checking The Coolant Level.............................................................. 699 Replacing The Coolant................................................................... 699 FUEL SYSTEM................................................................................. 702 Fuel Specifications..................................................................... 702 Filling The Fuel Tank................................................................... 702 Fuel Filter............................................................................. 703 Removing Air From The Fuel System....................................................... 704 ENGINE LUBRICATION SYSTEM................................................................... 706 Checking Engine Oil..................................................................... 706 Oil Chart............................................................................... 706 Replacing Oil And Filter................................................................ 706 HYDRAULIC/HYDROSTATIC SYSTEM................................................................ 708 Description............................................................................. 708 Checking And Adding Fluid............................................................... 708 Replacing The Hydraulic/Hydrostatic Filter.............................................. 709 Replacing Hydraulic Fluid............................................................... 709 FINAL DRIVE TRANSMISSION (CHAINCASE)........................................................ 712 Checking And Adding Oil................................................................. 712 AUXILIARY CONTROL LOCKBOLT.................................................................. 714 Removal................................................................................. 714 BOB-TACH.................................................................................... 716 Inspection And Maintenance.............................................................. 716 LUBRICATION OF THE BOBCAT LOADER............................................................ 718 Procedure............................................................................... 718 TIRE MAINTENANCE............................................................................ 720 Wheel Nuts.............................................................................. 720 Rotating................................................................................ 720 Mounting................................................................................ 720 SPARK ARRESTOR MUFFLER...................................................................... 722 Cleaning Procedure...................................................................... 722 PIVOT PINS.................................................................................. 724 Procedure............................................................................... 724 SEAT BAR RESTRAINT SYSTEM................................................................... 726 Description............................................................................. 726 Seat Bar Inspection..................................................................... 726 Seat Bar Maintenance.................................................................... 726 RUBBER COUPLER LUBRICATION.................................................................. 728 Procedure............................................................................... 728 HYDRAULIC SYSTEM................................................................................ 730 HYDRAULIC/HYDROSTATIC SCHEMATICS............................................................ 732 HYDRAULIC SYSTEM INFORMATION................................................................ 734 Tighten Procedures...................................................................... 738 Troubleshooting Chart................................................................... 738 CYLINDER (LIFT)............................................................................. 740 Checking................................................................................ 740 Removal And Installation................................................................ 741 Identification.......................................................................... 744 Disassembly And Assembly................................................................ 745 CYLINDER (TILT)............................................................................. 748 Checking................................................................................ 748 Removal And Installation................................................................ 748 Identification.......................................................................... 750 Disassembly And Assembly................................................................ 751 MAIN RELIEF VALVE........................................................................... 754 Checking The Main Relief Valve Without Auxiliaries...................................... 754 Checking The Main Relief Valve With Auxiliaries......................................... 755 Removal and Installation................................................................ 756 HYDRAULIC CONTROL VALVE..................................................................... 758 Removal And Installation................................................................ 758 Identification Chart.................................................................... 761 Disassembly And Assembly................................................................ 762 Load Check Valve........................................................................ 762 Main Releif Valve....................................................................... 763 Anti-Cavitation Check Valve............................................................. 764 Port Relief Valve....................................................................... 765 Rubber Boot (Lift)...................................................................... 766 Rubber Boot (Tilt)...................................................................... 766 Rubber Boot (Aux.)...................................................................... 766 Lift Spool Detent....................................................................... 767 Tilt Centering Spring................................................................... 771 Auxiliary Spool Detent.................................................................. 772 One Way Restrictors..................................................................... 772 Inspection.............................................................................. 773 Spool Seal Installation................................................................. 774 LIFT ARM BY-PASS CONTROL VALVE.............................................................. 776 Inspecting.............................................................................. 776 Removal and Installation................................................................ 776 Disassembly and Assembly................................................................ 777 TILT LOCK VALVE............................................................................. 778 Removal And Installation................................................................ 778 Disassembly and Assembly................................................................ 779 HYDRAULIC PUMP.............................................................................. 780 Check The Output Of The Hydraulic Pump.................................................. 780 Removal And Installation................................................................ 782 Identification.......................................................................... 784 Disassembly And Assembly................................................................ 785 Inspection.............................................................................. 787 HYDRAULIC FILTER HOUSING.................................................................... 788 Removal and Installation................................................................ 788 HYDRAULIC FLUID RESERVOIR................................................................... 790 Removal and Installation................................................................ 790 HYDROSTATIC SYSTEM.............................................................................. 792 HYDROSTATIC SYSTEM INFORMATION.............................................................. 794 Troubleshooting Chart................................................................... 794 Replenishing Valve Function............................................................. 795 CONTROL PANEL............................................................................... 796 Removal and Installation................................................................ 796 STEERING.................................................................................... 798 Lever Removal and Installation.......................................................... 798 Lever Disassembly And Assembly.......................................................... 799 Linkage Removal And Installation........................................................ 799 Pintle Lever Disassemby And Assembly.................................................... 801 Linkage Neutral Adjustment.............................................................. 803 HYDROSTATIC MOTOR........................................................................... 806 Removal And Installation................................................................ 806 Parts Identification.................................................................... 808 Disassembly And Assembly................................................................ 809 Inspection.............................................................................. 816 Timing The Hydrostatic Motor............................................................ 818 PORT BLOCK.................................................................................. 820 Removal And Installation................................................................ 820 Oil Cooler By-Pass Valve................................................................ 820 Hydraulic Oil Temperature Switch........................................................ 820 Charge Pressure By-Pass Valve........................................................... 821 HYDROSTATIC PUMP............................................................................ 822 Checking Charge Pressure................................................................ 822 Removal And Installation................................................................ 823 Drive Coupler Removal And Installation.................................................. 826 Parts Identification.................................................................... 827 Disassembly And Assembly................................................................ 828 Inspection.............................................................................. 832 OIL COOLER.................................................................................. 836 Removal and Installation................................................................ 836 DRIVE SYSTEM.................................................................................... 838 PARKING BRAKE............................................................................... 840 Disk Removal And Installation........................................................... 840 Traction Lock Guides Removal And Installation........................................... 841 DRIVE COMPONENTS............................................................................ 842 Axle Seal Removal And Installation...................................................... 842 Axle, Bearing, And Sprocket Removal And Installation.................................... 844 Chain Removal And Installation.......................................................... 848 CHAINCASE................................................................................... 850 Removing Oil From The Chaincase......................................................... 850 Front Cover Removal And Installation.................................................... 850 Rear Cover Removal And Installation..................................................... 851 MAIN FRAME...................................................................................... 852 SEAT BAR.................................................................................... 854 Removal And Installation................................................................ 854 Assembling Components................................................................... 857 Compression Spring Disassembly And Assembly............................................. 857 OPERATOR CAB................................................................................ 858 Gas Cylinder Removal And Installation................................................... 858 Gas Cylinder Disassembly And Assembly................................................... 859 Removal And Installation................................................................ 859 OPERATOR SEAT............................................................................... 864 Removal And Installation................................................................ 864 Seat Belt Removal And Installation...................................................... 864 BOB-TACH.................................................................................... 866 Removal And Installation................................................................ 866 Bob-Tach Lever And Wedge................................................................ 868 LIFT ARM.................................................................................... 870 Removal And Installation................................................................ 870 REAR GRILL.................................................................................. 874 Removal And Installation................................................................ 874 REAR DOOR................................................................................... 876 Removal And Installation................................................................ 876 Striker Removal and Installation........................................................ 877 Striker Disassembly and Assembly........................................................ 877 Adjusting The Striker................................................................... 877 Latch Removal and Installation.......................................................... 878 FUEL TANK................................................................................... 880 Removal And Installation................................................................ 880 Fuel Level Sender....................................................................... 880 CONTROL PEDALS.............................................................................. 882 Removal And Installation................................................................ 882 Pedal Adjustment........................................................................ 882 Pedal Interlock Linkage Removal And Installation........................................ 883 Pedal Interlock Linkage Adjustment...................................................... 884 Crossbar Linkage Removal And Installation............................................... 884 ELECTRICAL SYSTEM............................................................................... 886 ELECTRICAL SCHEMATICS....................................................................... 888 ELECTRICAL SYSTEM INFORMATION............................................................... 891 Troubleshooting......................................................................... 893 Description............................................................................. 894 Fuse Location........................................................................... 894 Relay Switches Location................................................................. 895 BATTERY..................................................................................... 897 Removal And Installation................................................................ 897 Using A Booster Battery (Jump Starting)................................................. 898 ALTERNATOR.................................................................................. 901 Removal And Installation................................................................ 901 Adjusting The Alternator Belt........................................................... 901 Description............................................................................. 902 Tests................................................................................... 902 Alternator Output Test.................................................................. 903 Full Field Test......................................................................... 903 Alternator Regulator Test............................................................... 904 Alternator Regulator Test Using Voltmeter............................................... 904 Parts Identification.................................................................... 905 Pulley Removal And Installation......................................................... 906 Disassembly And Assembly................................................................ 907 Rotor Continuity Test................................................................... 909 Stator Continuity Test.................................................................. 910 Rectifier Continuity (Diode) Test....................................................... 911 Brush Length............................................................................ 911 STARTER..................................................................................... 913 Removal And Installation................................................................ 913 Checking The Starter In The Loader...................................................... 914 Parts Identification.................................................................... 915 Disassembly............................................................................. 916 Inspection And Repair................................................................... 921 No Load Test............................................................................ 925 Assembly................................................................................ 926 INSTRUMENT PANEL............................................................................ 933 Removal And Installation................................................................ 933 LIGHTS...................................................................................... 935 Front Removal And Installation.......................................................... 935 BICS™ SYSTEM CONTROLLER..................................................................... 937 Trouble Shooting Guide.................................................................. 937 Removal And Installation................................................................ 938 BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON)................................................. 941 Inspecting The BICS™ Controller (Engine STOPPED - Key ON)............................... 941 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON).... 941 Inspecting The Seat Bar Sensor (Engine RUNNING)......................................... 941 Inspecting The Traction Lock (Engine RUNNING)........................................... 941 Inspecting The Lift Arm By-Pass Control................................................. 941 Additional Inspection For Loaders With Advanced Hand Controls........................... 941 Troubleshooting Chart................................................................... 942 SEAT BAR SENSOR............................................................................. 943 Troubleshooting Guide................................................................... 943 Seat Bar Sensor Test.................................................................... 944 Removal And Installation................................................................ 945 BICS™ Controller Seat Bar Sensor Circuit Test........................................... 947 TRACTION LOCK............................................................................... 949 Troubleshooting Guide................................................................... 949 Removal And Installation................................................................ 950 ENGINE SERVICE.................................................................................. 953 TROUBLESHOOTING............................................................................. 955 Chart................................................................................... 955 ENGINE SPEED CONTROL........................................................................ 957 Removal And Installation................................................................ 957 Disassembly............................................................................. 957 Linkage Bar Removal And Installation.................................................... 958 ENGINE SPEED CONTROL PLATE.................................................................. 959 Removal And Installation................................................................ 959 Governor Spring Removal................................................................. 959 Start Spring Removal.................................................................... 959 Idle Limit And Fuel Limit Adjustment.................................................... 960 MUFFLER..................................................................................... 961 Removal And Installation................................................................ 961 AIR CLEANER................................................................................. 963 Removal And Installation................................................................ 963 RADIATOR.................................................................................... 965 Removal And Installation................................................................ 965 BLOWER FAN HOUSING.......................................................................... 967 Removal And Installation................................................................ 967 ENGINE COMPONENTS AND TESTING............................................................... 969 Compression Checking.................................................................... 969 Glow Plugs Checking..................................................................... 970 Glow Plugs Removal And Installation..................................................... 971 Fuel Shut-Off Solenoid, Removal And Installation........................................ 972 Fuel Lift Pump Removal And Installation................................................. 973 Fuel Injection Pump, Checking........................................................... 973 Fuel Injection Pump Removal And Installation............................................ 974 Timing The Injection Pump............................................................... 976 Fuel Injector Nozzles Removal And Installation.......................................... 977 Checking Fuel Injector Nozzles.......................................................... 978 Engine Timing Installation.............................................................. 980 ENGINE...................................................................................... 981 Removal And Installation................................................................ 981 Engine Mounting Brackets Removal And Installation....................................... 985 FLYWHEEL.................................................................................... 987 Removal And Installation................................................................ 987 Flywheel Ring Gear...................................................................... 988 Housing Removal And Installation........................................................ 988 RECONDITIONING THE ENGINE................................................................... 989 Thermostat Removal And Installation..................................................... 989 Water Pump Removal And Installation..................................................... 989 Timing Gear Case Cover Removal And Installation......................................... 990 Oil Pump Removal And Installation....................................................... 992 Crankshaft Front Seal Removal And Installation.......................................... 994 Exhaust Manifold Removal And Installation............................................... 995 Valve Cover Removal And Installation.................................................... 996 Rocker Arm Removal And Installation..................................................... 997 Push Rod Removal And Installation....................................................... 998 Tappet Removal And Installation......................................................... 999 Cylinder Head Removal And Installation.................................................. 999 Checking Piston Top Clearance...........................................................1000 Disassembly.............................................................................1001 Assembly................................................................................1001 Servicing The Cylinder Head.............................................................1001 Combustion Chamber Removal And Installation.............................................1004 Idler Gear Removal And Installation.....................................................1005 Camshaft Removal And Installation.......................................................1006 Fuel Camshaft Removal And Installation..................................................1008 Oil Pan Removal And Installation........................................................1010 Governor Shaft Removal And Installation.................................................1011 Governor Fork Lever Removal And Installation............................................1014 Piston Removal And Installation.........................................................1015 Checking The Piston And Connecting Rod..................................................1016 Connecting Rod Alignment................................................................1017 Pison Ring Gap..........................................................................1017 Piston Ring Installation................................................................1018 Connecting Rod Installation.............................................................1018 Checking Engine Cylinder Bore...........................................................1019 Crankshaft Removal And Installation.....................................................1019 Checking Crankshaft Journal And Block Bearing...........................................1022 Checking The Crankshaft Journal And Main Bearing........................................1023 Connecting Rod Journal..................................................................1024 Checking the End Play Of The Crankshaft.................................................1025 Crankshaft Alignment....................................................................1025 Idler Gear And Crankshaft...............................................................1026 Idler Gear And Crankshaft Gear..........................................................1026 Idler Gear And Fuel Camshaft Gear.......................................................1027 Fuel Camshaft Gear And Governor Shaft Gear..............................................1027 RUBBER DRIVE COUPLER........................................................................1029 Removal And Installation................................................................1029 Disassembly.............................................................................1029 Assembly................................................................................1030 WATER FLANGE................................................................................1033 Removal And Installation................................................................1033 SPECIFICATIONS..................................................................................1035 LOADER SPECIFICATIONS.......................................................................1037 Machine Dimensions......................................................................1037 Performance.............................................................................1038 Controls................................................................................1038 Engine..................................................................................1038 Hydraulic System........................................................................1039 Electrical..............................................................................1039 Drive System............................................................................1040 Capacities..............................................................................1040 Tires...................................................................................1040 ENGINE SPECIFICATIONS.......................................................................1041 Engine Compression......................................................................1041 Fuel Injection Nozzles..................................................................1041 Fuel Injection Pump.....................................................................1041 Cylinder Head...........................................................................1041 Valves..................................................................................1041 Valve Springs...........................................................................1042 Rocker Arms.............................................................................1042 Camshaft................................................................................1042 Cylinders...............................................................................1042 Piston Rings............................................................................1043 Pistons.................................................................................1043 Crankshaft..............................................................................1043 Oil Pump................................................................................1044 Thermostat..............................................................................1044 Crankshaft Re-Grind Data................................................................1045 TORQUE SPECIFICATIONS FOR BOLTS.............................................................1047 Torque For General SAE Bolts............................................................1047 Torque For General Metric Bolts.........................................................1048 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................1049 O-ring Face Seal Connection.............................................................1049 Straight Thread O-ring Fitting..........................................................1050 Tubelines And Hoses.....................................................................1050 Flare Fitting...........................................................................1050 O-ring Flare Fitting....................................................................1051 Port Seal Fitting.......................................................................1053 HYDRAULIC FLUID SPECIFICATIONS..............................................................1055 Specifications..........................................................................1055 CONVERSIONS.................................................................................1057 Decimal And Millimeter Equivalents......................................................1057 U.S. To Metric Conversion...............................................................1057 SMR.............................................................................................1059 553-1.......................................................................................1059 BOBCAT 553 SKID STEER LOADERS S/N 528011001 & ABOVE S/N 528111001 & ABOVE...........................1061 MAINTENANCE SAFETY..............................................................................1063 ALPHABETICAL INDEX..............................................................................1065 CONTENTS........................................................................................1067 SAFETY INSTRUCTIONS.........................................................................1071 Fire Prevention.........................................................................1073 SERIAL NUMBER LOCATION......................................................................1075 Loader Serial Number....................................................................1075 Engine Serial Number....................................................................1075 DELIVERY REPORT.............................................................................1076 BOBCAT LOADER IDENTIFICATION................................................................1077 SAFETY AND MAINTENANCE..........................................................................1079 LIFTING AND BLOCKING THE LOADER.............................................................1081 Procedure...............................................................................1081 LIFT ARM SUPPORT DEVICE.....................................................................1083 Installing Lift Arm Support Device......................................................1083 Removing Lift Arm Support Device........................................................1084 OPERATOR CAB................................................................................1087 Description.............................................................................1087 Raising The Operator Cab................................................................1087 Lowering The Operator Cab...............................................................1088 Emergency Exit..........................................................................1088 TRANSPORTING THE BOBCAT LOADER..............................................................1091 Procedure...............................................................................1091 Stopping The Bobcat Loader..............................................................1091 TOWING THE LOADER...........................................................................1093 Procedure...............................................................................1093 REMOTE START................................................................................1095 Procedure...............................................................................1095 SERVICE SCHEDULE............................................................................1097 Chart...................................................................................1097 AIR CLEANER SERVICE.........................................................................1099 Replacing Filter Element................................................................1099 ENGINE COOLING SYSTEM.......................................................................1101 Cleaning The Cooling System.............................................................1101 Checking The Coolant Level..............................................................1102 Replacing The Coolant...................................................................1102 FUEL SYSTEM.................................................................................1105 Fuel Specifications.....................................................................1105 Filling The Fuel Tank...................................................................1105 Fuel Filter.............................................................................1106 Removing Air From The Fuel System.......................................................1107 ENGINE LUBRICATION SYSTEM...................................................................1109 Checking Engine Oil.....................................................................1109 Oil Chart...............................................................................1109 Replacing Oil And Filter................................................................1109 HYDRAULIC/HYDROSTATIC SYSTEM................................................................1111 Description.............................................................................1111 Checking And Adding Fluid...............................................................1111 Replacing The Hydraulic/Hydrostatic Filter..............................................1112 Replacing Hydraulic Fluid...............................................................1112 FINAL DRIVE TRANSMISSION (CHAINCASE)........................................................1115 Checking And Adding Oil.................................................................1115 AUXILIARY CONTROL LOCKBOLT..................................................................1117 Removal.................................................................................1117 BOB-TACH....................................................................................1119 Inspection And Maintenance..............................................................1119 LUBRICATION OF THE BOBCAT LOADER............................................................1121 Procedure...............................................................................1121 TIRE MAINTENANCE............................................................................1123 Wheel Nuts..............................................................................1123 Rotating................................................................................1123 Mounting................................................................................1123 SPARK ARRESTOR MUFFLER......................................................................1125 Cleaning Procedure......................................................................1125 PIVOT PINS..................................................................................1127 Procedure...............................................................................1127 SEAT BAR RESTRAINT SYSTEM...................................................................1129 Description.............................................................................1129 Seat Bar Inspection.....................................................................1129 Seat Bar Maintenance....................................................................1129 RUBBER COUPLER LUBRICATION..................................................................1131 Procedure...............................................................................1131 HYDRAULIC SYSTEM................................................................................1133 HYDRAULIC/HYDROSTATIC SCHEMATICS............................................................1135 HYDRAULIC SYSTEM INFORMATION................................................................1137 Tighten Procedures......................................................................1141 Troubleshooting Chart...................................................................1141 CYLINDER (LIFT).............................................................................1143 Checking................................................................................1143 Removal And Installation................................................................1144 Identification..........................................................................1147 Disassembly And Assembly................................................................1148 CYLINDER (TILT).............................................................................1151 Checking................................................................................1151 Removal And Installation................................................................1151 Identification..........................................................................1153 Disassembly And Assembly................................................................1154 MAIN RELIEF VALVE...........................................................................1157 Checking The Main Relief Valve Without Auxiliaries......................................1157 Checking The Main Relief Valve With Auxiliaries.........................................1158 Removal and Installation................................................................1159 HYDRAULIC CONTROL VALVE.....................................................................1161 Removal And Installation................................................................1161 Identification Chart....................................................................1164 Disassembly And Assembly................................................................1165 Load Check Valve........................................................................1165 Main Releif Valve.......................................................................1166 Anti-Cavitation Check Valve.............................................................1167 Port Relief Valve.......................................................................1168 Rubber Boot (Lift)......................................................................1169 Rubber Boot (Tilt)......................................................................1169 Rubber Boot (Aux.)......................................................................1169 Lift Spool Detent.......................................................................1170 Tilt Centering Spring...................................................................1174 Auxiliary Spool Detent..................................................................1175 One Way Restrictors.....................................................................1175 Inspection..............................................................................1176 Spool Seal Installation.................................................................1177 LIFT ARM BY-PASS CONTROL VALVE..............................................................1179 Inspecting..............................................................................1179 Removal and Installation................................................................1179 Disassembly and Assembly................................................................1180 TILT LOCK VALVE.............................................................................1181 Removal And Installation................................................................1181 Disassembly and Assembly................................................................1182 HYDRAULIC PUMP..............................................................................1183 Check The Output Of The Hydraulic Pump..................................................1183 Removal And Installation................................................................1185 Identification..........................................................................1187 Disassembly And Assembly................................................................1188 Inspection..............................................................................1190 HYDRAULIC FILTER HOUSING....................................................................1191 Removal and Installation................................................................1191 HYDRAULIC FLUID RESERVOIR...................................................................1193 Removal and Installation................................................................1193 HYDROSTATIC SYSTEM..............................................................................1195 HYDROSTATIC SYSTEM INFORMATION..............................................................1197 Troubleshooting Chart...................................................................1197 Replenishing Valve Function.............................................................1198 CONTROL PANEL...............................................................................1199 Removal and Installation................................................................1199 STEERING....................................................................................1201 Lever Removal and Installation..........................................................1201 Lever Disassembly And Assembly..........................................................1202 Linkage Removal And Installation........................................................1203 Pintle Lever Disassemby And Assembly....................................................1205 Linkage Neutral Adjustment..............................................................1207 HYDROSTATIC MOTOR...........................................................................1211 Removal And Installation................................................................1211 Parts Identification....................................................................1213 Disassembly And Assembly................................................................1214 Inspection..............................................................................1221 Timing The Hydrostatic Motor............................................................1223 PORT BLOCK..................................................................................1225 Removal And Installation................................................................1225 Oil Cooler By-Pass Valve................................................................1225 Hydraulic Oil Temperature Switch........................................................1225 Charge Pressure By-Pass Valve...........................................................1226 HYDROSTATIC PUMP............................................................................1227 Checking Charge Pressure................................................................1227 Removal And Installation................................................................1228 Drive Coupler Removal And Installation..................................................1231 Parts Identification....................................................................1232 Disassembly And Assembly................................................................1233 Inspection..............................................................................1237 OIL COOLER..................................................................................1241 Removal and Installation................................................................1241 DRIVE SYSTEM....................................................................................1243 PARKING BRAKE...............................................................................1245 Disk Removal And Installation...........................................................1245 Traction Lock Guides Removal And Installation...........................................1246 DRIVE COMPONENTS............................................................................1247 Axle Seal Removal And Installation......................................................1247 Axle, Bearing, And Sprocket Removal And Installation....................................1249 Chain Removal And Installation..........................................................1253 CHAINCASE...................................................................................1255 Removing Oil From The Chaincase.........................................................1255 Front Cover Removal And Installation....................................................1255 Rear Cover Removal And Installation.....................................................1256 MAIN FRAME......................................................................................1257 SEAT BAR....................................................................................1259 Removal And Installation................................................................1259 Assembling Components...................................................................1262 Compression Spring Disassembly And Assembly.............................................1262 OPERATOR CAB................................................................................1263 Gas Cylinder Removal And Installation...................................................1263 Gas Cylinder Disassembly And Assembly...................................................1264 Removal And Installation................................................................1264 OPERATOR SEAT...............................................................................1269 Removal And Installation................................................................1269 Seat Belt Removal And Installation......................................................1269 BOB-TACH....................................................................................1271 Removal And Installation................................................................1271 Bob-Tach Lever And Wedge................................................................1273 LIFT ARM....................................................................................1275 Removal And Installation................................................................1275 REAR GRILL..................................................................................1279 Removal And Installation................................................................1279 REAR DOOR...................................................................................1281 Removal And Installation................................................................1281 Striker Removal and Installation........................................................1282 Striker Disassembly and Assembly........................................................1282 Adjusting The Striker...................................................................1282 Latch Removal and Installation..........................................................1283 FUEL TANK...................................................................................1285 Removal And Installation................................................................1285 Fuel Level Sender.......................................................................1285 CONTROL PEDALS..............................................................................1287 Removal And Installation................................................................1287 Pedal Adjustment........................................................................1287 Pedal Interlock Linkage Removal And Installation........................................1288 Pedal Interlock Linkage Adjustment......................................................1289 Crossbar Linkage Removal And Installation...............................................1289 ELECTRICAL SYSTEM...............................................................................1291 ELECTRICAL SCHEMATICS.......................................................................1295 ELECTRICAL SYSTEM INFORMATION...............................................................1293 Troubleshooting.........................................................................1298 Description.............................................................................1299 Fuse Location...........................................................................1299 Relay Switches Location.................................................................1300 BATTERY.....................................................................................1302 Removal And Installation................................................................1302 Using A Booster Battery (Jump Starting).................................................1303 ALTERNATOR..................................................................................1306 Removal And Installation................................................................1306 Adjusting The Alternator Belt...........................................................1306 Description.............................................................................1307 Tests...................................................................................1307 Alternator Output Test..................................................................1308 Full Field Test.........................................................................1308 Alternator Regulator Test...............................................................1309 Alternator Regulator Test Using Voltmeter...............................................1309 Parts Identification....................................................................1310 Pulley Removal And Installation.........................................................1311 Disassembly And Assembly................................................................1312 Rotor Continuity Test...................................................................1314 Stator Continuity Test..................................................................1315 Rectifier Continuity (Diode) Test.......................................................1316 Brush Length............................................................................1316 STARTER.....................................................................................1318 Removal And Installation................................................................1318 Checking The Starter In The Loader......................................................1319 Parts Identification....................................................................1320 Disassembly.............................................................................1321 Inspection And Repair...................................................................1326 No Load Test............................................................................1330 Assembly................................................................................1331 INSTRUMENT PANEL............................................................................1338 Removal And Installation................................................................1338 LIGHTS......................................................................................1340 Front Removal And Installation..........................................................1340 BICS™ SYSTEM CONTROLLER.....................................................................1342 Trouble Shooting Guide..................................................................1342 Removal And Installation................................................................1343 BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON).................................................1346 Inspecting The BICS™ Controller (Engine STOPPED - Key ON)...............................1346 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....1346 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................1346 Inspecting The Traction Lock (Engine RUNNING)...........................................1346 Inspecting The Lift Arm By-Pass Control.................................................1346 Additional Inspection For Loaders With Advanced Hand Controls...........................1346 Troubleshooting Chart...................................................................1347 SEAT BAR SENSOR.............................................................................1348 Troubleshooting Guide...................................................................1348 Seat Bar Sensor Test....................................................................1349 Removal And Installation................................................................1350 BICS™ Controller Seat Bar Sensor Circuit Test...........................................1352 TRACTION LOCK...............................................................................1354 Troubleshooting Guide...................................................................1354 Removal And Installation................................................................1355 ENGINE SERVICE..................................................................................1358 TROUBLESHOOTING.............................................................................1362 Chart...................................................................................1362 ENGINE SPEED CONTROL........................................................................1364 Removal And Installation................................................................1364 Disassembly.............................................................................1364 Linkage Bar Removal And Installation....................................................1365 ENGINE SPEED CONTROL PLATE..................................................................1366 Removal And Installation................................................................1366 Governor Spring Removal.................................................................1366 Start Spring Removal....................................................................1366 Idle Limit And Fuel Limit Adjustment....................................................1367 MUFFLER.....................................................................................1368 Removal And Installation................................................................1368 AIR CLEANER.................................................................................1370 Removal And Installation................................................................1370 RADIATOR....................................................................................1372 Removal And Installation................................................................1372 BLOWER FAN HOUSING..........................................................................1374 Removal And Installation................................................................1374 ENGINE COMPONENTS AND TESTING...............................................................1376 Compression Checking....................................................................1376 Glow Plugs Checking.....................................................................1376 Glow Plugs Removal And Installation.....................................................1377 Fuel Shut-Off Solenoid, Removal And Installation........................................1378 Fuel Lift Pump Removal And Installation.................................................1379 Fuel Injection Pump, Checking...........................................................1379 Fuel Injection Pump Removal And Installation............................................1380 Timing The Injection Pump...............................................................1382 Fuel Injector Nozzles Removal And Installation..........................................1383 Checking Fuel Injector Nozzles..........................................................1384 Breather Removal And Installation.......................................................1386 Valve Clearance Adjustment..............................................................1386 ENGINE......................................................................................1388 Removal And Installation................................................................1388 Engine Mounting Brackets Removal And Installation.......................................1392 FLYWHEEL....................................................................................1394 Removal And Installation................................................................1394 Flywheel Ring Gear......................................................................1395 Housing Removal And Installation........................................................1395 RECONDITIONING THE ENGINE...................................................................1396 Thermostat Removal And Installation.....................................................1396 Water Pump Removal And Installation.....................................................1397 Timing Gear Case Cover Removal And Installation.........................................1397 Oil Pump Removal And Installation.......................................................1399 Checking Oil Pump.......................................................................1400 Crankshaft Front Seal Removal And Installation..........................................1402 Exhaust Manifold Removal And Installation...............................................1403 Valve Cover Removal And Installation....................................................1404 Rocker Arm Removal And Installation.....................................................1404 Push Rod Removal And Installation.......................................................1406 Cylinder Head Removal...................................................................1406 Cylinder Head Installation..............................................................1407 Tappet Removal And Installation.........................................................1407 Checking Piston Top Clearance...........................................................1408 Cylinder Head Disassembly...............................................................1409 Cylinder Head Assembly..................................................................1409 Servicing The Cylinder Head.............................................................1409 Cylinder Head Surface Flatness..........................................................1410 Cylinder Head Flaw......................................................................1410 Valve And Valve Guide Checking..........................................................1411 Valve Guide Replacement.................................................................1411 Reconditioning The Valve And Valve Seat.................................................1412 Correcting The Valve Seat...............................................................1412 Valve Spring............................................................................1413 Idler Gear Removal And Installation.....................................................1414 Camshaft Removal And Installation.......................................................1415 Camshaft Height.........................................................................1416 Camshaft Oil Clearance..................................................................1416 Camshaft Alignment......................................................................1417 Camshaft Gear Removal And Installation..................................................1417 Fuel Camshaft Removal And Installation..................................................1417 Engine Timing Gear Alignment............................................................1418 Governor Shaft Removal And Installation.................................................1419 Governor Fork Lever Removal And Installation............................................1422 Oil Pan Removal And Installation........................................................1423 Piston Removal..........................................................................1425 Piston Pin Removal And Installation.....................................................1426 Checking The Piston And Connecting Rod..................................................1426 Connecting Rod Alignment................................................................1427 Connecting Rod Bushing Removal And Installation.........................................1428 Piston Ring Gap.........................................................................1428 Checking Engine Cylinder Bore...........................................................1429 Piston Ring Installation................................................................1429 Connecting Rod Installation.............................................................1430 Piston Installation.....................................................................1430 Crankshaft End Play.....................................................................1431 Crankshaft Removal And Installation.....................................................1431 Crankshaft Disassembly And Assembly.....................................................1432 Checking Crankshaft Number One Journal And Block Bearing................................1433 Checking The Crankshaft Journals And Main Bearings......................................1434 Connecting Rod Journal..................................................................1436 Crankshaft Alignment....................................................................1437 RUBBER DRIVE COUPLER........................................................................1438 Removal And Installation................................................................1438 Disassembly.............................................................................1438 Assembly................................................................................1439 WATER FLANGE................................................................................1442 Removal And Installation................................................................1442 SPECIFICATIONS..................................................................................1444 LOADER SPECIFICATIONS.......................................................................1446 Machine Dimensions......................................................................1446 Performance.............................................................................1447 Controls................................................................................1447 Engine..................................................................................1447 Hydraulic System........................................................................1448 Electrical..............................................................................1448 Drive System............................................................................1449 Capacities..............................................................................1449 ENGINE SPECIFICATIONS - KUBOTA D1105-B......................................................1450 Engine Compression......................................................................1450 Fuel Injection Nozzles..................................................................1450 Fuel Injection Pump.....................................................................1450 Cylinder Head...........................................................................1450 Valves..................................................................................1450 Valve Springs...........................................................................1451 Rocker Arms.............................................................................1451 Camshaft................................................................................1451 Cylinders...............................................................................1451 Piston Rings............................................................................1452 Pistons.................................................................................1452 Crankshaft..............................................................................1452 Oil Pump................................................................................1453 Thermostat..............................................................................1453 Crankshaft Re-Grind Data................................................................1454 TORQUE SPECIFICATIONS FOR BOLTS.............................................................1456 Torque For General SAE Bolts............................................................1456 Torque For General Metric Bolts.........................................................1457 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................1458 O-ring Face Seal Connection.............................................................1458 Straight Thread O-ring Fitting..........................................................1459 Tubelines And Hoses.....................................................................1459 Flare Fitting...........................................................................1459 O-ring Flare Fitting....................................................................1460 Port Seal Fitting.......................................................................1462 HYDRAULIC FLUID SPECIFICATIONS..............................................................1464 Specifications..........................................................................1464 CONVERSIONS.................................................................................1466 Decimal And Millimeter Equivalents......................................................1466 U.S. To Metric Conversion...............................................................1466 SMR.............................................................................................1468 Revision No: 553-1..........................................................................1468 BOBCAT 553 SKID STEER LOADERS S/N 539112001 & ABOVE S/N 539412001 & ABOVE...........................1470 MAINTENANCE SAFETY..............................................................................1472 ALPHABETICAL INDEX..............................................................................1474 CONTENTS........................................................................................1476 FOREWORD....................................................................................1477 SAFETY INSTRUCTIONS.........................................................................1480 Fire Prevention.........................................................................1482 SERIAL NUMBER LOCATIONS.....................................................................1484 Loader Serial Number....................................................................1484 Engine Serial Number....................................................................1484 DELIVERY REPORT.............................................................................1485 LOADER IDENTIFICATION.......................................................................1486 SAFETY AND MAINTENANCE..........................................................................1488 LIFTING AND BLOCKING THE LOADER.............................................................1490 Procedure...............................................................................1490 LIFT ARM SUPPORT DEVICE.....................................................................1492 Installing..............................................................................1492 Removing................................................................................1493 OPERATOR CAB................................................................................1496 Description.............................................................................1496 Raising.................................................................................1496 Lowering................................................................................1497 TRANSPORTING LOADER ON A TRAILER............................................................1498 Loading And Unloading...................................................................1498 Fastening...............................................................................1498 TOWING THE LOADER...........................................................................1500 Procedure...............................................................................1500 REMOTE START................................................................................1502 Procedure...............................................................................1502 SERVICE SCHEDULE............................................................................1504 Chart...................................................................................1504 AIR CLEANER SERVICE.........................................................................1506 Replacing Filter Elements...............................................................1506 ENGINE COOLING SYSTEM.......................................................................1508 Cleaning................................................................................1508 Checking................................................................................1509 Removing And Replacing Coolant..........................................................1509 FUEL SYSTEM.................................................................................1512 Fuel Specifications.....................................................................1512 Filling The Fuel Tank...................................................................1512 Fuel Filter.............................................................................1513 Removing Air From The Fuel System.......................................................1513 ENGINE LUBRICATION SYSTEM...................................................................1514 Checking And Adding Engine Oil..........................................................1514 Oil Chart...............................................................................1514 Removing And Replacing Oil And Filter...................................................1515 HYDRAULIC/HYDROSTATIC SYSTEM................................................................1516 Checking And Adding Fluid...............................................................1516 Removing And Replacing The Hydraulic/Hydrostatic Filter.................................1516 Removing And Replacing The Hydraulic/Hydrostatic Fluid..................................1517 FINAL DRIVE TRANSMISSION (CHAINCASE)........................................................1518 Checking And Adding Oil.................................................................1518 Removing Oil From Chaincase.............................................................1518 AUXILIARY CONTROL LOCKBOLT..................................................................1520 Procedure...............................................................................1520 BOB-TACH....................................................................................1522 Inspection And Maintenance..............................................................1522 LUBRICATING THE BOBCAT......................................................................1524 Lubrication Locations...................................................................1524 TIRE MAINTENANCE............................................................................1526 Wheel Nuts..............................................................................1526 Rotating................................................................................1526 Mounting................................................................................1527 SPARK ARRESTOR MUFFLER......................................................................1528 Cleaning Procedure......................................................................1528 PIVOT PINS..................................................................................1530 Inspection And Maintenance..............................................................1530 SEAT BAR RESTRAINT SYSTEM...................................................................1532 Inspection And Maintenance..............................................................1532 RUBBER COUPLER LUBRICATION..................................................................1534 Procedure...............................................................................1534 LOADER STORAGE AND RETURN TO SERVICE........................................................1536 Storage.................................................................................1536 Return to Service.......................................................................1536 STOPPING THE ENGINE AND LEAVING THE LOADER..................................................1538 Procedure...............................................................................1538 Emergency Exit..........................................................................1539 HYDRAULIC SYSTEM................................................................................1540 HYDRAULIC/HYDROSTATIC SCHEMATICS............................................................1542 HYDRAULIC SYSTEM INFORMATION................................................................1544 Glossary Of Hydraulic / Hydrostatic Symbols.............................................1544 Troubleshooting Chart...................................................................1548 CYLINDER (LIFT).............................................................................1550 Testing.................................................................................1550 Removal And Installation................................................................1551 Parts Identification....................................................................1554 Disassembly And Assembly................................................................1555 CYLINDER (TILT).............................................................................1558 Testing.................................................................................1558 Removal And Installation................................................................1558 Parts Identification....................................................................1560 Disassembly And Assembly................................................................1561 MAIN RELIEF VALVE...........................................................................1564 Description.............................................................................1564 Testing With Auxiliaries................................................................1564 Testing Without Auxiliaries.............................................................1566 Removal and Installation................................................................1567 HYDRAULIC CONTROL VALVE.....................................................................1568 Description.............................................................................1568 BICS Valve Removal And Installation.....................................................1568 Identification Chart....................................................................1571 Disassembly And Assembly................................................................1572 Load Check Valve Removal And Installation...............................................1572 Main Relief Valve Removal And Installation..............................................1573 Anti-Cavitation Check Valve Removal And Installation....................................1574 Port Relief Valve Removal And Installation..............................................1575 Rubber Boot (Lift) Removal And Installation.............................................1576 Rubber Boot (Tilt) Removal And Installation.............................................1576 Rubber Boot (Auxiliary) Removal And Installation........................................1576 Lift Spool And Detent Removal And Installation..........................................1577 Tilt Spool Removal And Installation.....................................................1581 Auxiliary Spool And Detent Removal And Installation.....................................1582 One Way Restrictors Removal And Installation............................................1585 Spool Seal Installation.................................................................1586 LIFT ARM BY-PASS CONTROL VALVE..............................................................1588 Description.............................................................................1588 Testing.................................................................................1588 Removal And Installation................................................................1588 Disassembly And Assembly................................................................1589 TILT LOCK VALVE.............................................................................1590 Description.............................................................................1590 Testing.................................................................................1590 Removal And Installation................................................................1590 Disassembly And Assembly................................................................1591 HYDRAULIC PUMP..............................................................................1592 Description.............................................................................1592 Direct Pump Testing.....................................................................1592 Removal And Installation................................................................1593 Parts Identification....................................................................1595 Disassembly And Assembly................................................................1596 HYDRAULIC/HYDROSTATIC FILTER................................................................1598 Description.............................................................................1598 Housing Removal And Installation........................................................1598 Housing Disassembly And Assembly........................................................1599 HYDRAULIC FLUID RESERVOIR...................................................................1600 Description.............................................................................1600 Removal And Installation................................................................1600 Hydrauilc Fluid Screen..................................................................1601 OIL COOLER..................................................................................1602 Description.............................................................................1602 Removal And Installation................................................................1602 HYDROSTATIC SYSTEM..............................................................................1604 HYDROSTATIC SYSTEM INFORMATION..............................................................1606 Troubleshooting.........................................................................1606 Description.............................................................................1607 HYDROSTATIC MOTOR...........................................................................1608 Description.............................................................................1608 Removal And Installation................................................................1608 Parts Identification....................................................................1610 Disassembly And Assembly................................................................1611 Timing..................................................................................1619 PORT BLOCK..................................................................................1620 Description.............................................................................1620 Removal And Installation................................................................1620 Oil Cooler By-Pass Valve Removal And Installation.......................................1620 Hydraulic Oil Temperature Switch Removal And Installation...............................1620 Charge Pressure By-Pass Valve Removal And Installation..................................1621 HYDROSTATIC PUMP............................................................................1622 Description.............................................................................1622 Checking Charge Pressure................................................................1622 Removal And Installation................................................................1623 Drive Coupler Removal And Installation..................................................1626 Parts Identification....................................................................1628 Disassembly And Assembly................................................................1629 Inspection..............................................................................1633 DRIVE SYSTEM....................................................................................1636 PARKING BRAKE...............................................................................1638 Description.............................................................................1638 Disk Removal And Installation...........................................................1638 Traction Lock Guides Removal And Installation...........................................1639 DRIVE COMPONENTS............................................................................1642 Description.............................................................................1642 Axle Seal Removal And Installation......................................................1642 Chain Removal And Installation..........................................................1648 CHAINCASE...................................................................................1650 Description.............................................................................1650 Front Cover Removal And Installation....................................................1650 Rear Cover Removal And Installation.....................................................1650 MAIN FRAME......................................................................................1652 SEAT BAR....................................................................................1654 Description.............................................................................1654 Removal And Installation................................................................1654 Disassembly And Assembly................................................................1657 Compression Spring Disassembly And Assembly.............................................1657 OPERATOR CAB................................................................................1658 Gas Cylinder Removal And Installation...................................................1658 Gas Cylinder Disassembly And Assembly...................................................1659 Removal And Installation................................................................1659 OPERATOR SEAT...............................................................................1664 Removal And Installation................................................................1664 Seat Belt Removal And Installation......................................................1664 BOB-TACH....................................................................................1666 Description.............................................................................1666 Removal And Installation................................................................1666 Lever And Wedge Disassembly And Assembly................................................1668 LIFT ARM....................................................................................1670 Removal And Installation................................................................1670 REAR GRILL..................................................................................1674 Removal And Installation................................................................1674 REAR DOOR...................................................................................1676 Removal And Installation................................................................1676 Striker Removal And Installation........................................................1677 Striker Disassembly And Assembly........................................................1677 Striker Adjustment......................................................................1677 Latch Removal And Installation..........................................................1678 FUEL TANK...................................................................................1680 Removal And Installation................................................................1680 Fuel Level Sender Removal And Installation..............................................1680 CONTROL PEDALS AND LINKAGES.................................................................1682 Description.............................................................................1682 Removal And Installation................................................................1682 Pedal Adjustment........................................................................1682 Pedal Interlock Linkage Removal And Installation........................................1683 Pedal Interlock Linkage Adjustment......................................................1684 Crossbar Linkage Removal And Installation...............................................1684 CONTROL PANEL...............................................................................1686 Description.............................................................................1686 Removal And Installation................................................................1686 CONTROL LEVER...............................................................................1688 Description.............................................................................1688 Lever Removal And Installation..........................................................1688 Lever Disassembly And Assembly..........................................................1689 Linkage Removal And Installation........................................................1690 Pintle Lever Removal And Installation...................................................1692 Pintle Lever Disassemby And Assembly....................................................1692 WINDOW (REAR)...............................................................................1698 Removal.................................................................................1698 Installation............................................................................1698 WINDOW (TOP)................................................................................1700 Removal.................................................................................1700 Installation............................................................................1700 WINDOW (SIDE)...............................................................................1702 Removal And Installation................................................................1702 WINDOW (FRONT DOOR).........................................................................1704 Removal (Standard Window)...............................................................1704 Installation (Standard Window)..........................................................1704 Removal And Installation (Special Applications Window)..................................1706 ELECTRICAL SYSTEM & ANALYSIS....................................................................1708 ELECTRICAL SCHEMATICS.......................................................................1710 ELECTRICAL SYSTEM INFORMATION...............................................................1713 Glossary Of Electrical Symbols..........................................................1713 Description.............................................................................1717 Troubleshooting.........................................................................1718 Fuse And Relay Location And Identification..............................................1719 BATTERY.....................................................................................1721 Removal And Installation................................................................1721 Using A Booster Battery (Jump Starting).................................................1722 ALTERNATOR..................................................................................1725 Belt Adjustment.........................................................................1725 Charging System Inspection..............................................................1725 Alternator Voltage Testing..............................................................1726 Low Voltage Testing.....................................................................1727 High Voltage Testing....................................................................1727 Removal And Installation................................................................1728 Parts Identification....................................................................1729 STARTER.....................................................................................1731 Testing.................................................................................1731 Removal And Installation................................................................1732 Parts Identification....................................................................1733 INSTRUMENT PANELS...........................................................................1735 Left And Right Removal And Installation.................................................1735 LIGHTS......................................................................................1737 Front Removal And Installation..........................................................1737 Rear Removal And Installation...........................................................1738 Cab Light Removal And Installation......................................................1739 BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......................................................1741 Description.............................................................................1741 Inspecting The BICS System (Engine STOPPED - Key ON)....................................1741 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................1741 Inspecting The Traction Lock (Engine RUNNING)...........................................1741 Inspecting The Lift Arm By-Pass Control.................................................1741 Troubleshooting Chart...................................................................1742 Troubleshooting.........................................................................1743 Removal And Installation................................................................1744 SEAT BAR SENSOR.............................................................................1745 Description.............................................................................1745 Troubleshooting.........................................................................1745 Testing.................................................................................1746 Removal And Installation................................................................1747 Bobcat Interlock Control System (BICS) Circuit Test.....................................1749 TRACTION LOCK...............................................................................1751 Description.............................................................................1751 Troubleshooting.........................................................................1751 Removal And Installation................................................................1752 ENGINE SERVICE..................................................................................1755 ENGINE INFORMATION..........................................................................1759 Description.............................................................................1759 Specifications..........................................................................1760 Torque Values...........................................................................1764 Troubleshooting.........................................................................1765 Engine Removal And Installation.........................................................1767 Engine Mount Replacement................................................................1772 Compression - Checking..................................................................1773 ENGINE SPEED CONTROL........................................................................1775 Removal And Installation................................................................1775 Linkage Bar Removal And Installation....................................................1776 ENGINE SPEED CONTROL PLATE..................................................................1777 Removal And Installation................................................................1777 Governor Spring Removal.................................................................1777 Start Spring Removal....................................................................1777 Idle Limit And Fuel Limit Adjustment....................................................1778 MUFFLER.....................................................................................1779 Removal And Installation................................................................1779 AIR CLEANER.................................................................................1781 Housing Removal And Installation........................................................1781 ENGINE COOLING SYSTEM.......................................................................1783 Cooling Fan Removal And Installation....................................................1783 Radiator Removal And Installation.......................................................1784 Water Pump Removal And Installation.....................................................1787 Thermostat Housing Removal And Installation.............................................1787 Thermostat Testing......................................................................1788 LUBRICATION SYSTEM..........................................................................1789 Oil Pan Removal And Installation........................................................1789 Oil Pump Removal And Installation.......................................................1789 Oil Pump Inspection.....................................................................1789 Engine Oil Pressure - Testing...........................................................1790 FUEL SYSTEM.................................................................................1791 Fuel Camshaft Removal And Installation..................................................1791 Fuel Camshaft Governor Disassembly And Assembly.........................................1792 Fuel Shutoff Solenoid, Removal And Installation.........................................1797 Fuel Lift Pump Removal And Installation.................................................1797 Fuel Injection Pump, Checking...........................................................1798 Fuel Injection Pump Removal And Installation............................................1798 Injection Pump - Timing.................................................................1801 Fuel Injector Removal And Installation..................................................1802 Fuel Injector Nozzle Pressure - Checking................................................1804 Nozzle Spray Condition..................................................................1805 Valve Seat Tightness....................................................................1805 CYLINDER HEAD...............................................................................1807 Glow Plugs - Testing....................................................................1807 Glow Plugs Removal And Installation.....................................................1807 Closed Breather System - Checking.......................................................1808 Valve Clearance Adjustment..............................................................1809 Valve Timing - Checking.................................................................1809 Exhaust Manifold Removal And Installation...............................................1810 Cylinder Head Removal And Installation..................................................1810 Cylinder Head Disassembly And Assembly..................................................1811 Cylinder Head - Servicing...............................................................1812 Cylinder Head Top Clearance.............................................................1813 Valve Guide And Valve Checking..........................................................1814 Reconditioning The Valve And Valve Seat.................................................1816 Valve Springs...........................................................................1817 Valve Tappets...........................................................................1818 Rocker Arm And Shaft Removal And Installation...........................................1818 Rocker Arm And Shaft Disassembly And Assembly...........................................1818 Rocker Arm And Shaft - Checking.........................................................1819 CRANKSHAFT AND PISTONS......................................................................1821 Piston And Connecting Rod Removal And Installation......................................1821 Piston And Connecting Rod - Servicing...................................................1822 Cylinder Bore Checking..................................................................1826 Connecting Rod Alignment................................................................1826 Crankshaft And Bearing Removal And Installation.........................................1827 Crankshaft And Bearing - Servicing......................................................1828 CAMSHAFT AND TIMING GEARS...................................................................1835 Timing Gearcase Cover Removal And Installation..........................................1835 Timing Gears Backlash - Checking........................................................1837 Idler Gear And Shaft Removal And Installation...........................................1838 Idler Gear And Shaft Servicing..........................................................1838 Camshaft Removal And Installation.......................................................1839 Camshaft Servicing......................................................................1840 Camshaft Gear Removal And Installation..................................................1841 Engine Timing Gear Alignment............................................................1841 FLYWHEEL AND HOUSING........................................................................1843 Flywheel Removal And Installation.......................................................1843 Ring Gear Removal And Installation......................................................1843 Housing Removal And Installation........................................................1844 RUBBER DRIVE COUPLER........................................................................1845 Removal And Installation................................................................1845 Disassembly And Assembly................................................................1845 WATER FLANGE................................................................................1849 Removal And Installation................................................................1849 HEATER..........................................................................................1851 HEATER SYSTEM...............................................................................1853 Description.............................................................................1853 REGULAR MAINTENANCE.........................................................................1855 Filter Element Removal And Installation.................................................1855 Heater Coil.............................................................................1855 TROUBLESHOOTING.............................................................................1857 Electric System.........................................................................1857 Heater Valve Not Opening Or Closing.....................................................1857 Blower Motor Does Not Operate...........................................................1857 Blower Motor Operates Normally, But Air Flow Is Insufficient............................1857 HEATER UNIT.................................................................................1859 Removal And Installation................................................................1859 HEATER COIL.................................................................................1861 Removal And Installation................................................................1861 HEATER FAN..................................................................................1863 Blower Removal And Installation.........................................................1863 Disassembly And Assembly................................................................1863 HEATER MOTOR................................................................................1865 Removal And Installation................................................................1865 RESISTOR....................................................................................1867 Removal And Installation................................................................1867 Checking................................................................................1867 HEATER VALVE................................................................................1869 Removal And Installation................................................................1869 HEATER SWITCH...............................................................................1871 Removal And Installation................................................................1871 Checking The Switch.....................................................................1872 SPECIFICATIONS..................................................................................1873 553 LOADER SPECIFICATIONS...................................................................1875 Dimensions..............................................................................1875 Performance.............................................................................1876 Controls................................................................................1876 Engine..................................................................................1876 Hydraulic System........................................................................1877 Electrical..............................................................................1877 Drive System............................................................................1878 Capacities..............................................................................1878 Tires...................................................................................1878 TORQUE SPECIFICATIONS FOR BOLTS.............................................................1879 Torque For General SAE Bolts............................................................1879 Torque For General Metric Bolts.........................................................1880 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................1881 O-ring Face Seal Connection.............................................................1881 Straight Thread O-ring Fitting..........................................................1882 Tubelines And Hoses.....................................................................1882 Flare Fitting...........................................................................1882 O-ring Flare Fitting....................................................................1883 Port Seal Fitting.......................................................................1885 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS..................................................1887 Specifications..........................................................................1887 CONVERSIONS.................................................................................1889 Decimal And Millimeter Equivalents......................................................1889 U.S. To Metric Conversion Chart.........................................................1889 SMR.............................................................................................1891 553-1.......................................................................................1891
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