Bobcat 653 Loader Service Manual 6724493 (6-12) – PDF DOWNLOAD

Description

Bobcat 653 Loader Service Manual 6724493 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 653 Loader Service Manual 6724493 (6-12) – PDF DOWNLOAD

Language : English
Pages : 358
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 653 Loader Service Manual 6724493 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
SERIAL NUMBER LOCATIONS 13
LOADER SERIAL NUMBER 13
ENGINE SERIAL NUMBER 13
DELIVERY REPORT 13
BOBCAT LOADER IDENTIFICATION 14
PREVENTIVE MAINTENANCE 15
SERVICE SCHEDULE 17
LIFTING AND BLOCKING THE LOADER 18
Procedure 18
TRANSPORTING THE LOADER 19
Procedure 19
TOWING THE LOADER 19
Procedure 19
STOPPING THE BOBCAT LOADER 19
LIFTING THE LOADER 20
Four Point Lift 20
Single Point Lift 20
LIFT ARM SUPPORT DEVICE 21
Engaging The Lift Arm Support Device 21
Disengaging The Lift Arm Support Device 21
OPERATOR CAB 22
Description 22
Raising The Operator Cab 22
Lowering The Operator Cab 23
Raising The Operator Cab (Hand Controls) 24
Lowering The Operator Cab (Hand Controls) 25
Emergency Exit 26
SEAT BAR RESTRAINT SYSTEM 27
Description (Foot Controls) 27
Seat Bar Inspection (Foot Controls) 27
Seat Bar Maintenance (Foot Controls) 27
Description (Hand Controls) 28
Seat Bar Inspection (Hand Controls) 28
Seat Bar Maintenance (Hand Controls) 28
AIR CLEANER SERVICE 29
Replacing Filter Element 29
FUEL SYSTEM 30
Fuel Specifications 30
Filling The Fuel Tank 30
Fuel Filter 30
Removing Air From The Fuel System 31
ENGINE LUBRICATION SYSTEM 32
Checking Engne Oil 32
Replacing Oil And Filter 32
ENGINE COOLING SYSTEM 34
Cleaning The Cooling System 34
Checking The Coolant Level 34
Removing Coolant From The Cooling System 35
Proplylene Glycol 35
ALTERNATOR BELT 36
Adjusting The Alternator Belt 36
BOB-TACH 36
FAN GEARBOX 36
Checking And Maintaining 36
ELECTRICAL SYSTEM 37
Using A Booster Battery (Jump Starting) 37
HYDRAULIC / HYDROSTATIC SYSTEM 38
Replacing Hydraulic Fluid 38
Hydraulic Reservoir Breather Cap 39
SPARK ARRESTOR MUFFLER 40
Cleaning Procedure 40
TIRE MAINTENANCE 41
Wheel Nuts 41
Tire Rotation 41
Tire Mounting 41
FINAL DRIVE TRANSMISSION (CHAINCASE) 42
Checking And Adding Oil 42
Removing Oil From The Chaincase 42
DRIVE BELT 43
Adjusting The Drive Belt (Equipped With Fixed Drive Idler) 43
Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler 45
Drive Belt Replacement 47
LUBRICATION OF THE BOBCAT LOADER 48
Procedure 48
PIVOT PINS 49
REMOTE START SWITCH 50
Procedure 50
HYDRAULIC SYSTEM 53
TROUBLESHOOTING 55
HYDRAULIC SYSTEM INFORMATION 56
Flare Connections 56
O-Ring Face Seal Connection 56
Staright Thread O-Ring Fitting 56
Tubelines And Hoses 56
LIFT CYLINDER(S) 57
Checking The Lift Cylinder(s) For Internal Leakage 57
Removal And Installation 57
TILT CYLINDER 58
Checking The Tilt Cylinder For Internal Leakage 58
Removal And Installation 58
Rod End Seal Replacement 59
HYDRAULIC CYLINDER IDENTIFICATION 60
Lift Cylinder Components 60
Tilt Cylinder Components 61
HYDRAULIC CYLINDERS 62
Disassembly 62
Assembly 64
HYDRAULIC CONTROL VALVE 70
Removal And Installation 70
Checking The Main Relief Valve 73
Main Relief Valve Adjustment 74
Main Relief Valve Removal And Installation 74
Identification Chart 75
Disassembly And Assembly 76
Load Check Valve 76
Main Relief Valve 77
Port Relief Valve 77
Anti-Cavitation valve 78
Rubber Boot 79
Lift Spool Detent 80
Tilt Centering Spring 84
Auxiliary Spool 85
Auxiliary Electric Solenoid 86
Inspection 87
Identification & Installation Of Spool Seal 88
HYDRAULIC PUMP 89
Removal And Installation 89
Checking The Output Of The Hydraulic Pump 91
Disassembly And Assembly 93
Inspection 95
Identification 95
HYDRAULIC FILTER HOUSING 96
Removal And Installation 96
HYDRAULIC FLUID RESERVOIR 97
Removal And Installation 97
CONTROL PEDALS 98
Removal And Installation 98
Pedal Adjustment 98
PEDAL INTERLOCK LINKAGE 99
Removal And Installation 99
Adjustment 100
HYDROSTATIC SYSTEM 101
TROUBLESHOOTING 103
HYDROSTATIC SYSTEM INFORMATION 104
Replenishing Valve Function 104
CONTROL PANEL 105
Removal And Installation 105
Steering Shaft Removal And Installation 106
Steering Shaft Disassembly And Assembly 106
Steering Lever Removal And Installation 107
Rubber Boot Replacement 107
STEERING LINKAGE 108
Removal And Installation 108
Steering Linkage Adjustment 110
Steering Neutral Adjustment 112
HYDROSTATIC DRIVE MOTOR 114
Removal And Installation 114
Identification 115
Disassembly And Assembly 116
Inspection 120
HYDROSTATIC PUMP 121
Removal And Installation 121
Identification 124
Disassembly And Assembly 126
Inspection 134
Swashplate Pre-Load 136
DRIVE BELT HOUSING 137
Removal And Installation 137
SPRING LOADED DRIVE IDLER 139
Identification 139
Disassembly 140
Assembly 144
DRIVE BELT TENSIONER PULLEY 149
Removal And Installation 149
Disassembly 150
Assembly 152
Checking Pulley End Play 156
OIL COOLER 156
Removal And Installation 156
DRIVE SYSTEM 157
PARKING BRAKE 159
Removal And Installation 159
Disassembly And Assembly 159
PARKING BRAKE DISC 160
Removal And Installation 160
CHAINCASE FLUID 161
Removing Oil From The Chaincase 161
CHAINCASE COVERS 162
Center Chaincase Cover Removal And Installation 162
Front Chaincase Cover Removal And Installation 163
Rear Chaincase Cover Removal And Installation 163
MOTOR CARRIER 164
Shaft Seal Replacement 164
Removal And Installation 166
Disassembly 167
Assembly 168
AXLE SEAL 171
Removal And Installation 171
AXLE, SPROCKET AND BEARINGS 173
Removal And Installation 173
DRIVE CHAIN 177
Removal 177
MAIN FRAME 179
SEAT BAR 181
Removal And Installation 181
Assembly 183
Compressing The Gas Cylinder 184
OPERATOR CAB GAS CYLINDER 185
Removal And Installation 185
Disassembly And Assembly 185
OPERATOR CAB 186
Removal And Installation 186
OPERATOR SEAT 189
Removal And Installation 189
BOB-TACH 190
Removal And Installation 190
Bob-Tach Lever And Wedge 192
Bob-Tach Stops 193
LIFT ARMS 194
Removal And Installation 194
REAR GRILL 198
Removal And Installation 198
FUEL TANK 199
Removal And Installation 199
Fuel Level Sender 200
REAR DOOR 201
Removal And Installation 201
Hood Removal And Installation 202
Bumper Removal And Installation 202
Door Latch Removal And Installation 202
Door Latch And Catch Adjustment 203
ELECTRICAL SYSTEM 205
ELECTRICAL SCHEMATICS 207
TROUBLESHOOTING 229
ELECTRICAL SYSTEM INFORMATION 230
Description 230
Fuse Location 230
BATTERY 231
Removal And Installation 231
Servicing The Battery 232
Using A Booster Battery (Jump Starting) 233
ALTERNATOR 234
Alternator Output Test 234
Rectifier (Diode) Test 234
Alternator Regulator Test 235
Removal And Installation 236
Adjusting The Alternator Belt 236
Disassembly And Inspection 237
Stator Continuity Test 237
Stator Ground Test 237
Rotor Continuity Test 238
Rotor Ground Test 238
Rectifier Continuity (Diode) Test 238
Assembly 239
STARTER 240
Removal And Installation 240
Disassembly And Assembly 241
External Pinion 245
Inspection And Repair 246
Magnetic Switch Test 249
No Load Test 249
Parts Identification 250
STANDARD INSTRUMENT PANEL 251
Removal And Installation 251
FRONT LIGHTS 252
Removal And Installation 252
RELAY SWITCHES 252
Location 252
Glow Plug Preheat Relay 252
ENGINE SERVICE 253
TROUBLESHOOTING 255
ENGINE SPEED CONTROL 256
Removal And Installation 256
Disassembly 256
RADIATOR 257
Removal And Installation 257
ENGINE MUFFLER 258
Removal And Installation 258
BLOWER HOUSING/FAN GEARBOX 259
Removal And Installation 259
Tension Pulley Removal And Installation 262
Blower Fan Disassembly And Assembly 263
FAN GEARBOX 265
Disassembly 265
Assembly 270
Checking Backlash 275
Identification 278
AIR CLEANER 279
Removal And Installation 279
ENGINE 280
Removal And Installation 280
Engine Mount Replacement 285
FLYWHEEL 286
Removal And Installation 286
Flywheel Ring Gear 286
INJECTION PUMP TIMING 287
Checking Procedure 287
Adjusting Injection Pump Timing 288
TIMING BELT 289
Removal 289
Installation 291
FUEL INJECTION PUMP 292
Removal 292
Installation 293
FUEL INJECTOR NOZZLE 294
Removal And Installation 294
Checking The Injector Nozzle 295
CYLINDER LOCATION AND COMPRESSION 295
Data 295
GLOW PLUGS 296
Removal And Installation 296
Checking The Glow Plugs 296
CYLINDER HEAD 297
Removing The Cylinder Head 297
Disassembly Of The Cylinder Head 299
Servicing The Cylinder Head 300
Checking The Valves 301
Checking Valve Springs 301
Checking The Valve Guides 302
Checking The Valve Seats 302
Checking The Combustion Chamber 303
Reassejmbly Of The Cylinder Head 304
Installing The Cylinder Head 306
ENGINE BLOCK 309
Disassembly Of The Engine 309
Assembly Of The Engine 311
PISTONS AND CONNECTING RODS 315
Disassembly And Assembly 315
Checking The Piston 315
CRANKSHAFT AND BEARINGS 316
Checking The Crankshaft 316
CRANKSHAFT PULLEY 317
Removal And Installation 317
PEUGEOT ENGINE TOOL KIT MEL1474 318
ENGINE TORQUE 320
SYSTEM ANALYSIS 321
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 323
Inspecting The BICS™ Controller 323
Inspecting The Deactivation Of The Auxiliary Hydraulics System 323
Inspecting The Seat And Seat Bar Sensors 323
Inspecting The Traction Lock 323
Inspecting The Lift Arm By-Pass Control 323
Maintenance 323
Troubleshooting Chart 324
Troubleshooting Guide 325
BICS CONTROLLER 325
TRACTION LOCK 326
SEAT SENSOR 327
SEAT BAR SENSOR 328
LIFT LOCK BY-PASS VALVE 329
BICS™ SYSTEM CONTROLLER 330
Removal And Installation 330
Controller Test 331
SEAT BAR SENSOR 332
Removal And Installation 332
Seat Bar Sensor Test 333
SEAT SENSOR 334
Removal And Installation 334
Seat Sensor Test 335
TRACTION LOCK 336
Removal And Installation 336
LIFT LOCK BY-PASS VALVE 337
Removal And Installation 337
Disassembly And Assembly 338
TILT LOCK VALVE 339
Removal And Installation 339
Disassembly And Assembly 341
SPECIFICATIONS 343
SKID STEER LOADER SPECIFICATIONS 345
Performance 345
Controls 345
Engine 346
Hydraulic System 346
Electrical 346
Drive System 346
Capacities 346
Tires 347
Floor Pressure 347
ENGINE SPECIFICATIONS 348
Fuel Injection Nozzles 348
Fuel Injection Pump 348
Cylinder Head 348
Valves 348
Valve Springs 349
Valve Guides 349
Combustion Chamber 349
Cylinders 349
Piston Rings 349
Pistons 349
Connecting Rod 350
Crankshaft 350
TORQUE SPECIFICATIONS 351
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 353
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 354
DECIMAL AND MILLIMETER EQUIVALENTS 355
U S TO METRIC CONVERSION 355
SMR 357
653-1 357

DESCRIPTION:

Bobcat 653 Loader Service Manual 6724493 (6-12) – PDF DOWNLOAD

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS:

The following publications provide information on the safe use and maintenance of the loader and attachments:
? The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
? The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine maintenance
and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement Operation
& Maintenance Manuals can be ordered from your Bobcat loader dealer.
? The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
? The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The Handbook is available from your dealer in an English edition or a combination English, French, German,
Italian, Dutch, Spanish, Portuguese, Danish, Swedish & Finnish.
? The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
? The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.
? The Skid–Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish versions.
? The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

IMAGES PREVIEW OF THE MANUAL:

Customer Support: [email protected]

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V