Description
Bobcat S550 Skid-Steer Loader Service Manual Overview
The Bobcat S550 Skid-Steer Loader Service Manual (S/N AHGM11001 & Above, B3GY11001 & Above) is the comprehensive, factory-issue workshop manual prepared specifically for professional service mechanics and heavy equipment owners. Containing 1,240 pages of in-depth technical guidance, this manual covers the complete disassembly, inspection, rebuilding, adjustment, and diagnostic procedures for every major system on the Bobcat S550 loader. Whether executing routine periodic maintenance according to the factory service schedule, troubleshooting hydraulic relief circuits, rebuilding double-acting lift or tilt cylinders, or overhauling hydrostatic drive assemblies, this Bobcat S550 Skid-Steer Loader Service Manual delivers the authoritative technical documentation necessary to perform precision repairs with total confidence.
Document & File Details
- Manual Type: Factory Service Manual (Shop / Workshop Manual)
- Machine Brand: Bobcat
- Model: S550 Skid-Steer Loader
- Document Publication Number: 6990677enUS (Revision 07-18, H)
- Publication Date: July 2018
- Serial Number Coverage: S/N AHGM11001 & Above, S/N B3GY11001 & Above
- Applicable Engine Standard: Tier 4-B / Stage IV (T4-B S4-B)
- Language: English
- Page Count: 1,240 pages
- File Format: Portable Document Format (PDF)
Chapters Covered
- SAFETY AND MAINTENANCE (Section 10-01)
- Lifting and Blocking the Loader Procedures
- Lift Arm Support Device Installation and Removal
- Operator Cab (ROPS/FOPS, Cab Door Sensors, Special Applications Kit, Forestry Door & Window Kit)
- Transporting the Loader on a Trailer and Chain Fastening Procedures
- Towing Precautions and Machine Recovery
- Remote Start Tool Kit Operations (MEL1563 & Service Tool Kit 7217666)
- Service Schedule and Periodic Maintenance Intervals
- Engine Air Cleaner Servicing (Dual Element Filtration & Restriction Display Codes)
- Engine Cooling System Maintenance, Cleaning, and Propylene Glycol Fluid Standards
- Fuel System Requirements (Ultra-Low Sulfur Diesel ASTM D975/EN590, Biodiesel Blends B5/B7, Priming Bulb Air Bleed)
- Engine Lubrication System (API CJ-4/ACEA E9 Specifications, Filter & Drain Operations)
- Hydraulic and Hydrostatic Reservoir, Fluid Specifications, and Filter Servicing
- Final Drive Chaincase Transmission Maintenance and Fluid Level Inspection
- Bob-Tach Manual Lever and Power Bob-Tach Inspection and Mechanical Wedges
- Loader Lubrication Locations and Multipurpose Lithium Grease Guidelines
- Tire Maintenance, Rotation Patterns, Mounting Safety, and Wheel Nut Torques (217 N·m / 160 ft-lb)
- Pivot Pin Inspection, Hardware Retention, and Torque Settings
- Extended Loader Storage Protocols and Comprehensive Return-to-Service Procedures
- Safe Machine Shutdown and Cab Exit Procedures
- Operator Emergency Exit Systems (Window Latches, Rubber Cord, External Access)
- Seat Belt and Control Interlock Restraint System Inspections
- HYDRAULIC SYSTEM (Section 20-01)
- Hydraulic System Information and Standard ISO Schematic Symbols Glossary
- Comprehensive Hydraulic Troubleshooting Guide
- Double-Acting Hydraulic Lift Cylinders (Hydraulic Drift Testing, Removal, Disassembly, Rebuilding, Seal Replacement, and 1,152 N·m Piston Nut Torque)
- Double-Acting Hydraulic Tilt Cylinders (Testing, Removal, Taper Pivot Pin Removal, Resealing, and Assembly)
- Updated Hydraulic Lift and Tilt Cylinders for S/N B3GY11244 & Above (Gland Nut Tooling MEL1076, 780 N·m Piston Nut, 550 N·m Gland Head)
- Hydraulic Power Bob-Tach Cylinder (Testing, Leakage Verification, Removal, and Overhaul)
- Main Relief Valve (System Testing at Front Quick Couplers, Bench Testing, Pressure Adjustment, and Cartridge Service)
- Standard Hydraulic Control Valve (Foot-Pedal Mechanical Linkages, Spool Centering Blocks, Detent Mechanisms, BICS Solenoid Valves, Port Relief Valves, and Anti-Cavitation Cartridges)
- Advanced Control System (ACS) and Selectable Joystick Controls (SJC) Hydraulic Control Valves (Electronic Actuator Alignment and Diagnostic Spool Control)
- Lift Arm Manual Bypass Control Valve (Testing, Removal, and Spool Servicing)
- Standard Gear-Type Hydraulic Pump and Integrated Charge Pump (Direct Flow Testing, Line Tests, and Startup Protocols)
- Optional High-Flow Hydraulic Pump Section (Flow Divider Operation, Circuit Testing, and High-Flow Relief Valve Calibration)
- Hydraulic Filter Assemblies, Reservoir Strainer Screen, and Hydraulic Oil Cooler
- Bucket Position Valve (Self-Leveling Operation, Solenoid Testing, and Valve Teardown)
- Rear Auxiliary Hydraulic Diverter Valve and Multi-Connection Junction Manifolds
- Front Auxiliary Integrated Quick Coupler Block and Manual Pressure Release Procedures
- Automatic Ride Control System (Hydraulic Accumulator Pressure Checks, Nitrogen Charging, and Solenoid Isolation)
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Bobcat S550 Skid-Steer Loader Service Manual (S/N AHGM11001 & Above, B3GY11001 & Above) – PDF Workshop Repair Manual” are as follows:
MAINTENANCE SAFETYp. 3
CONTENTSp. 5
+FOREWORDp. 7
FOREWORDp. 9
SAFETY INSTRUCTIONSp. 11
+FIRE PREVENTIONp. 13
Maintenancep. 13
Operationp. 13
Electricalp. 13
Hydraulic Systemp. 13
Fuelingp. 13
Startingp. 13
Spark Arrester Exhaust Systemp. 13
Welding And Grindingp. 14
Fire Extinguishersp. 14
+SERIAL NUMBER LOCATIONSp. 15
Loader Serial Numberp. 15
Engine Serial Numberp. 15
DELIVERY REPORTp. 16
LOADER IDENTIFICATIONp. 17
+SAFETY AND MAINTENANCEp. 19
+LIFTING AND BLOCKING THE LOADERp. 23
+LIFT ARM SUPPORT DEVICEp. 25
Descriptionp. 25
Installingp. 26
Removingp. 27
+OPERATOR CABp. 29
Descriptionp. 29
Cab Door Sensorp. 29
Raisingp. 30
Loweringp. 31
Special Applications Kitp. 32
Special Applications Kit Inspection And Maintenancep. 32
Forestry Door And Window Kitp. 33
Forestry Door And Window Kit Inspection And Maintenancep. 33
+TRANSPORTING THE LOADER ON A TRAILERp. 35
Loading And Unloadingp. 35
Fasteningp. 35
+TOWING THE LOADERp. 37
+REMOTE START TOOL KIT – MEL1563p. 39
Remote Start Tool – MEL1563p. 39
Service Tool Harness Communicator – MEL1566p. 41
Remote Start Procedurep. 41
+REMOTE START TOOL (SERVICE TOOL) KIT – 7217666p. 45
Descriptionp. 45
Remote Start Tool (Service Tool) – 7022042p. 46
Loader Service Tool Harness – 6689747p. 47
Computer Service Tool Harness – 6689746p. 48
Remote Start Procedurep. 49
+SERVICE SCHEDULEp. 53
Maintenance Intervalsp. 53
+ENGINE AIR CLEANERp. 55
+ENGINE COOLING SYSTEMp. 57
Maintenance Platformp. 57
Cleaningp. 57
Checking And Adding Coolantp. 60
Removing And Replacing Coolantp. 61
+FUEL SYSTEMp. 63
Fuel Specificationsp. 63
Biodiesel Blend Fuelp. 63
Filling The Fuel Tankp. 64
Fuel Filterp. 65
Removing Air From The Fuel Systemp. 67
+ENGINE LUBRICATION SYSTEMp. 69
Checking And Adding Engine Oilp. 69
Engine Oil Chartp. 69
Removing And Replacing Oil And Filterp. 70
+HYDRAULIC / HYDROSTATIC SYSTEMp. 73
Checking And Adding Fluidp. 73
Hydraulic / Hydrostatic Fluid Chartp. 73
Removing And Replacing Hydraulic Fluidp. 74
Removing And Replacing Hydraulic / Hydrostatic Filterp. 76
Removing And Replacing Hydraulic Charge Filterp. 77
Replacing Reservoir Breather Capp. 79
+FINAL DRIVE TRANSMISSION (CHAINCASE)p. 81
Checking And Adding Fluidp. 81
Removing And Replacing Fluidp. 81
+BOB-TACH (HAND LEVER)p. 83
Inspection And Maintenancep. 83
+BOB-TACH (POWER)p. 85
Inspection And Maintenancep. 85
+LUBRICATING THE LOADERp. 87
Lubrication Locationsp. 87
+TIRE MAINTENANCEp. 91
Wheel Nutsp. 91
Rotatingp. 91
Mountingp. 92
+PIVOT PINSp. 93
Inspection And Maintenancep. 93
+LOADER STORAGE AND RETURN TO SERVICEp. 95
Storagep. 95
Return To Servicep. 95
+STOPPING THE ENGINE AND LEAVING THE LOADERp. 97
+EMERGENCY EXITp. 99
Rear Window Identificationp. 99
Rear Window Removal (Latches)p. 99
Rear Window Removal (Rubber Cord)p. 99
External Access (Rear Window With Latches)p. 100
External Access (Rear Window With Rubber Cord)p. 100
Front Doorp. 100
+SEAT BELTp. 103
Inspection And Maintenancep. 103
+HYDRAULIC SYSTEMp. 105
HYDRAULIC / HYDROSTATIC SCHEMATICSp. 111
+HYDRAULIC SYSTEM INFORMATIONp. 127
Glossary Of Hydraulic / Hydrostatic Symbolsp. 127
Troubleshootingp. 131
+CYLINDER (LIFT)p. 133
Testingp. 133
Removal And Installationp. 134
Parts Identificationp. 137
Disassemblyp. 138
Assemblyp. 140
+CYLINDER (TILT)p. 143
Testingp. 143
Removal And Installationp. 144
Base End Pivot Pin Removal And Installationp. 145
Parts Identificationp. 146
Disassemblyp. 147
Assemblyp. 149
+CYLINDER (LIFT) (B3GY11244 & ABOVE)p. 153
Testingp. 153
Removal And Installationp. 154
Parts Identificationp. 157
Disassemblyp. 158
Assemblyp. 160
+CYLINDER (TILT) (B3GY11244 & ABOVE)p. 165
Testingp. 165
Removal And Installationp. 166
Base End Pivot Pin Removal And Installationp. 167
Parts Identificationp. 168
Disassemblyp. 169
Assemblyp. 171
+CYLINDER (BOB-TACH)p. 175
Testingp. 175
Removal And Installationp. 176
Parts Identificationp. 177
Disassemblyp. 178
Assemblyp. 179
+MAIN RELIEF VALVEp. 183
Descriptionp. 183
Testingp. 184
Adjustingp. 186
Removal And Installationp. 187
+HYDRAULIC CONTROL VALVE (STANDARD)p. 189
Descriptionp. 189
Removal And Installationp. 190
Mount Bracket Removal And Installationp. 193
Identification Chartp. 194
Lift Load Check Valve Removal And Installationp. 195
Load Check Valve Removal And Installation (Tilt And Auxiliary)p. 196
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)p. 197
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)p. 197
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)p. 198
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)p. 198
Port Relief Valve Removal And Installationp. 199
Plug Removal And Installationp. 201
Rubber Boot Removal And Installationp. 202
End Cap Block Removal And Installationp. 202
Lift Spool And Detent Removal And Installationp. 203
Tilt Spool Removal And Installationp. 211
Auxiliary Spool Removal And Installationp. 213
Auxiliary Solenoid Removal And Installationp. 214
Solenoid Removal And Installationp. 215
Lock Valve Removal And Installationp. 216
Lift Arm Bypass Orifice Removal And Installationp. 218
Main Relief Valve Removal And Installationp. 218
Check Valve Removal And Installationp. 219
+HYDRAULIC CONTROL VALVE (ACS) OR (SJC)p. 221
Descriptionp. 221
Removal And Installationp. 221
Actuator Removal And Installation (In Loader)p. 225
Actuator Removal And Installation (Out Of Loader)p. 226
Identification Chartp. 229
Mount Bracket Removal And Installationp. 230
Lift Load Check Valve Removal And Installationp. 230
Load Check Valve Removal And Installation (Tilt And Auxiliary)p. 231
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)p. 232
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)p. 232
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)p. 233
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)p. 233
Port Relief Valve Removal And Installationp. 234
Plug Removal And Installationp. 236
End Cap Block Removal And Installationp. 237
Lift Spool Removal And Installationp. 237
Lift Spool Disassembly And Assemblyp. 239
Tilt Spool Removal And Installationp. 240
Auxiliary Spool Removal And Installationp. 242
Auxiliary Solenoid Removal And Installationp. 243
Solenoid Removal And Installationp. 244
Lock Valve Removal And Installationp. 245
Lift Arm Bypass Orifice Removal And Installationp. 247
Main Relief Valve Removal And Installationp. 247
Check Valve Removal And Installationp. 248
+LIFT ARM BYPASS CONTROL VALVEp. 249
Descriptionp. 249
Testingp. 249
Removal And Installationp. 250
Bracket Removal And Installationp. 251
Disassembly And Assemblyp. 251
+HYDRAULIC PUMPp. 253
Descriptionp. 253
Pump Test At Quick Couplersp. 254
Direct Pump Test (Standard Section)p. 256
Direct Pump Test (Charge Section)p. 258
Removal And Installationp. 260
Hydraulic Pump Startupp. 262
Parts Identificationp. 263
Disassembly And Assemblyp. 264
+HYDRAULIC PUMP (HIGH FLOW)p. 265
Descriptionp. 265
Pump Test At Quick Couplersp. 266
Direct Pump Test (Standard Section)p. 268
Direct Pump Test (Charge Section)p. 270
Direct Pump Test (High Flow Section)p. 272
High Flow Relief Valve Adjustmentp. 274
High Flow Relief Valve Removal And Installationp. 276
Solenoid Removal And Installationp. 277
Removal And Installationp. 278
Hydraulic Pump Startupp. 280
Parts Identificationp. 281
Disassembly And Assemblyp. 282
+HYDRAULIC / HYDROSTATIC FILTERSp. 283
Descriptionp. 283
Housing Removal And Installationp. 283
+HYDRAULIC FLUID RESERVOIRp. 285
Descriptionp. 285
Removal And Installationp. 285
Hydraulic Fluid Screenp. 286
+OIL COOLERp. 287
Removal And Installationp. 287
+BUCKET POSITION VALVEp. 289
Descriptionp. 289
Solenoid Removal And Installationp. 290
Solenoid Testingp. 292
Removal And Installationp. 292
Disassembly And Assemblyp. 294
+REAR AUXILIARY DIVERTER VALVEp. 295
Descriptionp. 295
Solenoid Testingp. 295
Removal And Installationp. 296
Disassembly And Assemblyp. 297
+BOB-TACH (POWER) BLOCK (S/N AHGM11001 – AHGM11756)p. 303
Descriptionp. 303
Removal And Installationp. 303
Disassembly And Assemblyp. 305
+BOB-TACH (POWER) BLOCK (S/N AHGM11757 & ABOVE)p. 313
Descriptionp. 313
Testing Relief Valvep. 314
Removal And Installationp. 316
Disassembly And Assemblyp. 318
+FRONT AUXILIARY HYDRAULIC COUPLER BLOCKp. 323
Descriptionp. 323
Removal And Installationp. 324
Disassembly And Assembly (FFI/FI)p. 324
Disassembly And Assembly (FFH/FH)p. 326
+AUTOMATIC RIDE CONTROLp. 329
Descriptionp. 329
Removal And Installationp. 330
Checking The Pressure In The Accumulatorp. 333
Adding Nitrogen To The Accumulatorp. 335
+HYDROSTATIC SYSTEMp. 337
+HYDROSTATIC SYSTEM INFORMATIONp. 339
Descriptionp. 339
Troubleshootingp. 340
+HYDROSTATIC DRIVE MOTORp. 341
Descriptionp. 341
Removal And Installationp. 341
Parts Identificationp. 344
Disassembly And Assemblyp. 345
+HYDROSTATIC DRIVE MOTOR (TWO-SPEED)p. 349
Descriptionp. 349
Removal And Installation (Left Side)p. 350
Removal And Installation (Right Side)p. 353
Parts Identificationp. 356
Disassemblyp. 357
Assemblyp. 369
+HYDROSTATIC MOTOR CARRIERp. 383
Descriptionp. 383
Shaft Seal Removal And Installationp. 384
Removal And Installationp. 386
Parts Identificationp. 388
Disassemblyp. 389
Assemblyp. 391
+HYDROSTATIC MOTOR CARRIER (TWO-SPEED)p. 395
Descriptionp. 395
Shaft Seal Removal And Installationp. 396
Removal And Installationp. 398
Parts Identificationp. 400
Disassemblyp. 401
Assemblyp. 403
+CHARGE PRESSUREp. 407
Descriptionp. 407
Testingp. 408
Adjustingp. 410
Sender Removal And Installation (Earlier Models)p. 412
Sender Removal And Installation (Later Models)p. 412
+HYDROSTATIC PUMPp. 413
Descriptionp. 413
Removal And Installationp. 414
Hydrostatic Pump Startupp. 415
Replenishing / High Pressure Relief Valve Removal And Installationp. 416
Parts Identification (Left Half)p. 417
Parts Identification (Right Half)p. 418
Disassemblyp. 419
Assemblyp. 426
+HYDROSTATIC PUMP (SJC)p. 433
Descriptionp. 433
Hydraulic Controller Removal And Installationp. 434
Removal And Installationp. 436
Hydrostatic Pump Startupp. 438
Parts Identificationp. 439
High Pressure Relief And Bypass Valvep. 440
Charge Relief Valvep. 441
Disassembly And Assemblyp. 442
Mechanical Neutral Adjustmentp. 455
Hydraulic Controller Neutral Adjustmentp. 459
+HYDROSTATIC PUMP (SJC) (S/N AHGM18001 & ABOVE)p. 463
Descriptionp. 463
Port Locations And Gauge Installationp. 464
Removal And Installationp. 465
Hydrostatic Pump Startupp. 467
Parts Identificationp. 468
High Pressure Relief And Bypass Valvep. 471
Charge Pressure Relief Valvep. 472
Disassembly And Assemblyp. 473
Mechanical Neutral Adjustmentp. 485
Hydraulic Controller Neutral Adjustmentp. 487
+DRIVE BELTp. 489
Belt Adjustmentp. 489
Stop Adjustmentp. 489
Belt Replacementp. 490
Tensioner Removal And Installation (Earlier Models)p. 492
Tensioner Disassembly And Assemblyp. 492
Tensioner Pulley Removal And Installation (Later Models)p. 493
Tensioner Pulley Disassembly And Assemblyp. 493
+TWO-SPEEDp. 495
Valve Block Removal And Installationp. 495
Valve Block Disassembly And Assemblyp. 496
+DRAIN MANIFOLDp. 497
Descriptionp. 497
Drain Manifold Removal And Installationp. 497
+DRIVE SYSTEMp. 499
+BRAKEp. 501
Descriptionp. 501
Disc Removal And Installationp. 501
+DRIVE COMPONENTSp. 503
Descriptionp. 503
Axle Seal Removal And Installationp. 504
Axle, Sprocket And Bearings Removal And Installationp. 506
Chain Removal And Installationp. 511
+CHAINCASEp. 513
Descriptionp. 513
Front Cover Removal And Installationp. 513
Center Cover Removal And Installationp. 514
Rear Cover Removal And Installationp. 515
+MAINFRAMEp. 517
+SEAT BARp. 521
Descriptionp. 521
Removal And Installationp. 521
Disassembly And Assemblyp. 522
Compression Spring Disassembly And Assemblyp. 523
+OPERATOR CABp. 525
Gas Spring Removal And Installationp. 525
Gas Spring Bracket Disassembly And Assemblyp. 526
Removal And Installationp. 527
+OPERATOR SEATp. 529
Removal And Installationp. 529
Seat Belt Removal And Installation (Retractable)p. 529
Seat Belt And Bracket Removal And Installation (Standard)p. 530
Seat Belt Bracket Removal And Installationp. 530
+OPERATOR SEAT (SUSPENSION)p. 531
Removal And Installationp. 531
Slide Rail Removal And Installationp. 531
Seat Belt Removal And Installationp. 532
Lower Cushion Removalp. 532
Lower Cushion Installationp. 533
Back Cushion Removal And Installationp. 533
Shock Removal And Installationp. 534
3-Point Seat Belt Removal And Installationp. 534
+BOB-TACH (HAND LEVER)p. 537
Descriptionp. 537
Removal And Installationp. 538
Lever And Wedge Disassembly And Assemblyp. 540
Pivot Pin Bushing And Seal Removal And Installationp. 542
+BOB-TACH (POWER)p. 543
Descriptionp. 543
Removal And Installationp. 544
Lever And Wedge Disassembly And Assemblyp. 547
Pivot Pin Bushing And Seal Removal And Installationp. 549
+LIFT ARMSp. 551
Removal And Installationp. 551
+REAR GRILLEp. 553
Removingp. 553
Installingp. 553
Shield Removal And Installationp. 554
+REAR DOOR (TAILGATE)p. 555
Removal And Installationp. 555
Striker Removal And Installationp. 556
Striker Disassembly And Assemblyp. 556
Striker Adjustingp. 556
Latch Removal And Installationp. 557
+FUEL TANKp. 559
Removal And Installationp. 559
Fuel Level Sender Removal And Installationp. 561
Fuel Fill Screen Removal And Installationp. 561
+CONTROL PEDALS AND LINKAGESp. 563
Descriptionp. 563
Pedal Removal And Installationp. 563
Linkage Removal And Installationp. 564
Pedal (Adjusting)p. 565
Floor Pan Removal And Installationp. 566
+CONTROL PEDALS AND LINKAGES (ACS)p. 567
Descriptionp. 567
Pedal Removal And Installationp. 567
Linkage Removal And Installationp. 568
Pedal (Adjusting)p. 568
Floor Pan Removal And Installationp. 569
+CONTROL PANELp. 571
Descriptionp. 571
Removal And Installationp. 572
Disassembly And Assemblyp. 574
Linkage Removal And Installationp. 578
Pintle Arm Disassembly And Assemblyp. 581
Linkage Neutral (Adjusting)p. 582
Linkage Travel (Adjusting)p. 586
Shock Removal And Installationp. 590
+CONTROL PANEL (SJC)p. 591
Descriptionp. 591
Removal And Installationp. 591
+CONTROL HANDLE / LEVERp. 593
Descriptionp. 593
Lever Removal And Installationp. 593
Boot Removal And Installationp. 594
+CONTROL HANDLE / LEVER (ACS)p. 595
Descriptionp. 595
Handle Sensor Removal And Installationp. 595
Handle Removal And Installationp. 598
Handle Disassembly And Assemblyp. 599
Lever Removal And Installationp. 599
Boot Removal And Installationp. 600
+CONTROL HANDLE / LEVER (SJC)p. 601
Descriptionp. 601
Joystick Testingp. 601
Joystick Removal And Installationp. 602
+ACCESS PANEL (INSIDE)p. 603
Removal And Installation (Left)p. 603
Removal And Installation (Right)p. 603
+ACCESS PANEL (INSIDE) (SJC)p. 605
Removal And Installation (Left)p. 605
Removal And Installation (Right)p. 605
+WINDOW (REAR)p. 607
Rear Window Identificationp. 607
Rear Window Removal (Latches)p. 607
Rear Window Removal (Rubber Cord)p. 607
External Access (Rear Window With Latches)p. 608
External Access (Rear Window With Rubber Cord)p. 608
Disassembly And Assembly (Latches)p. 609
+WINDOW (TOP)p. 611
Removal And Installationp. 611
+WINDOW (SIDE)p. 613
Removal And Installationp. 613
+CAB DOORp. 615
Descriptionp. 615
Removal And Installationp. 615
Disassembly And Assemblyp. 616
Aligningp. 617
Adjustingp. 618
Checking Operationp. 618
+ARMRESTp. 619
Descriptionp. 619
Removal And Installationp. 620
Disassembly And Assemblyp. 621
+LEFT SIDE LOWER PANELp. 623
Removal And Installationp. 623
Disassembly And Assemblyp. 625
+RIGHT SIDE LOWER PANELp. 627
Removal And Installationp. 627
Disassembly And Assemblyp. 629
+HEADLINERp. 631
Removal And Installationp. 631
+FAN DUCT PANELSp. 633
Removal And Installationp. 633
+ELECTRICAL SYSTEMp. 635
ELECTRICAL SCHEMATICSp. 641
+ELECTRICAL SYSTEM INFORMATIONp. 813
Glossary Of Electrical Symbolsp. 813
Standard Cab Harness Connectorsp. 816
Deluxe Cab Harness Connectorsp. 817
Mainframe Harness Connectors – Manual Controlsp. 818
Mainframe Harness Connectors – SJCp. 819
Engine Harness Connectorsp. 820
Descriptionp. 821
Troubleshootingp. 822
Fuse And Relay Location / Identificationp. 823
Solenoid Testingp. 828
+BATTERYp. 829
Removal And Installationp. 829
Battery Maintenancep. 830
Maintaining Battery Charge Levelp. 830
Battery Service During Machine Storagep. 830
Battery Testingp. 831
Battery Chargingp. 831
Using A Booster Battery (Jump Starting)p. 832
+ALTERNATORp. 833
Belt Adjustmentp. 833
Belt Replacementp. 834
Charging System Inspectionp. 835
Alternator Voltage Testingp. 836
Low Voltage Testingp. 836
High Voltage Testingp. 837
Removal And Installationp. 838
Parts Identificationp. 840
+STARTERp. 841
Testingp. 841
Removal And Installationp. 841
Parts Identificationp. 842
+INSTRUMENT PANELSp. 843
Left Panelp. 843
Display Screenp. 845
Right Panel (Standard Key Panel)p. 846
Right Panel (Keyless Start Panel)p. 847
Right Panel (Deluxe Instrumentation Panel)p. 848
Left Switch Panelp. 850
Right Switch Panelp. 850
Left Side Lower Panelp. 851
Right Side Lower Panelp. 851
Left Panel Removal And Installationp. 852
Right Panel (Standard Key Panel) Removal And Installationp. 852
Right Panel (Keyless Start Panel) Removal And Installationp. 853
Right Panel (Deluxe Instrumentation Panel) Removal And Installationp. 853
Key Switch Disassembly And Assemblyp. 854
Alarm Disassembly And Assemblyp. 854
Left Switch Panel Removal And Installationp. 855
Right Switch Panel Removal And Installationp. 855
+LIGHTSp. 857
Front Removal And Installationp. 857
Rear Removal And Installationp. 858
Cab Light Removal And Installation (Earlier Models)p. 858
Cab Light Removal And Installation (Later Models)p. 859
+BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)p. 861
Descriptionp. 861
Connector Identificationp. 862
Removal And Installationp. 868
+BOBCAT CONTROLLER (ACS)p. 869
Descriptionp. 869
Connector And Wire Identificationp. 870
Removal And Installationp. 871
+BOBCAT CONTROLLER (SJC) (DRIVE)p. 873
Descriptionp. 873
Connector Identificationp. 874
Removal And Installationp. 876
+ENGINE CONTROL UNIT (ECU)p. 877
Descriptionp. 877
Cleaningp. 878
Removal And Installationp. 879
+DIAGNOSTIC SERVICE CODESp. 881
Viewing Service Codesp. 881
Service Codes Listp. 882
+BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)p. 891
Descriptionp. 891
Inspecting The BICS™ (Engine STOPPED – Key ON)p. 892
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)p. 892
Inspecting The Seat Bar Sensor (Engine RUNNING)p. 892
Inspecting The Traction Lock And The Parking Brake (Engine RUNNING)p. 892
Inspecting The Lift Arm Bypass Controlp. 892
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)p. 892
Troubleshootingp. 893
+SEAT BAR SENSORp. 895
Descriptionp. 895
Troubleshootingp. 895
Testingp. 896
Removalp. 897
Installationp. 899
Bobcat Interlock Control System (BICS™) Circuit Testp. 900
+TRACTION LOCKp. 903
Descriptionp. 903
Troubleshootingp. 904
Inspectingp. 905
+CONTROL SYSTEM (ACS)p. 907
Descriptionp. 907
Troubleshootingp. 908
Handle Sensor Connector Disassembly And Assemblyp. 909
Switch Handle Removalp. 910
Switch Handle Installationp. 912
Actuator Connector Disassembly And Assemblyp. 915
Handle Lock Solenoid Removal And Installationp. 916
Handle Lock Solenoid Disassembly And Assemblyp. 916
Foot Sensor Removal And Installationp. 917
Foot Sensor Disassembly And Assemblyp. 918
Foot Sensor Lock Solenoid Removal And Installationp. 918
+ELECTRICAL / HYDRAULIC CONTROLSp. 919
Identification Chartp. 919
Descriptionp. 920
Identification Chart ACD Group 0p. 921
Identification Chart ACD Group 1p. 922
Identification Chart ACD Group 2p. 923
Identification Chart ACD Group 3p. 924
+ELECTRICAL / HYDRAULIC CONTROLS (ACS)p. 925
Identification Chartp. 925
Descriptionp. 926
Identification Chart ACD Group 0p. 927
Identification Chart ACD Group 1p. 928
Identification Chart ACD Group 2p. 929
Identification Chart ACD Group 3p. 930
+ELECTRICAL / HYDRAULIC CONTROLS (SJC)p. 931
Identification Chartp. 931
Descriptionp. 932
Identification Chart ACD Group 0p. 933
Identification Chart ACD Group 1p. 934
Identification Chart ACD Group 2p. 935
Identification Chart ACD Group 3p. 936
+SERVICE PC (LAPTOP COMPUTER)p. 937
Connecting Remote Start Toolp. 937
Connecting Remote Start Tool (Service Tool)p. 937
+CALIBRATIONp. 939
Descriptionp. 939
Actuator Testingp. 939
Lift And Tilt Calibration (SJC)p. 942
Hydrostatic Pump Calibration (SJC)p. 944
Lift And Tilt Calibration (ACS)p. 949
+STEERING DRIFT COMPENSATION (OPERATOR MODE)p. 951
Descriptionp. 951
Operationp. 951
+STEERING DRIFT COMPENSATION (SERVICE MODE)p. 953
Descriptionp. 953
Operationp. 953
+CONTROL PANEL SETUPp. 955
Right Panel Setup (Deluxe Instrumentation Panel)p. 955
+PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)p. 959
Password Descriptionp. 959
Changing The Owner Passwordp. 959
Changing The User Passwordsp. 960
Password Lockout Featurep. 960
+PASSWORD SETUP (KEYLESS START PANEL)p. 961
Password Descriptionp. 961
Changing The Owner Passwordp. 961
Password Lockout Featurep. 961
+MAINTENANCE CLOCKp. 963
Descriptionp. 963
Setupp. 964
Resetp. 967
+BACK-UP ALARM SYSTEMp. 969
Descriptionp. 969
Inspectingp. 969
Adjusting Switch Positionp. 970
Troubleshooting (Standard And ACS)p. 971
Troubleshooting (Joystick)p. 972
Alarm Removal And Installationp. 973
Switch Removal And Installationp. 973
+FRONT HORNp. 975
Removal And Installationp. 975
Troubleshootingp. 976
Troubleshooting (Joystick)p. 977
+ENGINE SPEED CONTROL (HAND)p. 979
Removal And Installationp. 979
+ENGINE SPEED CONTROL (FOOT)p. 981
Removal And Installationp. 981
Disassembly And Assemblyp. 982
Foot Throttle Calibrationp. 984
+CAMSHAFT AND CRANKSHAFT POSITION SENSORp. 987
Removal And Installationp. 987
+TELEMATICSp. 989
Descriptionp. 989
Removal And Installationp. 989
Procedurep. 990
+ENGINE SERVICEp. 991
+ENGINE INFORMATIONp. 995
Descriptionp. 995
Specificationsp. 996
Sensor Locationp. 998
Torque Valuesp. 1004
Troubleshootingp. 1006
Engine Removal And Installationp. 1008
Engine Mount Replacementp. 1017
Compression – Testingp. 1019
Injector Signal – Testingp. 1021
Injector Signal – Testing (In-Line)p. 1023
Oil Pressure Testing (At Oil Sensor On Block)p. 1025
Oil Pressure Testing (At Turbocharger Oil Inlet)p. 1027
+DIESEL OXIDATION CATALYST (DOC)p. 1029
Removal And Installationp. 1029
+AIR CLEANERp. 1031
Housing Removal And Installationp. 1031
+ENGINE COOLING SYSTEM (EARLIER MODELS)p. 1033
Radiator / Oil Cooler Removal And Installationp. 1033
Hydraulic Fan Descriptionp. 1036
Fan Duct Removal And Installationp. 1036
Hydraulic Fan Motor Assembly Removal And Installationp. 1037
Hydraulic Fan Motor Removal And Installationp. 1038
Hydraulic Fan Motor Disassembly And Assemblyp. 1040
Blower Housing Removal And Installationp. 1041
Water Pump Removal And Installationp. 1042
Thermostat Housing Removal And Installationp. 1043
Testing The Thermostatp. 1044
+ENGINE COOLING SYSTEM (LATER MODELS)p. 1045
Radiator / Oil Cooler Removal And Installationp. 1045
Hydraulic Fan Descriptionp. 1048
Reversible Hydraulic Fan Descriptionp. 1048
Fan Duct Removal And Installationp. 1048
Hydraulic Fan Motor Assembly Removal And Installationp. 1049
Hydraulic Fan Motor Removal And Installationp. 1050
Hydraulic Fan Motor Disassembly And Assemblyp. 1052
Hydraulic Fan Motor Assembly Removal And Installationp. 1060
Blower Housing Removal And Installationp. 1060
Water Pump Removal And Installationp. 1061
Thermostat Housing Removal And Installationp. 1062
Testing The Thermostatp. 1063
+LUBRICATION SYSTEMp. 1065
Descriptionp. 1065
Oil Pan Removal And Installationp. 1066
Oil Pump Removal And Installationp. 1067
Oil Pump Relief Valve Descriptionp. 1068
Oil Pump Relief Valve Removal And Installationp. 1068
Oil Cooler Removal And Installationp. 1069
Oil Filter Head Removal And Installationp. 1070
Oil Cooler Bypass Descriptionp. 1071
Oil Cooler Bypass Removal And Installationp. 1071
+FUEL SYSTEMp. 1073
Descriptionp. 1073
Transfer Pump / High Pressure Pump Removal And Installationp. 1074
Fuel Temperature Sensor Removal And Installationp. 1076
Fuel Cooler Removal And Installationp. 1077
Fuel Bypass Valve Removal And Installationp. 1077
Fuel Recirculation Valve Removal And Installationp. 1078
Fuel Rail Assembly Removal And Installationp. 1079
Fuel Injector Removal And Installationp. 1080
Injector Codingp. 1082
Removing Air From The Fuel Systemp. 1084
+CYLINDER HEADp. 1087
Glow Plugs Testingp. 1087
Glow Plug Removal And Installationp. 1088
Valve Clearance Adjustmentp. 1089
Cylinder Head Removal And Installationp. 1091
Cylinder Head Disassembly And Assemblyp. 1095
Cylinder Head Inspectionp. 1096
Cylinder Head Top Clearancep. 1097
Valve Step Heightp. 1098
Valve Stem Heightp. 1098
Valve Guidep. 1099
Valvep. 1099
Valve Springp. 1100
Rocker Arm Shaft Disassembly And Assemblyp. 1101
Rocker Arm Shaft Inspectionp. 1102
Push Rod Inspectionp. 1102
+CRANKSHAFT AND PISTONSp. 1103
Piston And Connecting Rod Removal And Installationp. 1103
Piston And Connecting Rod Inspectionp. 1104
Crankshaft Removal And Installationp. 1106
Cylinder Block Inspectionp. 1109
Crankshaft Inspectionp. 1111
Connecting Rod Inspectionp. 1111
Engine Component Classp. 1112
+CAMSHAFTp. 1115
Removal And Installationp. 1115
Inspectingp. 1116
+GEARCASEp. 1119
Gearcase Cover Removal And Installationp. 1119
Gear Backlashp. 1120
Gear Timingp. 1121
Idle Gear Removal And Installationp. 1122
Idle Gear Inspectionp. 1122
+TURBOCHARGERp. 1123
Descriptionp. 1123
Removal And Installationp. 1123
Inspectionp. 1126
+FLYWHEEL AND HOUSINGp. 1127
Flywheel Removal And Installationp. 1127
Ring Gear Removal And Installationp. 1128
Housing Removal And Installationp. 1128
+EXHAUST GAS RECIRCULATION (EGR) SYSTEMp. 1129
Descriptionp. 1129
Removal And Installationp. 1130
Disassembly And Assemblyp. 1134
+HEATING, VENTILATION AND AIR CONDITIONING (HVAC)p. 1137
+AIR CONDITIONING SYSTEM FLOWp. 1139
Descriptionp. 1139
Chartp. 1140
Componentsp. 1141
Safety Equipmentp. 1144
+REGULAR MAINTENANCEp. 1145
Filtersp. 1145
Belt Adjustmentp. 1146
Belt Replacementp. 1146
Air Conditioning Condenserp. 1146
Air Conditioning Lubricationp. 1146
Air Conditioning Service Chartp. 1147
Evaporator / Heater Coilp. 1148
+TROUBLESHOOTINGp. 1151
Blower Motor Does Not Operatep. 1151
Blower Motor Operates Normally, But Air Flow Is Insufficientp. 1151
Insufficient Cooling Although Air Flow And Compressor Operation Are Normalp. 1151
The Compressor Does Not Operate At All, Or Operates Improperlyp. 1151
Gauge Pressure Related Troubleshootingp. 1152
Troubleshooting Treep. 1154
Temperature / Pressure Chartp. 1158
Poor A/C Performancep. 1160
HVAC Repair And Leaksp. 1161
Electrical Systemp. 1162
Engine Coolant Bypassing The Heater Valvep. 1168
Heater Valve Not Opening Or Closingp. 1169
+SYSTEM CHARGING AND RECLAMATIONp. 1171
Refrigerant Identificationp. 1171
Reclamation And Charging With Recovery / Charging Unitp. 1172
+COMPRESSORp. 1175
Removal And Installationp. 1175
Oilp. 1176
Oil Checkp. 1177
+CONDENSERp. 1179
Removal And Installationp. 1179
+RECEIVER / DRIERp. 1181
Receiver / Drier Removal And Installationp. 1181
Pressure Switch Removal And Installationp. 1183
Schrader® Valve Removal And Installationp. 1184
+EVAPORATOR / HEATER UNITp. 1185
Removal And Installationp. 1185
+THERMOSTATp. 1187
Descriptionp. 1187
Removal And Installationp. 1188
+EXPANSION VALVEp. 1189
Removal And Installationp. 1189
+EVAPORATOR COILp. 1191
Removal And Installationp. 1191
+HEATER COILp. 1193
Removal And Installationp. 1193
+BLOWER FANp. 1195
Removal And Installationp. 1195
Disassembly And Assemblyp. 1195
+HEATER VALVEp. 1199
Removal And Installationp. 1199
+EVAPORATOR / HEATER COVERp. 1201
Removingp. 1201
Installingp. 1201
+SPECIFICATIONSp. 1203
+(S550) LOADER SPECIFICATIONSp. 1205
Machine Dimensionsp. 1205
Performancep. 1206
Enginep. 1206
Drive Systemp. 1207
Controlsp. 1207
Hydraulic Systemp. 1208
Electrical Systemp. 1209
Capacitiesp. 1209
Tiresp. 1210
+TECHINCAL SERVICE GUIDE SPECIFICATIONSp. 1211
Enginep. 1211
Engine Torquesp. 1211
Cooling Systemp. 1211
Loader Torquesp. 1212
Hydraulic / Hydrostatic Systemp. 1212
Fuel Consumptionp. 1212
+TORQUE SPECIFICATIONS FOR BOLTSp. 1213
Torque For General SAE Boltsp. 1213
Torque For General Metric Boltsp. 1214
+HYDRAULIC CONNECTION SPECIFICATIONSp. 1215
Straight Thread O-ring Fittingp. 1215
Flare Fittingp. 1216
Tubelines And Hosesp. 1216
+HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONSp. 1217
+CONVERSIONSp. 1219
Decimal And Millimeter Equivalent Chartp. 1219
U.S. To Metric Conversion Chartp. 1219
+SERVICE TOOLS REQUIREDp. 1221
Remote Start Toolsp. 1221
Hydraulic Toolsp. 1222
Mainframe And Drive Toolsp. 1225
Electrical Toolsp. 1228
Engine Toolsp. 1229
HVAC Toolsp. 1234
ALPHABETICAL INDEXp. 1235
- HYDROSTATIC SYSTEM (Section 30-01)
- DRIVE SYSTEM (Section 40-01)
- MAINFRAME (Section 50-01)
- ELECTRICAL SYSTEM (Section 60-01)
- ENGINE SERVICE (Section 70-01)
- HEATING, VENTILATION AND AIR CONDITIONING (HVAC) (Section 80-01)
- SPECIFICATIONS (Section SPEC-01)
- ALPHABETICAL INDEX (Section INDEX-01)
Taken as a unified technical resource, this factory manual gives mechanics and field technicians complete end-to-end guidance for maintaining, isolating faults within, and overhauling all working circuits of the loader. From tracing complex hydraulic schematic logic across manual and SJC joystick variations to executing precision mechanical reassembly with exact torque specifications, the text supplies the structured troubleshooting flows, dimensional limits, and disassembly sequences required to keep the machine performing to original factory benchmarks.
Hydraulic & Hydrostatic System Workshop Procedures
The hydraulic section provides in-depth repair protocols for every active fluid power assembly installed on the Bobcat S550. Technicians are provided with complete instructions for performing in-chassis cylinder drift testing, isolating base-end or rod-end internal packing bypass, and rebuilding the double-acting lift, tilt, and Bob-Tach cylinders using specialized service tools like the MEL1033 rod seal installer, MEL1075 and MEL1076 gland nut wrenches, and piston ring compressors. Critical torque values are documented at every stage, including the 1,152 N·m (850 ft-lb) torque specification for standard cylinder piston retaining nuts and the updated 780 N·m (575 ft-lb) torque and 550 N·m (405 ft-lb) gland head torque on serial numbers B3GY11244 and above. Detailed cutaways and step-by-step text outline complete teardown procedures for both mechanical-linkage standard control valves and electro-hydraulic ACS / SJC valves, including spool centering assemblies, detent balls and springs, anti-cavitation valves, port relief cartridges factory-set to 27,579 kPa (4,000 psi), and the main system relief valve operating at 23,787 to 24,132 kPa (3,450 to 3,500 psi). Additionally, the Bobcat S550 Service Manual details diagnostic testing and overhaul steps for both standard gear pumps (producing 64.7 L/min main flow and 49.2 L/min charge flow at high engine idle) and optional high-flow auxiliary pumps yielding an added 36.4 L/min for high-demand industrial attachments.
Preventive Maintenance, Safety Systems & Mechanical Servicing
Routine maintenance schedules in the manual establish strict 10-hour, 50-hour, 100-hour, 250-hour, 500-hour, 1,000-hour, and 1,500-hour operating intervals to protect critical mechanical components from premature failure. Illustrated procedures explain proper servicing of the dual-element air cleaner system, fuel water separation, and fuel system bleeding using the hand priming bulb for both ASTM D975 Grade 2-D/1-D ultra-low sulfur diesel and approved B5/B7 biodiesel blends. Detailed cooling system maintenance covers propylene glycol coolant testing with a refractometer, high-pressure core cleaning, and proper expansion tank level monitoring. Technicians will find complete instructions for servicing the Bobcat Interlock Control System (BICS™), testing cab door interlock sensors, calibrating traction locks, maintaining the ROPS/FOPS operator cab enclosure, and utilizing the MEL1563 or 7217666 Remote Start Tool kits for safe out-of-cab diagnostics when adjusting steering linkages or verifying charge pressure.
Professional Shop Capability & Instant Digital Access
Owning the complete Bobcat S550 Skid-Steer Loader Service Manual (S/N AHGM11001 & Above, B3GY11001 & Above) gives equipment owners, independent repair shops, and fleet mechanics the capability to handle everything from routine filter and oil changes to complete engine overhauls, hydrostatic pump calibration, and electrical harness tracing. Having access to genuine factory procedures ensures repairs are completed right the first time, preventing expensive guesswork, damaged replacement parts, and prolonged machine downtime. With exact torque settings, hydraulic schematics, and factory diagnostic trees at your fingertips, you can maintain machine safety, operational efficiency, and resale value throughout the working life of your loader. Delivered immediately as a downloadable digital PDF file after checkout, this manual requires no waiting for postal delivery and incurs no shipping fees. The file is fully compatible across desktop computers, laptops, tablets, and smartphones running Windows, macOS, Android, and iOS, allowing you to view detailed diagrams directly in the field or print specific procedural pages and exploded views to take straight to the service bay.
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