Bobcat 450, 453 Skid-Steer Loader Repair Service Manual - 6724259

450 (S/N: 561711001 & Above) - 453 (S/N: 561811001 & Above) 
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This workshop repair service manual PDF download for the 450, 453 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Loader 450, 453 
450 (S/N: 561711001 & Above)
453 (S/N: 561811001 & Above)


TABLE OF CONTENTS :

FOREWORD 
SAFETY INSTRUCTIONS 
SERIAL NUMBER LOCATIONS 
DELIVERY REPORT 
BOBCAT LOADER IDENTIFICATION 
PREVENTIVE MAINTENANCE 
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
MAIN FRAME 
ELECTRICAL SYSTEM 
ENGINE SERVICE 
BICS™ SYSTEM 
SPECIFICATIONS 
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6724259 (1–96)
Total Pages : 350


This Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
    SERIAL NUMBER LOCATIONS
    LOADER SERIAL NUMBER
    ENGINE SERIAL NUMBER
    DELIVERY REPORT
    BOBCAT SKID STEER LOADER IDENTIFICATION
    OPTIONS AND ACCESSORIES
    
PREVENTIVE MAINTENANCE
    SERVICE SCHEDULE
    LIFTING AND BLOCKING THE LOADER
        Procedure
    TRANSPORTING THE LOADER
        Procedure
    LIFTING THE LOADER
        Single Point Lift
    TOWING THE LOADER
    LIFT ARM SUPPORT DEVICE
        Engaging The Lift Arm Support Device
        Disengaging The Lift Arm Support Device
    OPERATOR CAB
        Description
        Emergency Exit
        Raising The Operator Cab
        Lowering The Operator Cab
    SEAT BAR RESTRAINT SYSTEM
        Seat Bar Inspection
        Seat Bar Maintenance
        Foot Pedal Clean Out
    AIR CLEANER SERVICE
        450 Loader
        453 Loader
    FUEL SYSTEM
        450 Loader
            Fuel Specifications
            Filling The Fuel Tank
            Fuel Filter
        453 Loader
            Fuel Specifications
            Filling the Fuel Tank
            Fuel Filter
            Removing Air From The Fuel System
    ENGINE LUBRICATION SYSTEM
        450 Loader
            Replacing Oil And Filter
        453 Loader
            Replacing Oil And Filter
    ENGINE COOLING SYSTEM
        450 Loader
            Cleaning The Cooling System
        453 Loader
            Checking The Coolant Level
            Cleaning The Cooling System
            Removing Coolant From The Cooling System
    ALTERNATOR BELT ADJUSTMENT (453)
    ELECTRICAL SYSTEM
        Description
    PIVOT PINS
    SPARK ARRESTOR MUFFLER
        Cleaning The Spark Arrestor Muffler
    HYDRAULIC/HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Replacing The Hydraulic/Hydrostatic Filter Element
        Removing The Hydraulic/Hydrostatic Fluid
    FINAL DRIVE TRANSMISSION (CHAINCASE)
        Checking And Adding Oil
    AUXILIARY CONTROL LOCKBOLT
    TIRE MAINTENANCE
        Wheel Nuts
        Tire Rotation
        Tire Inflation
    LUBRICATING THE LOADER
    BOB–TACH
    REMOTE START SWITCH
        Procedure
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    TROUBLESHOOTING
    HYDRAULIC SYSTEM INFORMATION
        Tighten Procedures
    LIFT CYLINDER(S)
        Removal and Installation
        Checking The Lift Cylinder For Internal Leakage
    TILT CYLINDER
        Removal And Installation
        Checking The Tilt Cylinder For Internal Leakage
    HYDRAULIC CYLINDERS
        Disassembly And Assembly
        Lift Cylinder Identification
    LIFT ARM BY–PASS BLOCK
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC CONTROL VALVE
        Checking The Main Relief Valve
        Main Relief Valve Removal And Installation
        Main Relief Valve Adjustment
        Removal And Installation
        Identification Chart
        Disassembly And Assembly
        Load Check Valve
        Main Relief Valve
        Anti–Cavitation Valve
        Rubber Boot
        Lift Spool Detent
        Tilt Centering Spring
        Auxiliary Spool Detent
        Spool Seal Installation
    HYDRAULIC PUMP
        Checking The Output Of The Hydraulic Pump
        Removal And Installation
        Disassembly And Assembly
        Parts Identification
    HYDRAULIC RESERVOIR
        Removal And Installation
    HYDRAULIC FILTER BLOCK
        Removal And Installation
        Disassembly And Assembly
            450 Filter Block
            453 Filter Block
    PEDAL INTERLOCK LINKAGE
        Removal And Installation
    CONTROL PEDALS
        Removal And Installation
        Pedal Adjustment
        
HYDROSTATIC SYSTEM
    TROUBLESHOOTING
    HYDROSTATIC SYSTEM INFORMATION
        Replenishing Valve Function
    CONTROL SHIELD AND STEERING LEVER PANELS
        Removal And Installation
    STEERING LEVERS AND STEERING LEVER PANELS 
        Removal And Installation
    STEERING LEVERS
        Removal And Installation
        Disassembly And Assembly
    STEERING LINKAGE
        Adjustment
        Pintle Arm Removal And Installation
        Pintle Arm Disassembly And Assembly
    DRIVE BELT
        Removal And Installation
            450 Loader
            453 Loader
    HYDR0STATIC PUMP
        Checking Charge Pressure
        Removal And Installation
            450 Loader
            453 Loader
        Parts Identification
        Disassembly And Assembly
        Inspection
    TENSION PULLEY AND SPRING
    Removal And Installation
    HYDROSTATIC MOTOR
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
        
DRIVE SYSTEM
    PARKING BRAKE PEDAL
        Removal And Installation
        Disassembly And Assembly
    CHAINCASE FLUID
        Removing Oil From The Chaincase
    CHAINCASE COVER
        Removal And Installation
        Disassembly And Assembly
    PARKING BRAKE DISC
        Removal And Installation
    AXLE HUB
        Removal And Installation
    AXLE SEAL
        Removal And Installation
    AXLE, BEARINGS, AND SPROCKET
        Removing The Axle
        Removing And Installing The Axle Bearing
        Removing The Bearing Races
        Installing The Bearing Races
        Installing The Inner Bearing And Axle Sprocket
    DRIVE CHAINS
        Removal And Installation
        
MAIN FRAME
    SEAT BAR
        Gas Spring Removal And Installation
        Compressing The Gas Spring
        Seat Bar Removal And Installation
        Assembly
    OPERATOR CAB
        Removal And Installation
    OPERATOR CAB GAS CYLINDER
        Removal And Installation
    OPERATOR SEAT
        Removal And Installation
    BOB–TACH
        Removal
        Installation
        Seal Removal And Installation
        Lever And Wedge Removal
        Lever And Wedge Installation
    LIFT ARMS
        Removal And Installation
    FUEL TANK
        Removal And Installation
    REAR WINDOW
        Removal And Installation
    REAR DOOR
        Exhaust Pipe Removal And Installation
        Removal And Installation
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    TROUBLESHOOTING
        Chart
    ELECTRICAL SYSTEM INFORMATION
        Description
        Fuse Location
        Relay Switches Location - 453 Only
    BATTERY
        Removal And Installation
        Maintenance
    ALTERNATOR (450)
        Checking The Alternator Circuit (450)
        Replacing The Stator
    ALTERNATOR (453)
        Removal And Installation
        Adjusting The Alternator Belt
        Alternator Output Test
        Alternator Regulator Test
        Disassembly and Inspection – Parts Identification
        Stator Continuity Test
        Stator Ground Test
        Rotor Continuity Test
        Rotor Ground Test
        Rectifier Continuity (Diode) Test
        Assembly
    STARTER (453)
        Removal And Installation
        Checking The Starter
        Parts Identification
        Disassembly, Assembly And Inspection
    STARTER (450)
        Checking The Starter
        Removal And Installation
        Disassembly, Assembly And Inspection
    INSTRUMENT PANEL
        Removal And Installation
    FRONT LIGHTS (OPTIONAL)
        Removal And Installation
    REAR LIGHT (OPTIONAL)
        Removal And Installation
        
ENGINE SERVICE
    ENGINE SERVICE (450)
        TROUBLESHOOTING
        IGNITION SYSTEM
            Spark Plugs
            Ignition Module Air Gap
            Testing Ignition Module Primary
            Testing Ignition Module Secondary
            Valve & Tappet Clearance
            Compression Test
        CARBURETOR AND GOVERNOR
            Carburetor Adjustment On The Engine
            Main Fuel Adjustment 
            Idle Fuel Adjustment
            Idle Speed Setting
            Shutdown Control Solenoid
            Governor And Adjustment
            Disassembly And Assembly
        ENGINE
            Removal And Installation
            Muffler Removal And Installation
            Intake Manifold Removal And Installation
            Breather and Valve Cover Removal And Installation
            Fuel Pump Removal And Installation
        ENGINE DISASSEMBLY
            Flywheel Removal And Installation
            Stator Removal and Installation
            Cylinder Head Removal
            Cylinder Barrel Removal
            Cylinder Barrel Inspection And Resizing
            Valve Removal And Installation
            Valve Guide Removal And Installation
            Valve Seat Insert Removal
            Valve Seat Insert Installation
            Valve Details
            Piston And Piston Rings
            Closure Plate
            Crankcase Halves
            Camshaft Removal
            Crankshaft Removal
            Connecting Rod Removal
            Governor Gear And Cross Shaft Removal
            Oil Pickup Removal
            OIl Pump Removal
        ENGINE ASSEMBLY
            Oil Pump Installation
            Cross Shaft And Governor Shaft Installation
            Connecting Rod Installation
            Crankshaft And Bearing Installation
            Tappets And Camshaft Installation
            Sealing The Crankcase
            Recommended Sealants
            Installing Camshaft Bore Plug
            Installing Crankcase Halves
            Front And Rear Seal Installation
            Filter Adapter Installation
            Installing Oil Pressure Relief Valve And Closure Plate
            Piston Installation
            Setting Valve To Tappet Clearance
            Cylinder Head Installation
    ENGINE SERVICE 453 (KUBOTA)
        TROUBLESHOOTING
        FUEL SYSTEM
            Replacing The Fuel Filter
            Removing The Air From The Fuel System
            Fuel Injection Pump
            Checking The Injection Pump
            Removing The Injection Pump
            Installing The Injection Pump
            Timing The Injection Pump
            Fuel Injector Nozzles
            Removing The Fuel Injector Nozzle
            Checking Fuel Injector Nozzles
            Installing The Fuel Injector Nozzle
            Checking Glow Plugs
            Engine Compression Test
        OIL COOLER & SHROUDING
            Removal And Installation
        RADIATOR
            Removal And Installation
        ENGINE SPEED CONTROL
            Adjustment
            Removal And Installation
        ENGINE
            Removal And Installation
        FLYWHEEL
            Removal And Installation
        FAN
            Removal And Installation
        CYLINDER HEAD
            Removing The Cylinder Head
            Disassembly Of The Cylinder Head
            Servicing The Cylinder Head
            Assembly Of The Cylinder Head
            Installing The Cylinder Head
        REPAIRING THE ENGINE
            Removing The Gearcase
            Removing The Timing Gear, Camshaft & Oil Pump
            Removing Pistons & Crankshaft
            Servicing The Timing Gear And Camshaft
            Servicing The Connecting Rods And Pistons
            Servicing The Crankshaft
            Servicing The Cylinder Liners
            Servicing The Oil Pump
            Servicing The Water Pump
        ASSEMBLY OF THE ENGINE
            Installing The Crankshaft
            Installing The Pistons
            Installing The Camshaft And Timing Gears
            Installing The Gearcase Cover
            
SYSTEMS ANALYSIS
    BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM)
        Inspecting The BICS™ System Controller (Engine STOPPED – Key ON)
        Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
        Inspecting The Traction Lock (Engine Running)
        Inspecting The Lift Arm By–Pass Control
        Maintenance
        Troubleshoot Chart
        Troubleshooting Guide
            BICS CONTROLLER
            TRACTION LOCK
            SEAT SENSOR
            SEAT BAR SENSOR
            LIFT LOCK BYPASS VALVE
    BICS™ SYSTEM CONTROLLER
        Removal And Installation
        Controller Test
    SEAT BAR SENSOR
        Removal And Installation
        Seat Bar Sensor Test
    SEAT SENSOR
        Removal And Installation
        Seat Sensor Test
    TRACTION LOCK
        Removal And Installation
    LIFT ARM BY–PASS BLOCK
        Removal And Installation
    LIFT AND TILT LOCK BY–PASS VALVE
        Disassembly And Assembly
        
SPECIFICATIONS
    450 LOADER SPECIFICATIONS 
        PERFORMANCE
        CONTROLS
        ENGINE
        HYDRAULIC SYSTEM
        ELECTRICAL
        DRIVE SYSTEM
        CAPACITIES
        TIRES
    ENGINE SPECIFICATIONS – 450 (KOHLER)
        Engine (General)
        Cylinder Bore
        Crankshaft
        Camshaft
        Connecting Rod
        Piston, Pin & Rings
        Valves, Guides & Tappet
        Oil Pump
        Engine Torque
    453 LOADER SPECIFICATIONS
        PERFORMANCE
        CONTROLS
        ENGINE
        HYDRAULIC SYSTEM
        ELECTRICAL
        DRIVE SYSTEM
        CAPACITIES
        TIRES
    ENGINE SPECIFICATIONS – 453 (KUBOTA)
        Fuel Injector Nozzles
        Fuel Injection Pump
        Cylinder Head
        Valves
        Valve Springs
        Rocker Arms
        Camshaft
        Cylinders
        Piston Rings
        Pistons
        Crankshaft
        Oil Pump
        Thermostat
        Crankshaft Re–Grind Data
        Engine Torque
    TORQUE SPECIFICATIONS FOR BOLTS
        Torque For General SAE Bolts
        Torque For General Metric Bolts
    HYDRAULIC CONNECTION SPECIFICATIONS
        O–ring Face Seal Connection
        Straight Thread O–ring Fitting
        Tubelines And Hoses
        Flare Fitting
        O–ring Flare Fitting
        Port Seal Fitting
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
        Specifications
    DECIMAL AND MILLIMETER EQUIVALENTS
    U.S. TO METRIC CONVERSION
    GLOSSARY OF HYDRAULIC SYMBOLS
    
SERVICE MANUAL REVISIONS
    450/453-1
    450/453-2
    450/453-3
    450/453-4
    450/453-5
    
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