Bobcat 453 Skid-Steer Loader Repair Service Manual - 6900363

(S/N: 515011001 & Above - S/N: 515111001 & Above) 
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This workshop repair service manual PDF download for the 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 453 
S/N: 515011001 & Above
S/N: 515111001 & 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 
SYSTEMS ANALYSIS 
SPECIFICATIONS 
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6900363 (5–97)
Total Pages : 294


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
    
PREVENTIVE MAINTENANCE
    SERVICE SCHEDULE
    LIFTING AND BLOCKING THE LOADER
        Procedure
    TRANSPORTING THE LOADER
        Procedure
    TOWING THE LOADER
        Procedure
    LIFT ARM SUPPORT DEVICE
        Engaging The Lift Arm Support Device
        Disengaging The Lift Arm Support Device
    OPERATOR CAB
        Description
        Raising The Operator Cab
        Lowering The Operator Cab
        Emergency Exit
    SEAT BAR RESTRAINT SYSTEM
        Description
        Inspectng The Seat Bar
        Maintaining The Seat Bar
    AIR CLEANER SERVICE
        Replacing Filter Element
    FUEL SYSTEM
        Fuel Specifications
        Filling The Fuel Tank
        Fuel Filter
        Removing Air From The Fuel System
    ENGINE LUBRICATION SYSTEM
        Checking Engine Oil
        Oil Chart
        Replacing Oil and Filter 
    ENGINE COOLING SYSTEM
        Checking The Coolant Level
        Cleaning The Cooling System
        Replacing the Coolant
    ALTERNATOR BELT
        Adjusting The Alternator Belt
    HYDRAULIC/HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Hydraulic/Hydrostatic Filter Replacement
        Replacing The Hydraulic/Hydrostatic Fluid
    SPARK ARRESTOR MUFFLER
        Cleaning Procedure
    TIRE MAINTENANCE
        Wheel Nuts
        Tire Rotation
        Tire Inflation
    FINAL DRIVE TRANSMISSION (CHAINCASE)
        Checking And Adding Oil
    AUXILIARY CONTROL LOCKBOLT
    LUBRICATING THE LOADER
        Procedure
    PIVOT PINS
    BOB–TACH
        Inspection And Maintenance
    REMOTE START SWITCH
        Procedure
        
HYDRAULIC SYSTEM
    HYDRAULIC SYSTEM INFORMATION
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    TROUBLESHOOTING
        Chart
    LIFT CYLINDER(S)
        Checking The Lift Cylinders
        Removal And Installation
    TILT CYLINDER
        Checking The Tilt Cylinder
        Removal And Installation
    HYDRAULIC CYLINDERS
        Lift Cylinder Parts Identification
        Tilt Cylinder Parts Identification
        Disassembly And Assembly
    BICS™ BLOCK VALVE
        Removal And Installation
        Disassembly And Assembly
    MAIN RELIEF VALVE
        Checking The Main Relief Valve
        Checking The Main Relief Valve With Auxiliaries
        Removal And Installation
        Main Relief Valve Adjustment
    HYDRAULIC CONTROL VALVE
        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
        Parts Identification
        Disassembly And Assembly
    HYDRAULIC RESERVOIR
        Removal And Installation
    HYDRAULIC FILTER BLOCK
        Removal And Installation
        Block Disassembly And Assembly
    PEDAL INTERLOCK LINKAGE
        Removal And Installation
    CONTROL PEDALS
        Removal and Installation
        Pedal Adjustment
        
HYDROSTATIC SYSTEM
    TROUBLESHOOTING
        Chart
    HYDROSTATIC SYSTEM INFORMATION
        Replenishing Valve Function
    CONTROL SHIELD 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
    HYDROSTATIC MOTOR
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection
        Assembly
    DRIVE BELT
        Removal And Installation
    CHARGE PRESSURE
        Checking
    HYDROSTATIC PUMP
        Parts Identification
        Removal And Installation
        Disassembly And Assembly
        Inspection
    TENSION PULLEY AND SPRING
        Removal And Installation
        
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 CHAIN
    Removal And Installation
    
MAIN FRAME
    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
    BATTERY
        Removal And Installation
        Servicing The Electrical System
        Using A Booster Battery (Jump Starting)
    ALTERNATOR
        Removal And Installation
        Adjusting The Alternator Belt
        Alternator Belt Removal And Installation
        Description
        Tests
        Alternator Output Test
        Full Field Test
        Alternator Regulator Test
        Alternator Regulator Test With Voltmeter
    STARTER
        Removal And Installation
        Checking The Starter In The Loader
        Parts Identification
        Disassembly
        Inspection And Repair
        No Load Test
        Assembly
    INSTRUMENT PANEL
        Removal And Installation
    FRONT LIGHTS (OPTIONAL)
        Removal And Installation
    REAR LIGHT (OPTIONAL)
        Removal And Installation
        
ENGINE SERVICE
    TROUBLESHOOTING
        Chart
    ENGINE SPEED CONTROL
        Adjustment
        Removal And Installation
    RADIATOR
        Removal And Installation
    RADIATOR MOUNTING BRACKET
        Removal And Installation
    FAN
        Removal And Installation
    FLYWHEEL
        Removal And Installation
    ENGINE MOUNTING BRACKET
        Removal And Installation
    VALVE CLEARANCE
        Ajustment
    FUEL INJECTION PUMP
        Checking The Injection Pump
        Removal
        Installation
        Timing Procedure
    FUEL INJECTOR NOZZLES
        Checking
        Removal
        Installation
    GLOW PLUGS
        Checking
    ENGINE COMPRESSION TEST
        Procedure
    ENGINE
        Removal And Installation
    CYLINDER HEAD
        Removal And Installation
        Inspection
        Top Clearance
    ROCKER ARM AND SHAFT
        Checking
    VALVE AND VALVE SPRINGS
        Valve Removal
        Checking Valve Spring
    VALVE GUIDE, VALVE AND VALVE SEAT
        Checking The Valve Guide
        Reconditioning The Valve And Valve Seat
    TIMING GEARCASE COVER
        Removal And Installation
    IDLER GEAR AND CAMSHAFT
        Removal And Installation
        Servicing The Idler Gear And Shaft
    TIMING GEARS
        Checking Backlash
    FUEL CAMSHAFT
        Removal And Installation
        Governor
    CRANKSHAFT GEAR
        Removal And Installation
    OIL PUMP
        Removal And Installation
        Oil Pump Service
        Checking Engine Oil Pressure
        Relief Valve
    PISTON AND CONNECTING ROD
        Removal And Installation
        Servicing The Piston And Connecting Rod
        Connecting Rod Alignment
    CRANKSHAFT AND BEARINGS
        Removal And Installation
        Inspection Of Crankshaft And Bearings
    CYLINDER  BORE
        Inspection
    HYDRAULIC OIL COOLER AND SHROUDING
        Removal And Installation
    THERMOSTAT
        Removal And Installation
    WATER PUMP
        Removal And Installation
        Disassembly And Assembly
        
SYSTEMS ANALYSIS
    BICS™ (With Press To Operate Button)
        Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
        Inspecting The Seat Bar Sensor (Engine RUNNING)
        Inspecting The Traction Lock (Engine RUNNING)
        Inspecting The Lift Arm By–Pass Control
        Troubleshooting Chart
        Inspecting The BICSTM 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
    BICS™ SYSTEM CONTROLLER
        Troubleshooting Guide
        Removal And Installation
    SEAT BAR SENSOR
        Troubleshooting Guide
        Seat Bar Sensor Test
        Removal And Installation
        BICS™ Controller Seat Bar Sensor Circuit Test
    SEAT SENSOR
        Troubleshooting Guide
        Seat Sensor Test
        Removal And Installation
        BICS™ Controller Seat Sensor Circuit Test
    TRACTION LOCK
        Troubleshooting Guide
        Removal And Installation
        
SPECIFICATIONS
    SKID STEER LOADER SPECIFICATIONS
        PERFORMANCE
        CONTROLS
        ENGINE
        HYDRAULIC SYSTEM
        ELECTRICAL
        DRIVE SYSTEM
        CAPACITIES
        TIRES
        FLOOR PRESSURE
    ENGINE SPECIFICATIONS
        Engine
        Fuel Injector Nozzles
        Fuel Injection Pump
        Cylinder Head
        Valves
        Valve Springs
        Rocker Arms
        Camshaft
        Cylinders
        Piston Rings
        Pistons
        Crankshaft
        Oil Pump
        Thermostat
        ENGINE BOLT TORQUE
        Re–Grinding The Crankshaft
    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
    
SERVICE MANUAL REVISIONS
    453-1
    453-2
    453-3
    453-4
    
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