Bobcat 553 Skid-Steer Loader Repair Service Manual - 6724024

(S/N: 513011001 & Above - S/N: 513031001 & Above) 
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This workshop repair service manual PDF download for the 553 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 553 
S/N: 513011001 & Above
S/N: 513031001 & Above - Europe Only


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™/BOSS® SYSTEM 
SPECIFICATIONS 
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6724024 (11–95)
Total Pages : 296


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
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
    SERIAL NUMBER LOCATIONS
    LOADER SERIAL NUMBER
    ENGINE SERIAL NUMBER
    DELIVERY REPORT
    553 BOBCAT 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
        Procedure
    STOPPING THE BOBCAT LOADER
    LIFT ARM SUPPORT DEVICE
        Installing And Removing Lift Arm Support Device
    OPERATOR CAB
        Description
        Emergency Exit
        Raising The Operator Cab
        Lowering The Operator Cab
    SEAT BAR RESTRAINT SYSTEM
        Description
        Seat Bar Inspection
        Seat Bar Maintenance
    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
        Replacing Oil And Filter 
    ENGINE COOLING SYSTEM
        Checking The Coolant Level
        Propylene Glycol
        Cleaning The Cooling System
        Removing Coolant From The Cooling System
    ALTERNATOR BELT
        Adjusting The Alternator Belt
    USING A BOOSTER BATTERY (Jump Starting)
        Procedure
    HYDRAULIC/HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Replacing Hydraulic/Hydrostatic Filter
        Replacing The Hydraulic Fluid
    SPARK ARRESTOR MUFFLER
        Cleaning Procedure
    TIRE MAINTENANCE
        Wheel Nuts
        Tire Rotation
        Tire Mounting
    FINAL DRIVE TRANSMISSION (CHAINCASE)
        Checking And Adding Oil
        Removing Oil From The Chaincase
    LUBRICATION OF THE LOADER
        Procedure
    REMOTE START SWITCH
        Procedure
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    TROUBLESHOOTING
    HYDRAULIC SYSTEM INFORMATION
        Flare Connections
        O–ring Face Seal Connection
        Straight Thread O–ring Fitting
        Tubelines and Hoses
    LIFT CYLINDER(S)
        Removal and Installation
        Checking The Lift Cylinder(s) For Internal Leakage
    TILT CYLINDER
        Removal And Installation
        Checking The Tilt Cylinder For Internal Leakage
    HYDRAULIC CYLINDER IDENTIFICATION
        Lift Cylinder Components
        Tilt Cylinder Components
    HYDRAULIC CYLINDER
        Disassembly
        Assembly
    HYDRAULIC CONTROL VALVE
        Removal And Installation
        Checking The Main Relief Valve
        Main Relief Valve Removal And Installation
        Main Relief Valve Adjustment
        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
        One Way Restrictors
        Inspection
        Spool Seal Installation
    HYDRAULIC PUMP
        Removal And Installation
        Checking The Output Of The Hydraulic Pump
        Main Relief Valve Adjustment
        Parts Identification
        Disassembly and Assembly
        Inspection
    HYDRAULIC FILTER HOUSING
        Removal And Installation
    HYDRAULIC FLUID RESERVOIR
        Removal And Installation
    CONTROL PEDALS
        Removal And Installation
        Pedal Adjustment
    PEDAL INTERLOCK LINKAGE
        Removal And Installation
        Adjustment
    CROSSMEMBER LINKAGE
        Removal And Installation
        
HYDROSTATIC SYSTEM
    TROUBLESHOOTING
    HYDROSTATIC SYSTEM INFORMATION
        Replenishing Valve Function
    CONTROL PANEL
        Removal And Installation
    STEERING LEVERS
        Removal And Installation
        Disassembly And Assembly
    STEERING LINKAGE
        Removal And Installation
        Pintle Lever Disassembly And Assembly
        Steering Neutral Adjustment
    HYDR0STATIC PUMP
        Checking Charge Pressure
        Removal And Installation
        Drive Coupler Removal And Installation
        Parts Identification
        Disassembly and Assembly
        Inspection
    PORT BLOCK
        Removal And Installation
        Oil Cooler Bypass Valve
        Hydraulic Oil Temperature Switch
        Charge Pressure Bypass Valve
    HYDROSTATIC DRIVE MOTOR
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        Inspection
        Timing The Hydrostatic Motor
        
DRIVE SYSTEM
    PARKING BRAKE
        Removal And Installation
        Disassembly And Assembly
    PARKING BRAKE DISC
        Removal And Installation
        Brake Disc Guide Removal And Installation
    CHAINCASE FLUID
        Removing Oil From The Chaincase
    CHAINCASE COVERS
        Front Cover Removal And Installation
        Rear Cover Removal And Installation
    AXLE SEAL
        Removal And Installation
    AXLE, BEARINGS, AND SPROCKET
        Removal And Installation
    DRIVE CHAIN
        Removal
        
MAIN FRAME
    SEAT BAR
        Removal And Installation
        Assembly
        Compressing The Gas Cylinder
    OPERATOR CAB GAS CYLINDER
        Removal And Installation
        Disassembly And Assembly
    OPERATOR CAB
        Removal And Installation
    OPERATOR SEAT
        Removal And Installation
    BOB–TACH
        Removal And Installation
        Bob–Tach Lever And Wedge
    LIFT ARMS
        Removal And Installation
    REAR GRILL
        Removal And Installation
    FUEL TANK
        Removal And Installation
        Fuel Level Sender
    REAR DOOR
        Removal And Installation
        Door Handle Adjustment
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    TROUBLESHOOTING
    ELECTRICAL SYSTEM INFORMATION
        Description
        Fuse Location
        Relay Switches Location
        Removing And Installing The Battery
    ALTERNATOR
        Alternator Belt Shield Removal And Installation
        Removal And Installation
        Adjusting The Alternator Belt
        Alternator Output Test
        Rectifier (Diode) 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 
        Removal And Installation
        Checking The Starter
        Disassembly And Assembly
        Parts Identification
        Cleaning And Inspection
        Replacing The Brushes
    INSTRUMENT PANEL
        Removal And Installation
    FRONT LIGHTS
        Removal And Installation
        
ENGINE SERVICE
    TROUBLESHOOTING
    ENGINE SPEED CONTROL
        Removal And Installation
        Disassembly
        Linkage Bar Removal And Installation
    RADIATOR
        Removal And Installation
    ENGINE MUFFLER
        Removal And Installation
    AIR CLEANER
        Removal And Installation
    FUEL FILTER 
        Removal And Installation
    ENGINE 
        Removal And Installation
    U–JOINT COUPLER
        Removal And Installation
        Disassemly And Assembly
    FLYWHEEL 
        Removal And Installation
        Flywheel Ring Gear
    BLOWER FAN HOUSING
        Removal And Installation
    ENGINE COMPRESSION
        Checking
    GLOW PLUGS
        Checking
        Removal And Installation
    FUEL INJECTION PUMP
        Checking The Injection Pump
        Removal And Installation
        Timing The Injection Pump
    FUEL INJECTOR NOZZLES
        Removal
        Installation
        Checking Fuel Injector Nozzles
    CYLINDER HEAD
        Removal
        Installation
        Disassembly
        Assembly
        Servicing The Cylinder Head
    TIMING GEARCASE COVER
        Removal
        Installation
    TIMING GEARS AND CAMSHAFT
        Removal
        Installation
        Servicing The Timing Gear And The Camshaft
    OIL PUMP
        Removal And Installation
        Servicing The Oil Pump
    WATER PUMP
        Removal And Installation
    PISTONS AND CRANKSHAFT
        Piston And Camshaft Removal
        Piston Installation
        Servicing The Pistons And Connecting Rods
        Crankshaft Installation
        Servicing The Crankshaft
        Servicing The Cylinder Liners
        
BICS™ SYSTEM
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
        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
        Troubleshooting 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 LOCK BYPASS VALVE
        Removal And Installation
        Disassembly And Assembly
    TILT LOCK VALVE
        Removal And Installation
        Disassembly And Assembly
        
SPECIFICATIONS
    LOADER SPECIFICATIONS
        LOADER DIMENSIONS
        OPERATIONS & PERFORMANCE
        ENGINE
        HYDRAULIC SYSTEM
        ELECTRICAL
        DRIVE SYSTEM
        CAPACITIES
        TIRES
        VIBRATION DATA
    ENGINE SPECIFICATIONS
        Fuel Injection Nozzles
        Fuel Injection Pump
        Cylinder Head
        Valves
        Valve Springs
        Rocker Arms
        Camshaft
        Cylinders
        Piston Rings
        Pistons
        Crankshaft
        Oil Pump
        Thermostat
        Grinding Specifications for the Crankshaft
    TORQUE SPECIFICATIONS FOR LOADER
        Specifications
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
        Specifications
    METRIC TORQUE SPECIFICATIONS FOR BOLTS
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS
    DECIMAL AND MILLIMETER EQUIVALENTS
    U.S. TO METRIC CONVERSION
    
SERVICE MANUAL REVISIONS
    553-1
    
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