Bobcat 553 Skid-Steer Loader Repair Service Manual - 6900450

(S/N: 516311001 & Above - S/N: 516411001 & 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: 516311001 & Above
S/N: 516411001 & 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 
SYSTEM ANALYSIS 
SPECIFICATIONS 
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6900450 (1–98)
Total Pages : 366


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
    TOWING THE LOADER
        Procedure
    STOPPING THE BOBCAT LOADER
    LIFT ARM SUPPORT DEVICE
        Engaging The Lift Arm Support Device
        Disengaging The Lift Arm Support Device
    OPERATOR CAB
        Raising The Operator Cab
        Lowering The Operator Cab
        Emergency Exit
    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
        Oil Chart
        Replacing Oil And Filter
    ENGINE COOLING SYSTEM
        Cleaning The Cooling System
        Replacing The Coolant
    ALTERNATOR BELT
        Adjusting The Alternator Belt
    HYDRAULIC/HYDROSTATIC SYSTEM
        Description
        Checking And Adding Fluid
        Replacing The Hydraulic/Hydrostatic Filter
        Replacing Hydraulic Fluid
    SPARK ARRESTOR MUFFLER
        Cleaning Procedure
    TIRE MAINTENANCE
        Wheel Nuts
        Tire Rotation
        Tire Mounting
    FINAL DRIVE TRANSMISSION (CHAINCASE)
        Checking And Adding Oil
    LUBRICATING THE BOBCAT LOADER
        Procedure
    PIVOT PINS
    BOB–TACH
        Inspection And Maintenance
    AUXILIARY CONTROL LOCKBOLT
        Removal
    U–JOINT LUBRICATION
        Procedure
    REMOTE START SWITCH
        Procedure
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    GLOSSARY OF HYDRAULIC / HYDROSTATIC SYMBOLS 
    TROUBLESHOOTING
    HYDRAULIC SYSTEM INFORMATION
        Tighten Procedures
    LIFT CYLINDERS
        Checking The Lift Cylinder(s)
        Removal And Installation
    TILT CYLINDER
        Checking The Tilt Cylinder
        Removal And Installation
    HYDRAULIC CYLINDER
        Lift Cylinder Identification
        Tilt Cylinder Identification
        Disassembly And Assembly
    MAIN RELIEF VALVE
        Checking The Main Relief Valve Without Auxiliaries
        Checking The Main Relief Valve With Auxiliaries
        Removal And Installation
        Adjustment
    HYDRAULIC CONTROL VALVE
        Removal And Installation
        Identification Chart
        Disassembly and Assembly
        Load Check Valve
        Main Relief Valve
        Anti–Cavitation Check Valve
        Rubber Boot
        Lift Spool Detent
        Tilt Centering Spring
        One Way Restrictors
        Inspection
        Spool Seal Installation
    HYDRAULIC PUMP
        Checking The Output Of The Hydraulic Pump
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        Inspection
    HYDRAULIC FLUID RESERVOIR
        Removal And Installation
    LIFT LOCK BY–PASS VALVE
        Removal And Installation
        Disassembly and Assembly
    TILT LOCK VALVE
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC FILTER HOUSING
        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
    HYDROSTATIC MOTOR
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        Inspection
        Timing The Hydrostatic Motor
    HYDROSTATIC 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 By–Pass Valve
        Hydraulic Oil Temperature Switch
        Charge Pressure By–Pass Valve
    OIL COOLER
        Removal and Installation
        
DRIVE SYSTEM
    PARKING BRAKE
        Removal And Installation
        Disassembly And Assembly
    PARKING BRAKE DISC
        Removal and Installation
    TRACTION LOCK GUIDES
        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
        Assembling Components
        Compression Spring Disassembly And Assembly
    OPERATOR CAB GAS CYLINDER
        Removal And Installation
        Disassembly And Assembly
    OPERATOR CAB
        Removal And Installation
    OPERATOR SEAT
        Removal And Installation
    REAR DOOR
        Removal And Installation
        Door Latch Adjustment
        Striker Removal And Installation (S/N 516313551 & Above) & (S/N 516415035 & Above)
        Striker Disassembly And Assembly (S/N 516313551 & Above) & (S/N 516415035 & Above)
        Adjusting The Striker (S/N 516313551 & Above) & (S/N 516415035 & Above) 
        Latch Removal And Installation (S/N 516313551 & Above) & (S/N 516415035 & Above)
    FUEL TANK
        Removal And Installation
        Fuel Level Sender
    BOB–TACH
        Removal And Installation
        Bob–Tach Lever And Wedge
    LIFT ARMS
        Removal and Installation
    REAR GRILL
        Removal And Installation
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    TROUBLESHOOTING
    ELECTRICAL SYSTEM INFORMATION
        Description
        Fuse Location
        Relay Switches Location
    BATTERY
        Removal And Installation
    USING A BOOSTER BATTERY (JUMP STARTING)
        Procedure
    ALTERNATOR
        Removal And Installation
        Adjusting The Alternator Belt
        Description
        Tests
        Alternator Output Test
        Full Field Test
        Alternator Regulator Test
        Alternator Regulator Test With Voltmeter
        Parts Identification
        Pulley Removal And Installation
        Disassembly And Assembly
        Rotor Continuity Test
        Stator Continuity Test
        Rectifier Continuity (Diode) Test
        Brush Length
    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
        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
    ENGINE 
        Removal And Installation
    U–JOINT COUPLER
        Removal And Installation
        Disassembly and Assembly
    RUBBER DRIVE COUPLER
        Removal And Installation
        Disassembly
        Assembly
    FLYWHEEL 
        Removal And Installation
    FLYWHEEL HOUSING
        Flywheel Ring Gear
        Removal And Installation
    ENGINE MOUNTING BRACKETS
        Removal and Installation
    BLOWER FAN HOUSING
        Removal And Installation
    ENGINE COMPRESSION
        Checking
    GLOW PLUGS
        Checking
        Removal And Installation
    FUEL SHUT–OFF SOLENOID
        Removal And Installation
    FUEL LIFT PUMP
        Removal And Installation
    FUEL INJECTION PUMP
        Checking The Injection Pump
        Removal And Installation
        Timing The Injection Pump
    FUEL INJECTOR NOZZLES
        Removal and Installation
        Checking Fuel Injector Nozzles
    THERMOSTAT
        Removal And Installation
    WATER PUMP
        Removal And Installation
    TIMING GEAR CASE COVER
        Removal And Installation
    OIL PUMP
        Removal And Installation
    CRANKSHAFT FRONT SEAL
        Removal And Installation
    ENGINE SPEED CONTROL PLATE
        Removal And Installation
        Governor Spring Removal
        Start Spring Removal
        Idle Limit And Fuel Limit Adjustment
    EXHAUST MANIFOLD
        Removal And Installation
    VALVE COVER
        Removal And Installation
    ROCKER ARM
        Removal And Installation
    PUSH ROD
        Removal And Installation
    TAPPET
        Removal And Installation
    WATER FLANGE
        Removal And Installation
    CYLINDER HEAD
        Removal
        Installation
        Checking Piston Top Clearance
        Disassembly
        Assembly
        Servicing The Cylinder Head
        Combustion Chamber Removal And Installation
    IDLER GEAR
        Removal And Installation
    CAMSHAFT
        Removal And Installation
    FUEL CAMSHAFT
        Removal And Installation
    OIL PAN
        Removal And Installation
    GOVERNOR SHAFT
        Removal And Installation
    GOVERNOR FORK LEVER
        Removal And Installation
    PISTON
        Removal And Installation
        Checking The Piston And Connecting Rod
        Connecting Rod Alignment
        Piston Ring Gap
        Piston Ring Installation
        Connecting Rod Installation
        Checking Engine Cylinder Bore
    CRANKSHAFT
        Removal And Installation
        Checking Crankshaft Journal And Block Bearing
        Checking The Crankshaft Journal And Main Bearing
        Connecting Rod Journal
        Checking The End Play Of The Crankshaft
        Crankshaft Alignment
    ENGINE TIMING
        Installation
    TIMING GEAR BACKLASH
        Idler Gear And Crankshaft
        Idler Gear And Camshaft Gear
        Idler Gear And Fuel Camshaft Gear
        Fuel Camshaft Gear And Governor Shaft Gear
        
SYSTEMS ANALYSIS
    BICS™ – BOBCAT INTERLOCK CONTROL SYSTEM
        BICS™ (With Press To Operate Button)
            Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
            Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
            nspecting The Seat Bar Sensor (Engine RUNNING)
            Inspecting The Traction Lock (Engine RUNNING)
            Inspecting The Lift Arm By–Pass Control
            Additional Inspection For Loaders With Advanced Hand Controls
            Troubleshooting Chart
        BICS™ (Without Press To Operate Button)
            Inspecting The BICS Controller (Engine STOPPED –Key ON)
            Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED–Key ON)
            Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
            nspecting The Traction Lock (Engine RUNNING)
            Inspecting The Lift Arm By–Pass Control
            Maintenance
            Troubleshooting 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
    LOADER SPECIFICATIONS
        Loader Dimensions
        Performance
        Controls
        Engine
        Hydraulic System
        Electrical
        Drive System
        Capacities
        Tires
    ENGINE SPECIFICATIONS
        Engine Compression
        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
    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
        
SERVICE MANUAL REVISIONS
    553-1
    553-2
    553-3
    
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