Bobcat 653 Skid-Steer Loader Repair Service Manual - 6724493

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This workshop repair service manual PDF download for the 653 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 653 BICS 


TABLE OF CONTENTS :

PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
SYSTEMS ANALYSIS
SPECIFICATION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6724493 (12-95) Revised (1-97)
Total Pages : 356


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 LOADER IDENTIFICATION
    
PREVENTIVE MAINTENANCE
    SERVICE SCHEDULE
    LIFTING AND BLOCKING THE LOADER
        Procedure
    TRANSPORTING THE LOADER
        Procedure
    TOWING THE LOADER
        Procedure
    STOPPING THE BOBCAT LOADER
    LIFTING THE LOADER
        Four Point Lift
        Single Point Lift
    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
        Raising The Operator Cab (Hand Controls)
        Lowering The Operator Cab (Hand Controls)
        Emergency Exit
    SEAT BAR RESTRAINT SYSTEM
        Description (Foot Controls)
        Seat Bar Inspection (Foot Controls)
        Seat Bar Maintenance (Foot Controls)
        Description (Hand Controls)
        Seat Bar Inspection (Hand Controls)
        Seat Bar Maintenance (Hand Controls)
    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 Engne Oil
        Replacing Oil And Filter
    ENGINE COOLING SYSTEM
        Cleaning The Cooling System
        Checking The Coolant Level
        Removing Coolant From The Cooling System
        Proplylene Glycol
    ALTERNATOR BELT
        Adjusting The Alternator Belt
    BOB-TACH
    FAN GEARBOX
        Checking And Maintaining
    ELECTRICAL SYSTEM
        Using A Booster Battery (Jump Starting)
    HYDRAULIC / HYDROSTATIC SYSTEM
        Replacing Hydraulic Fluid
        Hydraulic Reservoir Breather Cap
    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
    DRIVE BELT
        Adjusting The Drive Belt (Equipped With Fixed Drive Idler)
        Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler
        Drive Belt Replacement
    LUBRICATION OF THE BOBCAT LOADER
        Procedure
    PIVOT PINS
    REMOTE START SWITCH
        Procedure
        
HYDRAULIC SYSTEM
    TROUBLESHOOTING
    HYDRAULIC SYSTEM INFORMATION
        Flare Connections
        O-Ring Face Seal Connection
        Staright Thread O-Ring Fitting
        Tubelines And Hoses
    LIFT CYLINDER(S)
        Checking The Lift Cylinder(s) For Internal Leakage
        Removal And Installation
    TILT CYLINDER
        Checking The Tilt Cylinder For Internal Leakage
        Removal And Installation
        Rod End Seal Replacement
    HYDRAULIC CYLINDER IDENTIFICATION
        Lift Cylinder Components
        Tilt Cylinder Components
    HYDRAULIC CYLINDERS
        Disassembly
        Assembly
    HYDRAULIC CONTROL VALVE
        Removal And Installation
        Checking The Main Relief Valve
        Main Relief Valve Adjustment
        Main Relief Valve Removal And Installation
        Identification Chart
        Disassembly And Assembly
        Load Check Valve
        Main Relief Valve
        Port Relief Valve
        Anti-Cavitation valve
        Rubber Boot
        Lift Spool Detent
        Tilt Centering Spring
        Auxiliary Spool
        Auxiliary Electric Solenoid
        Inspection
        Identification & Installation Of Spool Seal
    HYDRAULIC PUMP
        Removal And Installation
        Checking The Output Of The Hydraulic Pump
        Disassembly And Assembly
        Inspection
        Identification
    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
        
HYDROSTATIC SYSTEM
    TROUBLESHOOTING
    HYDROSTATIC SYSTEM INFORMATION
        Replenishing Valve Function
    CONTROL PANEL
        Removal And Installation
        Steering Shaft Removal And Installation
        Steering Shaft Disassembly And Assembly
        Steering Lever Removal And Installation
        Rubber Boot Replacement
    STEERING LINKAGE
        Removal And Installation
        Steering Linkage Adjustment
        Steering Neutral Adjustment
    HYDROSTATIC DRIVE MOTOR
        Removal And Installation
        Identification
        Disassembly And Assembly
        Inspection
    HYDROSTATIC PUMP
        Removal And Installation
        Identification
        Disassembly And Assembly
        Inspection
        Swashplate Pre-Load
    DRIVE BELT HOUSING
        Removal And Installation
    SPRING LOADED DRIVE IDLER
        Identification
        Disassembly
        Assembly
    DRIVE BELT TENSIONER PULLEY
        Removal And Installation
        Disassembly
        Assembly
        Checking Pulley End Play
    OIL COOLER
        Removal And Installation
        
DRIVE SYSTEM
    PARKING BRAKE
        Removal And Installation
        Disassembly And Assembly
    PARKING BRAKE DISC
        Removal And Installation
    CHAINCASE FLUID
        Removing Oil From The Chaincase
    CHAINCASE COVERS
        Center Chaincase Cover Removal And Installation
        Front Chaincase Cover Removal And Installation
        Rear Chaincase Cover Removal And Installation
    MOTOR CARRIER
        Shaft Seal Replacement
        Removal And Installation
        Disassembly
        Assembly
    AXLE SEAL
        Removal And Installation
    AXLE, SPROCKET AND BEARINGS
        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
        Bob-Tach Stops
    LIFT ARMS
        Removal And Installation
    REAR GRILL
        Removal And Installation
    FUEL TANK
        Removal And Installation
        Fuel Level Sender
    REAR DOOR
        Removal And Installation
        Hood Removal And Installation
        Bumper Removal And Installation
        Door Latch Removal And Installation
        Door Latch And Catch Adjustment
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    TROUBLESHOOTING
    ELECTRICAL SYSTEM INFORMATION
        Description
        Fuse Location
    BATTERY
        Removal And Installation
        Servicing The Battery
        Using A Booster Battery (Jump Starting)
    ALTERNATOR
        Alternator Output Test
        Rectifier (Diode) Test
        Alternator Regulator Test
        Removal And Installation
        Adjusting The Alternator Belt
        Disassembly And Inspection
        Stator Continuity Test
        Stator Ground Test
        Rotor Continuity Test
        Rotor Ground Test
        Rectifier Continuity (Diode) Test
        Assembly
    STARTER
        Removal And Installation
        Disassembly And Assembly
        External Pinion
        Inspection And Repair
        Magnetic Switch Test
        No Load Test
        Parts Identification
    STANDARD INSTRUMENT PANEL
        Removal And Installation
    FRONT LIGHTS
        Removal And Installation
    RELAY SWITCHES
        Location
        Glow Plug Preheat Relay
        
ENGINE SERVICE
    TROUBLESHOOTING
    ENGINE SPEED CONTROL
        Removal And Installation
        Disassembly
    RADIATOR
        Removal And Installation
    ENGINE MUFFLER
        Removal And Installation
    BLOWER HOUSING/FAN GEARBOX
        Removal And Installation
        Tension Pulley Removal And Installation
        Blower Fan Disassembly And Assembly
    FAN GEARBOX
        Disassembly
        Assembly
        Checking Backlash
        Identification
    AIR CLEANER
        Removal And Installation
    ENGINE
        Removal And Installation
        Engine Mount Replacement
    FLYWHEEL
        Removal And Installation
        Flywheel Ring Gear
    INJECTION PUMP TIMING
        Checking Procedure
        Adjusting Injection Pump Timing
    TIMING BELT
        Removal
        Installation
    FUEL INJECTION PUMP
        Removal
        Installation
    FUEL INJECTOR NOZZLE
        Removal And Installation
        Checking The Injector Nozzle
    CYLINDER LOCATION AND COMPRESSION
        Data
    GLOW PLUGS
        Removal And Installation
        Checking The Glow Plugs
    CYLINDER HEAD
        Removing The Cylinder Head
        Disassembly Of The Cylinder Head
        Servicing The Cylinder Head
        Checking The Valves
        Checking Valve Springs
        Checking The Valve Guides
        Checking The Valve Seats
        Checking The Combustion Chamber
        Reassejmbly Of The Cylinder Head
        Installing The Cylinder Head
    ENGINE BLOCK
        Disassembly Of The Engine
        Assembly Of The Engine
    PISTONS AND CONNECTING RODS
        Disassembly And Assembly
        Checking The Piston
    CRANKSHAFT AND BEARINGS
        Checking The Crankshaft
    CRANKSHAFT PULLEY
        Removal And Installation
    PEUGEOT ENGINE TOOL KIT MEL1474
    ENGINE TORQUE
    
SYSTEM ANALYSIS
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
        Inspecting The BICS™ Controller 
        Inspecting The Deactivation Of The Auxiliary Hydraulics System
        Inspecting The Seat And Seat Bar Sensors
        Inspecting The Traction Lock
        Inspecting The Lift Arm By-Pass Control
        Maintenance
        Troubleshooting Chart
        Troubleshooting Guide
            BICS CONTROLLER
            TRACTION LOCK
            SEAT SENSOR
            SEAT BAR SENSOR
            LIFT LOCK BY-PASS 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 BY-PASS VALVE
        Removal And Installation
        Disassembly And Assembly
    TILT LOCK VALVE
        Removal And Installation
        Disassembly And Assembly
        
SPECIFICATIONS
    SKID STEER LOADER SPECIFICATIONS
        Performance
        Controls
        Engine
        Hydraulic System
        Electrical
        Drive System
        Capacities
        Tires
        Floor Pressure
    ENGINE SPECIFICATIONS
        Fuel Injection Nozzles
        Fuel Injection Pump
        Cylinder Head
        Valves
        Valve Springs
        Valve Guides
        Combustion Chamber
        Cylinders
        Piston Rings
        Pistons
        Connecting Rod
        Crankshaft
    TORQUE SPECIFICATIONS
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS
    DECIMAL AND MILLIMETER EQUIVALENTS
    U.S. TO METRIC CONVERSION
    
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