BOBCAT 453 SKID STEER LOADER Service Repair Manual SN 515011001 & Above

Service Manual S/N 515011001 & Above S/N 515111001 & Above

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM) 6900363 (5–97)

Printed in U.S.A.

© Bobcat Company 1997

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

CORRECT

CORRECT

B-10731a

B-12365

B-7469

Never service the Bobcat SkidSteer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-11799

B-15231

B-15280

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device.

Replace it if damaged.

Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged.

Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

WRONG

WRONG

B-6590

B-6580 B-16102

B-6589 B-16102

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust loader with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Never fill fuel tank with engine running, while smoking or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used.

Use eye protection approved for type of welding.

Keep rear door closed except for service. Close and latch door before operating the loader.

Lead-acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact.

Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer.

MSW01-0805

ALPHABETICAL INDEX AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . .

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . .

AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . .

AXLE, BEARINGS AND SPROCKET . . . . . . . . . . . .

AXLE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AXLE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–1 6–1 1–1 1–1 4–1 4–1 4–1

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 BICS™ (With Press To Operate Button) . . . . . . . . . . 8–1 BICS™ (Without Press To Operate Button) . . . . . . . 8–1 BICS™ BLOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 BICS™ SYSTEM CONTROLLER . . . . . . . . . . . . . . . . 8–1 BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1 CHAINCASE COVERS . . . . . . . . . . . . . . . . . . . . . . . .

CHAINCASE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL SHIELD AND STEERING LEVER PANELS . . . . . . . . . . . . . . . . . .

CRANKSHAFT AND BEARINGS . . . . . . . . . . . . . . . .

CRANKSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–1 4–1 2–1 3–1 7–1 7–1 7–1 7–1

DECIMAL & MILLIMETER EQUIVALENTS . . . . . . . 9–1 DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 ELECTRICAL SYSTEM INFORMATION . . . . . . . . .

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COMPRESSTION TEST . . . . . . . . . . . . . . .

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . .

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . .

ENGINE MOUNTING BRACKET . . . . . . . . . . . . . . . .

ENGINE OIL COOLER AND SHROUDING . . . . . . .

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . .

6–1 7–1 7–1 1–1 1–1 7–1 7–1 9–1 7–1

FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . 1–1 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 FRONT LIGHTS (OPTIONAL) . . . . . . . . . . . . . . . . . . 6–1 FUEL CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . 7–1 FUEL INJECTOR NOZZLES . . . . . . . . . . . . . . . . . . . . 7–1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 7–1 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 HYDRAULIC CONNECTION SPECIFICATION . . . .

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . .

HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC FILTER BLOCK . . . . . . . . . . . . . . . . . . .

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . .

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . .

HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . .

HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . .

HYDROSTATIC SYSTEM INFORMATION . . . . . . . .

9–1 2–1 2–1 2–1 9–1 1–1 2–1 2–1 2–1 3–1 3–1 3–1

IDLER GEAR AND CAMSHAFT . . . . . . . . . . . . . . . . . 7–1 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . .

LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFT CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFTING AND BLOCKING THE LOADER . . . . . . . .

LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . .

LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . .

Revised Mar. 99

1–1 5–1 2–1 1–1 1–1 9–1 1–1

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1 OPERATOR CAB GAS CYLINDER . . . . . . . . . . . . . . . 5–1 OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 PARKING BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . .

PARKING BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . .

PEDAL INTERLOCK LINKAGE . . . . . . . . . . . . . . . . . .

PISTONS AND CONNECTING ROD . . . . . . . . . . . . .

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–1 4–1 2–1 7–1 1–1

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RADIATOR MOUNTING BRACKET . . . . . . . . . . . . . .

REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR LIGHTS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . .

REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE START SWITCH . . . . . . . . . . . . . . . . . . . . . .

ROCKER ARM AND SHAFT . . . . . . . . . . . . . . . . . . . . .

7–1 7–1 5–1 6–1 5–1 1–1 7–1

SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . .

SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . .

STANDARD TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .

5–1 1–1 8–1 8–1 1–1 1–1 9–1 6–1 3–1 3–1

TENSION PULLEY AND SPRING . . . . . . . . . . . . . . . . 3–1 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 TIMING GEARCASE COVER . . . . . . . . . . . . . . . . . . . . 7–1 TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TORQUE SPECIFICATION FOR BOLTS . . . . . . . . . . 9–1 TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . . 1–1 TROUBLESHOOTING . . . . . . . . . . . . 2–1, 3–1, 6–1, 7–1 U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . . 9–1 VALVE & VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . 7–1 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 VALE GUIDE, VALVE & VALVE SEAT . . . . . . . . . . . . . 7–1 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SYSTEMS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

HYDROSTATIC SYSTEM

DRIVE SYSTEM

MAIN FRAME

ELECTRICAL SYSTEM

ENGINE SERVICE

SYSTEMS ANALYSIS

SPECIFICATIONS

Revised Mar. 99

i

453 Bobcat Loader Service Manual

FOREWORD This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

A general inspection of the following items must be made after the loader has had service or repair: 9. The parking brake function correctly.

1. Check that the ROPS/FOPS (Including sidescreens) is in good condition and is not modified.

must

2. Check that ROPS mounting hardware is tightened and is Melroe approved.

10. Enclosure door latches must open and close freely.

3. The seat belt must be correctly installed, functional and in good condition.

11. Bob–Tach wedges and linkages must function correctly and be in good condition.

4. The seat bar and pedal interlocks must be correctly adjusted, clean and lubricated.

12. Safety treads must in good condition.

5. Check lift arm support device, replace if damaged.

13. Check for correct function of indicator lamps (Optional on some models).

6. Machine signs must be legible and in the correct location.

14. Check hydraulic fluid level, engine oil level and fuel supply.

WARNING

7. Steering levers and foot pedals must return to neutral.

15. Inspect for fuel, oil or hydraulic fluid leaks.

8. Check for correct function of the work lights.

16. Lubricate the loader.

Revised Mar. 99

ii

453 Bobcat Loader Service Manual

17. Check the condition of the battery and cables.

18. Inspect the air cleaner for damage or leaks. Check the condition of the element.

19. Check the electrical charging system.

20. Check tires for wear and pressure.

21. Inspect for loose or broken parts or connections.

22. Operate the loader and check all functions.

23. Check for any field modification not completed.

24. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer.

Recommend to the owner that all necessary corrections be made before the machine is returned to service.

Revised Mar. 99

iii

453 Bobcat Loader Service Manual

SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.

W–2003–0199

The following publications provide information on the safe use and maintenance of the loader and attachments:

• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.

• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine maintenance

and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.

• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.

• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the

operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.

• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.

• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and repair work.

• The Skid–Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.

• The Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and correct service procedures for Bobcat Skid–Steer loaders.

• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

This notice identifies procedures which must be followed to avoid damage to the machine.

I–2019–0284

W–2044–1285

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

SIO5–0299

Revised Jan. 01

v

453 Bobcat Loader Service Manual

SAFETY INSTRUCTIONS (Cont’d) • Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing protection or loader special applications kit are required for some work. See your dealer for Melroe Safety equipment.

• Know where fire extinguisher and first aid kit are located and how to use them.

• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check

for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti–freeze.

• Do not use ether or starting fluids on engines which have glow plugs. These starting aids can cause explosion and injure you or bystanders.

• Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.

• Stop the engine and let it cool before adding fuel. No smoking!

• Use the procedure in the Operation & Maintenance or Service Manuals for connecting the battery.

A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].

A

P–3705

SI06–0398

Revised Oct. 98

vi

453 Bobcat Loader Service Manual

SERIAL NUMBER LOCATIONS

A

Always use the serial number of the loader when requesting service information or when ordering parts.

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

LOADER SERIAL NUMBER The loader serial number plate is located on the inside of the operator cab on the right fender and in front of the seat [A].

P–04399

Explanation of loader Serial Number: XXXX

XXXXX

B

Module 2. – Production Sequence (Series) Module 1. – Model/Engine Combination ENGINE SERIAL NUMBER The engine serial number is located on the engine fuel injection pump. [B].

P–09791

DELIVERY REPORT

C

The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [C].

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453 Bobcat Loader Service Manual

BOBCAT SKID STEER LOADER IDENTIFICATION 453ServiceManual#6900363(S/N515011001&Above)–ContentsSection

◊ OPERATING LIGHTS SEAT BAR OPERATOR HANDBOOK

GRAB HANDLES STEERING LEVER

OPERATOR SEAT

SAFETY TREAD

TILT CYLINDER

BUCKET OPERATOR CAB (ROPS & FOPS)

◊ OPERATING LIGHT

UPRIGHTS LIFT ARM SUPPORT DEVICE LIFT ARMS

REAR DOOR

LIFT CYLINDER

TIRES*

B–14268 B–14269

◊ FACTORY OPTION OR FIELD ACCESSORY (Not Standard Equipment) * TIRES – Flotation tires (Optional) are shown. Bobcats are base–equipped with standard tires.

BUCKET – Several different buckets and other attachments are available for the Bobcat loader.

ROPS, FOPS – Roll–Over Protective Structure,Falling Object Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. The Bobcat loader is base– equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level). viii

453 Bobcat Loader Service Manual

PREVENTIVE MAINTENANCE Page Number

PREVENTIVE MAINTENANCE

AIR CLEANER SERVICE Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 ALTERNATOR BELT Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19 AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24 BOB–TACH Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27 ENGINE COOLING SYSTEM Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 ENGINE LUBRICATION SYSTEM Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 FINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24 FUEL SYSTEM Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–14 1–15 1–14 1–16

HYDRAULIC/HYDROSTATIC SYSTEM Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20 Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 Replacing The Hydraulic/Hydrostatic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 1–21 LIFT ARM SUPPORT DEVICE Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Disengaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . 1–8 LIFTING AND BLOCKING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 LUBRICATING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–25 OPERATOR CAB Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–9 1–11 1–10 1–9

Continued On Next Page Revised Jan. 01

–1–1–

453 Bobcat Loader Service Manual

PREVENTIVE MAINTENANCE (Cont’d) Page Number PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27 REMOTE START SWITCH Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28 SEAT BAR RESTRAINT SYSTEM Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 SPARK ARRESTOR MUFFLER Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22 TIRE MAINTENANCE Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23 TOWING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 TRANSPORTING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

Revised Jan. 01

–1–2–

453 Bobcat Loader Service Manual

SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader.

Instructions are necessary before operating or servicing machine.

Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–1298

ITEM Engine Air Cleaner Engine Oil Engine Cooling System Tires Indicators, Gauges & Lights (Opt.) Seat Belt and Seat Bar

Safety Signs (Decals) and Safety Tread Lift Arm and Bob–Tach Pivot Pin and Wedges Engine Fuel Filter Hyd. Fluid, Hoses & Tubelines Bobcat Interlock Control System (BICS™) Battery Control Pedals & Steering Bob–Tach Wheel Nuts Parking Brake Alternator Belt Engine Oil & Filter Hydraulic Filter Element Spark Arrestor Muffler Drive Belt Steering Lever Pivots Engine Fuel Filter Hydraulic Reservoir Breather Final Drive Trans (Chaincase) Hydraulic/Hydrostatic Reservoir Bobcat Interlock Control System (BICS™)

SERVICE REQUIRED

8–10

50

100

250

500 1000

Empty the dust cup & replace the filter element as needed.

Check the oil level & add oil as needed.

Clean debris from oil cooler and radiator. Check coolant level in recovery tank and add as needed.

Check the air pressure & for damaged tires.

Check for correct operation of all indicators, gauges & lights (Opt.).

Check the condition of seat belt. Check the seat bar & pedal interlocks for correct operation. Clean dirt and debris from moving parts.

Check for damaged signs and safety treads. Replace any signs or safety treads that are damaged or worn.

Lubricate with multi–purpose lithium based grease.

Remove the water from the filter.

Check fluid level & add as needed. Check for damage & leaks. Repair & replace as needed.

Check BICS™ System Controller functions. Clean dirt, debris or objects from under or behind seat as required.

Check cables, connections & electrolyte level. Add distilled water as needed Check for correct operation repair or adjust as needed.

Check locking levers & wedges for condition & operation.

Check for loose wheel nuts & tighten to 40–45 ft.–lbs.

(54–61 Nm) torque.

Check operation.

Check tension & adjust as needed.

Replace oil & filter. See engine Oil Chart.

Replace filter element.

Clean the spark chamber.

Check drive belt for condition and tension.

Lubricate grease fittings and oil hole in the steering shaft.

Replace filter element.

Replace the breather cap.

Replace the fluid.

Replace the fluid.

Check the lift arm by–pass control

Check wheel nut torque every 8 hours for the first 24 hours.

Also replace hydraulic/hydrostatic filter element when the transmission warning light stays on for five minutes after the fluid is at operating temperature.

Or every 12 months.

Revised Mar. 99

–1–3–

453 Bobcat Loader Service Manual

A

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing.

Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death [A].

W–2003–1298

LIFTING AND BLOCKING THE LOADER Procedure B–07023

Always park the loader on a level surface.

Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.

W–2017–0286

B

Put a floor jack under the rear of the loader [B].

Lift the rear of the loader and install jackstands [B].

P–07288

Put the floor jack under the front of the loader [C].

C

Lift the front of the loader and put jackstands under the loader frame.

NOTE: Make sure the jackstands do not touch the tires.

P–07289

Revised Mar. 99

–1–4–

453 Bobcat Loader Service Manual

TRANSPORTING THE LOADER

A

Procedure Be sure the transport and towing vehicles are of adequate size and capacity.

Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

SUPPORT

W–2058–0494

B–06198

B

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A].

The rear of the trailer must be blocked or supported [A] when loading or unloading the loader to prevent the front end of the trailer from raising up.

Use the following procedure to fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up or down slopes [B].

Fully lower any bucket or attachment. Stop the engine.

Engage the parking brake.

P–09921

Fasten chains at the front using the slots in the axle gussets [B]. Couterweight is removed (Inset) to show clarity. DO NOT operate with counterweight removed.

P–09926

P–09927 B–6200

Fasten the rear of the loader as shown with a loop of chain trhough the tie down provided [C].

C

P–09925

Revised Mar. 99

–1–5–

P–09924

453 Bobcat Loader Service Manual

TOWING THE LOADER

A

Procedure To prevent damage to the loaders hydrostatic system, the loader must be towed only a short distance at slow speed.

(Example: Moving the loader onto a transport vehicle).

Relief valve release tool set MEL1220 is available from your dealer. Tool must be installed before towing.

Raise the operator cab. (See Page 1–9 for the correct procedure.)

Clean the area around the hydrostatic pumps.

E–01457 B–06924

Remove the high pressure relief valve from one side of each hydrostatic pump [A] and install the relief valve tubes. Install the plugs and tighten.

The towing chain (or cable) must be rated at 1–1/2 times the weight of the loader. (See SPECIFICATIONS Page 9–1.)

Turn the key switch to ON and press the traction lock override button.

Tow the Bobcat at 2 MPH (3,2 km/hr) or less for not more than 25 feet (7,6 meters).

If the electrical system is not functioning, contact your Bobcat loader dealer. (Part of the brake system must be disassembled to move the loader.)

Do not push or pull the machine at more than 2 MPH (3,2 km/h) or for a distance of more than 25 feet (7,6 meters) with the towing tool in place.

I–2017–0389

Revised Mar. 99

–1–6–

453 Bobcat Loader Service Manual

LIFT ARM SUPPORT DEVICE 1.

A

1

P–09773

P–07139

B

Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.

W–2059–0598

1

Engaging The Lift Arm Support Device Put jackstands under the rear corners of the loader (Inset) [A].

Disconnect the spring from the lift arm support device retaining pin (Item 1) [A], hold the support device and remove the retaining pin.

P–09810

Lower the lift arm support device on top of the lift cylinder.

Fasten the free end of the spring (Item 1) [B] to the lift arm support device so there will be no interference with the support device engagement.

C

With the operator in the seat, seat belt fastened and seat bar lowered, start the engine. Loader without seat sensors press the green PRESS TO OPERATE Button.

Raise the lift arms until the lift arm support device drops onto the lift cylinder rod [C].

Lower the lift arms slowly until the support device is held between the lift arm and the lift cylinder. Stop the engine.

Raise the seat bar and move pedals until both pedals lock.

P–09800

D

Install the retaining pin (Item 1) [D] into the rear of the lift arm support device below the cylinder rod.

Service lift arm support device if damaged or if parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death.

1

W–2271–1197 P–09808

Revised Mar. 99

–1–7–

453 Bobcat Loader Service Manual

LIFT ARM SUPPORT DEVICE (Cont’d)

A

Disengaging The Lift Arm Support Device Remove the retaining pin (Item 1) [A] from the lift arm support device.

1

P–09808

B

Connect the spring from the lift arm support device to the tubeline bracket (Item 1) [B] on the lift arms.

With the operator in the seat, seat belt fastened and seat bar lowered, start the engine. Loaders without seat sensor press the green PRESS TO OPERATE Button.

Raise the lift arms a small amount and the spring will lift the support device off the lift cylinder rod. Lower the lift arms. Stop the engine.

1

Raise the seat bar and move pedals until both pedals lock.

Disconnect the spring from the bracket.

P–09807

C

Raise the support device into storage position and insert pin through lift arm support device and bracket (Item 1) [C].

Connect spring to pin [C].

1 P–07139

Revised Mar. 99

–1–8–

453 Bobcat Loader Service Manual

OPERATOR CAB

A

Description

1

The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged. The seat belt must be worn for roll over protection.

ROPS/FOPS Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level l.

Level l – Protection from falling bricks, small concrete blocks and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services.

P–09771

B

Check with your dealer if the operator cab has been changed.

The operator cab fastening nuts (Item 1) [A] must be tightened to 40–50 ft.–lbs. (54–68 Nm) torque.

Before the cab or the lift arms are raised for service, jackstands must be put under the rear corners of the frame. Failure to use jackstands can allow the machine to tip backward causing injury or death.

P–09773

W–2014–0895

Raising The Operator Cab Stop the loader on a level surface. Put the lift arms all the way down.

Install jackstands under the rear of the loader frame [B].

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Melroe Company. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

Open the rear door. (See REAR DOOR Page .)

If the lift arms must be up while raising the cab, install the lift arm support device. (See Engaging The Lift Arm Support Device Page 1–7.)

W–2069–1285

Remove the two fasteners (Item 1) [A] at the front (both sides) of the operator cab.

Stand on the ground. Lift slowly until operator cab is all the way up [B].

The operator cab will lock in the raised position.

Revised Mar. 99

–1–9–

453 Bobcat Loader Service Manual

OPERATOR CAB (Cont’d)

A

Lowering The Operator Cab

1

Hold the operator cab. Release the locking mechanism by pushing the lever (Item 1) [A] inward from the locked position (Item 2) [A] and turning the lever until it stays in the unlocked position [B].

2

The cab must be held to prevent falling while hand is in access hole.

P–09823

W–2205–0695

B REMOVE YOUR HAND FROM THE HOLE BEFORE LOWERING THE OPERATOR CAB Stand on the ground and pull down on the operator cab.

Avoid slippery surfaces when lowering the cab.

NOTE: Guide the operator cab over the fastening bolts to prevent thread damage.

P–09825

Install the cab washers and nuts. Tighten the nuts (Item 1) [C] (both sides) to 40–50 ft.–lbs. (54–68 Nm) torque.

C 1

P–09771

Revised Oct. 98

–1–10–

453 Bobcat Loader Service Manual

OPERATOR CAB (Cont’d)

A

Emergency Exit The front opening on the operator cab and rear window provide exits.

Pull on the tag at the top of the rear window to remove the rubber cord [A].

Push the rear window out of the rear of the operator cab.

P–09829

B

Exit through the rear of the operator cab [B].

P–09774

Revised Mar. 99

–1–11–

453 Bobcat Loader Service Manual

SEAT BAR RESTRAINT SYSTEM

A

Description The seat bar restraint system has a pivoting seat bar with arm rests and has spring loaded interlocks for the lift and tilt control pedals. The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt pedals are locked when returned to the neutral position.

AVOID INJURY OR DEATH The seat bar system must lock the lift and tilt control pedals in neutral when the seat bar is up. Service the system if pedals do not lock correctly.

W–2105–1285

Inspectng The Seat Bar Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Loaders without seat sensors press the green PRESS TO OPERATE Button. Operate each foot pedal to check both the lift and tilt functions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground.

P–09790

Raise the seat bar, try to move each pedal. The pedals must be firmly locked in neutral position. There must be no motion of the tilt (bucket) or the lift arms when the pedals are pushed.

B

Pull the seat bar down, Loaders without seat sensors press the green PRESS TO OPERATE Button and lower the lift arms. Operate the lift pedal. While the lift arms are going up, raise the seat bar and the lift arms should stop.

Lower the seat bar, Loaders without seat sensors press the green PRESS TO OPERATE Button, lower the lift arms and put the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the foot pedals to be sure that the pedals are firmly locked in the neutral position. Unbuckle the seat belt.

P–04400

Maintaining The Seat Bar See the SERVICE SCHEDULE Page 1–3 and on the loader for correct service interval.

Clean any debris or dirt from the moving parts [A] & [B].

Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).

If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust pedal control linkage. Replace parts that are worn or damaged. Use only genuine Melroe replacement parts.

Revised Mar. 99

–1–12–

453 Bobcat Loader Service Manual

AIR CLEANER SERVICE

A

Replacing Filter Element See the SERVICE SCHEDULE Page 1–3 for the interval to service the air cleaner system.

Check the air intake hose for damage. Check the air cleaner housing for damage. Check to make sure all connections are tight.

Service the air cleaner as follows: Loosen the wing nut (Item 1) [A].

1 P–09767

Remove the cover (Item 1) [B], remove the dust cup (Item 2) [B]. Empty the debris from the dust cover.

B

1

2

P–09768

C

Remove the wing nut (Item 1) [C] from the air filter.

1

P–09766

Remove the air filter (Item 1) [D].

D

NOTE: Make sure all sealing surfaces are free of dirt and debris.

1

Install a new air filter using the wing nut.

Install the dust cup and cover.

P–09765

Revised Mar. 99

–1–13–

453 Bobcat Loader Service Manual

FUEL SYSTEM

A

Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1.

2

The following is one suggested blending guideline which should prevent fuel gelling problems: Temp. F°/C° +15o(–9o) Down to –20o/–29o Below –20o/–29o

No. 2 100% 50% 0%

1

No. 1 0% 50% 100%

We recommend an operator contact their fuel supplier for local recommendations.

P–09831

The fuel gauge (Item 1) [A] and the fuel shut off valve (Item 2) [A] are located on the right side of the loader.

B

Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can cause an explosion or fire.

1

W–2063–0887

P–09830

Filling The Fuel Tank Remove the fuel fill cap (Item 1) [B].

C

Use a clean, approved safety container to add fuel of the correct specifications. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING [B].

WRONG

Install and tighten the fuel fill cap (Item 1) [B].

B–06108

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

Revised Jan. 01

–1–14–

453 Bobcat Loader Service Manual

FUEL SYSTEM (Cont’d)

A

OFF

1 ON Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285 P–09831

Fuel Filter

B

Drain Water: See the SERVICE SCHEDULE Page 1–3 for the service interval when to remove the water from the fuel filter.

Turn the fuel shut–off valve (Item 1) [A] clockwise to shut off the fuel supply.

Loosen the drain (Item 1) [B] at the bottom of the filter element to drain the water from the filter. Close the drain.

Open the shut–off valve (Item 1) [A] to turn on the fuel supply.

1

Replace Fuel Filter:

P–09880

See the SERVICE SCHEDULE Page 1–3 for the service interval when to replace the fuel filter.

Clean the area around the fuel filter.

Close the shut–off valve (Item 1) [A].

Remove the fuel filter [B].

NOTE: Be sure the filter gasket is removed with the old fuel filter.

Install the new filter element hand tight.

Open the shut–off valve (Item 1) [A].

Revised Jan. 01

–1–15–

453 Bobcat Loader Service Manual

FUEL SYSTEM (Cont’d)

A

Removing Air From The Fuel System After replacing the fuel filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine.

1

Open the rear door. The engine must be cool.

2

Open the vent plug (Item 1) [A].

Operate the hand pump (priming bulb) (Item 2) [A] until fuel flows from the vent plug with no air bubbles.

Close the vent plug.

P–09880

With the operator in the seat, seat belt fastened and seat bar lowered, and parking brake engaged, start the engine.

B

NOTE: If engine fails to start, remove air from the fuel injection pump as follows: Put jackstands under the rear of the frame. (See Page 1–4.)

Raise the operator cab. (See Page 1–9.)

1

Open the valve (Item 1) [B] on the injector pump and squeeze the hand pump several times until fuel flows from the valve.

Close the valve (Item 1) [B].

P–09912

Lower the operator cab. (See Page 1–10.)

Start the engine.

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

Revised Jan. 01

–1–16–

453 Bobcat Loader Service Manual

ENGINE LUBRICATION SYSTEM

A

Checking Engine Oil Check the oil level every day.

2

1

Stop the engine and remove the dipstick (Item 1) [A].

Keep the oil level between the marks on the dipstick.

Use a good quality motor oil that meets API Service Classification of CD or better. (See Oil Chart below.)

Oil Chart RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)

C° –40

–34

–29

–23

–18

–13

–7

–1

+4

+10

+15

+21

+27

+32

P–09892 +38

+43 +49

SAE 40W or 20W–50

B

SAE 10W–30 SAE 15W–40 SAE 30W

* SAE 5W–30 SAE 20W–20 SAE 10W SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

P–09882 –40 –30

–20

–10

0

+10

+20

+30

+40

+50

+60

+70

+80

+90 +100 +110 +120

F°

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION CD, CF4, CG4 )

C

* Can be used ONLY when available with appropriate diesel rating.

Replacing Oil and Filter

1

See the SERVICE SCHEDULE Page 1–3 for the service interval for replacing the engine oil and filter.

Run the engine until it is at operating temperature. Stop the engine.

Open the rear door and remove the cap from the end of the hose. Drain the oil into a container [B].

P–09874

Remove the filter (Item 2) [A].

Clean the filter housing surface. Put clean oil on the gasket of the new filter. Install the filter and hand tighten.

Install and tighten the cap on the drain hose.

Turn the oil fill cap (Item 1) [C] counterclockwise to remove the cap.

Fill to capacity. (See SPECIFICATION Section Page 9–1.)

Start the engine and let it run for about 5 minutes. Check for leaks at the filter. Check the oil level. Add oil until the level is at the FULL mark on the dipstick. Install the oil fill cap (Item 1) [C].

NOTE: DO NOT overfill the crankcase.

Revised Jan. 01

–1–17–

453 Bobcat Loader Service Manual

ENGINE COOLING SYSTEM

A

Check the cooling system every day to prevent overheating, loss of performance or engine damage.

Checking The Coolant Level

1

Open the rear door.

The coolant recovery tank (Item 1) [A] is located between the radiator and the right upright.

The coolant level in the recovery tank must be between the maximum and minimum mark when engine is cool.

NOTE: The loader is factory filled with propylene glycol coolant. DO NOT mix propylene glycol with ethylene glycol.

P–09816

B

Add premixed coolant; 47% water and 53% propylene glycol to the recovery tank if the coolant level is low.

One gallon and one pint of propylene glycol mixed with one gallon of water is the correct mixture of coolant to provide a –34°F (–37°C) freeze protection.

1

Use a refractometer to check the condition of propylene glycol in your cooling system.

NOTE: Coolant testing strips are available for checking the coolant condition. (See your Bobcat loader dealer.)

P–09881

Cleaning The Cooling System Open the rear door.

C

Use safety goggles when using air or water under pressure. Do not use cold water to clean a hot engine. Failure to obey warnings can cause serious injury.

W–2064–1285

Use air pressure or water pressure to remove the debris in the area of the radiator and oil cooler.

P–09818

D

If debris is a problem, check with your dealer about the special debris screens.

Replacing the Coolant Open the rear door.

1

Place the drain hose (Item 1) [B] into a clean container.

Raise the operator cab. (See Page 1–9.)

Remove the radiator cap [C].

Open the drain valve (Item 1) [D]. Located on the front engine by the fuel lift pump. Turn the valve counterclockwise to open.

Revised Jan. 01

P–09806

–1–18–

453 Bobcat Loader Service Manual

ALTERNATOR BELT

A

Adjusting The Alternator Belt

1

Stop the engine.

Loosen the mounting bolts (Item 1) [A] to move the alternator.

1

P–09895

B

Set the belt tension to 1/4 inch (6 mm) movement between pulleys with 15 pounds (67 N) of force [B].

Tighten the adjustment bolts.

P–09770

Revised Jan. 01

–1–19–

453 Bobcat Loader Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM

A

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

W–2072–0496

1

Checking And Adding Fluid Use only recommended fluid in the hydraulic system.

(See SPECIFICATIONS Page 9–1 for the correct fluid.)

Stop the loader on a level surface. Lower the lift arms and tilt the Bob–Tach fully back.

Stop the engine.

Open the rear door. Remove the dipstick (Item 1) [A].

The fluid level is correct if the fluid level is between the marks on the dipstick.

P–09865

NOTE: The dipstick may indicate an incorrect level of fluid when first removed because of expansion or contraction of oil in the fill tube.

Always (1) remove the dipstick, (2) wipe the dipstick, (3) insert the dipstick again and (4) re–check the fluid level.

If fluid is needed , remove the dipstick (Item 1) [A] and add fluid to the reservoir until the level is correct.

Revised Jan. 01

–1–20–

453 Bobcat Loader Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Hydraulic/Hydrostatic Filter Replacement See the SERVICE SCHEDULE Page 1–3 for the correct service interval.

Stop the engine. Open the rear door. Raise the operator cab. (See Page 1–9 for the correct procedure.) Clean the area around the filter housing. Remove the plug (Item 1) [A] from the filter housing (located on the outside of the loader at the right side).

1

After the fluid is drained from the filter, install the plug (Item 1) [A] and tighten.

P–07302

B

Remove the filter element (Item 1) [B].

Clean the surface of the filter housing where the filter element seal contacts the filter housing.

Put grease on the seal of the filter element, install the element and hand tighten only.

1

Lower the operator cab.

Start the engine and operate the loader through the hydraulic and hydrostatic functions. Stop the engine.

Check the fluid level and add fluid to the reservoir as needed.

P–07527

Replacing The Hydraulic/Hydrostatic Fluid

C

See the SERVICE SCHEDULE Page 1–3 for the service interval to replace the fluid. The fluid must also be replaced if it becomes contaminated and after any major repairs.

Stop the engine. Open the rear door.

Remove the fill cap/dipstick.

Loosen the nut (Item 1) [C] which fastens the fill tube to the loader frame.

1

Loosen the clamp at the fill tube, turn the fill tube down to drain the fluid from the reservoir [C].

After the fluid is removed, put the fill tube in the correct position, tighten the hose clamp and tighten the bolt.

P–09863

Replace the hydraulic filter element.

Add hydraulic/hydrostatic fluid to the reservoir. (See SPECIFICATIONS, Page 9–1 for the correct fluid.)

Do Not over fill the reservoir.

Revised Jan. 01

–1–21–

453 Bobcat Loader Service Manual

SPARK ARRESTOR MUFFLER

A

See the SERVICE SCHEDULE Page 1–3 for correct service interval. Do not operate the loader with a defective exhaust system.

Cleaning Procedure

1

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles. Failure to obey can cause serious injury.

P–09764

W–2011–1285

When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside.

Exhaust fumes contain odorless, invisible gases which can kill without warning.

W–2050–1285

This loader is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation.

Stop the engine. Open the rear door.

Remove the plug (Item 1) [A] from the bottom of the muffler.

If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC. Make reference to local laws and regulations for spark arrestor requirements.

Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.

I–2022–0595

W–2068–1285

When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death.

W–2006–0284

Start the engine.

Have a second person (wearing safety goggles) hold a block of wood over the outlet of the muffler (with the engine running) for about 10 seconds.

Stop the engine and install the plug. Close the rear door.

Revised Jan. 01

–1–22–

453 Bobcat Loader Service Manual

TIRE MAINTENANCE

A

Wheel Nuts See the SERVICE SCHEDULE Page 1–3 for the service interval to check the wheel nuts. The correct torque is 40–45 ft.–lbs. (54–61 Nm) torque.

Tire Rotation Check the tires regularly for wear, damage and pressure.

(See SPECIFICATIONS Page 9–1 for the correct tire pressure.)

Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [C].

B–09976

It is important to keep the same size tires on each side of the loader. If different sizes are used, each tire will be turning at a different rate and cause excessive wear. The tread bars of all the tires must face the same direction.

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for the correct pressure before operating the loader.

Inflate tires to the MAXIMUM pressure shown on the sidewall of the tire. DO NOT mix brands of tires used on the same loader.

I–2057–0794

Tire Inflation Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage.

The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire, avoid excessive pressure which can rupture the tire and cause serious injury or death. During inflation of the tire, check the tire pressure frequently to avoid over inflation.

Do not inflate tires above specified pressure.

Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.

W–2078–1285

Revised Jan. 01

–1–23–

453 Bobcat Loader Service Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

A

The chaincase contains the final drive sprockets and the chains and is filled with the same type of fluid as is used in the hydraulic system. (See SPECIFICATIONS, Page 9–1.)

1

Checking And Adding Oil Put the loader on a level surface.Remove the plug (Item 1) [A] from the front of the chaincase. If the fluid can be reached with the tip of your finger through the hole, the level is correct.

Add fluid through the check plug hole until the fluid flows from the hole. Install and tighten the plug.

P–07561

AUXILIARY CONTROL LOCKBOLT

B

The Auxiliary control has a lockbolt (Item 1) [B] that must be removed to use the optional auxiliary hydraulics.

Raise the operator cab. (See Page 1–9.)

1

Remove the nut and bolt (Item 1) [B] from the right hand steering lever.

P–09787

Revised Jan. 01

–1–24–

453 Bobcat Loader Service Manual

LUBRICATING THE LOADER

A

453ServiceManual#6900363(S/N515011001&Above)–PreventiveMaintenanceSectionPart1of2

Procedure Lubricate the loader as specified in the SERVICE SCHEDULE Page 1–3 for the best performance of the loader.

Record the operating hours each time you lubricate the Bobcat loader.

1

Always use a good quality lithium based multi–purpose grease when you lubricate the loader. Apply the lubricant until extra grease shows.

Lubricate the following locations on the loader: P–07548

Base End Lift Cylinder (Item 1–Both sides) [A].

B Rod End Lift Cylinder (Item 1–Both sides) [B].

1 P–07549

C

Lift Arm Pivot Pin (Item 1–Both sides) [C].

1

P–07553

Rod End Tilt Cylinder (Item 1) [D].

D

1

P–07560

Revised Jan. 01

–1–25–

453 Bobcat Loader Service Manual

LUBRICATING THE LOADER (Cont’d)

A

Procedure (Cont’d)

1

Base End Tilt Cylinder (Item 1) [A].

P–07552

B

Bob–Tach pivot pins (Item 1) [B] (Both sides).

1

P–07150

C

Steering shaft pivot bearings (Item 1) [C] (Both sides).

NOTE: If the steering levers do not move freely, see page 3–1 to disassemble and lubricate the plastic bushings.

1

P–07554

Revised Jan. 01

–1–26–

453 Bobcat Loader Service Manual

PIVOT PINS

A

All pivot pins, lift arms and cylinders have a large pin held in position with lockbolts and retainer (Item 1) [A] & [B].

Check that the lockbolts are tightened to 8–10 ft.–lbs.

(11–13 Nm) torque.

Do not over–tighten.

1 P–07161

B

1

P–07173

BOB–TACH

C

Inspection And Maintenance

1

Move the Bob–Tach lever to engage the wedges [C]. The levers and wedges must move freely.

The wedges must extend through the holes in the attachment mounting frame (Item 1) [D].

P–09887

Bob–Tach wedges must extend through the holes in attachment. Lever(s) must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death.

D

W–2102–0497

Inspect the mounting frame on the attachment and the Bpb–Tach, linkages and wedges for excessive wear or damage. Replace anyu parts that are damaged, bent, or missing. Keep all fasteners tight.

Look for cracked welds. Contact your Bobcat dealer for repair or replacement parts.

1

Lubricate the wedges (See SERVICE SCHEDULE,Page 1–3 and LUBRICATION OF THE BOBCAT LOADER, Page 1–25.)

Revised Jan. 01

P–09889

–1–27–

453 Bobcat Loader Service Manual

REMOTE START SWITCH

A

Procedure The tool listed will be needed to do the following procedure: MEL1429–B – Remote Start Switch Kit Kit Includes:

1

MEL1429–1 Adapter MEL1429–2 Start Switch MEL1429–3 Adapter The Remote Start Switch is required when the operator cab is in the raised position for service and the service technician needs to start the engine. The operator cab wire harness connectors must be separated from the engine wiring harness connector under the cab.

The remote start switch is required when the service technician is adjusting the steering linkage and checking the hydraulic/hydrostatic system.

Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.

P–07523

W–2017–0286

Lift and block the loader. (See Page 1–4.)

Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.

W–2059–0598 Raise the lift arms and install the lift arm support device.

(See Page 1–7.)

Raise the operator cab. (See Page 1–9.)

Connect the remote start switch to the connectors (Item 1) [A].

Revised Jan. 01

–1–28–

453 Bobcat Loader Service Manual

REMOTE START SWITCH (Cont’d)

A

Procedure (Cont’d) NOTE: On late model loaders, the connector on the BICS™ harness is a round 7–pin connector, NOT a rectangular 8–pin connector. Use the adapter (Item 1) [A] if your loader has a round 7–pin BICS harness connector.

1 P–07101

Put the traction lock override switch (Item 1) [B] in the ON position so the traction function is locked. The wheels are not able to turn.

B

1

Turn the key to the right and start the engine.

P–04713

Move the traction lock override switch (Item 1) [C] to the OFF position so the traction function is unlocked. The wheels are now able to turn.

C 1

P–04714

Revised Jan. 01

–1–29–

453 Bobcat Loader Service Manual

HYDRAULIC SYSTEM Page Number BICS™ BLOCK VALVE Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16

HYDRAULIC SYSTEM

CONTROL PEDALS Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42 HYDRAULIC CONTROL VALVE Anti–Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tilt Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–26 2–31 2–25 2–24 2–27 2–25 2–25 2–23 2–26 2–32 2–31

HYDRAULIC CYLINDERS Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14 Lift Cylinder Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13 Tilt Cylinder Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13 HYDRAULIC FILTER BLOCK Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–40 Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–41 HYDRAULIC PUMP Checking The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . .

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–33 2–37 2–36 2–34

HYDRAULIC RESERVOIR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39 HYDRAULIC SYSTEM INFORMATION Glossary Of Hydraulic/Hydrostatic Symbols For Loaders . . . . . . . . . . . 2–3 LIFT CYLINDER(S) Checking The Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9

Continued On Next Page

Revised Mar. 99

–2–1–

453 Bobcat Loader Service Manual

HYDRAULIC SYSTEM (Cont’d) Page Number MIAN RELIEF VALVE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking The Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking The Main Relief Valve With Auxiliaries . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–22 2–20 2–21 2–22

PEDAL INTERLOCK LINKAGE Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42 TILT CYLINDER Checking The Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7

Revised Mar. 99

–2–2–

453 Bobcat Loader Service Manual

HYDRAULIC SYSTEM INFORMATION

Revised Mar. 99

–2–3–

453 Bobcat Loader Service Manual

HYDRAULIC SYSTEM INFORMATION (Cont’d)

Revised Mar. 99

–2–4–

453 Bobcat Loader Service Manual

HYDRAULIC SYSTEM INFORMATION (Cont’d)

Revised Mar. 99

–2–5–

453 Bobcat Loader Service Manual

HYDRAULIC/HYDROSTATIC SCHEMATIC 453 (S/N 515011001-13712) (S/N 515111001-13619) (PRINTED JANUARY 2001) V-0059legend

LEGEND 1

RESERVOIR: Capacity . . . . . . . . . 5.3 Qts. (5,0 L)

2

FILTER - HYDRAULIC/HYDROSTATIC (CANISTER)

3

CHARGE PRESSURE SWITCH: 17-21 PSI (118-144 kPa) TEMPERATURE SWITCH 225-232 degrees F. (108-111 degrees C.) RELIEF VALVE - CHARGE: 85 PSI (586 kPa)

4

5

6

BY PASS VALVE - COOLER: 275 PSI (1896 kPa)

7

FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDRAULIC/ HYDROSTATIC MOTOR

8

VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDRAULIC/ HYDROSTATIC PUMP

9

HYDRAULIC PUMP: Gear Type . . . 6.8 GPM (25,7 L/min.) at 3000 RPM

10

RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 3400 PSI (23440 kPa)

11

REPLENISHING VALVE

17 ANTICAVITATION VALVE 18 FILTER - BICS CONTROL VALVE 19

CHECK VALVE - BICS CONTROL VALVE

20

SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL

21

PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY PASS

22

CHECK VALVE - BICS CONTROL VALVE

23 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL 24 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL 25 CHECK VALVE - BUCKET POSITION VALVE 26

FLOW DIVIDER ADJUSTMENT VALVE

27

RESTRICTION - HYDRAULIC FILTER

12 RELIEF VALVE - MAIN: 1400-1450 PSI (9652-9996 kPa) at Front Quick Couplers 13 LOAD CHECK VALVE 14

PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL

15

CHECK VALVE - BUCKET POSITION VALVE

16 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL

Printed in U.S.A.

NOTE: Unless otherwise specified springs have NO significant pressure value.

V-0059legend (1-10-01)

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