Service Manual S/N 528011001 & Above S/N 528111001 & Above
EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 6903125 (2-06)
Printed in U.S.A.
© Bobcat Company 2006
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 ........................................................ 70-01 AIR CLEANER SERVICE ....................................... 10-01 ALTERNATOR ........................................................ 60-01 AUXILIARY CONTROL LOCKBOLT....................... 10-01 BATTERY................................................................ 60-01 BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON) ............................................................ 60-01 BLOWER FAN HOUSING....................................... 70-01 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) ....................... 60-01 BOB-TACH ............................................... 10-01, 50-01 CHAINCASE ........................................................... 40-01 CONTROL PANEL .................................................. 30-01 CONTROL PEDALS ............................................... 50-01 CONVERSIONS ............................................SPEC-01 CYLINDER (LIFT) ................................................... 20-01 CYLINDER (TILT) ............................................... 20-01 DRIVE COMPONENTS .......................................... 40-01 ELECTRICAL SYSTEM INFORMATION ................ 60-01 ENGINE ................................................................. 70-01 ENGINE COMPONENTS AND TESTING .............. 70-01 ENGINE COOLING SYSTEM ................................. 10-01 ENGINE LUBRICATION SYSTEM.......................... 10-01 ENGINE SPECIFICATIONS ...........................SPEC-01 ENGINE SPEED CONTROL .................................. 70-01 FINAL DRIVE TRANSMISSION (CHAINCASE) .. 10-01 FLYWHEEL .......................................................... 70-01 FUEL SYSTEM ....................................................... 10-01 FUEL TANK............................................................. 50-01 HYDRAULIC CONTROL VALVE............................. 20-01 HYDRAULIC FILTER HOUSING ............................20-01 HYDRAULIC FLUID RESERVOIR..........................20-01 HYDRAULIC FLUID SPECIFICATIONS ............SPEC-01 HYDRAULIC PUMP ................................................20-01 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS .......................... SPEC-01 HYDRAULIC/HYDROSTATIC SYSTEM ................. 10-01 HYDRAULIC SYSTEM INFORMATION.................. 20-01 HYDROSTATIC MOTOR .....................................30-01 HYDROSTATIC PUMP ........................................30-01 HYDROSTATIC SYSTEM INFORMATION ......... 30-01 INSTRUMENT PANEL ............................................ 60-01
LIFT ARM ................................................................50-01 LIFT ARM BY-PASS CONTROL VALVE..................20-01 LIFT ARM SUPPORT DEVICE ........................... 10-01 LIFTING AND BLOCKING THE LOADER...............10-01 LIGHTS ................................................................60-01 LOADER SPECIFICATIONS ............................. SPEC-01 LUBRICATION OF THE BOBCAT LOADER ...........10-01 MAIN RELIEF VALVE ..............................................20-01 MUFFLER................................................................70-01 OIL COOLER...........................................................30-01 OPERATOR CAB .........................................10-01, 50-01 OPERATOR SEAT...................................................50-01 PARKING BRAKE...................................................40-01 PIVOT PINS ...........................................................10-01 PORT BLOCK.........................................................30-01 RADIATOR ..............................................................70-01 REAR DOOR .......................................................50-01 REAR GRILL .......................................................50-01 RECONDITIONING THE ENGINE ..........................70-01 REMOTE START .................................................10-01 RUBBER COUPLER LUBRICATION ..................... 10-01 RUBBER DRIVE COUPLER .................................. 70-01 SEAT BAR ...............................................................50-01 SEAT BAR RESTRAINT SYSTEM ......................... 01-01 SERVICE SCHEDULE ............................................10-01 SPARK ARRESTOR MUFFLER..............................10-01 STARTER ................................................................60-01 STEERING ............................................................. 30-01 TIRE MAINTENANCE .............................................10-01 TORQUE SPECIFICATIONS FOR BOLTS ... SPEC-01 TOWING THE LOADER ..........................................10-01 TRANSPORTING THE BOBCAT LOADER.............10-01 TROUBLESHOOTING ............................................70-01 WATER FLANGE.....................................................70-01
SAFETY & MAINTENANCE
CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
HYDRAULIC SYSTEM
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX DELIVERY REPORT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .X
BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . .XI SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDROSTATIC SYSTEM
DRIVE SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
MAIN FRAME
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
ENGINE SERVICE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS
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553 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: 1. Check lift arm support device, replace if damaged. (Stored Position)
9. The parking brake function correctly.
2. Check that ROPS mounting hardware is tightened and is Bobcat 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 must be correctly adjusted, clean and lubricated.
12. Safety treads must be 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.
7. Steering levers and foot pedals must return to neutral.
15. Inspect for fuel, hydraulic fluid leaks.
8. Check for correct function of the work lights
16. Lubricate the loader.
II
must
oil
or
553 Bobcat Loader Service Manual
17. Check the condition of the battery and cables.
22. Operate the loader and check all functions.
18. Inspect the air cleaner for damage or leaks. Check the condition of the element.
23. Check for any field modification not completed.
19. Check the electrical charging system.
24. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer.
20. Check tires for wear and pressure.
Recommend to the owner that all necessary corrections be made before the machine is returned to service.
21. Inspect for loose or broken parts or connections.
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.
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553 Bobcat Loader Service Manual
SAFETY INSTRUCTIONS
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
Safety Alert Symbol This symbol with a warning statement means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.
•
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 machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
•
Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
•
An Operator’s Handbook fastened to the operator cab. It’s 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 AEM Safety Manual delivered with the machine gives general safety information.
•
The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
•
The Skid-Steer Loader Operator Training Course is available through your local dealer or at www.training.bobcat.com or www.bobcat.com. This course is intended to provide rules and practices of correct operation of the Skid-Steer Loader. The course is available in English and Spanish versions.
•
Service Safety Training Courses are available from your Bobcat dealer or at www.training.bobcat.com or www.bobcat.com. They provide information for safe and correct service procedures.
•
The Skid-Steer Loader Safety Video is available from your Bobcat dealer or at www.training.bobcat.com or www.bobcat.com.
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 instructions can cause injury or death. W-2003-0903
WARNING Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death. W-2044-1285
IMPORTANT This notice identifies procedures which must be followed to avoid damage to the machine. I-2019-0284
SI SSL-0206 SM
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553 Bobcat Loader Service Manual
SAFETY INSTRUCTIONS (CONT’D)
•
Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.
•
Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped).
Fire Prevention The machine and attachments have components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.
Figure 1
Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential hazard. The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot. •
Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.
•
The operator cab, 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.
•
Do not use ether or starting fluids on any engine which has glow plugs. These starting aids can cause explosion and injure you or bystanders.
•
Always clean the machine, disconnect the battery, and disconnect the wiring from the controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding. Have good ventilation when grinding or welding painted parts. Wear a 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!
•
Know where fire extinguishers and first aid kits are located and how to use them. Fire extinguishers are available from your Bobcat dealer [Figure 1].
SI SSL-0206 SM
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553 Bobcat Loader Service Manual
SERIAL NUMBER LOCATION
Engine Serial Number
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.
Figure 3
1
Loader Serial Number Figure 2
N-09931
The engine serial number (Item 1) [Figure 3] is in the location shown.
P10725
The loader serial number plate is located on the outside of the loader frame [Figure 2]. Explanation of loader Serial Number: XXXX Model/ Engine Version
XXXXX Production Sequence (Series)
1. The four digit Model/Engine Combination Module number identifies the model number and engine combination. 2. The five digit Production Sequence Number identifies the order which the loader is produced.
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553 Bobcat Loader Service Manual
DELIVERY REPORT Figure 4
B-16315
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 [Figure 4].
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553 Bobcat Loader Service Manual
BOBCAT LOADER IDENTIFICATION FRONT LIGHTS OPERATOR SEAT WITH SEAT BELT SEAT BAR GRAB HANDLES STEERING LEVER STABILIZER ROD TILT CYLINDER † BUCKET
QUICK COUPLERS
BUCKET STEPS SAFETY TREAD
REAR WINDOW
OPERATOR CAB (ROPS & FOPS)
UPRIGHTS REAR GRILL LIFT ARM TAIL LIGHT
LIFT CYLINDER
REAR LIGHT
REAR DOOR
* TIRES
B-15064 B-15065
OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment) * TIRES - The Bobcat loader is factory equipped with heavy duty flotation tires. See Specifications Section and your Bobcat dealer for available tires. † BUCKET - Several different buckets and other attachments are available for the Bobcat loader. ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAEJ1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level).
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553 Bobcat Loader Service Manual
SAFETY & MAINTENANCE
SAFETY AND MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . 10-140-1 Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
SAFETY & MAINTENANCE
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . .
10-90-1 10-90-2 10-90-1 10-90-2
DRIVE SYSTEM
10-110-1 10-110-1 10-110-1 10-110-1
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
ELECTRICAL SYSTEM & ANALYSIS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Air From The Fuel System . . . . . . . . . . . . . . .
10-100-1 10-100-1 10-100-2 10-100-1 10-100-3
ENGINE SERVICE
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . Replacing The Hydraulic/Hydrostatic Filter . . . . . . . . . . .
10-120-1 10-120-1 10-120-1 10-120-2 10-120-2
SPECIFICATIONS
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Installing Lift Arm Support Device . . . . . . . . . . . . . . . . . . . 10-20-1 Removing Lift Arm Support Device . . . . . . . . . . . . . . . . . . 10-20-2 LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 LUBRICATION OF THE BOBCAT LOADER. . . . . . . . . . . . . 10-160-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1 Continued On Next Page
10-01
553 Bobcat Loader Service Manual
SAFETY AND MAINTENANCE (CONT’D) OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . .
10-30-1 10-30-1 10-30-2 10-30-2 10-30-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1 REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 RUBBER COUPLER LUBRICATION . . . . . . . . . . . . . . . . . . 10-210-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-200-1 10-200-1 10-200-1 10-200-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-180-1 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-170-1 10-170-1 10-170-1 10-170-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . 10-40-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1 Stopping The Bobcat Loader . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
10-02
553 Bobcat Loader Service Manual
LIFTING AND BLOCKING THE LOADER
Figure 10-10-2
Figure 10-10-1
P10938 B-7023A
Lift the rear of the loader and install jackstands [Figure 10-10-2]. Figure 10-10-3
WARNING 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
Procedure
P10917
Always park the loader on a level surface. Lift the front of the loader and put jackstands under the loader frame [Figure 10-10-3].
WARNING
NOTE: Make sure the jackstands do not touch the tires.
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
10-10-1
553 Bobcat Loader Service Manual
Put jackstands under the rear corners of the loader frame.
LIFT ARM SUPPORT DEVICE Installing Lift Arm Support Device
Remove any attachment before raising the lift arms.
WARNING 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.
Disconnect the spring from the approved lift arm support device retaining pin (Item 1) [Figure 10-20-1]. Hold onto the lift arm support device (Item 2) [Figure 10-20-1] and remove the retaining pin. Figure 10-20-2
W-2059-0598
1
WARNING 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. W-2271-1197
P10703
Lower the lift arm support device on top of the lift cylinder. Hook the free end of the spring (Item 1) [Figure 10-20-2] to the lift arm support device so there will be no interference with the support device engagement. With the operator in the seat, seat belt fastened and seat bar lowered, start the engine. Loaders without seat sensors Press the green PRESS TO OPERATE Button. Figure 10-20-1
2 1
P10706
Maintenance and service work can be done with the lift arms lowered. If the lift arms are raised for service, use the following procedure:
10-20-1
553 Bobcat Loader Service Manual
LIFT ARM SUPPORT DEVICE (CONT’D)
Removing Lift Arm Support Device
Installing Lift Arm Support Device (Cont’d)
Figure 10-20-5
Figure 10-20-3
1 P-10707
1 P10702 P10708
Remove the pin from the lift arm support device.
Raise the lift arms, until the lift arm support device (Item 1) [Figure 10-20-3] drops onto the lift cylinder rod.
Connect the spring (Item 1) [Figure 10-20-5] from the lift arm support device to the bracket below the lift arms.
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 foot pedals (or hand controls) until both lock.
With the operator in the seat, seat belt fastened and seat bar lowered, start the engine. Loaders without seat sensors press the green PRESS TO OPERATE Button.
Figure 10-20-4 Raise the lift arms a small amount and the spring will lift the support device off the lift cylinder rod. Lower the lift arms and stop the engine. Raise the seat bar and move pedals until both lock. Disconnect the spring from the bracket.
1
P10701
Install pin (Item 1) [Figure 10-20-4] into the rear of the lift arm support device below the cylinder rod.
10-20-2
553 Bobcat Loader Service Manual
LIFT ARM SUPPORT DEVICE (CONT’D) Removing Lift Arm Support Device (Cont’d) Figure 10-20-6
1
P10706
Raise the support device into storage position and insert pin (Item 1) [Figure 10-20-6] through lift arm support device and bracket. Connect spring to pin.
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553 Bobcat Loader Service Manual
the operator cab, install the lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
OPERATOR CAB Description 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 I. Level II is available. Level I - Protection from falling bricks, small concrete blocks, and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services.
Put jackstands under the rear corners of loader (Inset) [Figure 10-30-2]. Loosen the nut (both sides) at the corner of the operator cab [Figure 10-30-1]. Remove the nut and plate (both sides) [Figure 10-30-1].
WARNING 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. W-2014-0895
Level II - Protection from falling trees, rocks; for machines involved in site clearing, overhead demolition or forestry.
WARNING WARNING Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death. W-2069-1299
Both sets of fasteners at the front of the operator cab (ROPS) must be assembled as shown in this manual. Failure to secure ROPS correctly can cause injury or death. W-2005-1189
Figure 10-30-2
Raising The Operator Cab Figure 10-30-1
P-9773
P10724
P10719
Lift on the grab handle and bottom of the operator cab slowly until the cab latching mechanism engages and the cab is all the way up [Figure 10-30-2].
P10723
Stop the loader on a level surface. Lower the lift arms. Stop the engine. If the lift arms must be up while raising
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553 Bobcat Loader Service Manual
OPERATOR CAB (CONT'D)
Emergency Exit
Lowering The Operator Cab
Figure 10-30-4
Figure 10-30-3
P-10715
P0660
The front opening on the operator cab and rear window provide exits.
P10713
Pull down on the bottom of the operator cab until it stops at the latching mechanism. Release the latching mechanism [Figure 10-30-3] and pull the cab all the way down.
Rear Window (If Equipped)
Install the plate and nut (both sides) [Figure 10-30-1].
Push the rear window out of the rear of the operator cab.
Tighten the nuts [Figure 10-30-1] to 40-50 ft.-lbs. (54-68 Nm) torque.
Figure 10-30-5
Pull on the tag on the top of the rear window to remove the rubber cord [Figure 10-30-4].
P10722
Exit through the rear of the operator cab [Figure 10-305].
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553 Bobcat Loader Service Manual
OPERATOR CAB (CONT'D) Emergency Exit (Cont’d) Figure 10-30-6
P9216
Front Door (If Equipped) NOTE: When an Operator Cab Enclosure Kit is installed, the window of the front door can be used as an emergency exit. [Figure 10-30-6]. Pull the plastic loop at the top of the window in the front door to remove the rubber cord [Figure 10-30-6]. Figure 10-30-7
P9217
Push the window out with your foot [Figure 10-30-7] at any corner of the window. Exit through the front door.
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553 Bobcat Loader Service Manual
TRANSPORTING THE BOBCAT LOADER
Figure 10-40-2
Procedure
WARNING 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.
P10731
W-2058-0494
Figure 10-40-1
P10730
SUPPORT P10732
P-10726A P-10726
A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [Figure 1040-1]. The rear of the trailer must be blocked or supported [Figure 10-40-1] when loading or unloading the loader to prevent the front end of the trailer from raising up.
P10728
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 [Figure 10-40-2]. •
Lower the bucket or attachment to the floor.
•
Stop the engine.
•
Engage the parking brake.
•
Install chains at the front and rear loader tie down positions (Inset) [Figure 10-40-2].
Stopping The Bobcat Loader When the steering levers are moved to the neytral position, the hydrostatic transmission will act as a service brake and stop the loader. 10-40-1
553 Bobcat Loader Service Manual
Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)
TOWING THE LOADER Procedure
The towing chain (or cable) must be rated at 1 and 1/2 times the weight of the loader. (See LOADER SPECIFICATIONS on Page SPEC-10-1.)
IMPORTANT Never attempt to start the engine by pushing or pulling. Hydrostatic pumps and motors will be damaged.
•
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).
I-2001-0285
If the electrical system is not functioning, contact your Bobcat loader dealer. (Part of the brake system must be disassembled to move the loader.)
IMPORTANT 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
Figure 10-50-1
B-6924 E-1457A
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 Raising The Operator Cab on Page 10-30-1.) Clean the area around the hydrostatic pumps. Remove the high pressure relief valve from one side of each hydrostatic pump [Figure 10-50-1] and install the relief valve tubes. Install the plugs and tighten.
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553 Bobcat Loader Service Manual
The Remote Start Switch is required when the service technician is adjusting the steering linkage, checking the hydraulic/hydrostatic system.
REMOTE START Procedure
Lift and block the loader.(See Procedure on Page 10-101.)
WARNING 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
WARNING 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.
Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device on Page 10-20-1.) Raise the operator cab. (See Procedure on Page 10-101.) NOTE: On current model loaders, the connector on the BICS harness is round (7-pin) connector, not a rectangular (8-pin) connector. Use the adapter harness (Item 1) [Figure 10-60-1] to connect the remote start switch to the loader harness. Figure 10-60-2
W-2017-0286
1
1
Figure 10-60-1
P10965
Disconnect the operator cab wire harness (Item 1) [Figure 10-60-2] from the engine wire harness.
1 P7101
The tool listed below will be needed to do the following procedure: MEL1429C - Remote Start Switch
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553 Bobcat Loader Service Manual
REMOTE START (CONT'D)
Figure 10-60-4
Procedure (Cont'd) Figure 10-60-3 1
1
P4713
Put the traction lock override switch (Item 1) [Figure 1060-4] in the ON position so the traction function is locked. The wheels are not able to turn.
1
Turn the key to the right and start the engine. Figure 10-60-5
1
P10966
2 Connect the remote start switch to the engine harness connectors (Item 1) [Figure 10-60-3].
P4714
Move the traction lock override switch (Item 1) [Figure 10-60-5] to the OFF position so the traction function is unlocked. The wheels are now able to turn. The auxiliary mode switch (Item 2) [Figure 10-60-5] is used to turn the front auxiliary quick couplers ON and OFF during relief pressure and flow tests.
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553 Bobcat Loader Service Manual
SERVICE SCHEDULE Chart 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.
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 instructions can cause injury or death. W-2003-0903 SERVICE SCHEDULE
ITEM
HOURS
SERVICE REQUIRED
■
8-10
50 100 200 250 500 1000
Engine Oil Check the oil level and add as needed. Engine Air Filter and Air System Check display panel. Service only when required. Check for leaks and damaged components. Engine Cooling System Clean debris from oil cooler, radiator & grill. Tires Check for damaged tires and correct air pressure. Seat Belt and Seat Bar and Check the condition of seat belt. Check the sear bar and pedal interlocks for Control Interlocks correct operation. Clean dirt and debris from moving parts. Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or safety treads that are damaged or worn. Indicators and Lights (Opt.) Check for correct operation of all indicators and lights. Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab. Lift Arms, Bob-Tach Pivot Pins Lubricate with multi-purpose lithium based grease. and Wedges Engine Fuel Filter Remove the trapped water. Bobcat Interlock Control Check BICS™ System Controller functions. Clean dirt, debris or objects Systems (BICS™) from under or behind seat as required. Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair Tubelines or replace as needed. Control Pedals & Steering Check for correct operation. Repair or adjust as needed. Wheel Nuts Parking Brake Alrernation Belt Battery Engine/Hydro. Drive Belt Alternator Belt Final Drive Trans. (Chaincase) Spark Arrestor Muffler Battery Engine Oil and Filter Fuel Filter Steering Lever Pivots
U Joint Hyd./Hydros Filter Hyd Reservoir Breather Cap Hydraulic/Hydrostatic Reservoir Chaincase Bobcat Interlock Control System (BICS™)
❏Check for loose wheel nuts and tighten to 105-115 ft.-lbs. (142-156 Nm) torque Check operation. Check tension & adjust as needed. Check cables, connections and electrolyte level. Add distilled water as needed. Check for wear or damage. Check idler arm stop. Check tension and adjust as needed. Check fulid level and add as needed. Clean the sprk chamber. Check cables, connections & electrolyte level. Add distilled water as needed. Replace oil and filter. Use CD or better grade oil and Bobcat filter. Replace filter element. Grease two fittings. Add oil to steering shaft. Grease three fitting with correct grease. ● Replace the filter element. Replace the reservoir 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.
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553 Bobcat Loader Service Manual
AIR CLEANER SERVICE
Figure 10-80-3
Replacing Filter Element Figure 10-80-1
1
P10734
Outer Element: P10747
(See SERVICE SCHEDULE on Page 10-70-1) 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. Replace the large (outer) filter element only when the red ring shows in the window (Item 1) [Figure 10-80-1] of the condition indicator.
Pull the outer filter element from the air cleaner housing [Figure 10-80-3]. NOTE: Make sure all sealing surfaces are free of dirt and debris. Install a new outer element. Install the dust cover and fasten the clamps.
NOTE: Push the button on the condition indicator (See Inset) and start the engine. If the red ring does not show, do not replace the filter element [Figure 10-80-1]. Figure 10-80-2
1
2
P10733
Disengage the clamps (Item 1) [Figure 10-80-2] and remove the dust cover (Item 2) [Figure 10-80-2].
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553 Bobcat Loader Service Manual
AIR CLEANER SERVICE (CONT’D) Replacing Filter Element (Cont’d) Figure 10-80-4
P10729
Inner Element: Only replace the inner filter element under the following conditions [Figure 10-80-4]: •
Replace the inner filter element every third time the outer filter is replaced.
•
Replace the inner filter element when the red ring still shows in the condition indicator window after the outer filter is replaced.
Pull the inner filter element from the air cleaner housing. NOTE: Make sure all sealing surfaces are free of dirt and debris. Install the new inner element. Record the operating hours of the loader on the decal inside the rear door.
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553 Bobcat Loader Service Manual
ENGINE COOLING SYSTEM
Figure 10-90-2
Cleaning The Cooling System
WARNING Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure. • Flying debris or loose material is present. • Engine is running. • Tools are being used. W-2019-1285 P10743
Figure 10-90-1 Use air pressure or water pressure to remove the debris in the area of the radiator and oil cooler [Figure 10-90-2]. Install the rear grill and close the rear door.
1
P10749
Check the cooling system every day to prevent overheating, loss of performance or engine damage. Open the rear door. Remove the access panel from the blower housing (Item 1) [Figure 10-90-1]. Remove the rear grill. (See Removal And Installation Page 50-60-1.)
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553 Bobcat Loader Service Manual
ENGINE COOLING SYSTEM (CONT’D)
Replacing The Coolant
Checking The Coolant Level
IMPORTANT
Figure 10-90-3
AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze. Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage. 1
Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system. Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.
P10760
I-2124-0497
Open the rear door. The coolant recovery tank (Item 1) [Figure 10-90-3] must be at the FULL COLD mark when engine is cool.
Figure 10-90-4
Propylene Glycol NOTE: The loader is factory filled with propylene glycol coolant. DO NOT mix propylene glycol with ethylene glycol.
1
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. P10744
Use a refractometer to check the condition of propylene glycol in your cooling system. Close the rear door before operating the loader.
Open the rear door. Remove the rear grill. (See Removal And Installation Page 50-60-1.) Remove the radiator cap (Item 1) [Figure 10-90-4].
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553 Bobcat Loader Service Manual
ENGINE COOLING SYSTEM (CONT’D)
Figure 10-90-6
Replacing The Coolant (Cont’d) Figure 10-90-5
1
P10760
1 Fill the coolant recovery tank 1/3 full with premixed coolant (Item 1) [Figure 10-90-6].
P10687
Connect a hose to the coolant drain valve (Item 1) [Figure 10-90-5] or use a funnel to keep coolant from getting into the engine compartment. Open the valve and drain all the coolant into a container. Close the valve. Fill the radiator with premixed coolant and install the radiator cap. (See Checking The Coolant Level Page 1090-2 for premix recommendations.)
Check the radiator cap for correct pressure rating or overheating can result. Check for leaks in the cooling system. Check for worn or damaged hoses, clamps or radiator. Check for loose or worn water pump belt. Replace damaged parts immediately to prevent leaks and overheating. Install the radiator cap and the rear grill and close the rear door.
10-90-3
553 Bobcat Loader Service Manual
FUEL SYSTEM
Figure 10-100-1
Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1. The following is one suggested blending guideline which should prevent fuel gelling during cold temperatures: TEMP. F° (C°)
NO. 2
NO. 1
+15° (-9°)
100%
0%
Down to -20° (-29°)
50%
50%
Below -20° (-29°)
0%
100%
1
P10710
Contact your fuel supplier for local recommendations.
Remove the fuel fill cap (Item 1) [Figure 10-100-1]
Filling The Fuel Tank
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!
WARNING Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.
Install and tighten the fuel fill cap (Item 1) [Figure 10100-1].
W-2063-0887
WARNING 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
10-100-1
553 Bobcat Loader Service Manual
FUEL SYSTEM (CONT’D)
Replacing Filter:
Fuel Filter
Clean the area around the fuel filter.
Figure 10-100-2
Close the shut-off valve (Item 1) [Figure 10-100-2]. Remove the fuel filter element (Item 2) [Figure 10-100-3] Install the new filter element. Tighten the fuel filter. Open the shut-off valve [Figure 10-100-2]
1
P10714
Figure 10-100-3
2
1 P10678
(See SERVICE SCHEDULE on Page 10-70-1), for the service interval for removing water from, or replacing the fuel filter. Removing Water Shut-off the fuel supply (Item 1) [Figure 10-100-2] (turn clockwise). Loosen the drain at the bottom of the filter element (Item 1) [Figure 10-100-3] to drain water from the filter. Open the shut-off valve [Figure 10-100-2].
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553 Bobcat Loader Service Manual
FUEL SYSTEM (CONT’D)
WARNING
Removing Air From The Fuel System Figure 10-100-4
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.
3
W-2103-1285
After replacing the 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. Open the vent plug (Item 1) [Figure 10-100-4] on top of the fuel filter head. P-10679
Operate the hand pump (Item 2) [Figure 10-100-4] until fuel flows from the vent with no air bubbles. Tighten the vent plug. Operate the hand pump [Figure 10-100-4] until it feels solid. Move the engine speed control to minimum RPM. Open the valve (Item 3) [Figure 10-100-4] and squeeze the hand pump several times. Start the engine. When the engine runs smoothly, close the valve (Item 3) [Figure 10-100-4]. Close the rear door.
P-10675
1
2
P-10678
10-100-3
553 Bobcat Loader Service Manual
ENGINE LUBRICATION SYSTEM
Replacing Oil And Filter
Checking Engine Oil
Figure 10-110-2
Figure 10-110-1
1
2 P13624
Check the engine oil level every day before starting the engine for the work shift. Open the rear door and remove the dipstick (Item 1) [Figure 10-110-1]. Keep the oil level between the marks on the dipstick.
1
Use a good quality motor oil that meets API Service Classification of CD or better (See Oil Chart 10-110-1.) Install the dipstick and close the rear door.
P10689
(See SERVICE SCHEDULE on Page 10-70-1), for the service interval for replacing the engine oil and filter.
Oil Chart RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
Run the engine until it is at operating temperature. Stop the engine. Open the rear door. Remove the cap (Item 1) [Figure 10-110-2] from the end of the hose and drain the oil into a container. Dispose of used oil in an environmentally safe manner. Remove the filter (Item 2) [Figure 10-110-2]. Clean the filter housing surface. Put clean oil on the gasket of the new filter. Install the filter and hand tighten. Install the cap on the drain hose and tighten.
*
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE(DIESEL ENGINES MUST USE API CLASSIFICATION CD, CF4, CG4)
Can be used ONLY when available with appropriate diesel rating.
10-110-1
553 Bobcat Loader Service Manual
ENGINE LUBRICATION SYSTEM (CONT’D) Replacing Oil And Filter (Cont’d) Figure 10-110-3
1 1
P-10677
P10689
Remove the oil fill cap (Item 1) [Figure 10-110-3]. Use a good quality motor oil that meets API Service Classification of CD or better. (See Oil Chart 10-110-1.) Fill to capacity. (See Capacities on Page SPEC-10-4.) 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) [Figure 10-110-3]. NOTE: DO NOT overfill the crankcase. Record the operating hours of the loader on the decal inside the rear door. Close the rear door before operating the loader.
10-110-2
553 Bobcat Loader Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM
Figure 10-120-2
Description The hydraulic and hydrostatic systems use the same hydraulic fluid reservoir. The system has an engine driven pump that supplies fluid to the control valve, lift and tilt cylinders.
1
Fluid also goes from the control valve to the hydrostatic transmission pumps to provide charge pressure and cooling. A filter is installed on the right side of the engine compartment. This filter cleans the fluid for the hydrostatic transmission. The oil cooler is under the radiator. The oil cooler cools the hydraulic fluid before it returns to the hydrostatic pump.
P10697
Remove the filler cap (Item 1) [Figure 10-120-2]. Add fluid to the reservoir until it shows in the sight gauge [Figure 10-120-1].
Checking And Adding Fluid Install the filler cap [Figure 10-120-2]. Figure 10-120-1
1
P10693
Use only recommended fluid in the hydraulic/hydrostatic system. (See Hydraulic System on Page SPCE-10-3.) Put the loader on a level surface. Lower the lift arms and put the attachment flat on the ground. Stop the engine. Hydraulic fluid must show in the sight gauge (Item 1) [Figure 10-120-1].
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553 Bobcat Loader Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)
Replacing Hydraulic Fluid
Replacing The Hydraulic/Hydrostatic Filter
Figure 10-120-4
Figure 10-120-3
1 1
P10697 P10685
(See SERVICE SCHEDULE on Page 10-70-1) for the correct service interval to replace the filter.
(See SERVICE SCHEDULE on Page 10-70-1), for the service interval to replace the fluid. Replace the fluid if it becomes contaminated and after any major repairs. Remove the filler cap (Item 1) [Figure 10-120-4].
Stop the engine. Open the rear door. Clean the area around the filter housing and remove the filter element (Item 1) [Figure 10-120-3]. Clean the surface where the filter seal contacts the filter housing. Lubricate the rubber gasket with grease. Install the filter element and hand tighten. Operate the loader and check for leaks at the filter. Check fluid level in the reservoir and add as needed. Close the rear door.
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553 Bobcat Loader Service Manual
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D) Replacing Hydraulic Fluid (Cont’d) Figure 10-120-5
1
P10695
Remove the screen (Item 1) [Figure 10-120-5]. Wash the screen in clean solvent. Install the screen in the hydraulic reservoir. Remove the fluid from the hydraulic reservoir. (See Replacing Hydraulic Fluid on Page 10-120-2.) Remove the filter element. Install a new filter element. (See Replacing The Hydraulic/Hydrostatic Filter on Page 10-120-2.) Add hydraulic/hydrostatic fluid to the reservoir. (See LOADER SPECIFICATIONS on Page SPCE-10-1.) DO NOT fill above the sight glass. Install the filler cap. Close the rear door. Operate the loader. Stop the engine. Check the fluid level and add as needed.
WARNING AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual. W-2012-0497
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553 Bobcat Loader Service Manual
FINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Oil Figure 10-130-1
1
P10699
The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic/ hydrostatic system. (See LOADER SPECIFICATIONS on Page SPCE-10-1.) Drive the loader on a level surface. Stop the engine. Remove the plug (Item 1) [Figure 10-130-1] from the front of the chaincase housing. If oil can be reached with the tip of the your finger through the hole the oil level is correct. If the level is low, add oil through the check plug hole until the oil flows from the hole. Install and tighten the plug.
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553 Bobcat Loader Service Manual
AUXILIARY CONTROL LOCKBOLT Removal Figure 10-140-1
1
P10754
The auxiliary control has a lockbolt (Item 1) [Figure 10140-1] that must be removed to use the optional auxiliary hydraulics. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the nut and bolt (Item 1) [Figure 10-140-1] at the right hand steering lever. Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)
10-140-1
553 Bobcat Loader Service Manual
BOB-TACH
Figure 10-150-3
Inspection And Maintenance Bob-Tach Wedge
WARNING Bob-Tach wedges must extend through the holes in attachment. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death. W-2102-0588
Wedge Must Contact Lower Edge Of Hole In The Attachment
Figure 10-150-1
B-15177
Figure 10-150-4 1 N-17033
N-17031
Move the Bob-Tach levers to engage the wedges [Figure 10-150-1]. The levers and wedges must move freely. The wedges must extend through the holes in the attachment mounting frame (Item 1) [Figure 10-150-1].
TS-1062
The spring loaded wedge (Item 1) [Figure 10-150-1] must contact the lower edge of the hole in the attachment (Item 1) [Figure 10-150-2] and [Figure 10-150-3].
Figure 10-150-2 If the wedge does not contact the lower edge of the hole [Figure 10-150-2] and [Figure 10-150-3], the attachment will be loose and can come off the Bob-Tach. Inspect the mounting frame on the attachment and the Bob-Tach, linkages and wedges for excessive wear or damage [Figure 10-150-4]. Replace any 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
N-17034
Lubricate the wedges. (See SERVICE SCHEDULE on Page 10-70-1) and (See LUBRICATION OF THE BOBCAT LOADER on Page 10-160-1.)
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553 Bobcat Loader Service Manual
LUBRICATION OF THE BOBCAT LOADER
Figure 10-160-3
Procedure Figure 10-160-1
1
3
P10698
3. Lift Arm Pivot Pin (Both Sides) [Figure 10-160-3] P10694
Figure 10-160-4 Lubricate the loader as specified in the SERVICE SCHEDULE, Contents Page 10-01, for the best performance of the loader.
4
Record the operating hours each time you lubricate the Bobcat loader. Always use a good quality lithium based multi-purpose grease when you lubricate the loader. Apply lubricant until extra grease shows. Lubricate the following locations on the loader: 1. Rod End Lift Cylinder (Both Sides) [Figure 10-160-1].
P10758
Figure 10-160-2 4. Base End Tilt Cylinder (Both Sides) [Figure 10-1604].
2
P10698
2. Base End Lift Cylinder (Both Sides) [Figure 10-1602].
10-160-1
553 Bobcat Loader Service Manual
LUBRICATION OF THE BOBCAT LOADER (CONT’D) Procedure (Cont’d) Figure 10-160-5
5
6
7
P10696
5. Rod End Tilt [Figure 10-160-5] 6. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-5] 7. Bob-Tach Wedge (Both Sides) [Figure 10-160-5] Figure 10-160-6
8
P10709
8. 250 Hours: Steering Lever Shaft Bearings two [Figure 10-160-6] (The opposite end is lubricated under the cab.). Put oil in the hole of the cross shaft where the right and left steering shafts meet under the cab.
10-160-2
553 Bobcat Loader Service Manual
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.
TIRE MAINTENANCE Wheel Nuts Figure 10-170-1
Mounting 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.
P10704
(See SERVICE SCHEDULE on Page 10-70-1), for the service interval to check the wheel nuts. The correct torque is 105-115 ft.-lbs. (142-156 Nm) torque [Figure 10-170-1].
During inflation of the tire, check the tire pressure frequently to avoid over inflation.
WARNING
Rotating Check the tires regularly for wear, damage and pressure. (See LOADER SPECIFICATIONS on Page SPEC-10-1.)
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
Figure 10-170-2
IMPORTANT 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
B-9976
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 [Figure 10-170-2]. 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.
10-170-1
553 Bobcat Loader Service Manual
SPARK ARRESTOR MUFFLER
WARNING
Cleaning Procedure
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.
IMPORTANT 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.
W-2068-1285
Figure 10-180-1
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.
1
I-2022-0595 P10692
WARNING
(See SERVICE SCHEDULE on Page 10-70-1), for service interval for cleaning the spark arrestor muffler.
Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles. Failure to obey can cause serious injury. W-2011-1285
Do not operate the loader with a defective exhaust system. Stop the engine. Open the rear door. Cover the battery with a fire retardant material.
WARNING
Remove the plug (Item 1) [Figure 10-180-1] at the bottom of the muffler.
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
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.
10-180-1
553 Bobcat Loader Service Manual
PIVOT PINS Procedure Figure 10-190-1
1
P10698
All lift arm and cylinder pivots have a large pin held in position with a retainer bolt and lock nut (Item 1) [Figure 10-190-1]. Check that the lock nuts are tightened to 18-20 ft.-lbs. (24-27 Nm) torque.
10-190-1
553 Bobcat Loader Service Manual
SEAT BAR RESTRAINT SYSTEM
Seat Bar Maintenance
Description
Figure 10-200-1
WARNING Clean (Both Sides)
AVOID INJURY OR DEATH The seat bar system must lock the lift and tilt control pedals in neutral when the sear bar is up. Service the system if pedals do not lock correctly. W-2105-1285
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.
P10361
Figure 10-200-2
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. Seat Bar Inspection 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.
Clean (Both Sides)
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. Raise the seat bar. Try to move each foot 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. Pull the seat bar down. Loaders without seat sensors press the green PRESS TO OPERATE Button. Lower the lift arms. Operate the lift pedals. While the lift arms are going up, raise the seat bar and the lift arms should stop. Lower the seat bar, lower the lift arms and place 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.
P10717
(See SERVICE SCHEDULE on Page 10-70-1), and on the loader for correct service interval. Clean any debris or dirt from the moving parts [Figure 10-200-1] & [Figure 10-200-2]. 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 Bobcat replacement parts.
10-200-1
553 Bobcat Loader Service Manual
RUBBER COUPLER LUBRICATION Procedure Figure 10-210-1
1
P-31910
(See SERVICE SCHEDULE on Page 10-70-1), for the correct service interval to lubricate the rubber coupler grease fitting (Item 1) [Figure 10-210-1]. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Use the special U-joint grease (P/N 6599719) for correct lubrication for the U-joint. Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)
10-210-1
553 Bobcat Loader Service Manual
HYDRAULIC SYSTEM CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-20-1 20-20-1 20-20-6 20-20-5 20-20-2
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-21-1 20-21-1 20-21-4 20-21-3 20-21-1
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . 20-40-1 Anti-Cavitation Check Valve. . . . . . . . . . . . . . . . . . . . . . . . 20-40-7 Auxiliary Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-40-5 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16 Lift Spool Detent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10 Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5 Main Releif Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6 One Way Restrictors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15 Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1 Rubber Boot (Lift). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9 Rubber Boot (Tilt). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9 Rubber Boot (Aux.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9 Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17 Tilt Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
HYDRAULIC SAFETY SYSTEM &
DRIVE SYSTEM
ELECTRICAL SYSTEM & ANALYSIS ENGINE SERVICE
SPECIFICATIONS
HYDRAULIC FILTER HOUSING. . . . . . . . . . . . . . . . . . . . . . . 20-70-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1 HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . 20-80-1 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check The Output Of The Hydraulic Pump . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-60-1 20-60-1 20-60-6 20-60-5 20-60-8 20-60-3
Continued On Next Page
20-01
553 Bobcat Loader Service Manual
HYDRAULIC SYSTEM (CONT’D) HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . 20-10-1 Tighten Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5 LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-50-1 20-50-2 20-50-1 20-50-1
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Main Relief Valve With Auxiliaries. . . . . . . . Checking The Main Relief Valve Without Auxiliaries . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-30-1 20-30-2 20-30-1 20-30-3
TILT LOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-1 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-51-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-1
20-02
553 Bobcat Loader Service Manual
HYDRAULIC/HYDROSTATIC SCHEMATIC 553 (S/N 528011001 AND ABOVE) (S/N 528111001 AND ABOVE) (PRINTED MARCH 2004) V-0515legend
LEGEND 1
RESERVOIR: Capacity . . . . . . . . . 9.2 Qts. (8,7 L)
2
DRIVE MOTOR SHUTTLE VALVE
17
PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL
18 FILTER - TILT LOCK VALVE (SCREEN) 3 4
5
CHARGE PRESSURE SWITCH: 30-40 PSI (2,7-2,8 Bar) HYDRAULIC FLUID TEMPERATURE SWITCH: 224-234 degrees F. (107-112 degrees C.) FILTER - HYDRAULIC/HYDROSTATIC (CANISTER)
19
CHECK VALVE - TILT LOCK VALVE
20
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT/TILT CONTROL
21
PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY PASS CHECK VALVE - LIFT LOCK VALVE
6
SPRING LOADED FILTER BYPASS VALVE: 45-55 PSI (3,1-3,8 Bar)
22
7
FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDRAULIC/ HYDROSTATIC MOTOR
23 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL
8
VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDRAULIC/ HYDROSTATIC PUMP
24 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL
9
HYDRAULIC PUMP: Gear Type . . . . . . 11 GPM (42 L/min.) at High Engine Idle
25 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF)
10
RELIEF/REPLENISHING VALVE - HIGH PRESSURE: 3750 PSI (259 Bar)
26
11
REPLENISHING VALVE
12 DUAL STAGE RELIEF VALVE - MAIN: 2300/3000 PSI (159/207 Bar) at Front Quick Couplers 13 LOAD CHECK VALVE 14 DIFFERENTIAL PRESSURE SWITCH: 25-46 PSI (1,7-3,2 Bar) 15 ONE WAY RESTRICTOR VALVE - LIFT: 0.125" (3,175 mm) 16 ONE WAY RESTRICTOR VALVE - TILT: 0.109" (2,769 mm)
FLOW DIVIDER ADJUSTMENT VALVE
27 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL 28 CHECK VALVE - BUCKET POSITION VALVE 29
ANTICAVITATION
30
ANTICAVITATION
31
OIL COOLER BY-PASS 117-135 PSI (8,1-9,3 Bar)
32
CHARGE RELIEF VALVE 45-65 PSI (3,1-4,5 Bar)
33
PORT RELIEF VALVE 3500 PSI (241 Bar)
NOTE: Unless otherwise specified springs have NO significant pressure value.
Printed in U.S.A.
V-0515legend (3-4-04)
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