Bobcat 450, 453 Skid-Steer Loader Service Manual – 6724259 (1–96)

450 (S/N: 561711001 & Above) – 453 (S/N: 561811001 & Above)
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This workshop repair service manual PDF download for the 450, 453 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Loader 450, 453
450 (S/N: 561711001 & Above)
453 (S/N: 561811001 & Above)

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
BICS™ SYSTEM
SPECIFICATIONS
SERVICE MANUAL REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6724259 (1–96)
Total Pages : 350

This Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
LOADER SERIAL NUMBER
ENGINE SERIAL NUMBER
DELIVERY REPORT
BOBCAT SKID STEER LOADER IDENTIFICATION
OPTIONS AND ACCESSORIES

PREVENTIVE MAINTENANCE
SERVICE SCHEDULE
LIFTING AND BLOCKING THE LOADER
Procedure
TRANSPORTING THE LOADER
Procedure
LIFTING THE LOADER
Single Point Lift
TOWING THE LOADER
LIFT ARM SUPPORT DEVICE
Engaging The Lift Arm Support Device
Disengaging The Lift Arm Support Device
OPERATOR CAB
Description
Emergency Exit
Raising The Operator Cab
Lowering The Operator Cab
SEAT BAR RESTRAINT SYSTEM
Seat Bar Inspection
Seat Bar Maintenance
Foot Pedal Clean Out
AIR CLEANER SERVICE
450 Loader
453 Loader
FUEL SYSTEM
450 Loader
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
453 Loader
Fuel Specifications
Filling the Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
450 Loader
Replacing Oil And Filter
453 Loader
Replacing Oil And Filter
ENGINE COOLING SYSTEM
450 Loader
Cleaning The Cooling System
453 Loader
Checking The Coolant Level
Cleaning The Cooling System
Removing Coolant From The Cooling System
ALTERNATOR BELT ADJUSTMENT (453)
ELECTRICAL SYSTEM
Description
PIVOT PINS
SPARK ARRESTOR MUFFLER
Cleaning The Spark Arrestor Muffler
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Replacing The Hydraulic/Hydrostatic Filter Element
Removing The Hydraulic/Hydrostatic Fluid
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
AUXILIARY CONTROL LOCKBOLT
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Tire Inflation
LUBRICATING THE LOADER
BOB–TACH
REMOTE START SWITCH
Procedure

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
TROUBLESHOOTING
HYDRAULIC SYSTEM INFORMATION
Tighten Procedures
LIFT CYLINDER(S)
Removal and Installation
Checking The Lift Cylinder For Internal Leakage
TILT CYLINDER
Removal And Installation
Checking The Tilt Cylinder For Internal Leakage
HYDRAULIC CYLINDERS
Disassembly And Assembly
Lift Cylinder Identification
LIFT ARM BY–PASS BLOCK
Removal And Installation
Disassembly And Assembly
HYDRAULIC CONTROL VALVE
Checking The Main Relief Valve
Main Relief Valve Removal And Installation
Main Relief Valve Adjustment
Removal And Installation
Identification Chart
Disassembly And Assembly
Load Check Valve
Main Relief Valve
Anti–Cavitation Valve
Rubber Boot
Lift Spool Detent
Tilt Centering Spring
Auxiliary Spool Detent
Spool Seal Installation
HYDRAULIC PUMP
Checking The Output Of The Hydraulic Pump
Removal And Installation
Disassembly And Assembly
Parts Identification
HYDRAULIC RESERVOIR
Removal And Installation
HYDRAULIC FILTER BLOCK
Removal And Installation
Disassembly And Assembly
450 Filter Block
453 Filter Block
PEDAL INTERLOCK LINKAGE
Removal And Installation
CONTROL PEDALS
Removal And Installation
Pedal Adjustment

HYDROSTATIC SYSTEM
TROUBLESHOOTING
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function
CONTROL SHIELD AND STEERING LEVER PANELS
Removal And Installation
STEERING LEVERS AND STEERING LEVER PANELS
Removal And Installation
STEERING LEVERS
Removal And Installation
Disassembly And Assembly
STEERING LINKAGE
Adjustment
Pintle Arm Removal And Installation
Pintle Arm Disassembly And Assembly
DRIVE BELT
Removal And Installation
450 Loader
453 Loader
HYDR0STATIC PUMP
Checking Charge Pressure
Removal And Installation
450 Loader
453 Loader
Parts Identification
Disassembly And Assembly
Inspection
TENSION PULLEY AND SPRING
Removal And Installation
HYDROSTATIC MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly

DRIVE SYSTEM
PARKING BRAKE PEDAL
Removal And Installation
Disassembly And Assembly
CHAINCASE FLUID
Removing Oil From The Chaincase
CHAINCASE COVER
Removal And Installation
Disassembly And Assembly
PARKING BRAKE DISC
Removal And Installation
AXLE HUB
Removal And Installation
AXLE SEAL
Removal And Installation
AXLE, BEARINGS, AND SPROCKET
Removing The Axle
Removing And Installing The Axle Bearing
Removing The Bearing Races
Installing The Bearing Races
Installing The Inner Bearing And Axle Sprocket
DRIVE CHAINS
Removal And Installation

MAIN FRAME
SEAT BAR
Gas Spring Removal And Installation
Compressing The Gas Spring
Seat Bar Removal And Installation
Assembly
OPERATOR CAB
Removal And Installation
OPERATOR CAB GAS CYLINDER
Removal And Installation
OPERATOR SEAT
Removal And Installation
BOB–TACH
Removal
Installation
Seal Removal And Installation
Lever And Wedge Removal
Lever And Wedge Installation
LIFT ARMS
Removal And Installation
FUEL TANK
Removal And Installation
REAR WINDOW
Removal And Installation
REAR DOOR
Exhaust Pipe Removal And Installation
Removal And Installation

ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
TROUBLESHOOTING
Chart
ELECTRICAL SYSTEM INFORMATION
Description
Fuse Location
Relay Switches Location – 453 Only
BATTERY
Removal And Installation
Maintenance
ALTERNATOR (450)
Checking The Alternator Circuit (450)
Replacing The Stator
ALTERNATOR (453)
Removal And Installation
Adjusting The Alternator Belt
Alternator Output Test
Alternator Regulator Test
Disassembly and Inspection – Parts Identification
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Rectifier Continuity (Diode) Test
Assembly
STARTER (453)
Removal And Installation
Checking The Starter
Parts Identification
Disassembly, Assembly And Inspection
STARTER (450)
Checking The Starter
Removal And Installation
Disassembly, Assembly And Inspection
INSTRUMENT PANEL
Removal And Installation
FRONT LIGHTS (OPTIONAL)
Removal And Installation
REAR LIGHT (OPTIONAL)
Removal And Installation

ENGINE SERVICE
ENGINE SERVICE (450)
TROUBLESHOOTING
IGNITION SYSTEM
Spark Plugs
Ignition Module Air Gap
Testing Ignition Module Primary
Testing Ignition Module Secondary
Valve & Tappet Clearance
Compression Test
CARBURETOR AND GOVERNOR
Carburetor Adjustment On The Engine
Main Fuel Adjustment
Idle Fuel Adjustment
Idle Speed Setting
Shutdown Control Solenoid
Governor And Adjustment
Disassembly And Assembly
ENGINE
Removal And Installation
Muffler Removal And Installation
Intake Manifold Removal And Installation
Breather and Valve Cover Removal And Installation
Fuel Pump Removal And Installation
ENGINE DISASSEMBLY
Flywheel Removal And Installation
Stator Removal and Installation
Cylinder Head Removal
Cylinder Barrel Removal
Cylinder Barrel Inspection And Resizing
Valve Removal And Installation
Valve Guide Removal And Installation
Valve Seat Insert Removal
Valve Seat Insert Installation
Valve Details
Piston And Piston Rings
Closure Plate
Crankcase Halves
Camshaft Removal
Crankshaft Removal
Connecting Rod Removal
Governor Gear And Cross Shaft Removal
Oil Pickup Removal
OIl Pump Removal
ENGINE ASSEMBLY
Oil Pump Installation
Cross Shaft And Governor Shaft Installation
Connecting Rod Installation
Crankshaft And Bearing Installation
Tappets And Camshaft Installation
Sealing The Crankcase
Recommended Sealants
Installing Camshaft Bore Plug
Installing Crankcase Halves
Front And Rear Seal Installation
Filter Adapter Installation
Installing Oil Pressure Relief Valve And Closure Plate
Piston Installation
Setting Valve To Tappet Clearance
Cylinder Head Installation
ENGINE SERVICE 453 (KUBOTA)
TROUBLESHOOTING
FUEL SYSTEM
Replacing The Fuel Filter
Removing The Air From The Fuel System
Fuel Injection Pump
Checking The Injection Pump
Removing The Injection Pump
Installing The Injection Pump
Timing The Injection Pump
Fuel Injector Nozzles
Removing The Fuel Injector Nozzle
Checking Fuel Injector Nozzles
Installing The Fuel Injector Nozzle
Checking Glow Plugs
Engine Compression Test
OIL COOLER & SHROUDING
Removal And Installation
RADIATOR
Removal And Installation
ENGINE SPEED CONTROL
Adjustment
Removal And Installation
ENGINE
Removal And Installation
FLYWHEEL
Removal And Installation
FAN
Removal And Installation
CYLINDER HEAD
Removing The Cylinder Head
Disassembly Of The Cylinder Head
Servicing The Cylinder Head
Assembly Of The Cylinder Head
Installing The Cylinder Head
REPAIRING THE ENGINE
Removing The Gearcase
Removing The Timing Gear, Camshaft & Oil Pump
Removing Pistons & Crankshaft
Servicing The Timing Gear And Camshaft
Servicing The Connecting Rods And Pistons
Servicing The Crankshaft
Servicing The Cylinder Liners
Servicing The Oil Pump
Servicing The Water Pump
ASSEMBLY OF THE ENGINE
Installing The Crankshaft
Installing The Pistons
Installing The Camshaft And Timing Gears
Installing The Gearcase Cover

SYSTEMS ANALYSIS
BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM)
Inspecting The BICS™ System Controller (Engine STOPPED – Key ON)
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
Inspecting The Traction Lock (Engine Running)
Inspecting The Lift Arm By–Pass Control
Maintenance
Troubleshoot Chart
Troubleshooting Guide
BICS CONTROLLER
TRACTION LOCK
SEAT SENSOR
SEAT BAR SENSOR
LIFT LOCK BYPASS VALVE
BICS™ SYSTEM CONTROLLER
Removal And Installation
Controller Test
SEAT BAR SENSOR
Removal And Installation
Seat Bar Sensor Test
SEAT SENSOR
Removal And Installation
Seat Sensor Test
TRACTION LOCK
Removal And Installation
LIFT ARM BY–PASS BLOCK
Removal And Installation
LIFT AND TILT LOCK BY–PASS VALVE
Disassembly And Assembly

SPECIFICATIONS
450 LOADER SPECIFICATIONS
PERFORMANCE
CONTROLS
ENGINE
HYDRAULIC SYSTEM
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
ENGINE SPECIFICATIONS – 450 (KOHLER)
Engine (General)
Cylinder Bore
Crankshaft
Camshaft
Connecting Rod
Piston, Pin & Rings
Valves, Guides & Tappet
Oil Pump
Engine Torque
453 LOADER SPECIFICATIONS
PERFORMANCE
CONTROLS
ENGINE
HYDRAULIC SYSTEM
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
ENGINE SPECIFICATIONS – 453 (KUBOTA)
Fuel Injector Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Rocker Arms
Camshaft
Cylinders
Piston Rings
Pistons
Crankshaft
Oil Pump
Thermostat
Crankshaft Re–Grind Data
Engine Torque
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O–ring Face Seal Connection
Straight Thread O–ring Fitting
Tubelines And Hoses
Flare Fitting
O–ring Flare Fitting
Port Seal Fitting
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION
GLOSSARY OF HYDRAULIC SYMBOLS

SERVICE MANUAL REVISIONS
450/453-1
450/453-2
450/453-3
450/453-4
450/453-5

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