Bobcat 453 Skid-Steer Loader Repair Service Manual – 6900363

(S/N: 515011001 & Above – S/N: 515111001 & Above)
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This workshop repair service manual PDF download for the 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 453
S/N: 515011001 & Above
S/N: 515111001 & 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
SYSTEMS ANALYSIS
SPECIFICATIONS
SERVICE MANUAL REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6900363 (5–97)
Total Pages : 294

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

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

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM INFORMATION
HYDRAULIC / HYDROSTATIC SCHEMATICS
TROUBLESHOOTING
Chart
LIFT CYLINDER(S)
Checking The Lift Cylinders
Removal And Installation
TILT CYLINDER
Checking The Tilt Cylinder
Removal And Installation
HYDRAULIC CYLINDERS
Lift Cylinder Parts Identification
Tilt Cylinder Parts Identification
Disassembly And Assembly
BICS™ BLOCK VALVE
Removal And Installation
Disassembly And Assembly
MAIN RELIEF VALVE
Checking The Main Relief Valve
Checking The Main Relief Valve With Auxiliaries
Removal And Installation
Main Relief Valve Adjustment
HYDRAULIC CONTROL VALVE
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
Parts Identification
Disassembly And Assembly
HYDRAULIC RESERVOIR
Removal And Installation
HYDRAULIC FILTER BLOCK
Removal And Installation
Block Disassembly And Assembly
PEDAL INTERLOCK LINKAGE
Removal And Installation
CONTROL PEDALS
Removal and Installation
Pedal Adjustment

HYDROSTATIC SYSTEM
TROUBLESHOOTING
Chart
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function
CONTROL SHIELD 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
HYDROSTATIC MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
DRIVE BELT
Removal And Installation
CHARGE PRESSURE
Checking
HYDROSTATIC PUMP
Parts Identification
Removal And Installation
Disassembly And Assembly
Inspection
TENSION PULLEY AND SPRING
Removal And Installation

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 CHAIN
Removal And Installation

MAIN FRAME
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
BATTERY
Removal And Installation
Servicing The Electrical System
Using A Booster Battery (Jump Starting)
ALTERNATOR
Removal And Installation
Adjusting The Alternator Belt
Alternator Belt Removal And Installation
Description
Tests
Alternator Output Test
Full Field Test
Alternator Regulator Test
Alternator Regulator Test With Voltmeter
STARTER
Removal And Installation
Checking The Starter In The Loader
Parts Identification
Disassembly
Inspection And Repair
No Load Test
Assembly
INSTRUMENT PANEL
Removal And Installation
FRONT LIGHTS (OPTIONAL)
Removal And Installation
REAR LIGHT (OPTIONAL)
Removal And Installation

ENGINE SERVICE
TROUBLESHOOTING
Chart
ENGINE SPEED CONTROL
Adjustment
Removal And Installation
RADIATOR
Removal And Installation
RADIATOR MOUNTING BRACKET
Removal And Installation
FAN
Removal And Installation
FLYWHEEL
Removal And Installation
ENGINE MOUNTING BRACKET
Removal And Installation
VALVE CLEARANCE
Ajustment
FUEL INJECTION PUMP
Checking The Injection Pump
Removal
Installation
Timing Procedure
FUEL INJECTOR NOZZLES
Checking
Removal
Installation
GLOW PLUGS
Checking
ENGINE COMPRESSION TEST
Procedure
ENGINE
Removal And Installation
CYLINDER HEAD
Removal And Installation
Inspection
Top Clearance
ROCKER ARM AND SHAFT
Checking
VALVE AND VALVE SPRINGS
Valve Removal
Checking Valve Spring
VALVE GUIDE, VALVE AND VALVE SEAT
Checking The Valve Guide
Reconditioning The Valve And Valve Seat
TIMING GEARCASE COVER
Removal And Installation
IDLER GEAR AND CAMSHAFT
Removal And Installation
Servicing The Idler Gear And Shaft
TIMING GEARS
Checking Backlash
FUEL CAMSHAFT
Removal And Installation
Governor
CRANKSHAFT GEAR
Removal And Installation
OIL PUMP
Removal And Installation
Oil Pump Service
Checking Engine Oil Pressure
Relief Valve
PISTON AND CONNECTING ROD
Removal And Installation
Servicing The Piston And Connecting Rod
Connecting Rod Alignment
CRANKSHAFT AND BEARINGS
Removal And Installation
Inspection Of Crankshaft And Bearings
CYLINDER BORE
Inspection
HYDRAULIC OIL COOLER AND SHROUDING
Removal And Installation
THERMOSTAT
Removal And Installation
WATER PUMP
Removal And Installation
Disassembly And Assembly

SYSTEMS ANALYSIS
BICS™ (With Press To Operate Button)
Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
Inspecting The Seat Bar Sensor (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The Lift Arm By–Pass Control
Troubleshooting Chart
Inspecting The BICSTM 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
BICS™ SYSTEM CONTROLLER
Troubleshooting Guide
Removal And Installation
SEAT BAR SENSOR
Troubleshooting Guide
Seat Bar Sensor Test
Removal And Installation
BICS™ Controller Seat Bar Sensor Circuit Test
SEAT SENSOR
Troubleshooting Guide
Seat Sensor Test
Removal And Installation
BICS™ Controller Seat Sensor Circuit Test
TRACTION LOCK
Troubleshooting Guide
Removal And Installation

SPECIFICATIONS
SKID STEER LOADER SPECIFICATIONS
PERFORMANCE
CONTROLS
ENGINE
HYDRAULIC SYSTEM
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
FLOOR PRESSURE
ENGINE SPECIFICATIONS
Engine
Fuel Injector Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Rocker Arms
Camshaft
Cylinders
Piston Rings
Pistons
Crankshaft
Oil Pump
Thermostat
ENGINE BOLT TORQUE
Re–Grinding The Crankshaft
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

SERVICE MANUAL REVISIONS
453-1
453-2
453-3
453-4

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