Bobcat 520, 530, 533 Skid-Steer Loader Repair Service Manual – 6556407

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This workshop repair service manual PDF download for the 520, 530 & 533 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 520
Bobcat Loader 530
Bobcat Loader 533

TABLE OF CONTENTS :

PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE (520, 530)
ENGINE SERVICE (533)
TECHNICAL DATA
ALPHABETICAL INDEX
SERVICE BULLETINS
SERVICE MANUAL REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6556407 (3-87)
Total Pages : 172

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
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS

PREVENTIVE MAINTENANCE
INTRODUCTION
Symbols
Serial Number Identification
Loader Serial Number
Engine Serial Number
Pre-Delivery Inspection
30 Hour Inspection
PREVENTIVE MAINTENANCE
SERVICE SCHEDULE
ENGINE SERVICE
AIR CLEANER SYSTEM
FUEL SYSTEM
FUEL SYSTEM SERVICE
FUEL FILTER
ENGINE LUBRICATION SYSTEM
CHANGING ENGINE OIL AND FILTER (520/530)
CHANGING OIL AND FILTER (533)
ENGINE COOLING SYSTEM (520/530)
ENGINE COOLING SYSTEM (533)
ELECTRICAL SYSTEM
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC FLUID
Checking And Adding Fluid
Hydraulic / Hydrostatic Fluid Replacement
HYDRAULIC FILTER REPLACEMENT
FINAL DRIVE TRANSMISSION (CHAINCASE)
TIRE MAINTENANCE
Tire Rotation
LUBRICATION OF LOADER
BOB-TACH
PIVOT PINS
FUEL INJECTION PUMP RESERVOIR (533)

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC CIRCUIT
GENERAL INFORMATION
Keeping Parts And Work Area Clean
37° Flare Connections
Straight Thread O-Ring Connections
Tubelines And Hoses
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM
HYDRAULIC PUMP
Checking Output Of The Pump
PROBLEM ANALYSIS
CHECKING RELIEF VALVE
To Check Release Pressure
Relief Valve Removal And Replacement
CHECKING OUTPUT OF VANE PUMP
VANE PUMP REPAIR
Removal
Disassembly
Inspection
Assembly
Pump Istallation
CHECKING CONTROL VALVE AND CYLINDERS
To Check Lift Cylinders
To Check Tilt Cylinders
HYDRAULIC CYLINDER REPAIR
Removal And Installation
Disassembly And Repair
CONTROL VALVE REPAIR
Removal
Disassembly And Inspection
Assembly Of Valve
ADJUSTMENT OF PEDAL LINKAGE
HYDRAULIC HOSES
Hydraullic Hose Protection
QUICK COUPLERS
Restriction In The Quick-Couplers

HYDROSTATIC SYSTEM
HYDROSTATIC CIRCUIT
TROUBLESHOOTING CHART
REPLENISHING VALVE
Checking The Replenishing Valves
BY-PASS VALVE REPAIR
REMOVAL AND INSTALLATION OF PUMP ASSEMBLY
REPAIR OF HYDROSTATIC PUMP ASSEMBLY
Pump Disassembly
Assembly
HYDROSTATIC MOTOR REMOVAL AND INSTALLATION
Installation
HYDROSTATIC MOTOR REPAIR
Disassembly And Inspection
Assembly
STEERING LINKAGE
Adjustment (Old Style Linkage)
Adjustment (New Style Linkage)

DRIVE SYSTEM
DRIVE CHAINS
Chain Replacement
AXLES AND BEARINGS
Removal Procedure For All Four Axles
Assembly And Installation
BRAKE PAD REPLACEMENT

MAIN FRAME
REMOVAL OF ROPS (OPERATOR GUARD)
REPLACEMENT OF PIVOT PINS
Bushing Replacement
BOB-TACH
To Check The Wedges
Removal Of Bob-Tach
Bob-Tach Over Center Stop
REMOVAL OF FUEL TANK AND HYDRAULIC RESERVOIR

ELECTRICAL SYSTEM
ELECTRICAL CIRCUITRY
PROBLEM ANALYSIS CHARTS
CHECKS AND REPAIRS OF THE ELECTRICAL SYSTEM (520/530)
Checking A.C. Voltage
Alternator Repair
Replacement Of The Stator
STARTER
To Check The Starter
Removal Of Starter
Disassembly And Repair
CHECKS AND REPAIRS OF THE ELECTRICAL SYSTEM (533)
To Check The Wiring
To Check The Generator Output
To Check The Regulator
To Check The Engine Pre-Heat
GENERATOR SERVICE
Removal Of The Generator
Disassembly
STARTER
Checking The Starter
CHECKING ELECTRICAL WIRING
STARTER SUPPORT BRACKET

ENGINE SERVICE (520/530)
TROUBLESHOOTING THE ENGINE
CHECKS AND ADJUSTMENTS
Oil Pressure
Valve Clearance
Compression
Adjustment Of The Carburetor
Throttle And Govenor Linkage
Ignition System Adjustment
CARBURETOR REPAIR
Removal
Disassembly And Inspection
Assembly
REPAIR OF THE GOVENOR
Removal
Installation
ENGINE
Removal And Installation Of The Engine
REPAIR OF THE ENGINE
Flywheel
Repair Of The Valves And Guides
TIMING COVER, TIMING GEARS, CAMSHAFT
Timing Cover
Timing Gears
Camshaft And Tappets
OIL PUMP AND RELIEF VALVE
Adjust Gear Clearance For Engine Oil Pump
PISTONS, RODS, CRANKSHAFT
CYLINDER HEADS
INTAKE AND EXHAUST MANIFOLD
ENGINE HEAT SHIELD

ENGINE SERVICE (533)
ENGINE OVERHAUL
DISASSEMBLY OF ENGINE
CLEANING AND INSPECTION
DISASSEMBLY AND ASSEMBLY OF ROCKER SHAFT
Disassembly
DISASSEMBLY OF THE CYLINDER HEAD
Inspection
Inspection Of The Combustion Chambers
Inspection Or The Valves And Valve Guides
Inspection And Correction Of The Valve Seats
Inspection Of The Valve Springs
Inspection Of The Push-Rods And Tappets
Installation Of The Hot Plugs
Assembly Of The Valve System
CYLINDER BLOCK
Inspection Of The Cylinder Block For Cracks
Distortion Of The Cylinder Block Upper Surface
Correction Of Cylinder Bores
PISTONS AND PISTON RING ASSEMBLIES
Disassembly
Inspection Of Pistons
Inspection Of Piston Ring Clearance
Assembly Of Piston And Connecting Rods
Connecting Rods
Clearance Between The Small-End Bushing And Piston Pin
Clearance Between The Big-End Bearing And Crankpin
Connecting Rod Bearings
Connecting Rod Bearing Oil Clearance
CRANKSHAFT BEARINGS
Crankshaft
FLYWHEEL AND RING GEAR
CAMSHAFT
TIMING GEAR
MANIFOLD ASSEMBLY
ASSEMBLY OF ENGINE
Special Cautions
Assembly
Method Of Adjustment
DISASSEMBLY, INSPECTION AND ASSEMBLY OF THE OIL PUMP
Inspection
DISASSEMBLY, INSPECTION AND ASSEMBLY OF THE OIL FILTER ASSEMBLY
Disassembly And Assembly
Inspection
WATER PUMP
Disassembly Of Water Pump
Inspection
Assembly
INJECTION NOZZLES
Disassembly Of The Nozzle Holder Assembly
Inspection Of The Nozzle Holder Assemblies
Assembling The Nozzle
INJECTION PUMP
Removal Of Pump
To Remove The Pump Drive Gear
To Install The Pump Drive Gear
Installation And Timing Of Injection Pump

TECHNICAL DATA
FUEL SPECIFICATIONS
LUBRICANTS
Gasoline Engine (520/530)
Diesel Engine (533)
Hydraulic System
Chaincase
LOADER SPECIFICATIONS (520/530)
Operating Specifications
Engine
Electrical
Hydraulics System
Power Train
Capacities
Tires
LOADER SPECIFICATIONS (533)
Operating
Engine
Electrical
Hydraulic System
Power Train
Capacities
Tires
LOADER TORQUE SPECIFICATIONS
GASOLINE ENGINE TORQUE SPECIFICATIONS (520/530)
DIESEL ENGINE TORQUE SPECIFICATIONS (533)
HYDROSTATIC PUMP TORQUE SPECIFICATIONS
HYDRAULIC MOTOR TORQUE SPECIFICATIONS
HYDRAULIC / HYDROSTATIC SYSTEM
SEAL INSTALLING TOOLS
FITS, CLEARANCE, ADJUSTMENTS (520/530)
Engine
Cylinder Bore
Crankshaft
Connecting Rod
Piston, Pin & Rings
Valves, Guides, Tappets
FITS, CLEARANCE, ADJUSTMENTS (533)
Valves
Glow Plugs
Starting Motor
Generator
Oil Pump
DIMENSIONAL SPECIFICATIONS
Cylinder Head
Cylinder Block
Piston Rings
Connecting Rods
Crankshaft
Camshaft
Timing Gears
Manifolds
Oil Pump
GENERAL tORQUE SPECIFICATIONS
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
DECIMALS AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION

ALPHABETICAL INDEX

SERVICE BULLETINS
530-001
530-002
530-003
530-004
530-005
530-006
530-007
530-008

SERVICE MANUAL REVISIONS
530-009

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