Bobcat 553 Skid-Steer Loader Repair Service Manual – 6903125

(S/N: 528011001 & Above – S/N: 528111001 & Above)
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This workshop repair service manual PDF download for the 553 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 553
S/N: 528011001 & Above
S/N: 528111001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
SERIAL NUMBER LOCATION
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6903125 (2-06)
Total Pages : 409

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
SAFETY INSTRUCTIONS
Fire Prevention
SERIAL NUMBER LOCATION
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Installing Lift Arm Support Device
Removing Lift Arm Support Device
OPERATOR CAB
Description
Raising The Operator Cab
Lowering The Operator Cab
Emergency Exit
TRANSPORTING THE BOBCAT LOADER
Procedure
Stopping The Bobcat Loader
TOWING THE LOADER
Procedure
REMOTE START
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Element
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking The Coolant Level
Replacing The Coolant
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
HYDRAULIC/HYDROSTATIC SYSTEM
Description
Checking And Adding Fluid
Replacing The Hydraulic/Hydrostatic Filter
Replacing Hydraulic Fluid
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
AUXILIARY CONTROL LOCKBOLT
Removal
BOB-TACH
Inspection And Maintenance
LUBRICATION OF THE BOBCAT LOADER
Procedure
TIRE MAINTENANCE
Wheel Nuts
Rotating
Mounting
SPARK ARRESTOR MUFFLER
Cleaning Procedure
PIVOT PINS
Procedure
SEAT BAR RESTRAINT SYSTEM
Description
Seat Bar Inspection
Seat Bar Maintenance
RUBBER COUPLER LUBRICATION
Procedure

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Tighten Procedures
Troubleshooting Chart
CYLINDER (LIFT)
Checking
Removal And Installation
Identification
Disassembly And Assembly
CYLINDER (TILT)
Checking
Removal And Installation
Identification
Disassembly And Assembly
MAIN RELIEF VALVE
Checking The Main Relief Valve Without Auxiliaries
Checking The Main Relief Valve With Auxiliaries
Removal and Installation
HYDRAULIC CONTROL VALVE
Removal And Installation
Identification Chart
Disassembly And Assembly
Load Check Valve
Main Releif Valve
Anti-Cavitation Check Valve
Port Relief Valve
Rubber Boot (Lift)
Rubber Boot (Tilt)
Rubber Boot (Aux.)
Lift Spool Detent
Tilt Centering Spring
Auxiliary Spool Detent
One Way Restrictors
Inspection
Spool Seal Installation
LIFT ARM BY-PASS CONTROL VALVE
Inspecting
Removal and Installation
Disassembly and Assembly
TILT LOCK VALVE
Removal And Installation
Disassembly and Assembly
HYDRAULIC PUMP
Check The Output Of The Hydraulic Pump
Removal And Installation
Identification
Disassembly And Assembly
Inspection
HYDRAULIC FILTER HOUSING
Removal and Installation
HYDRAULIC FLUID RESERVOIR
Removal and Installation

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Replenishing Valve Function
CONTROL PANEL
Removal and Installation
STEERING
Lever Removal and Installation
Lever Disassembly And Assembly
Linkage Removal And Installation
Pintle Lever Disassemby And Assembly
Linkage Neutral Adjustment
HYDROSTATIC MOTOR
Removal And Installation
Parts Identification
Disassembly And Assembly
Inspection
Timing The Hydrostatic Motor
PORT BLOCK
Removal And Installation
Oil Cooler By-Pass Valve
Hydraulic Oil Temperature Switch
Charge Pressure By-Pass Valve
HYDROSTATIC PUMP
Checking Charge Pressure
Removal And Installation
Drive Coupler Removal And Installation
Parts Identification
Disassembly And Assembly
Inspection
OIL COOLER
Removal and Installation

DRIVE SYSTEM
PARKING BRAKE
Disk Removal And Installation
Traction Lock Guides Removal And Installation
DRIVE COMPONENTS
Axle Seal Removal And Installation
Axle, Bearing, And Sprocket Removal And Installation
Chain Removal And Installation
CHAINCASE
Removing Oil From The Chaincase
Front Cover Removal And Installation
Rear Cover Removal And Installation

MAIN FRAME
SEAT BAR
Removal And Installation
Assembling Components
Compression Spring Disassembly And Assembly
OPERATOR CAB
Gas Cylinder Removal And Installation
Gas Cylinder Disassembly And Assembly
Removal And Installation
OPERATOR SEAT
Removal And Installation
Seat Belt Removal And Installation
BOB-TACH
Removal And Installation
Bob-Tach Lever And Wedge
LIFT ARM
Removal And Installation
REAR GRILL
Removal And Installation
REAR DOOR
Removal And Installation
Striker Removal and Installation
Striker Disassembly and Assembly
Adjusting The Striker
Latch Removal and Installation
FUEL TANK
Removal And Installation
Fuel Level Sender
CONTROL PEDALS
Removal And Installation
Pedal Adjustment
Pedal Interlock Linkage Removal And Installation
Pedal Interlock Linkage Adjustment
Crossbar Linkage Removal And Installation

ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting
Description
Fuse Location
Relay Switches Location
BATTERY
Removal And Installation
Using A Booster Battery (Jump Starting)
ALTERNATOR
Removal And Installation
Adjusting The Alternator Belt
Description
Tests
Alternator Output Test
Full Field Test
Alternator Regulator Test
Alternator Regulator Test Using Voltmeter
Parts Identification
Pulley Removal And Installation
Disassembly And Assembly
Rotor Continuity Test
Stator Continuity Test
Rectifier Continuity (Diode) Test
Brush Length
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
LIGHTS
Front Removal And Installation
BICS™ SYSTEM CONTROLLER
Trouble Shooting Guide
Removal And Installation
BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON)
Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
Inspecting The Seat Bar Sensor (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The Lift Arm By-Pass Control
Additional Inspection For Loaders With Advanced Hand Controls
Troubleshooting Chart
SEAT BAR SENSOR
Troubleshooting Guide
Seat Bar Sensor Test
Removal And Installation
BICS™ Controller Seat Bar Sensor Circuit Test
TRACTION LOCK
Troubleshooting Guide
Removal And Installation

ENGINE SERVICE
TROUBLESHOOTING
Chart
ENGINE SPEED CONTROL
Removal And Installation
Disassembly
Linkage Bar Removal And Installation
ENGINE SPEED CONTROL PLATE
Removal And Installation
Governor Spring Removal
Start Spring Removal
Idle Limit And Fuel Limit Adjustment
MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
RADIATOR
Removal And Installation
BLOWER FAN HOUSING
Removal And Installation
ENGINE COMPONENTS AND TESTING
Compression Checking
Glow Plugs Checking
Glow Plugs Removal And Installation
Fuel Shut-Off Solenoid, Removal And Installation
Fuel Lift Pump Removal And Installation
Fuel Injection Pump, Checking
Fuel Injection Pump Removal And Installation
Timing The Injection Pump
Fuel Injector Nozzles Removal And Installation
Checking Fuel Injector Nozzles
Breather Removal And Installation
Valve Clearance Adjustment
ENGINE
Removal And Installation
Engine Mounting Brackets Removal And Installation
FLYWHEEL
Removal And Installation
Flywheel Ring Gear
Housing Removal And Installation
RECONDITIONING THE ENGINE
Thermostat Removal And Installation
Water Pump Removal And Installation
Timing Gear Case Cover Removal And Installation
Oil Pump Removal And Installation
Checking Oil Pump
Crankshaft Front Seal Removal And Installation
Exhaust Manifold Removal And Installation
Valve Cover Removal And Installation
Rocker Arm Removal And Installation
Push Rod Removal And Installation
Cylinder Head Removal
Cylinder Head Installation
Tappet Removal And Installation
Checking Piston Top Clearance
Cylinder Head Disassembly
Cylinder Head Assembly
Servicing The Cylinder Head
Cylinder Head Surface Flatness
Cylinder Head Flaw
Valve And Valve Guide Checking
Valve Guide Replacement
Reconditioning The Valve And Valve Seat
Correcting The Valve Seat
Valve Spring
Idler Gear Removal And Installation
Camshaft Removal And Installation
Camshaft Height
Camshaft Oil Clearance
Camshaft Alignment
Camshaft Gear Removal And Installation
Fuel Camshaft Removal And Installation
Engine Timing Gear Alignment
Governor Shaft Removal And Installation
Governor Fork Lever Removal And Installation
Oil Pan Removal And Installation
Piston Removal
Piston Pin Removal And Installation
Checking The Piston And Connecting Rod
Connecting Rod Alignment
Connecting Rod Bushing Removal And Installation
Piston Ring Gap
Checking Engine Cylinder Bore
Piston Ring Installation
Connecting Rod Installation
Piston Installation
Crankshaft End Play
Crankshaft Removal And Installation
Crankshaft Disassembly And Assembly
Checking Crankshaft Number One Journal And Block Bearing
Checking The Crankshaft Journals And Main Bearings
Connecting Rod Journal
Crankshaft Alignment
RUBBER DRIVE COUPLER
Removal And Installation
Disassembly
Assembly
WATER FLANGE
Removal And Installation

SPECIFICATIONS
LOADER SPECIFICATIONS
Machine Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
ENGINE SPECIFICATIONS – KUBOTA D1105-B
Engine Compression
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Rocker Arms
Camshaft
Cylinders
Piston Rings
Pistons
Crankshaft
Oil Pump
Thermostat
Crankshaft Re-Grind Data
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 FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion

SERVICE MANUAL REVISION
Revision No: 553-1

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