Bobcat 553 Skid-Steer Loader Repair Service Manual – 6904705

(S/N: 539112001 & Above – S/N: 539412001 & 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: 539112001 & Above
S/N: 539412001 & Above

TABLE OF CONTENTS :

DELIVERY REPORT
FOREWORD
LOADER IDENTIFICATION
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATER
SPECIFICATIONS
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : 6904705 (3-06)
Total Pages : 423

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
Fire Prevention
SERIAL NUMBER LOCATIONS
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
LOADER IDENTIFICATION

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Installing
Removing
OPERATOR CAB
Description
Raising
Lowering
TRANSPORTING LOADER ON A TRAILER
Loading And Unloading
Fastening
TOWING THE LOADER
Procedure
REMOTE START
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Elements
ENGINE COOLING SYSTEM
Cleaning
Checking
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Removing And Replacing The Hydraulic/Hydrostatic Filter
Removing And Replacing The Hydraulic/Hydrostatic Fluid
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
Removing Oil From Chaincase
AUXILIARY CONTROL LOCKBOLT
Procedure
BOB-TACH
Inspection And Maintenance
LUBRICATING THE BOBCAT
Lubrication Locations
TIRE MAINTENANCE
Wheel Nuts
Rotating
Mounting
SPARK ARRESTOR MUFFLER
Cleaning Procedure
PIVOT PINS
Inspection And Maintenance
SEAT BAR RESTRAINT SYSTEM
Inspection And Maintenance
RUBBER COUPLER LUBRICATION
Procedure
LOADER STORAGE AND RETURN TO SERVICE
Storage
Return to Service
STOPPING THE ENGINE AND LEAVING THE LOADER
Procedure
Emergency Exit

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting Chart
CYLINDER (LIFT)
Testing
Removal And Installation
Parts Identification
Disassembly And Assembly
CYLINDER (TILT)
Testing
Removal And Installation
Parts Identification
Disassembly And Assembly
MAIN RELIEF VALVE
Description
Testing With Auxiliaries
Testing Without Auxiliaries
Removal and Installation
HYDRAULIC CONTROL VALVE
Description
BICS Valve Removal And Installation
Identification Chart
Disassembly And Assembly
Load Check Valve Removal And Installation
Main Relief Valve Removal And Installation
Anti-Cavitation Check Valve Removal And Installation
Port Relief Valve Removal And Installation
Rubber Boot (Lift) Removal And Installation
Rubber Boot (Tilt) Removal And Installation
Rubber Boot (Auxiliary) Removal And Installation
Lift Spool And Detent Removal And Installation
Tilt Spool Removal And Installation
Auxiliary Spool And Detent Removal And Installation
One Way Restrictors Removal And Installation
Spool Seal Installation
LIFT ARM BY-PASS CONTROL VALVE
Description
Testing
Removal And Installation
Disassembly And Assembly
TILT LOCK VALVE
Description
Testing
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP
Description
Direct Pump Testing
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC/HYDROSTATIC FILTER
Description
Housing Removal And Installation
Housing Disassembly And Assembly
HYDRAULIC FLUID RESERVOIR
Description
Removal And Installation
Hydrauilc Fluid Screen
OIL COOLER
Description
Removal And Installation

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting
Description
HYDROSTATIC MOTOR
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
Timing
PORT BLOCK
Description
Removal And Installation
Oil Cooler By-Pass Valve Removal And Installation
Hydraulic Oil Temperature Switch Removal And Installation
Charge Pressure By-Pass Valve Removal And Installation
HYDROSTATIC PUMP
Description
Checking Charge Pressure
Removal And Installation
Drive Coupler Removal And Installation
Parts Identification
Disassembly And Assembly
Inspection

DRIVE SYSTEM
PARKING BRAKE
Description
Disk Removal And Installation
Traction Lock Guides Removal And Installation
DRIVE COMPONENTS
Description
Axle Seal Removal And Installation
Chain Removal And Installation
CHAINCASE
Description
Front Cover Removal And Installation
Rear Cover Removal And Installation

MAIN FRAME
SEAT BAR
Description
Removal And Installation
Disassembly And Assembly
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
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
LIFT ARM
Removal And Installation
REAR GRILL
Removal And Installation
REAR DOOR
Removal And Installation
Striker Removal And Installation
Striker Disassembly And Assembly
Striker Adjustment
Latch Removal And Installation
FUEL TANK
Removal And Installation
Fuel Level Sender Removal And Installation
CONTROL PEDALS AND LINKAGES
Description
Removal And Installation
Pedal Adjustment
Pedal Interlock Linkage Removal And Installation
Pedal Interlock Linkage Adjustment
Crossbar Linkage Removal And Installation
CONTROL PANEL
Description
Removal And Installation
CONTROL LEVER
Description
Lever Removal And Installation
Lever Disassembly And Assembly
Linkage Removal And Installation
Pintle Lever Removal And Installation
Pintle Lever Disassemby And Assembly
WINDOW (REAR)
Removal
Installation
WINDOW (TOP)
Removal
Installation
WINDOW (SIDE)
Removal And Installation
WINDOW (FRONT DOOR)
Removal (Standard Window)
Installation (Standard Window)
Removal And Installation (Special Applications Window)

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Description
Troubleshooting
Fuse And Relay Location And Identification
BATTERY
Removal And Installation
Using A Booster Battery (Jump Starting)
ALTERNATOR
Belt Adjustment
Charging System Inspection
Alternator Voltage Testing
Low Voltage Testing
High Voltage Testing
Removal And Installation
Parts Identification
STARTER
Testing
Removal And Installation
Parts Identification
INSTRUMENT PANELS
Left And Right Removal And Installation
LIGHTS
Front Removal And Installation
Rear Removal And Installation
Cab Light Removal And Installation
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
Description
Inspecting The BICS 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
Troubleshooting Chart
Troubleshooting
Removal And Installation
SEAT BAR SENSOR
Description
Troubleshooting
Testing
Removal And Installation
Bobcat Interlock Control System (BICS) Circuit Test
TRACTION LOCK
Description
Troubleshooting
Removal And Installation

ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Torque Values
Troubleshooting
Engine Removal And Installation
Engine Mount Replacement
Compression – Checking
ENGINE SPEED CONTROL
Removal And Installation
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
Housing Removal And Installation
ENGINE COOLING SYSTEM
Cooling Fan Removal And Installation
Radiator Removal And Installation
Water Pump Removal And Installation
Thermostat Housing Removal And Installation
Thermostat Testing
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor Disassembly And Assembly
Fuel Shutoff Solenoid, Removal And Installation
Fuel Lift Pump Removal And Installation
Fuel Injection Pump, Checking
Fuel Injection Pump Removal And Installation
Injection Pump – Timing
Fuel Injector Removal And Installation
Fuel Injector Nozzle Pressure – Checking
Nozzle Spray Condition
Valve Seat Tightness
CYLINDER HEAD
Glow Plugs – Testing
Glow Plugs Removal And Installation
Closed Breather System – Checking
Valve Clearance Adjustment
Valve Timing – Checking
Exhaust Manifold Removal And Installation
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Cylinder Head Top Clearance
Valve Guide And Valve Checking
Reconditioning The Valve And Valve Seat
Valve Springs
Valve Tappets
Rocker Arm And Shaft Removal And Installation
Rocker Arm And Shaft Disassembly And Assembly
Rocker Arm And Shaft – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore Checking
Connecting Rod Alignment
Crankshaft And Bearing Removal And Installation
Crankshaft And Bearing – Servicing
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash – Checking
Idler Gear And Shaft Removal And Installation
Idler Gear And Shaft Servicing
Camshaft Removal And Installation
Camshaft Servicing
Camshaft Gear Removal And Installation
Engine Timing Gear Alignment
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation
RUBBER DRIVE COUPLER
Removal And Installation
Disassembly And Assembly
WATER FLANGE
Removal And Installation

HEATER
HEATER SYSTEM
Description
REGULAR MAINTENANCE
Filter Element Removal And Installation
Heater Coil
TROUBLESHOOTING
Electric System
Heater Valve Not Opening Or Closing
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
HEATER UNIT
Removal And Installation
HEATER COIL
Removal And Installation
HEATER FAN
Blower Removal And Installation
Disassembly And Assembly
HEATER MOTOR
Removal And Installation
RESISTOR
Removal And Installation
Checking
HEATER VALVE
Removal And Installation
HEATER SWITCH
Removal And Installation
Checking The Switch

SPECIFICATIONS
553 LOADER SPECIFICATIONS
Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tires
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
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion Chart

SERVICE MANUAL REVISION
553-1

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