Bobcat 653 Skid-Steer Loader Repair Service Manual – 6724493

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This workshop repair service manual PDF download for the 653 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 653 BICS

TABLE OF CONTENTS :

PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
SYSTEMS ANALYSIS
SPECIFICATION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6724493 (12-95) Revised (1-97)
Total Pages : 356

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

PREVENTIVE MAINTENANCE
SERVICE SCHEDULE
LIFTING AND BLOCKING THE LOADER
Procedure
TRANSPORTING THE LOADER
Procedure
TOWING THE LOADER
Procedure
STOPPING THE BOBCAT LOADER
LIFTING THE LOADER
Four Point Lift
Single Point Lift
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
Raising The Operator Cab (Hand Controls)
Lowering The Operator Cab (Hand Controls)
Emergency Exit
SEAT BAR RESTRAINT SYSTEM
Description (Foot Controls)
Seat Bar Inspection (Foot Controls)
Seat Bar Maintenance (Foot Controls)
Description (Hand Controls)
Seat Bar Inspection (Hand Controls)
Seat Bar Maintenance (Hand Controls)
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 Engne Oil
Replacing Oil And Filter
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking The Coolant Level
Removing Coolant From The Cooling System
Proplylene Glycol
ALTERNATOR BELT
Adjusting The Alternator Belt
BOB-TACH
FAN GEARBOX
Checking And Maintaining
ELECTRICAL SYSTEM
Using A Booster Battery (Jump Starting)
HYDRAULIC / HYDROSTATIC SYSTEM
Replacing Hydraulic Fluid
Hydraulic Reservoir Breather Cap
SPARK ARRESTOR MUFFLER
Cleaning Procedure
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Tire Mounting
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
Removing Oil From The Chaincase
DRIVE BELT
Adjusting The Drive Belt (Equipped With Fixed Drive Idler)
Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler
Drive Belt Replacement
LUBRICATION OF THE BOBCAT LOADER
Procedure
PIVOT PINS
REMOTE START SWITCH
Procedure

HYDRAULIC SYSTEM
TROUBLESHOOTING
HYDRAULIC SYSTEM INFORMATION
Flare Connections
O-Ring Face Seal Connection
Staright Thread O-Ring Fitting
Tubelines And Hoses
LIFT CYLINDER(S)
Checking The Lift Cylinder(s) For Internal Leakage
Removal And Installation
TILT CYLINDER
Checking The Tilt Cylinder For Internal Leakage
Removal And Installation
Rod End Seal Replacement
HYDRAULIC CYLINDER IDENTIFICATION
Lift Cylinder Components
Tilt Cylinder Components
HYDRAULIC CYLINDERS
Disassembly
Assembly
HYDRAULIC CONTROL VALVE
Removal And Installation
Checking The Main Relief Valve
Main Relief Valve Adjustment
Main Relief Valve Removal And Installation
Identification Chart
Disassembly And Assembly
Load Check Valve
Main Relief Valve
Port Relief Valve
Anti-Cavitation valve
Rubber Boot
Lift Spool Detent
Tilt Centering Spring
Auxiliary Spool
Auxiliary Electric Solenoid
Inspection
Identification & Installation Of Spool Seal
HYDRAULIC PUMP
Removal And Installation
Checking The Output Of The Hydraulic Pump
Disassembly And Assembly
Inspection
Identification
HYDRAULIC FILTER HOUSING
Removal And Installation
HYDRAULIC FLUID RESERVOIR
Removal And Installation
CONTROL PEDALS
Removal And Installation
Pedal Adjustment
PEDAL INTERLOCK LINKAGE
Removal And Installation
Adjustment

HYDROSTATIC SYSTEM
TROUBLESHOOTING
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function
CONTROL PANEL
Removal And Installation
Steering Shaft Removal And Installation
Steering Shaft Disassembly And Assembly
Steering Lever Removal And Installation
Rubber Boot Replacement
STEERING LINKAGE
Removal And Installation
Steering Linkage Adjustment
Steering Neutral Adjustment
HYDROSTATIC DRIVE MOTOR
Removal And Installation
Identification
Disassembly And Assembly
Inspection
HYDROSTATIC PUMP
Removal And Installation
Identification
Disassembly And Assembly
Inspection
Swashplate Pre-Load
DRIVE BELT HOUSING
Removal And Installation
SPRING LOADED DRIVE IDLER
Identification
Disassembly
Assembly
DRIVE BELT TENSIONER PULLEY
Removal And Installation
Disassembly
Assembly
Checking Pulley End Play
OIL COOLER
Removal And Installation

DRIVE SYSTEM
PARKING BRAKE
Removal And Installation
Disassembly And Assembly
PARKING BRAKE DISC
Removal And Installation
CHAINCASE FLUID
Removing Oil From The Chaincase
CHAINCASE COVERS
Center Chaincase Cover Removal And Installation
Front Chaincase Cover Removal And Installation
Rear Chaincase Cover Removal And Installation
MOTOR CARRIER
Shaft Seal Replacement
Removal And Installation
Disassembly
Assembly
AXLE SEAL
Removal And Installation
AXLE, SPROCKET AND BEARINGS
Removal And Installation
DRIVE CHAIN
Removal

MAIN FRAME
SEAT BAR
Removal And Installation
Assembly
Compressing The Gas Cylinder
OPERATOR CAB GAS CYLINDER
Removal And Installation
Disassembly And Assembly
OPERATOR CAB
Removal And Installation
OPERATOR SEAT
Removal And Installation
BOB-TACH
Removal And Installation
Bob-Tach Lever And Wedge
Bob-Tach Stops
LIFT ARMS
Removal And Installation
REAR GRILL
Removal And Installation
FUEL TANK
Removal And Installation
Fuel Level Sender
REAR DOOR
Removal And Installation
Hood Removal And Installation
Bumper Removal And Installation
Door Latch Removal And Installation
Door Latch And Catch Adjustment

ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
TROUBLESHOOTING
ELECTRICAL SYSTEM INFORMATION
Description
Fuse Location
BATTERY
Removal And Installation
Servicing The Battery
Using A Booster Battery (Jump Starting)
ALTERNATOR
Alternator Output Test
Rectifier (Diode) Test
Alternator Regulator Test
Removal And Installation
Adjusting The Alternator Belt
Disassembly And Inspection
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Rectifier Continuity (Diode) Test
Assembly
STARTER
Removal And Installation
Disassembly And Assembly
External Pinion
Inspection And Repair
Magnetic Switch Test
No Load Test
Parts Identification
STANDARD INSTRUMENT PANEL
Removal And Installation
FRONT LIGHTS
Removal And Installation
RELAY SWITCHES
Location
Glow Plug Preheat Relay

ENGINE SERVICE
TROUBLESHOOTING
ENGINE SPEED CONTROL
Removal And Installation
Disassembly
RADIATOR
Removal And Installation
ENGINE MUFFLER
Removal And Installation
BLOWER HOUSING/FAN GEARBOX
Removal And Installation
Tension Pulley Removal And Installation
Blower Fan Disassembly And Assembly
FAN GEARBOX
Disassembly
Assembly
Checking Backlash
Identification
AIR CLEANER
Removal And Installation
ENGINE
Removal And Installation
Engine Mount Replacement
FLYWHEEL
Removal And Installation
Flywheel Ring Gear
INJECTION PUMP TIMING
Checking Procedure
Adjusting Injection Pump Timing
TIMING BELT
Removal
Installation
FUEL INJECTION PUMP
Removal
Installation
FUEL INJECTOR NOZZLE
Removal And Installation
Checking The Injector Nozzle
CYLINDER LOCATION AND COMPRESSION
Data
GLOW PLUGS
Removal And Installation
Checking The Glow Plugs
CYLINDER HEAD
Removing The Cylinder Head
Disassembly Of The Cylinder Head
Servicing The Cylinder Head
Checking The Valves
Checking Valve Springs
Checking The Valve Guides
Checking The Valve Seats
Checking The Combustion Chamber
Reassejmbly Of The Cylinder Head
Installing The Cylinder Head
ENGINE BLOCK
Disassembly Of The Engine
Assembly Of The Engine
PISTONS AND CONNECTING RODS
Disassembly And Assembly
Checking The Piston
CRANKSHAFT AND BEARINGS
Checking The Crankshaft
CRANKSHAFT PULLEY
Removal And Installation
PEUGEOT ENGINE TOOL KIT MEL1474
ENGINE TORQUE

SYSTEM ANALYSIS
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Inspecting The BICS™ Controller
Inspecting The Deactivation Of The Auxiliary Hydraulics System
Inspecting The Seat And Seat Bar Sensors
Inspecting The Traction Lock
Inspecting The Lift Arm By-Pass Control
Maintenance
Troubleshooting Chart
Troubleshooting Guide
BICS CONTROLLER
TRACTION LOCK
SEAT SENSOR
SEAT BAR SENSOR
LIFT LOCK BY-PASS 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 LOCK BY-PASS VALVE
Removal And Installation
Disassembly And Assembly
TILT LOCK VALVE
Removal And Installation
Disassembly And Assembly

SPECIFICATIONS
SKID STEER LOADER SPECIFICATIONS
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tires
Floor Pressure
ENGINE SPECIFICATIONS
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Valve Guides
Combustion Chamber
Cylinders
Piston Rings
Pistons
Connecting Rod
Crankshaft
TORQUE SPECIFICATIONS
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION

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