Bobcat Loaders 520, 530, 533, 553 Repair Service Manuals
Catalog:
Model:
Complete repair service manual with Electrical Wiring Diagrams for Bobcat 520, 530, 533, 553 Loaders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Bobcat Loaders 520, 530, 533, 553 workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
6549811 (10-76) - 520 Loader Operation & Maintenance Manual.pdf
6556152 (5-80) - 500 Series (533) Loader Operation & Maintenance Manual.pdf
6556175 (5-80) - 500 Series (533) Loader Operation & Maintenance Manual.pdf
6556407 (3-87) - 520, 530, 533 Loader Service Manual.pdf
6556407 (6-12) - 520, 530, 533 Loader Service Manual.pdf
6724024 (6-12) - 553 Service Manual.pdf
6724024 (11-95) - 553 Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,011 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
6549811 (10-76) - 520 Loader Operation & Maintenance Manual...1
FOREWORD...4
CONTENTS...4
520 BOBCAT LOADER PICTORIAL NOMEMCLATURE...5
OPERATING INSTRUCTIONS...6
OPERATING INSTRUCTIONS...8
CONTROLS...9
DASH PANEL...9
HOUR METER...10
THROTTLE CONTROL...10
CHOKE CONTROL...10
STEERING CONTROLS...10
PARKING BRAKE...11
HYDRAULIC CONTROLS...12
STARTING PROCEDURE...12
Pre-Starting Inspection...12
Starting...13
Normal Starting Condition...13
Cold Temperature Starting Condition...14
BOBCAT OPERATION...14
Bucket Size...14
Installing Attachment...14
To Remove Attachment...15
Operating The Bobcat Loader...15
Operating Hints...15
Filling Bucket From A Pile...16
Digging The Bucket...16
Breaking Ground...16
Loading...16
Backfilling...17
TRANSPORTING THE BOBCAT...17
ACCESSORIES...18
Front And Rear Lights...18
Flasher Lights...18
Parking Brake...19
Fire Extinguisher...19
Rear Window...19
Front Mounted Auxiliary Hydraulics...19
PREVENTIVE MAINTENANCE...20
SERVICE & MAINTENANCE...21
BOBCAT SERVICE SCHEDULE...22
ENGINE SERVICE...23
AIR CLEANER SYSTEM...23
FUEL SYSTEM...23
FUEL SYSTEM SERVICE...24
FUEL FILTER...24
ENGINE LUBRICATION SYSTEM...24
CHANGING ENGINE OIL AND FILTER...25
ENGINE COOLING SYSTEM...25
ELECTRICAL SYSTEM...26
HYDRAULIC SYSTEM...27
HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...27
Checking And Adding Fluid...27
Draining The Hydraulic Reservoir...28
HYDRAULIC FILTER REPLACEMENT...28
FINAL DRIVE TRANSMISSION (CHAINCASE)...28
TIRE MAINTENANCE...29
Tire Rotation...29
LUBRICATION OF LOADER...29
BOB-TACH...30
PIVOT PINS...30
PRE-DELIVERY INSPECTION...31
DELIVERY REPORT...31
THIRTY HOUR INSPECTION...31
TROUBLESHOOTING...32
TROUBLESHOOTING THE ENGINE...34
TROUBLESHOOTING THE DRIVE SYSTEM...35
TROUBLESHOOTING THE HYDRAULIC SYSTEM...36
MAJOR PARTS...38
MAIN FRAME PARTS...40
HYDRAULIC CYLINDER CIRCUITRY...41
HYDRAULIC SYSTEM...42
DRIVE SYSTEM...43
KOHLER ENGINE PARTS...44
ELECTRICAL SYSTEM...45
HYDROSTATIC SYSTEM...46
GENERAL INFORMATION...48
LOADER SPECIFICATIONS...50
Operation & Performance...50
Engine...50
Hydraulic System...51
Hydraulic Cylinders...51
Hydrostatic Transmission & Final Drive...51
Hydraulic Fluid...51
Electrical...51
Tires...51
Fluid Capactities...51
Torque Specifications...51
WARRANTY...52
6556152 (5-80) - 500 Series (533) Loader Operation & Maintenance Manual...54
FOREWORD...58
CONTENTS...58
533 BOBCAT LOADER...59
OPERATING INSTRUCTIONS...60
OPERATING INSTRUCTIONS...62
CONTROLS...63
DASH PANEL...63
THROTTLE CONTROL...64
STEERING CONTROLS...64
PARKING BRAKE...65
HYDRAULIC CONTROLS...65
STARTING PROCEDURE...66
Pre-Starting Inspection...66
Starting...67
Normal Starting Condition...67
Cold Temperature Starting Condition...67
BOBCAT OPERATION...68
Bucket Size...68
To Install An Attachment...68
To Remove Attachment...68
OPERATING THE BOBCAT LOADER...69
OPERATING PROCEDURE...69
To Fill The Bucket From Extra Material...69
To Remove Material From The Bucket...69
Digging...70
To Make Ground Level...70
To Fill Holes...70
STOPPING THE BOBCAT...71
TRANSPORTING THE BOBCAT...71
PREVENTIVE MAINTENANCE...72
SERVICE SCHEDULE...74
ENGINE SERVICE...75
AIR CLEANER SYSTEM...75
FUEL SYSTEM...75
FUEL SYSTEM SERVICE...76
FUEL FILTER...76
ENGINE LUBRICATION SYSTEM...76
REPLACEMENT OF ENGINE OIL AND FILTER...77
To Replace Engine Oil And Filter...77
FUEL INJUECTION PUMP RESERVOIR...78
ENGINE COOLING SYSTEM...78
ELECTRICAL SYSTEM...79
USING AN EXTRA BATTERY...81
HYDRAULIC SYSTEM...82
HYDRAULIC / HYDROSTATIC OIL RESERVOIR...85
Checking And Adding Hydraulic Oil...85
To Change Hydraulic Oil In Hydraulic Reservoir...85
REPLACEMENT OF HYDRAULIC FILTER...86
FINAL DRIVE TRANSMISSION (CHAINCASE)...86
TIRE ROTATION...86
LUBRICATION OF LOADER...87
BOB-TACH...87
PIVOT PINS...88
AUXILIARY CONTROL LOCKBOLT...88
FORMS...88
Delivery Report...88
Thirty Hour Inspection...88
TROUBLESHOOTING...90
TROUBLESHOOTING THE ENGINE...92
TROUBLESHOOTING THE DRIVE SYSTEM...93
TROUBLESHOOTING THE HYDRAULIC SYSTEM...94
MAJOR PARTS...96
MAIN FRAME...98
SEAT & FUEL SYSTEM...99
DRIVE SYSTEM...100
HYDRAULIC SYSTEM...101
HYDROSTATIC SYSTEM...102
HAND CONTROLS...103
ROPS ELECTRICAL SYSTEM...104
ENGINE ELECTRICAL SYSTEM...105
ENGINE & ATTACHING PARTS...106
DECALS...107
GENERAL INFORMATION...108
LOADER SPECIFICATIONS...110
Operational & Performance...110
Engine...111
Loader Hydraulics...111
Electrical...111
Drive System...111
Capacities...111
Tires...111
WARRANTY...114
6556175 (5-80) - 500 Series (533) Loader Operation & Maintenance Manual...115
FOREWORD...119
CONTENTS...119
530 BOBCAT LOADER...120
OPERATING INSTRUCTIONS...121
OPERATING INSTRUCTIONS...123
CONTROLS...124
DASH PANEL...124
THROTTLE CONTROL...125
CHOKE CONTROL...125
STEERING CONTROLS...125
PARKING BRAKE...126
HYDRAULIC CONTROLS...126
STARTING PROCEDURE...127
Pre-Starting Inspection...127
Starting...128
Normal Starting Condition...128
Cold Temperature Starting Condition...128
BOBCAT OPERATION...129
Bucket Size...129
Installing Attachment...129
Removal Of Attachments...129
OPERATION OF THE BOBCAT LOADER...130
OPERATING PROCEDURE...130
Filling The Bucket...130
To Empty The Bucket...130
Digging...131
Leveling...131
Backfilling...131
TRANSPORTING THE BOBCAT...132
STOPPING THE BOBCAT...132
PREVENTIVE MAINTENANCE...133
SERVICE SCHEDULE...135
ENGINE SERVICE...136
AIR CLEANER SYSTEM...136
FUEL SYSTEM...136
Fuel System Service...137
FUEL FILTER...137
ENGINE LUBRICATION SYSTEM...137
REPLACEMENT OF ENGINE OIL AND FILTER...138
ENGINE COOLING SYSTEM...138
ELECTRICAL SYSTEM...139
USING AN EXTRA BATTERY...140
TO INSTALL A NEW BATTERY...141
HYDRAULIC SYSTEM...141
HYDRAULIC / HYDROSTATIC OIL RESERVOIR...143
To Check And Add Oil...143
To Remove Hydraulic Oil...143
REPLACEMENT OF HYDRAULIC FILTER...144
FINAL DRIVE TRANSMISSION (CHAINCASE)...144
TIRE MAINTENANCE...144
Tire Rotation...144
LUBRICATION OF THE LOADER...145
BOB-TACH...145
PIVOT PINS...146
AUXILIARY CONTROL LOCKBOLT...146
DELIVERY REPORT...146
THIRTY HOUR INSPECTION...146
TROUBLESHOOTING...147
TROUBLESHOOTING THE ENGINE...149
TROUBLESHOOTING THE DRIVE SYSTEM...150
TROUBLESHOOTING THE HYDRAULIC SYSTEM...151
MAJOR PARTS...153
MAIN FRAME...155
SEAT & FUEL SYSTEM...156
DRIVE SYSTEM...157
HYDRAULIC SYSTEM...158
HYDROSTATIC SYSTEM...159
HAND CONTROLS...160
ROPS ELECTRICAL SYSTEM...161
ENGINE ELECTRICAL SYSTEM...162
ENGINE & ATTACHING PARTS...163
DECALS...164
GENERAL INFORMATION...165
LOADER SPECIFICATIONS...167
Operation & Performance...167
Engine...167
Hydraulic System...168
Hydraulic Cylinders...168
Hydrostatic Transmission & Final Drive...168
Hydraulic Oil...168
Electrical...168
Tires...168
Fluid Capacities...168
Torque Specifications...168
WARRANTY...169
6556407 (3-87) - 520, 530, 533 Loader Service Manual...171
MAINTENANCE SAFETY...173
CONTENTS...175
FOREWORD...175
SAFETY INSTRUCTIONS...177
PREVENTIVE MAINTENANCE...179
INTRODUCTION...181
Symbols...181
Serial Number Identification...181
Loader Serial Number...181
Engine Serial Number...181
Pre-Delivery Inspection...182
30 Hour Inspection...182
PREVENTIVE MAINTENANCE...183
SERVICE SCHEDULE...183
ENGINE SERVICE...184
AIR CLEANER SYSTEM...184
FUEL SYSTEM...185
FUEL SYSTEM SERVICE...185
FUEL FILTER...185
ENGINE LUBRICATION SYSTEM...186
CHANGING ENGINE OIL AND FILTER (520/530)...186
CHANGING OIL AND FILTER (533)...187
ENGINE COOLING SYSTEM (520/530)...188
ENGINE COOLING SYSTEM (533)...188
ELECTRICAL SYSTEM...189
HYDRAULIC SYSTEM...190
HYDRAULIC / HYDROSTATIC FLUID...190
Checking And Adding Fluid...190
Hydraulic / Hydrostatic Fluid Replacement...191
HYDRAULIC FILTER REPLACEMENT...191
FINAL DRIVE TRANSMISSION (CHAINCASE)...191
TIRE MAINTENANCE...192
Tire Rotation...192
LUBRICATION OF LOADER...192
BOB-TACH...193
PIVOT PINS...193
FUEL INJECTION PUMP RESERVOIR (533)...194
HYDRAULIC SYSTEM...195
HYDRAULIC / HYDROSTATIC SCHEMATICS...197
HYDRAULIC CIRCUIT...217
GENERAL INFORMATION...217
Keeping Parts And Work Area Clean...217
37° Flare Connections...217
Straight Thread O-Ring Connections...218
Tubelines And Hoses...218
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM...218
HYDRAULIC PUMP...219
Checking Output Of The Pump...219
PROBLEM ANALYSIS...221
CHECKING RELIEF VALVE...222
To Check Release Pressure...222
Relief Valve Removal And Replacement...222
CHECKING OUTPUT OF VANE PUMP...222
VANE PUMP REPAIR...223
Removal...223
Disassembly...223
Inspection...223
Assembly...223
Pump Istallation...224
CHECKING CONTROL VALVE AND CYLINDERS...224
To Check Lift Cylinders...224
To Check Tilt Cylinders...224
HYDRAULIC CYLINDER REPAIR...224
Removal And Installation...224
Disassembly And Repair...224
CONTROL VALVE REPAIR...225
Removal...225
Disassembly And Inspection...225
Assembly Of Valve...226
ADJUSTMENT OF PEDAL LINKAGE...227
HYDRAULIC HOSES...227
Hydraullic Hose Protection...227
QUICK COUPLERS...228
Restriction In The Quick-Couplers...228
HYDROSTATIC SYSTEM...229
HYDROSTATIC CIRCUIT...231
TROUBLESHOOTING CHART...231
REPLENISHING VALVE...234
Checking The Replenishing Valves...234
BY-PASS VALVE REPAIR...234
REMOVAL AND INSTALLATION OF PUMP ASSEMBLY...234
REPAIR OF HYDROSTATIC PUMP ASSEMBLY...235
Pump Disassembly...235
Assembly...236
HYDROSTATIC MOTOR REMOVAL AND INSTALLATION...237
Installation...237
HYDROSTATIC MOTOR REPAIR...237
Disassembly And Inspection...237
Assembly...238
STEERING LINKAGE...241
Adjustment (Old Style Linkage)...241
Adjustment (New Style Linkage)...241
DRIVE SYSTEM...243
DRIVE CHAINS...245
Chain Replacement...245
AXLES AND BEARINGS...245
Removal Procedure For All Four Axles...245
Assembly And Installation...246
BRAKE PAD REPLACEMENT...247
MAIN FRAME...249
REMOVAL OF ROPS (OPERATOR GUARD)...251
REPLACEMENT OF PIVOT PINS...251
Bushing Replacement...252
BOB-TACH...253
To Check The Wedges...253
Removal Of Bob-Tach...255
Bob-Tach Over Center Stop...255
REMOVAL OF FUEL TANK AND HYDRAULIC RESERVOIR...256
ELECTRICAL SYSTEM...257
ELECTRICAL CIRCUITRY...259
PROBLEM ANALYSIS CHARTS...259
CHECKS AND REPAIRS OF THE ELECTRICAL SYSTEM (520/530)...266
Checking A.C. Voltage...266
Alternator Repair...266
Replacement Of The Stator...266
STARTER...266
To Check The Starter...266
Removal Of Starter...266
Disassembly And Repair...267
CHECKS AND REPAIRS OF THE ELECTRICAL SYSTEM (533)...267
To Check The Wiring...267
To Check The Generator Output...268
To Check The Regulator...268
To Check The Engine Pre-Heat...268
GENERATOR SERVICE...269
Removal Of The Generator...269
Disassembly...269
STARTER...271
Checking The Starter...271
CHECKING ELECTRICAL WIRING...272
STARTER SUPPORT BRACKET...272
ENGINE SERVICE (520/530)...273
TROUBLESHOOTING THE ENGINE...275
CHECKS AND ADJUSTMENTS...276
Oil Pressure...276
Valve Clearance...276
Compression...276
Adjustment Of The Carburetor...276
Throttle And Govenor Linkage...276
Ignition System Adjustment...277
CARBURETOR REPAIR...277
Removal...277
Disassembly And Inspection...278
Assembly...278
REPAIR OF THE GOVENOR...278
Removal...278
Installation...279
ENGINE...279
Removal And Installation Of The Engine...279
REPAIR OF THE ENGINE...279
Flywheel...279
Repair Of The Valves And Guides...280
TIMING COVER, TIMING GEARS, CAMSHAFT...280
Timing Cover...280
Timing Gears...280
Camshaft And Tappets...281
OIL PUMP AND RELIEF VALVE...281
Adjust Gear Clearance For Engine Oil Pump...281
PISTONS, RODS, CRANKSHAFT...282
CYLINDER HEADS...283
INTAKE AND EXHAUST MANIFOLD...283
ENGINE HEAT SHIELD...283
ENGINE SERVICE (533)...285
ENGINE OVERHAUL...287
DISASSEMBLY OF ENGINE...287
CLEANING AND INSPECTION...289
DISASSEMBLY AND ASSEMBLY OF ROCKER SHAFT...289
Disassembly...289
DISASSEMBLY OF THE CYLINDER HEAD...290
Inspection...290
Inspection Of The Combustion Chambers...290
Inspection Or The Valves And Valve Guides...291
Inspection And Correction Of The Valve Seats...291
Inspection Of The Valve Springs...292
Inspection Of The Push-Rods And Tappets...292
Installation Of The Hot Plugs...292
Assembly Of The Valve System...293
CYLINDER BLOCK...293
Inspection Of The Cylinder Block For Cracks...293
Distortion Of The Cylinder Block Upper Surface...293
Correction Of Cylinder Bores...293
PISTONS AND PISTON RING ASSEMBLIES...294
Disassembly...294
Inspection Of Pistons...294
Inspection Of Piston Ring Clearance...294
Assembly Of Piston And Connecting Rods...294
Connecting Rods...295
Clearance Between The Small-End Bushing And Piston Pin...295
Clearance Between The Big-End Bearing And Crankpin...295
Connecting Rod Bearings...295
Connecting Rod Bearing Oil Clearance...296
CRANKSHAFT BEARINGS...296
Crankshaft...296
FLYWHEEL AND RING GEAR...297
CAMSHAFT...297
TIMING GEAR...297
MANIFOLD ASSEMBLY...297
ASSEMBLY OF ENGINE...297
Special Cautions...297
Assembly...298
Method Of Adjustment...300
DISASSEMBLY, INSPECTION AND ASSEMBLY OF THE OIL PUMP...301
Inspection...301
DISASSEMBLY, INSPECTION AND ASSEMBLY OF THE OIL FILTER ASSEMBLY...301
Disassembly And Assembly...301
Inspection...302
WATER PUMP...302
Disassembly Of Water Pump...302
Inspection...302
Assembly...302
INJECTION NOZZLES...303
Disassembly Of The Nozzle Holder Assembly...304
Inspection Of The Nozzle Holder Assemblies...304
Assembling The Nozzle...304
INJECTION PUMP...304
Removal Of Pump...304
To Remove The Pump Drive Gear...305
To Install The Pump Drive Gear...305
Installation And Timing Of Injection Pump...305
TECHNICAL DATA...307
FUEL SPECIFICATIONS...309
LUBRICANTS...309
Gasoline Engine (520/530)...309
Diesel Engine (533)...309
Hydraulic System...309
Chaincase...309
LOADER SPECIFICATIONS (520/530)...310
Operating Specifications...310
Engine...310
Electrical...310
Hydraulics System...310
Power Train...310
Capacities...310
Tires...310
LOADER SPECIFICATIONS (533)...311
Operating...311
Engine...311
Electrical...311
Hydraulic System...311
Power Train...311
Capacities...311
Tires...311
LOADER TORQUE SPECIFICATIONS...312
GASOLINE ENGINE TORQUE SPECIFICATIONS (520/530)...312
DIESEL ENGINE TORQUE SPECIFICATIONS (533)...312
HYDROSTATIC PUMP TORQUE SPECIFICATIONS...312
HYDRAULIC MOTOR TORQUE SPECIFICATIONS...312
HYDRAULIC / HYDROSTATIC SYSTEM...312
SEAL INSTALLING TOOLS...313
FITS, CLEARANCE, ADJUSTMENTS (520/530)...313
Engine...313
Cylinder Bore...313
Crankshaft...313
Connecting Rod...313
Piston, Pin & Rings...313
Valves, Guides, Tappets...313
FITS, CLEARANCE, ADJUSTMENTS (533)...314
Valves...314
Glow Plugs...314
Starting Motor...314
Generator...314
Oil Pump...314
DIMENSIONAL SPECIFICATIONS...314
Cylinder Head...314
Cylinder Block...315
Piston Rings...315
Connecting Rods...315
Crankshaft...316
Camshaft...316
Timing Gears...316
Manifolds...317
Oil Pump...317
GENERAL tORQUE SPECIFICATIONS...317
STANDARD TORQUE SPECIFICATIONS FOR BOLTS...318
DECIMALS AND MILLIMETER EQUIVALENTS...319
U.S. TO METRIC CONVERSION...319
ALPHABETICAL INDEX...321
SERVICE BULLETINS...325
530-001...325
530-002...327
530-003...329
530-004...331
530-005...333
530-006...335
530-007...337
530-008...339
SERVICE MANUAL REVISIONS...341
530-009...341
6556407 (6-12) - 520, 530, 533 Loader Service Manual...343
MAINTENANCE SAFETY...345
CONTENTS...347
FOREWORD...347
SAFETY INSTRUCTIONS...349
PREVENTIVE MAINTENANCE...351
INTRODUCTION...353
Symbols...353
Serial Number Identification...353
Loader Serial Number...353
Engine Serial Number...353
Pre-Delivery Inspection...354
30 Hour Inspection...354
PREVENTIVE MAINTENANCE...355
SERVICE SCHEDULE...355
ENGINE SERVICE...356
AIR CLEANER SYSTEM...356
FUEL SYSTEM...357
FUEL SYSTEM SERVICE...357
FUEL FILTER...357
ENGINE LUBRICATION SYSTEM...358
CHANGING ENGINE OIL AND FILTER (520/530)...358
CHANGING OIL AND FILTER (533)...359
ENGINE COOLING SYSTEM (520/530)...360
ENGINE COOLING SYSTEM (533)...360
ELECTRICAL SYSTEM...361
HYDRAULIC SYSTEM...362
HYDRAULIC / HYDROSTATIC FLUID...362
Checking And Adding Fluid...362
Hydraulic / Hydrostatic Fluid Replacement...363
HYDRAULIC FILTER REPLACEMENT...363
FINAL DRIVE TRANSMISSION (CHAINCASE)...363
TIRE MAINTENANCE...364
Tire Rotation...364
LUBRICATION OF LOADER...364
BOB-TACH...365
PIVOT PINS...365
FUEL INJECTION PUMP RESERVOIR (533)...366
HYDRAULIC SYSTEM...367
HYDRAULIC / HYDROSTATIC SCHEMATICS...369
HYDRAULIC CIRCUIT...389
GENERAL INFORMATION...389
Keeping Parts And Work Area Clean...389
37° Flare Connections...389
Straight Thread O-Ring Connections...390
Tubelines And Hoses...390
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM...390
HYDRAULIC PUMP...391
Checking Output Of The Pump...391
PROBLEM ANALYSIS...393
CHECKING RELIEF VALVE...394
To Check Release Pressure...394
Relief Valve Removal And Replacement...394
CHECKING OUTPUT OF VANE PUMP...394
VANE PUMP REPAIR...395
Removal...395
Disassembly...395
Inspection...395
Assembly...395
Pump Istallation...396
CHECKING CONTROL VALVE AND CYLINDERS...396
To Check Lift Cylinders...396
To Check Tilt Cylinders...396
HYDRAULIC CYLINDER REPAIR...396
Removal And Installation...396
Disassembly And Repair...396
CONTROL VALVE REPAIR...397
Removal...397
Disassembly And Inspection...397
Assembly Of Valve...398
ADJUSTMENT OF PEDAL LINKAGE...399
HYDRAULIC HOSES...399
Hydraullic Hose Protection...399
QUICK COUPLERS...400
Restriction In The Quick-Couplers...400
HYDROSTATIC SYSTEM...401
HYDROSTATIC CIRCUIT...403
TROUBLESHOOTING CHART...403
REPLENISHING VALVE...406
Checking The Replenishing Valves...406
BY-PASS VALVE REPAIR...406
REMOVAL AND INSTALLATION OF PUMP ASSEMBLY...406
REPAIR OF HYDROSTATIC PUMP ASSEMBLY...407
Pump Disassembly...407
Assembly...408
HYDROSTATIC MOTOR REMOVAL AND INSTALLATION...409
Installation...409
HYDROSTATIC MOTOR REPAIR...409
Disassembly And Inspection...409
Assembly...410
STEERING LINKAGE...413
Adjustment (Old Style Linkage)...413
Adjustment (New Style Linkage)...413
DRIVE SYSTEM...415
DRIVE CHAINS...417
Chain Replacement...417
AXLES AND BEARINGS...417
Removal Procedure For All Four Axles...417
Assembly And Installation...418
BRAKE PAD REPLACEMENT...419
MAIN FRAME...421
REMOVAL OF ROPS (OPERATOR GUARD)...423
REPLACEMENT OF PIVOT PINS...423
Bushing Replacement...424
BOB-TACH...425
To Check The Wedges...425
Removal Of Bob-Tach...427
Bob-Tach Over Center Stop...427
REMOVAL OF FUEL TANK AND HYDRAULIC RESERVOIR...428
ELECTRICAL SYSTEM...429
ELECTRICAL CIRCUITRY...431
PROBLEM ANALYSIS CHARTS...431
CHECKS AND REPAIRS OF THE ELECTRICAL SYSTEM (520/530)...438
Checking A.C. Voltage...438
Alternator Repair...438
Replacement Of The Stator...438
STARTER...438
To Check The Starter...438
Removal Of Starter...438
Disassembly And Repair...439
CHECKS AND REPAIRS OF THE ELECTRICAL SYSTEM (533)...439
To Check The Wiring...439
To Check The Generator Output...440
To Check The Regulator...440
To Check The Engine Pre-Heat...440
GENERATOR SERVICE...441
Removal Of The Generator...441
Disassembly...441
STARTER...443
Checking The Starter...443
CHECKING ELECTRICAL WIRING...444
STARTER SUPPORT BRACKET...444
ENGINE SERVICE (520/530)...445
TROUBLESHOOTING THE ENGINE...447
CHECKS AND ADJUSTMENTS...448
Oil Pressure...448
Valve Clearance...448
Compression...448
Adjustment Of The Carburetor...448
Throttle And Govenor Linkage...448
Ignition System Adjustment...449
CARBURETOR REPAIR...449
Removal...449
Disassembly And Inspection...450
Assembly...450
REPAIR OF THE GOVENOR...450
Removal...450
Installation...451
ENGINE...451
Removal And Installation Of The Engine...451
REPAIR OF THE ENGINE...451
Flywheel...451
Repair Of The Valves And Guides...452
TIMING COVER, TIMING GEARS, CAMSHAFT...452
Timing Cover...452
Timing Gears...452
Camshaft And Tappets...453
OIL PUMP AND RELIEF VALVE...453
Adjust Gear Clearance For Engine Oil Pump...453
PISTONS, RODS, CRANKSHAFT...454
CYLINDER HEADS...455
INTAKE AND EXHAUST MANIFOLD...455
ENGINE HEAT SHIELD...455
ENGINE SERVICE (533)...457
ENGINE OVERHAUL...459
DISASSEMBLY OF ENGINE...459
CLEANING AND INSPECTION...461
DISASSEMBLY AND ASSEMBLY OF ROCKER SHAFT...461
Disassembly...461
DISASSEMBLY OF THE CYLINDER HEAD...462
Inspection...462
Inspection Of The Combustion Chambers...462
Inspection Or The Valves And Valve Guides...463
Inspection And Correction Of The Valve Seats...463
Inspection Of The Valve Springs...464
Inspection Of The Push-Rods And Tappets...464
Installation Of The Hot Plugs...464
Assembly Of The Valve System...465
CYLINDER BLOCK...465
Inspection Of The Cylinder Block For Cracks...465
Distortion Of The Cylinder Block Upper Surface...465
Correction Of Cylinder Bores...465
PISTONS AND PISTON RING ASSEMBLIES...466
Disassembly...466
Inspection Of Pistons...466
Inspection Of Piston Ring Clearance...466
Assembly Of Piston And Connecting Rods...466
Connecting Rods...467
Clearance Between The Small-End Bushing And Piston Pin...467
Clearance Between The Big-End Bearing And Crankpin...467
Connecting Rod Bearings...467
Connecting Rod Bearing Oil Clearance...468
CRANKSHAFT BEARINGS...468
Crankshaft...468
FLYWHEEL AND RING GEAR...469
CAMSHAFT...469
TIMING GEAR...469
MANIFOLD ASSEMBLY...469
ASSEMBLY OF ENGINE...469
Special Cautions...469
Assembly...470
Method Of Adjustment...472
DISASSEMBLY, INSPECTION AND ASSEMBLY OF THE OIL PUMP...473
Inspection...473
DISASSEMBLY, INSPECTION AND ASSEMBLY OF THE OIL FILTER ASSEMBLY...473
Disassembly And Assembly...473
Inspection...474
WATER PUMP...474
Disassembly Of Water Pump...474
Inspection...474
Assembly...474
INJECTION NOZZLES...475
Disassembly Of The Nozzle Holder Assembly...476
Inspection Of The Nozzle Holder Assemblies...476
Assembling The Nozzle...476
INJECTION PUMP...476
Removal Of Pump...476
To Remove The Pump Drive Gear...477
To Install The Pump Drive Gear...477
Installation And Timing Of Injection Pump...477
TECHNICAL DATA...479
FUEL SPECIFICATIONS...481
LUBRICANTS...481
Gasoline Engine (520/530)...481
Diesel Engine (533)...481
Hydraulic System...481
Chaincase...481
LOADER SPECIFICATIONS (520/530)...482
Operating Specifications...482
Engine...482
Electrical...482
Hydraulics System...482
Power Train...482
Capacities...482
Tires...482
LOADER SPECIFICATIONS (533)...483
Operating...483
Engine...483
Electrical...483
Hydraulic System...483
Power Train...483
Capacities...483
Tires...483
LOADER TORQUE SPECIFICATIONS...484
GASOLINE ENGINE TORQUE SPECIFICATIONS (520/530)...484
DIESEL ENGINE TORQUE SPECIFICATIONS (533)...484
HYDROSTATIC PUMP TORQUE SPECIFICATIONS...484
HYDRAULIC MOTOR TORQUE SPECIFICATIONS...484
HYDRAULIC / HYDROSTATIC SYSTEM...484
SEAL INSTALLING TOOLS...485
FITS, CLEARANCE, ADJUSTMENTS (520/530)...485
Engine...485
Cylinder Bore...485
Crankshaft...485
Connecting Rod...485
Piston, Pin & Rings...485
Valves, Guides, Tappets...485
FITS, CLEARANCE, ADJUSTMENTS (533)...486
Valves...486
Glow Plugs...486
Starting Motor...486
Generator...486
Oil Pump...486
DIMENSIONAL SPECIFICATIONS...486
Cylinder Head...486
Cylinder Block...487
Piston Rings...487
Connecting Rods...487
Crankshaft...488
Camshaft...488
Timing Gears...488
Manifolds...489
Oil Pump...489
GENERAL tORQUE SPECIFICATIONS...489
STANDARD TORQUE SPECIFICATIONS FOR BOLTS...490
DECIMALS AND MILLIMETER EQUIVALENTS...491
U.S. TO METRIC CONVERSION...491
ALPHABETICAL INDEX...493
SERVICE BULLETINS...497
530-001...497
530-002...499
530-003...501
530-004...503
530-005...505
530-006...507
530-007...509
530-008...511
SERVICE MANUAL REVISIONS...513
530-009...513
530-10...515
6724024 (11-95) - 553 Service Manual...517
MAINTENANCE SAFETY...519
CONTENTS...521
FOREWORD...523
SAFETY INSTRUCTIONS...525
SERIAL NUMBER LOCATIONS...527
LOADER SERIAL NUMBER...527
ENGINE SERIAL NUMBER...527
DELIVERY REPORT...527
553 BOBCAT LOADER IDENTIFICATION...528
OPTIONS AND ACCESSORIES...529
PREVENTIVE MAINTENANCE...531
SERVICE SCHEDULE...533
LIFTING AND BLOCKING THE LOADER...534
Procedure...534
TRANSPORTING THE LOADER...535
Procedure...535
LIFTING THE LOADER...536
Single Point Lift...536
TOWING THE LOADER...536
Procedure...536
STOPPING THE BOBCAT LOADER...536
LIFT ARM SUPPORT DEVICE...537
Installing And Removing Lift Arm Support Device...537
OPERATOR CAB...537
Description...537
Emergency Exit...538
Raising The Operator Cab...538
Lowering The Operator Cab...538
SEAT BAR RESTRAINT SYSTEM...539
Description...539
Seat Bar Inspection...539
Seat Bar Maintenance...539
AIR CLEANER SERVICE...540
Replacing Filter Element...540
FUEL SYSTEM...542
Fuel Specifications...542
Filling The Fuel Tank...542
Fuel Filter...542
Removing Air From The Fuel System ...543
ENGINE LUBRICATION SYSTEM...544
Checking Engine Oil...544
Replacing Oil And Filter ...544
ENGINE COOLING SYSTEM...546
Checking The Coolant Level...546
Propylene Glycol...546
Cleaning The Cooling System...546
Removing Coolant From The Cooling System...546
ALTERNATOR BELT...548
Adjusting The Alternator Belt...548
USING A BOOSTER BATTERY (Jump Starting)...549
Procedure...549
HYDRAULIC/HYDROSTATIC SYSTEM...550
Checking And Adding Fluid...550
Replacing Hydraulic/Hydrostatic Filter...551
Replacing The Hydraulic Fluid...551
SPARK ARRESTOR MUFFLER...552
Cleaning Procedure...552
TIRE MAINTENANCE...553
Wheel Nuts...553
Tire Rotation...553
Tire Mounting...553
FINAL DRIVE TRANSMISSION (CHAINCASE)...554
Checking And Adding Oil...554
Removing Oil From The Chaincase...554
LUBRICATION OF THE LOADER...555
Procedure...555
REMOTE START SWITCH...557
Procedure...557
HYDRAULIC SYSTEM...559
HYDRAULIC / HYDROSTATIC SCHEMATICS...561
TROUBLESHOOTING...565
HYDRAULIC SYSTEM INFORMATION...566
Flare Connections...566
O–ring Face Seal Connection...566
Straight Thread O–ring Fitting...566
Tubelines and Hoses...566
LIFT CYLINDER(S)...567
Removal and Installation...567
Checking The Lift Cylinder(s) For Internal Leakage...567
TILT CYLINDER...568
Removal And Installation...568
Checking The Tilt Cylinder For Internal Leakage...569
HYDRAULIC CYLINDER IDENTIFICATION...570
Lift Cylinder Components...570
Tilt Cylinder Components...571
HYDRAULIC CYLINDER...572
Disassembly...572
Assembly...574
HYDRAULIC CONTROL VALVE...580
Removal And Installation...580
Checking The Main Relief Valve...583
Main Relief Valve Removal And Installation...584
Main Relief Valve Adjustment...584
Identification Chart...585
Disassembly And Assembly...586
Load Check Valve...586
Main Relief Valve...587
Anti–Cavitation Valve...588
Rubber Boot...589
Lift Spool Detent...590
Tilt Centering Spring...594
Auxiliary Spool Detent...594
One Way Restrictors...595
Inspection...595
Spool Seal Installation...596
HYDRAULIC PUMP...597
Removal And Installation...597
Checking The Output Of The Hydraulic Pump...598
Main Relief Valve Adjustment...599
Parts Identification...600
Disassembly and Assembly...601
Inspection...602
HYDRAULIC FILTER HOUSING...603
Removal And Installation...603
HYDRAULIC FLUID RESERVOIR...604
Removal And Installation...604
CONTROL PEDALS...605
Removal And Installation...605
Pedal Adjustment...605
PEDAL INTERLOCK LINKAGE...606
Removal And Installation...606
Adjustment...607
CROSSMEMBER LINKAGE...608
Removal And Installation...608
HYDROSTATIC SYSTEM...609
TROUBLESHOOTING...611
HYDROSTATIC SYSTEM INFORMATION...612
Replenishing Valve Function...612
CONTROL PANEL...613
Removal And Installation...613
STEERING LEVERS...614
Removal And Installation...614
Disassembly And Assembly...615
STEERING LINKAGE...616
Removal And Installation...616
Pintle Lever Disassembly And Assembly...618
Steering Neutral Adjustment...619
HYDR0STATIC PUMP...621
Checking Charge Pressure...621
Removal And Installation...622
Drive Coupler Removal And Installation...625
Parts Identification...626
Disassembly and Assembly...627
Inspection...631
PORT BLOCK...634
Removal And Installation...634
Oil Cooler Bypass Valve...634
Hydraulic Oil Temperature Switch...634
Charge Pressure Bypass Valve...634
HYDROSTATIC DRIVE MOTOR...635
Removal And Installation...635
Parts Identification...637
Disassembly And Assembly...638
Inspection...645
Timing The Hydrostatic Motor...646
DRIVE SYSTEM...647
PARKING BRAKE...649
Removal And Installation...649
Disassembly And Assembly...649
PARKING BRAKE DISC...650
Removal And Installation...650
Brake Disc Guide Removal And Installation...651
CHAINCASE FLUID...652
Removing Oil From The Chaincase...652
CHAINCASE COVERS...652
Front Cover Removal And Installation...652
Rear Cover Removal And Installation...652
AXLE SEAL...653
Removal And Installation...653
AXLE, BEARINGS, AND SPROCKET...655
Removal And Installation...655
DRIVE CHAIN...659
Removal...659
MAIN FRAME...661
SEAT BAR...663
Removal And Installation...663
Assembly...665
Compressing The Gas Cylinder...666
OPERATOR CAB GAS CYLINDER...667
Removal And Installation...667
Disassembly And Assembly...667
OPERATOR CAB...668
Removal And Installation...668
OPERATOR SEAT...671
Removal And Installation...671
BOB–TACH...672
Removal And Installation...672
Bob–Tach Lever And Wedge...674
LIFT ARMS...676
Removal And Installation...676
REAR GRILL...679
Removal And Installation...679
FUEL TANK...680
Removal And Installation...680
Fuel Level Sender...680
REAR DOOR...681
Removal And Installation...681
Door Handle Adjustment...682
ELECTRICAL SYSTEM...683
ELECTRICAL SCHEMATICS...685
TROUBLESHOOTING...707
ELECTRICAL SYSTEM INFORMATION...708
Description...708
Fuse Location...708
Relay Switches Location...708
Removing And Installing The Battery...709
ALTERNATOR...710
Alternator Belt Shield Removal And Installation...710
Removal And Installation...711
Adjusting The Alternator Belt...711
Alternator Output Test...712
Rectifier (Diode) Test...712
Alternator Regulator Test...713
Disassembly And Inspection – Parts Identification...714
Stator Continuity Test...714
Stator Ground Test...714
Rotor Continuity Test...715
Rotor Ground Test...715
Rectifier Continuity (Diode) Test...715
Assembly...716
STARTER ...717
Removal And Installation...717
Checking The Starter...717
Disassembly And Assembly...718
Parts Identification...718
Cleaning And Inspection...719
Replacing The Brushes...719
INSTRUMENT PANEL...720
Removal And Installation...720
FRONT LIGHTS...721
Removal And Installation...721
ENGINE SERVICE...723
TROUBLESHOOTING...726
ENGINE SPEED CONTROL...728
Removal And Installation...728
Disassembly...728
Linkage Bar Removal And Installation...729
RADIATOR...730
Removal And Installation...730
ENGINE MUFFLER...732
Removal And Installation...732
AIR CLEANER...732
Removal And Installation...732
FUEL FILTER ...733
Removal And Installation...733
ENGINE ...734
Removal And Installation...734
U–JOINT COUPLER...738
Removal And Installation...738
Disassemly And Assembly...738
FLYWHEEL ...739
Removal And Installation...739
Flywheel Ring Gear...739
BLOWER FAN HOUSING...740
Removal And Installation...740
ENGINE COMPRESSION...741
Checking...741
GLOW PLUGS...742
Checking...742
Removal And Installation...743
FUEL INJECTION PUMP...744
Checking The Injection Pump...744
Removal And Installation...745
Timing The Injection Pump...748
FUEL INJECTOR NOZZLES...750
Removal...750
Installation...750
Checking Fuel Injector Nozzles...751
CYLINDER HEAD...752
Removal...752
Installation...754
Disassembly...756
Assembly...756
Servicing The Cylinder Head...757
TIMING GEARCASE COVER...760
Removal...760
Installation...762
TIMING GEARS AND CAMSHAFT...763
Removal...763
Installation...766
Servicing The Timing Gear And The Camshaft...767
OIL PUMP...769
Removal And Installation...769
Servicing The Oil Pump...769
WATER PUMP...770
Removal And Installation...770
PISTONS AND CRANKSHAFT...771
Piston And Camshaft Removal...771
Piston Installation...772
Servicing The Pistons And Connecting Rods...773
Crankshaft Installation...775
Servicing The Crankshaft...775
Servicing The Cylinder Liners...777
BICS™ SYSTEM...779
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...781
Inspecting The BICS System Controller (Engine STOPPED – Key ON)...781
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)...781
Inspecting The Traction Lock (Engine RUNNING)...781
Inspecting The Lift Arm By–Pass Control...781
Maintenance...781
Troubleshooting Chart...782
TROUBLESHOOTING GUIDE...783
BICS CONTROLLER...783
TRACTION LOCK...784
SEAT SENSOR...785
SEAT BAR SENSOR...786
LIFT LOCK BYPASS VALVE...787
BICS™ SYSTEM CONTROLLER...788
Removal And Installation...788
Controller Test...789
SEAT BAR SENSOR...790
Removal And Installation...790
Seat Bar Sensor Test...791
SEAT SENSOR...792
Removal And Installation...792
Seat Sensor Test...793
TRACTION LOCK...794
Removal And Installation...794
LIFT LOCK BYPASS VALVE...795
Removal And Installation...795
Disassembly And Assembly...796
TILT LOCK VALVE...797
Removal And Installation...797
Disassembly And Assembly...798
SPECIFICATIONS...799
LOADER SPECIFICATIONS...801
LOADER DIMENSIONS...801
OPERATIONS & PERFORMANCE...801
ENGINE...801
HYDRAULIC SYSTEM...802
ELECTRICAL...802
DRIVE SYSTEM...802
CAPACITIES...802
TIRES...802
VIBRATION DATA...802
ENGINE SPECIFICATIONS...803
Fuel Injection Nozzles...803
Fuel Injection Pump...803
Cylinder Head...803
Valves...803
Valve Springs...803
Rocker Arms...803
Camshaft...803
Cylinders...804
Piston Rings...804
Pistons...804
Crankshaft...804
Oil Pump...804
Thermostat...804
Grinding Specifications for the Crankshaft...805
TORQUE SPECIFICATIONS FOR LOADER...806
Specifications...806
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...807
Specifications...807
METRIC TORQUE SPECIFICATIONS FOR BOLTS...808
STANDARD TORQUE SPECIFICATIONS FOR BOLTS...809
DECIMAL AND MILLIMETER EQUIVALENTS...810
U.S. TO METRIC CONVERSION...810
SERVICE MANUAL REVISIONS...811
553-1...811
6724024 (6-12) - 553 Service Manual...813
MAINTENANCE SAFETY...815
CONTENTS...817
FOREWORD...819
SAFETY INSTRUCTIONS...821
SERIAL NUMBER LOCATIONS...823
LOADER SERIAL NUMBER...823
ENGINE SERIAL NUMBER...823
DELIVERY REPORT...823
553 BOBCAT LOADER IDENTIFICATION...824
OPTIONS AND ACCESSORIES...825
PREVENTIVE MAINTENANCE...827
SERVICE SCHEDULE...829
LIFTING AND BLOCKING THE LOADER...830
Procedure...830
TRANSPORTING THE LOADER...831
Procedure...831
LIFTING THE LOADER...832
Single Point Lift...832
TOWING THE LOADER...832
Procedure...832
STOPPING THE BOBCAT LOADER...832
LIFT ARM SUPPORT DEVICE...833
Installing And Removing Lift Arm Support Device...833
OPERATOR CAB...833
Description...833
Emergency Exit...834
Raising The Operator Cab...834
Lowering The Operator Cab...834
SEAT BAR RESTRAINT SYSTEM...835
Description...835
Seat Bar Inspection...835
Seat Bar Maintenance...835
AIR CLEANER SERVICE...836
Replacing Filter Element...836
FUEL SYSTEM...838
Fuel Specifications...838
Filling The Fuel Tank...838
Fuel Filter...838
Removing Air From The Fuel System ...839
ENGINE LUBRICATION SYSTEM...840
Checking Engine Oil...840
Replacing Oil And Filter ...840
ENGINE COOLING SYSTEM...842
Checking The Coolant Level...842
Propylene Glycol...842
Cleaning The Cooling System...842
Removing Coolant From The Cooling System...842
ALTERNATOR BELT...844
Adjusting The Alternator Belt...844
USING A BOOSTER BATTERY (Jump Starting)...845
Procedure...845
HYDRAULIC/HYDROSTATIC SYSTEM...846
Checking And Adding Fluid...846
Replacing Hydraulic/Hydrostatic Filter...847
Replacing The Hydraulic Fluid...847
SPARK ARRESTOR MUFFLER...848
Cleaning Procedure...848
TIRE MAINTENANCE...849
Wheel Nuts...849
Tire Rotation...849
Tire Mounting...849
FINAL DRIVE TRANSMISSION (CHAINCASE)...850
Checking And Adding Oil...850
Removing Oil From The Chaincase...850
LUBRICATION OF THE LOADER...851
Procedure...851
REMOTE START SWITCH...853
Procedure...853
HYDRAULIC SYSTEM...855
HYDRAULIC / HYDROSTATIC SCHEMATICS...857
TROUBLESHOOTING...861
HYDRAULIC SYSTEM INFORMATION...862
Flare Connections...862
O–ring Face Seal Connection...862
Straight Thread O–ring Fitting...862
Tubelines and Hoses...862
LIFT CYLINDER(S)...863
Removal and Installation...863
Checking The Lift Cylinder(s) For Internal Leakage...863
TILT CYLINDER...864
Removal And Installation...864
Checking The Tilt Cylinder For Internal Leakage...865
HYDRAULIC CYLINDER IDENTIFICATION...866
Lift Cylinder Components...866
Tilt Cylinder Components...867
HYDRAULIC CYLINDER...868
Disassembly...868
Assembly...870
HYDRAULIC CONTROL VALVE...876
Removal And Installation...876
Checking The Main Relief Valve...879
Main Relief Valve Removal And Installation...880
Main Relief Valve Adjustment...880
Identification Chart...881
Disassembly And Assembly...882
Load Check Valve...882
Main Relief Valve...883
Anti–Cavitation Valve...884
Rubber Boot...885
Lift Spool Detent...886
Tilt Centering Spring...890
Auxiliary Spool Detent...890
One Way Restrictors...891
Inspection...891
Spool Seal Installation...892
HYDRAULIC PUMP...893
Removal And Installation...893
Checking The Output Of The Hydraulic Pump...894
Main Relief Valve Adjustment...895
Parts Identification...896
Disassembly and Assembly...897
Inspection...898
HYDRAULIC FILTER HOUSING...899
Removal And Installation...899
HYDRAULIC FLUID RESERVOIR...900
Removal And Installation...900
CONTROL PEDALS...901
Removal And Installation...901
Pedal Adjustment...901
PEDAL INTERLOCK LINKAGE...902
Removal And Installation...902
Adjustment...903
CROSSMEMBER LINKAGE...904
Removal And Installation...904
HYDROSTATIC SYSTEM...905
TROUBLESHOOTING...907
HYDROSTATIC SYSTEM INFORMATION...908
Replenishing Valve Function...908
CONTROL PANEL...909
Removal And Installation...909
STEERING LEVERS...910
Removal And Installation...910
Disassembly And Assembly...911
STEERING LINKAGE...912
Removal And Installation...912
Pintle Lever Disassembly And Assembly...914
Steering Neutral Adjustment...915
HYDR0STATIC PUMP...917
Checking Charge Pressure...917
Removal And Installation...918
Drive Coupler Removal And Installation...921
Parts Identification...922
Disassembly and Assembly...923
Inspection...927
PORT BLOCK...930
Removal And Installation...930
Oil Cooler Bypass Valve...930
Hydraulic Oil Temperature Switch...930
Charge Pressure Bypass Valve...930
HYDROSTATIC DRIVE MOTOR...931
Removal And Installation...931
Parts Identification...933
Disassembly And Assembly...934
Inspection...941
Timing The Hydrostatic Motor...942
DRIVE SYSTEM...943
PARKING BRAKE...945
Removal And Installation...945
Disassembly And Assembly...945
PARKING BRAKE DISC...946
Removal And Installation...946
Brake Disc Guide Removal And Installation...947
CHAINCASE FLUID...948
Removing Oil From The Chaincase...948
CHAINCASE COVERS...948
Front Cover Removal And Installation...948
Rear Cover Removal And Installation...948
AXLE SEAL...949
Removal And Installation...949
AXLE, BEARINGS, AND SPROCKET...951
Removal And Installation...951
DRIVE CHAIN...955
Removal...955
MAIN FRAME...957
SEAT BAR...959
Removal And Installation...959
Assembly...961
Compressing The Gas Cylinder...962
OPERATOR CAB GAS CYLINDER...963
Removal And Installation...963
Disassembly And Assembly...963
OPERATOR CAB...964
Removal And Installation...964
OPERATOR SEAT...967
Removal And Installation...967
BOB–TACH...968
Removal And Installation...968
Bob–Tach Lever And Wedge...970
LIFT ARMS...972
Removal And Installation...972
REAR GRILL...975
Removal And Installation...975
FUEL TANK...976
Removal And Installation...976
Fuel Level Sender...976
REAR DOOR...977
Removal And Installation...977
Door Handle Adjustment...978
ELECTRICAL SYSTEM...979
ELECTRICAL SCHEMATICS...981
TROUBLESHOOTING...1003
ELECTRICAL SYSTEM INFORMATION...1004
Description...1004
Fuse Location...1004
Relay Switches Location...1004
Removing And Installing The Battery...1005
ALTERNATOR...1006
Alternator Belt Shield Removal And Installation...1006
Removal And Installation...1007
Adjusting The Alternator Belt...1007
Alternator Output Test...1008
Rectifier (Diode) Test...1008
Alternator Regulator Test...1009
Disassembly And Inspection – Parts Identification...1010
Stator Continuity Test...1010
Stator Ground Test...1010
Rotor Continuity Test...1011
Rotor Ground Test...1011
Rectifier Continuity (Diode) Test...1011
Assembly...1012
STARTER ...1013
Removal And Installation...1013
Checking The Starter...1013
Disassembly And Assembly...1014
Parts Identification...1014
Cleaning And Inspection...1015
Replacing The Brushes...1015
INSTRUMENT PANEL...1016
Removal And Installation...1016
FRONT LIGHTS...1017
Removal And Installation...1017
ENGINE SERVICE...1019
TROUBLESHOOTING...1022
ENGINE SPEED CONTROL...1024
Removal And Installation...1024
Disassembly...1024
Linkage Bar Removal And Installation...1025
RADIATOR...1026
Removal And Installation...1026
ENGINE MUFFLER...1028
Removal And Installation...1028
AIR CLEANER...1028
Removal And Installation...1028
FUEL FILTER ...1029
Removal And Installation...1029
ENGINE ...1030
Removal And Installation...1030
U–JOINT COUPLER...1034
Removal And Installation...1034
Disassemly And Assembly...1034
FLYWHEEL ...1035
Removal And Installation...1035
Flywheel Ring Gear...1035
BLOWER FAN HOUSING...1036
Removal And Installation...1036
ENGINE COMPRESSION...1037
Checking...1037
GLOW PLUGS...1038
Checking...1038
Removal And Installation...1039
FUEL INJECTION PUMP...1040
Checking The Injection Pump...1040
Removal And Installation...1041
Timing The Injection Pump...1044
FUEL INJECTOR NOZZLES...1046
Removal...1046
Installation...1046
Checking Fuel Injector Nozzles...1047
CYLINDER HEAD...1048
Removal...1048
Installation...1050
Disassembly...1052
Assembly...1052
Servicing The Cylinder Head...1053
TIMING GEARCASE COVER...1056
Removal...1056
Installation...1058
TIMING GEARS AND CAMSHAFT...1059
Removal...1059
Installation...1062
Servicing The Timing Gear And The Camshaft...1063
OIL PUMP...1065
Removal And Installation...1065
Servicing The Oil Pump...1065
WATER PUMP...1066
Removal And Installation...1066
PISTONS AND CRANKSHAFT...1067
Piston And Camshaft Removal...1067
Piston Installation...1068
Servicing The Pistons And Connecting Rods...1069
Crankshaft Installation...1071
Servicing The Crankshaft...1071
Servicing The Cylinder Liners...1073
BICS™ SYSTEM...1075
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...1077
Inspecting The BICS System Controller (Engine STOPPED – Key ON)...1077
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)...1077
Inspecting The Traction Lock (Engine RUNNING)...1077
Inspecting The Lift Arm By–Pass Control...1077
Maintenance...1077
Troubleshooting Chart...1078
TROUBLESHOOTING GUIDE...1079
BICS CONTROLLER...1079
TRACTION LOCK...1080
SEAT SENSOR...1081
SEAT BAR SENSOR...1082
LIFT LOCK BYPASS VALVE...1083
BICS™ SYSTEM CONTROLLER...1084
Removal And Installation...1084
Controller Test...1085
SEAT BAR SENSOR...1086
Removal And Installation...1086
Seat Bar Sensor Test...1087
SEAT SENSOR...1088
Removal And Installation...1088
Seat Sensor Test...1089
TRACTION LOCK...1090
Removal And Installation...1090
LIFT LOCK BYPASS VALVE...1091
Removal And Installation...1091
Disassembly And Assembly...1092
TILT LOCK VALVE...1093
Removal And Installation...1093
Disassembly And Assembly...1094
SPECIFICATIONS...1095
LOADER SPECIFICATIONS...1097
LOADER DIMENSIONS...1097
OPERATIONS & PERFORMANCE...1097
ENGINE...1097
HYDRAULIC SYSTEM...1098
ELECTRICAL...1098
DRIVE SYSTEM...1098
CAPACITIES...1098
TIRES...1098
VIBRATION DATA...1098
ENGINE SPECIFICATIONS...1099
Fuel Injection Nozzles...1099
Fuel Injection Pump...1099
Cylinder Head...1099
Valves...1099
Valve Springs...1099
Rocker Arms...1099
Camshaft...1099
Cylinders...1100
Piston Rings...1100
Pistons...1100
Crankshaft...1100
Oil Pump...1100
Thermostat...1100
Grinding Specifications for the Crankshaft...1101
TORQUE SPECIFICATIONS FOR LOADER...1102
Specifications...1102
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1103
Specifications...1103
METRIC TORQUE SPECIFICATIONS FOR BOLTS...1104
STANDARD TORQUE SPECIFICATIONS FOR BOLTS...1105
DECIMAL AND MILLIMETER EQUIVALENTS...1106
U.S. TO METRIC CONVERSION...1106
SERVICE MANUAL REVISIONS...1107
553-1...1107
553-2...1109
Bobcat Loaders 520, 530, 533, 553 Repair Service Manuals
