Complete repair service manual with Electrical Wiring Diagrams for Bobcat 553 Skid-Steer Loader, with technical information to maintain, diagnose, and repair like professional mechanics.

Bobcat 553 Skid-Steer Loaders 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.

6724696 (10-98) - 553 Operation & Maintenance Manual.pdf
6900385 (7-98) - 553 Operation & Maintenance Manual.pdf
6900450 (1-98) - 553 Service Manual.pdf
6900450 (6-12) - 553 Service Manual.pdf
6900785 (1-01) - 553 Operation & Maintenance Manual.pdf
6901823 (1-05) - 553 Operation & Maintenance Manual.pdf
6901824 (3-06) - 553 Service Manual.pdf
6901824 (6-12) - 553 Service Manual.pdf
6902827 (3-05) - 553 Operation & Maintenance Manual.pdf
6903125 (2-06) - 553 Service Manual.pdf
6903125 (6-12) - 553 Service Manual.pdf
6904701 (5-07) - 553 Skid-Steer Loader Operation & Maintenance Manual.pdf
6904705 (3-06) - 553 Skid-Steer Loader Service Manual.pdf
6904705 (10-12) - 553 Skid-Steer Loader Service Manual.pdf

PRODUCT DETAILS:
Total Pages: 3,221 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
6724696 (10-98) - 553 Operation & Maintenance Manual....1
  OPERATOR SAFETY WARNINGS....3
  CONTENTS....5
    MELROE COMPANY IS ISO 9001 CERTIFIED....6
    REGULAR MAINTENANCE ITEMS....6
  FOREWORD....7
    SERIAL NUMBER LOCATIONS....9
      Loader Serial Number....9
      Engine Serial Number....9
    DELIVERY REPORT....9
    BOBCAT SKID STEER LOADER IDENTIFICATION....10
    OPTIONS AND ACCESSORIES....11
  SAFETY....13
    SAFETY INSTRUCTIONS....15
      Safety Is The Operator's Responsibility....15
      Before Operating The Bobcat Loader....16
      Safe Operation Needs A Qualified Operator....16
    FIRE PREVENTION....17
    MACHINE SIGNS (DECALS)....18
  OPERATING INSTRUCTIONS....21
    INSTRUMENT PANEL....23
      Front Panel....23
      Side Console....23
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....24
      Lift Arm By-Pass Control....25
      Traction Lock Override....25
      Seat Sensor Override (If Equipped)....25
    ENGINE SPEED CONTROL....26
    ENGINE STOP CONTROL....26
    PARKING BRAKE....26
    STEERING LEVERS....27
    STOPPING THE BOBCAT LOADER....27
    SEAT BAR RESTRAINT SYSTEM....28
    HYDRAULIC CONTROLS....30
      Foot Pedals....30
      Bucket Position Valve Operation (Option Or Field Accessory)....30
      Auxiliary Hydraulics ....31
      Quick Couplers (Flush Face)....31
      Auxiliary Hydraulics Operation....32
    DAILY INSPECTION....33
    GETTING READY FOR OPERATION....34
    STARTING THE ENGINE....35
      Normal Starting Condition....36
      Cold Temperature Starting....37
      Warming The Hydraulic / Hydrostatic System....37
    STOPPING THE ENGINE....37
    ATTACHMENTS AND BUCKETS....38
      Installation....39
      Removal....39
    OPERATING PROCEDURES....40
      Filling The Bucket....41
      Emptying The Bucket....41
      Digging Into The Ground....42
      Leveling The Ground (Using Lift Arm Float Position)....43
      Backfilling....43
    PARKING THE BOBCAT LOADER....44
    TRANSPORTING THE BOBCAT LOADER...44
    LIFTING THE LOADER....45
    TOWING THE LOADER....45
    STOPPING THE BOBCAT LOADER....45
  PREVENTIVE MAINTENANCE....47
    MAINTENANCE SAFETY....48
    SERVICE SCHEDULE....49
    LIFT ARM SUPPORT DEVICE....50
      Installing The Lift Arm Support Device....50
      Removing The Lift Arm Support Device....50
    OPERATOR CAB....51
      Raising The Operator Cab....51
      Lowering The Operator Cab....51
      Emergency Exit....52
    SEAT BAR RESTRAINT SYSTEM....53
      Inspecting The Seat Bar....53
      Maintaining The Seat Bar....53
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....54
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)....54
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)....54
      Inspecting The Traction Lock (Engine RUNNING)....54
      Inspecting The Lift Arm By-Pass Control....54
      Maintenance....54
    REAR DOOR....55
      Adjusting The Latch....55
    REAR GRILL....56
    AIR CLEANER SERVICE....57
    FUEL SYSTEM....59
      Fuel Specifications....59
      Filling The Fuel Tank....59
      Fuel Filter....59
      Removing Air From The Fuel System....60
    ENGINE LUBRICATION SYSTEM....61
      Checking Engine Oil....61
      Oil Chart....61
      Replacing Oil And Filter....61
    ENGINE COOLING SYSTEM....63
      Cleaning The Cooling System....63
      Checking The Coolant Level....63
      Replacing The Coolant....64
    ALTERNATOR BELT ADJUSTMENT....65
    ELECTRICAL SYSTEM....65
      Description....65
      Electrical System Maintenance....65
      Fuse Location....65
      Using A Booster Battery (Jump Starting)....66
      Removing And Installing Battery....67
    HYDRAULIC / HYDROSTATIC SYSTEM....68
      Checking And Adding Fluid....68
      Replacing The Hydraulic / Hydrostatic Filter....69
      Replacing Hydraulic Fluid....69
    SPARK ARRESTOR MUFFLER....70
    TIRE MAINTENANCE....71
      Wheel Nuts....71
      Tire Rotation....71
      Tire Mounting....71
    FINAL DRIVE TRANSMISSION (CHAINCASE)....72
      Checking And Adding Oil....72
    LUBRICATING THE BOBCAT LOADER....73
    PIVOT PINS....75
    BOB-TACH....75
    AUXILIARY CONTROL LOCKBOLT....76
    U-JOINT LUBRICATION....76
  SYSTEMS ANALYSIS....77
    TROUBLESHOOTING THE ENGINE....79
    TROUBLESHOOTING THE DRIVE SYSTEM....80
    TROUBLESHOOTING THE HYDRAULIC SYSTEM....81
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....82
  MACHINE SIGN TRANSLATION....83
    IMPORTANT - 6560573....85
    WARNING - 6579511....86
    WARNING - 6579510....87
    SERVICE SCHEDULE - 6708212....88
    WARNING - 6579528....90
    DANGER - 6722302....90
    WARNING - 6577754....90
    DANGER - 6572301....90
  SPECIFICATIONS....91
    LOADER DIMENSIONS....93
    OPERATIONS & PERFORMANCE....93
    ENGINE....93
    HYDRAULIC SYSTEM....94
    ELECTRICAL....94
    DRIVE SYSTEM....94
    CAPACITIES....94
    TIRES....94
    MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES....95
    ADDITIONAL PUBLICATIONS....97
  WARRANTY....99
6900385 (7-98) - 553 Operation & Maintenance Manual....101
  OPERATOR SAFETY WARNINGS....102
  CONTENTS....103
    MELROE COMPANY IS ISO 9001 CERTIFIED....104
    REGULAR MAINTENANCE ITEMS....104
  FOREWORD....105
    SERIAL NUMBER LOCATIONS....107
      Loader Serial Number....107
      Engine Serial Number....107
    DELIVERY REPORT....107
    BOBCAT SKID STEER LOADER IDENTIFICATION....108
    OPTIONS AND ACCESSORIES....109
  SAFETY....111
    SAFETY INSTRUCTIONS....113
      Safety Is The Operator's Responsibility....113
      Before Operating The Bobcat Loader....114
      Safe Opertion Needs A Qualified Operator....114
    FIRE PREVENTION....115
    MACHINE SIGNS (DECALS)....116
  OPERATING INSTRUCTIONS....119
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....122
      Lift Arm By-Pass Control....123
      Traction Lock Override....123
      Seat Sensor Override (If Equipped)....123
    INSTRUMENT PANEL....121
      Front Panel....121
      Side Console....121
    ENGINE SPEED CONTROL....124
    PARKING BRAKE....124
    STEERING LEVERS....125
    STOPPING THE BOBCAT LOADER....125
    SEAT BAR RESTRAINT SYSTEM....126
    HYDRAULIC CONTROLS....128
      Foot Pedals....128
      Lift Arm Operation....128
      Lift Arm Float Position....128
      Tilt Operation (Bucket)....128
      Bucket Position Valve Operation (If Equipped)....128
      Auxiliary Hydraulics (If Equipped)....129
      Quick Couplers (Flush Face)....129
      Auxiliary Hydraulics....130
      Relieving Hydraulic Pressure....130
    DAILY INSPECTION....131
    GETTING READY FOR OPERATION....132
    STARTING THE ENGINE....133
      Normal Starting....134
      Cold Temperature Starting....135
      Warming The Hydraulic / Hydrostatic System....135
    STOPPING THE ENGINE....135
    ATTACHMENTS AND BUCKETS....136
      Installing The Bucket Or Attachment....137
      Removing The Bucket Or Attachment....138
    OPERATING PROCEDURE....139
      Filling The Bucket....140
      Emptying The Bucket....140
      Digging Into The Ground....141
      Leveling The Ground (Using Lift Arms In Float Position)....142
      Backfilling....142
    PARKING THE BOBCAT LOADER....143
    TRANSPORTING THE BOBCAT LOADER....143
    LIFTING THE BOBCAT LOADER....144
    TOWING THE LOADER....144
    STOPPING THE BOBCAT LOADER....144
  PREVENTIVE MAINTENANCE....145
    MAINTENANCE SAFETY....146
    SERVICE SCHEDULE....147
    LIFT ARM SUPPORT DEVICE....148
      Engaging The Lift Arm Support Device....148
      Disengaging The Lift Arm Support Device....149
    OPERATOR CAB....150
      Raising The Operator Cab....150
      Lowering The Operator Cab....150
      Emergency Exits....151
    SEAT BAR RESTRAINT SYSTEM....152
      Inspecting The Seat Bar....152
      Maintaining The Seat Bar....152
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....153
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)....153
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)....153
      Inspecting The Traction Lock (Engine RUNNING)....153
      Inspecting The Lift Arm By-Pass Control....153
      Maintenance....153
    REAR DOOR....154
      Adjusting The Latch....154
    REAR GRILL....154
    AIR CLEANER SERVICE....155
    FUEL SYSTEM....156
      Fuel Specifications....156
      Filling The Fuel Tank....156
      Fuel Filter....156
      Removing Air From The Fuel System....157
    ENGINE LUBRICATION SYSTEM....158
      Checking Engine Oil....158
      Oil Chart....158
      Replacing Oil And Filter....158
    ENGINE COOLING SYSTEM....160
      Cleaning The Cooling System....160
      Checking The Coolant Level....160
      Replacing The Coolant....161
    ALTERNATOR BELT ADJUSTMENT....162
    ELECTRICAL SYSTEM....162
      Description....162
      Electrical System Maintenance....162
      Fuse Location....162
      Using A Booster Battery (Jump Starting)....163
      Removing And Installing The Battery....164
    HYDRAULIC/HYDROSTATIC SYSTEM....165
      Checking And Adding Fluid....165
      Replacing The Hydraulic/Hydrostatic Filter....166
      Replacing Hydraulic Fluid....166
    SPARK ARRESTOR MUFFLER....167
    TIRE MAINTENANCE....168
      Wheel Nuts....168
      Tire Rotation....168
      Tire Mounting....168
    FINAL DRIVE TRANSMISSION (CHAINCASE)....168
      Checking And Adding Oil....168
    LUBRICATING THE BOBCAT LOADER....169
    PIVOT PINS....170
    BOB–TACH....171
      Inspection And Maintenance....171
    AUXILIARY CONTROL LOCKBOLT....172
    U–JOINT LUBRICATION....172
  SYSTEMS ANALYSIS....173
    TROUBLESHOOTING THE ENGINE....175
    TROUBLESHOOTING THE DRIVE SYSTEM....176
    TROUBLESHOOTING THE HYDRAULIC SYSTEM....177
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....178
      Troubleshooting Chart....178
  MACHINE SIGN TRANSLATIONS....179
    IMPORTANT - 6560573....181
    WARNING - 6579511....182
    WARNING - 6579510....183
    SERVICE SCHEDULE....184
    WARNING - 6579528....186
    DANGER - 6572302....186
    WARNING - 6577754....186
    DANGER - 6572301....186
  SPECIFICATIONS....187
    PERFORMANCE....189
    CONTROLS....189
    ENGINE....189
    HYDRAULIC SYSTEM....190
    ELECTRICAL....190
    DRIVE SYSTEM....190
    CAPACITIES....190
    TIRES....190
    FLOOR PRESSURE....190
    MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES....191
    ADDITIONAL PUBLICATIONS....193
  WARRANTY....195
6900450 (1-98) - 553 Service Manual....197
  MAINTENANCE SAFETY....199
  ALPHABETICAL INDEX....201
  CONTENTS....203
    FOREWORD....205
    SAFETY INSTRUCTIONS....207
    SERIAL NUMBER LOCATIONS....209
    LOADER SERIAL NUMBER....209
    ENGINE SERIAL NUMBER....209
    DELIVERY REPORT....209
    BOBCAT SKID STEER LOADER IDENTIFICATION....210
  PREVENTIVE MAINTENANCE....211
    SERVICE SCHEDULE....213
    LIFTING AND BLOCKING THE LOADER....214
      Procedure....214
    TOWING THE LOADER....215
      Procedure....215
    STOPPING THE BOBCAT LOADER....216
    LIFT ARM SUPPORT DEVICE....217
      Engaging The Lift Arm Support Device....217
      Disengaging The Lift Arm Support Device....218
    OPERATOR CAB....219
      Raising The Operator Cab....219
      Lowering The Operator Cab....219
      Emergency Exit....220
    SEAT BAR RESTRAINT SYSTEM....221
      Description....221
      Seat Bar Inspection....221
      Seat Bar Maintenance....221
    AIR CLEANER SERVICE....222
      Replacing Filter Element....222
    FUEL SYSTEM....223
      Fuel Specifications....223
      Filling The Fuel Tank....223
      Fuel Filter....223
      Removing Air From The Fuel System....224
    ENGINE LUBRICATION SYSTEM....225
      Checking Engine Oil....225
      Oil Chart....225
      Replacing Oil And Filter....225
    ENGINE COOLING SYSTEM....227
      Cleaning The Cooling System....227
      Replacing The Coolant....228
    ALTERNATOR BELT....229
      Adjusting The Alternator Belt....229
    HYDRAULIC/HYDROSTATIC SYSTEM....230
      Description....230
      Checking And Adding Fluid....230
      Replacing The Hydraulic/Hydrostatic Filter....231
      Replacing Hydraulic Fluid....231
    SPARK ARRESTOR MUFFLER....232
      Cleaning Procedure....232
    TIRE MAINTENANCE....233
      Wheel Nuts....233
      Tire Rotation....233
      Tire Mounting....233
    FINAL DRIVE TRANSMISSION (CHAINCASE)....234
      Checking And Adding Oil....234
    LUBRICATING THE BOBCAT LOADER....235
      Procedure....235
    PIVOT PINS....236
    BOB–TACH....237
      Inspection And Maintenance....237
    AUXILIARY CONTROL LOCKBOLT....238
      Removal....238
    U–JOINT LUBRICATION....238
      Procedure....238
    REMOTE START SWITCH....239
      Procedure....239
  HYDRAULIC SYSTEM....241
    HYDRAULIC / HYDROSTATIC SCHEMATICS....243
    GLOSSARY OF HYDRAULIC / HYDROSTATIC SYMBOLS ....247
    TROUBLESHOOTING....251
    HYDRAULIC SYSTEM INFORMATION....252
      Tighten Procedures....252
    LIFT CYLINDERS....253
      Checking The Lift Cylinder(s)....253
      Removal And Installation....254
    TILT CYLINDER....256
      Checking The Tilt Cylinder....256
      Removal And Installation....257
    HYDRAULIC CYLINDER....259
      Lift Cylinder Identification....259
      Tilt Cylinder Identification....260
      Disassembly And Assembly....261
    MAIN RELIEF VALVE....263
      Checking The Main Relief Valve Without Auxiliaries....263
      Checking The Main Relief Valve With Auxiliaries....264
      Removal And Installation....265
      Adjustment....265
    HYDRAULIC CONTROL VALVE....266
      Removal And Installation....266
      Identification Chart....269
      Disassembly and Assembly....270
      Load Check Valve....270
      Main Relief Valve....271
      Anti–Cavitation Check Valve....272
      Rubber Boot....273
      Lift Spool Detent....274
      Tilt Centering Spring....278
      One Way Restrictors....279
      Inspection....279
      Spool Seal Installation....280
    HYDRAULIC PUMP....281
      Checking The Output Of The Hydraulic Pump....281
      Removal And Installation....283
      Parts Identification....284
      Disassembly And Assembly....285
      Inspection....286
    HYDRAULIC FLUID RESERVOIR....287
      Removal And Installation....287
    LIFT LOCK BY–PASS VALVE....288
      Removal And Installation....288
      Disassembly and Assembly....289
    TILT LOCK VALVE....290
      Removal And Installation....290
      Disassembly And Assembly....291
    HYDRAULIC FILTER HOUSING....292
      Removal And Installation....292
    CONTROL PEDALS....293
      Removal And Installation....293
      Pedal Adjustment....293
    PEDAL INTERLOCK LINKAGE....294
      Removal And Installation....294
      Adjustment....295
    CROSSMEMBER LINKAGE....296
      Removal And Installation....296
  HYDROSTATIC SYSTEM....297
    TROUBLESHOOTING....299
    HYDROSTATIC SYSTEM INFORMATION....300
      Replenishing Valve Function....300
    CONTROL PANEL....301
      Removal And Installation....301
    STEERING LEVERS....302
      Removal And Installation....302
      Disassembly And Assembly....303
    STEERING LINKAGE....304
      Removal And Installation....304
      Pintle Lever Disassembly And Assembly....306
      Steering Neutral Adjustment....307
    HYDROSTATIC MOTOR....309
      Removal And Installation....309
      Parts Identification....311
      Disassembly And Assembly....312
      Inspection....319
      Timing The Hydrostatic Motor....320
    HYDROSTATIC PUMP....321
      Checking Charge Pressure....321
      Removal And Installation....322
      Drive Coupler Removal And Installation....325
      Parts Identification....326
      Disassembly And Assembly....327
      Inspection....331
    PORT BLOCK....334
      Removal And Installation....334
      Oil Cooler By–Pass Valve....334
      Hydraulic Oil Temperature Switch....334
      Charge Pressure By–Pass Valve....334
    OIL COOLER....335
      Removal and Installation....335
  DRIVE SYSTEM....337
    PARKING BRAKE....339
      Removal And Installation....339
      Disassembly And Assembly....339
    PARKING BRAKE DISC....340
      Removal and Installation....340
    TRACTION LOCK GUIDES....341
      Removal and Installation....341
    CHAINCASE FLUID....342
      Removing Oil From The Chaincase....342
    CHAINCASE COVERS....342
      Front Cover Removal And Installation....342
      Rear Cover Removal And Installation....342
    AXLE SEAL....343
      Removal And Installation....343
    AXLE, BEARINGS, AND SPROCKET....345
      Removal And Installation....345
    DRIVE CHAIN....349
      Removal....349
  MAIN FRAME....351
    SEAT BAR....353
      Removal And Installation....353
      Assembling Components....356
      Compression Spring Disassembly And Assembly....356
    OPERATOR CAB GAS CYLINDER....357
      Removal And Installation....357
      Disassembly And Assembly....357
    OPERATOR CAB....358
      Removal And Installation....358
    OPERATOR SEAT....361
      Removal And Installation....361
    REAR DOOR....362
      Removal And Installation....362
      Door Latch Adjustment....363
      Striker Removal And Installation (S/N 516313551 & Above) & (S/N 516415035 & Above)....364
      Striker Disassembly And Assembly (S/N 516313551 & Above) & (S/N 516415035 & Above)....364
      Adjusting The Striker (S/N 516313551 & Above) & (S/N 516415035 & Above) ....364
      Latch Removal And Installation (S/N 516313551 & Above) & (S/N 516415035 & Above)....365
    FUEL TANK....366
      Removal And Installation....366
      Fuel Level Sender....366
    BOB–TACH....367
      Removal And Installation....367
      Bob–Tach Lever And Wedge....369
    LIFT ARMS....371
      Removal and Installation....371
    REAR GRILL....375
      Removal And Installation....375
  ELECTRICAL SYSTEM....377
    ELECTRICAL SCHEMATICS....379
    TROUBLESHOOTING....411
    ELECTRICAL SYSTEM INFORMATION....412
      Description....412
      Fuse Location....412
      Relay Switches Location....412
    BATTERY....413
      Removal And Installation....413
    USING A BOOSTER BATTERY (JUMP STARTING)....414
      Procedure....414
    ALTERNATOR....415
      Removal And Installation....415
      Adjusting The Alternator Belt....415
      Description....416
      Tests....416
      Alternator Output Test....416
      Full Field Test....417
      Alternator Regulator Test....417
      Alternator Regulator Test With Voltmeter....417
      Parts Identification....418
      Pulley Removal And Installation....419
      Disassembly And Assembly....419
      Rotor Continuity Test....422
      Stator Continuity Test....423
      Rectifier Continuity (Diode) Test....424
      Brush Length....424
    STARTER....425
      Removal And Installation....425
      Checking The Starter In The Loader....425
      Parts Identification....426
      Disassembly....427
      Inspection And Repair....432
      No Load Test....435
      Assembly....436
    INSTRUMENT PANEL....443
      Removal And Installation....443
    FRONT LIGHTS....444
      Removal And Installation....444
  ENGINE SERVICE....445
    TROUBLESHOOTING....448
    ENGINE SPEED CONTROL....450
      Removal and Installation....450
      Disassembly....450
      Linkage Bar Removal And Installation....451
    RADIATOR....452
      Removal And Installation....452
    ENGINE MUFFLER....454
      Removal And Installation....454
    AIR CLEANER....454
      Removal And Installation....454
    ENGINE ....455
      Removal And Installation....455
    U–JOINT COUPLER....460
      Removal And Installation....460
      Disassembly and Assembly....460
    RUBBER DRIVE COUPLER....461
      Removal And Installation....461
      Disassembly....461
      Assembly....462
    FLYWHEEL ....464
      Removal And Installation....464
    FLYWHEEL HOUSING....465
      Flywheel Ring Gear....465
      Removal And Installation....465
    ENGINE MOUNTING BRACKETS....465
      Removal and Installation....465
    BLOWER FAN HOUSING....466
      Removal And Installation....466
    ENGINE COMPRESSION....467
      Checking....467
    GLOW PLUGS....468
      Checking....468
      Removal And Installation....469
    FUEL SHUT–OFF SOLENOID....470
      Removal And Installation....470
    FUEL LIFT PUMP....471
      Removal And Installation....471
    FUEL INJECTION PUMP....472
      Checking The Injection Pump....472
      Removal And Installation....473
      Timing The Injection Pump....475
    FUEL INJECTOR NOZZLES....476
      Removal and Installation....476
      Checking Fuel Injector Nozzles....477
    THERMOSTAT....478
      Removal And Installation....478
    WATER PUMP....478
      Removal And Installation....478
    TIMING GEAR CASE COVER....479
      Removal And Installation....479
    OIL PUMP....481
      Removal And Installation....481
    CRANKSHAFT FRONT SEAL....483
      Removal And Installation....483
    ENGINE SPEED CONTROL PLATE....485
      Removal And Installation....485
      Governor Spring Removal....485
      Start Spring Removal....485
      Idle Limit And Fuel Limit Adjustment....486
    EXHAUST MANIFOLD....486
      Removal And Installation....486
    VALVE COVER....487
      Removal And Installation....487
    ROCKER ARM....488
      Removal And Installation....488
    PUSH ROD....489
      Removal And Installation....489
    TAPPET....489
      Removal And Installation....489
    WATER FLANGE....490
      Removal And Installation....490
    CYLINDER HEAD....490
      Removal....490
      Installation....490
      Checking Piston Top Clearance....491
      Disassembly....492
      Assembly....492
      Servicing The Cylinder Head....493
      Combustion Chamber Removal And Installation....495
    IDLER GEAR....496
      Removal And Installation....496
    CAMSHAFT....497
      Removal And Installation....497
    FUEL CAMSHAFT....499
      Removal And Installation....499
    OIL PAN....501
      Removal And Installation....501
    GOVERNOR SHAFT....502
      Removal And Installation....502
    GOVERNOR FORK LEVER....505
      Removal And Installation....505
    PISTON....507
      Removal And Installation....507
      Checking The Piston And Connecting Rod....507
      Connecting Rod Alignment....508
      Piston Ring Gap....508
      Piston Ring Installation....508
      Connecting Rod Installation....509
      Checking Engine Cylinder Bore....509
    CRANKSHAFT....510
      Removal And Installation....510
      Checking Crankshaft Journal And Block Bearing....512
      Checking The Crankshaft Journal And Main Bearing....513
      Connecting Rod Journal....514
      Checking The End Play Of The Crankshaft....515
      Crankshaft Alignment....515
    ENGINE TIMING....516
      Installation....516
    TIMING GEAR BACKLASH....516
      Idler Gear And Crankshaft....516
      Idler Gear And Camshaft Gear....517
      Idler Gear And Fuel Camshaft Gear....517
      Fuel Camshaft Gear And Governor Shaft Gear....517
  SYSTEMS ANALYSIS....519
    BICS™ – BOBCAT INTERLOCK CONTROL SYSTEM....521
      BICS™ (With Press To Operate Button)....521
        Inspecting The BICS™ Controller (Engine STOPPED – Key ON)....521
        Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)....521
        nspecting The Seat Bar Sensor (Engine RUNNING)....521
        Inspecting The Traction Lock (Engine RUNNING)....521
        Inspecting The Lift Arm By–Pass Control....521
        Additional Inspection For Loaders With Advanced Hand Controls....521
        Troubleshooting Chart....522
      BICS™ (Without Press To Operate Button)....523
        Inspecting The BICS Controller (Engine STOPPED –Key ON)....523
        Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED–Key ON)....523
        Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)....523
        nspecting The Traction Lock (Engine RUNNING)....523
        Inspecting The Lift Arm By–Pass Control....523
        Maintenance....524
        Troubleshooting Chart....525
    BICS™ SYSTEM CONTROLLER....526
      Troubleshooting Guide....526
      Removal And Installation....527
    SEAT BAR SENSOR....528
      Troubleshooting Guide....528
      Seat Bar Sensor Test....529
      Removal And Installation....530
      BICS™ Controller Seat Bar Sensor Circuit Test....531
    SEAT SENSOR....532
      Troubleshooting Guide....532
      Seat Sensor Test....533
      Removal And Installation....534
      BICS™ Controller Seat Sensor Circuit Test....535
    TRACTION LOCK....536
      Troubleshooting Guide....536
      Removal and Installation....537
  SPECIFICATIONS....539
    LOADER SPECIFICATIONS....541
      Loader Dimensions....541
      Performance....541
      Controls....541
      Engine....541
      Hydraulic System....542
      Electrical....542
      Drive System....542
      Capacities....542
      Tires....542
    ENGINE SPECIFICATIONS....543
      Engine Compression....543
      Fuel Injection Nozzles....543
      Fuel Injection Pump....543
      Cylinder Head....543
      Valves....543
      Valve Springs....543
      Rocker Arms....543
      Camshaft....543
      Cylinders....544
      Piston Rings....544
      Pistons....544
      Crankshaft....544
      Oil Pump....544
      Thermostat....544
      Grinding Specifications for the Crankshaft....545
    TORQUE SPECIFICATIONS FOR LOADER....547
      Specifications....547
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....548
      Specifications....548
    METRIC TORQUE SPECIFICATIONS FOR BOLTS....549
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS....550
    DECIMAL AND MILLIMETER EQUIVALENTS....551
    U.S. TO METRIC CONVERSION....551
    HYDRAULIC CONNECTION SPECIFICATIONS....552
      O–ring Face Seal Connection....552
      Straight Thread O–ring Fitting....552
      Tubelines And Hoses....552
      Flare Fitting....552
      O–ring Flare Fitting....553
      Port Seal Fitting....555
  SERVICE MANUAL REVISIONS....557
    553-1....557
    553-2....559
    553-3....561
6900450 (6-12) - 553 Service Manual....563
  MAINTENANCE SAFETY....565
  ALPHABETICAL INDEX....567
  CONTENTS....569
    FOREWORD....571
    SAFETY INSTRUCTIONS....573
    SERIAL NUMBER LOCATIONS....575
    LOADER SERIAL NUMBER....575
    ENGINE SERIAL NUMBER....575
    DELIVERY REPORT....575
    BOBCAT SKID STEER LOADER IDENTIFICATION....576
  PREVENTIVE MAINTENANCE....577
    SERVICE SCHEDULE....579
    LIFTING AND BLOCKING THE LOADER....580
      Procedure....580
    TOWING THE LOADER....581
      Procedure....581
    STOPPING THE BOBCAT LOADER....582
    LIFT ARM SUPPORT DEVICE....583
      Engaging The Lift Arm Support Device....583
      Disengaging The Lift Arm Support Device....584
    OPERATOR CAB....585
      Raising The Operator Cab....585
      Lowering The Operator Cab....585
      Emergency Exit....586
    SEAT BAR RESTRAINT SYSTEM....587
      Description....587
      Seat Bar Inspection....587
      Seat Bar Maintenance....587
    AIR CLEANER SERVICE....588
      Replacing Filter Element....588
    FUEL SYSTEM....589
      Fuel Specifications....589
      Filling The Fuel Tank....589
      Fuel Filter....589
      Removing Air From The Fuel System....590
    ENGINE LUBRICATION SYSTEM....591
      Checking Engine Oil....591
      Oil Chart....591
      Replacing Oil And Filter....591
    ENGINE COOLING SYSTEM....593
      Cleaning The Cooling System....593
      Replacing The Coolant....594
    ALTERNATOR BELT....595
      Adjusting The Alternator Belt....595
    HYDRAULIC/HYDROSTATIC SYSTEM....596
      Description....596
      Checking And Adding Fluid....596
      Replacing The Hydraulic/Hydrostatic Filter....597
      Replacing Hydraulic Fluid....597
    SPARK ARRESTOR MUFFLER....598
      Cleaning Procedure....598
    TIRE MAINTENANCE....599
      Wheel Nuts....599
      Tire Rotation....599
      Tire Mounting....599
    FINAL DRIVE TRANSMISSION (CHAINCASE)....600
      Checking And Adding Oil....600
    LUBRICATING THE BOBCAT LOADER....601
      Procedure....601
    PIVOT PINS....602
    BOB–TACH....603
      Inspection And Maintenance....603
    AUXILIARY CONTROL LOCKBOLT....604
      Removal....604
    U–JOINT LUBRICATION....604
      Procedure....604
    REMOTE START SWITCH....605
      Procedure....605
  HYDRAULIC SYSTEM....607
    HYDRAULIC / HYDROSTATIC SCHEMATICS....609
    GLOSSARY OF HYDRAULIC / HYDROSTATIC SYMBOLS ....613
    TROUBLESHOOTING....617
    HYDRAULIC SYSTEM INFORMATION....618
      Tighten Procedures....618
    LIFT CYLINDERS....619
      Checking The Lift Cylinder(s)....619
      Removal And Installation....620
    TILT CYLINDER....622
      Checking The Tilt Cylinder....622
      Removal And Installation....623
    HYDRAULIC CYLINDER....625
      Lift Cylinder Identification....625
      Tilt Cylinder Identification....626
      Disassembly And Assembly....627
    MAIN RELIEF VALVE....629
      Checking The Main Relief Valve Without Auxiliaries....629
      Checking The Main Relief Valve With Auxiliaries....630
      Removal And Installation....631
      Adjustment....631
    HYDRAULIC CONTROL VALVE....632
      Removal And Installation....632
      Identification Chart....635
      Disassembly and Assembly....636
      Load Check Valve....636
      Main Relief Valve....637
      Anti–Cavitation Check Valve....638
      Rubber Boot....639
      Lift Spool Detent....640
      Tilt Centering Spring....644
      One Way Restrictors....645
      Inspection....645
      Spool Seal Installation....646
    HYDRAULIC PUMP....647
      Checking The Output Of The Hydraulic Pump....647
      Removal And Installation....649
      Parts Identification....650
      Disassembly And Assembly....651
      Inspection....652
    HYDRAULIC FLUID RESERVOIR....653
      Removal And Installation....653
    LIFT LOCK BY–PASS VALVE....654
      Removal And Installation....654
      Disassembly and Assembly....655
    TILT LOCK VALVE....656
      Removal And Installation....656
      Disassembly And Assembly....657
    HYDRAULIC FILTER HOUSING....658
      Removal And Installation....658
    CONTROL PEDALS....659
      Removal And Installation....659
      Pedal Adjustment....659
    PEDAL INTERLOCK LINKAGE....660
      Removal And Installation....660
      Adjustment....661
    CROSSMEMBER LINKAGE....662
      Removal And Installation....662
  HYDROSTATIC SYSTEM....663
    TROUBLESHOOTING....665
    HYDROSTATIC SYSTEM INFORMATION....666
      Replenishing Valve Function....666
    CONTROL PANEL....667
      Removal And Installation....667
    STEERING LEVERS....668
      Removal And Installation....668
      Disassembly And Assembly....669
    STEERING LINKAGE....670
      Removal And Installation....670
      Pintle Lever Disassembly And Assembly....672
      Steering Neutral Adjustment....673
    HYDROSTATIC MOTOR....675
      Removal And Installation....675
      Parts Identification....677
      Disassembly And Assembly....678
      Inspection....685
      Timing The Hydrostatic Motor....686
    HYDROSTATIC PUMP....687
      Checking Charge Pressure....687
      Removal And Installation....688
      Drive Coupler Removal And Installation....691
      Parts Identification....692
      Disassembly And Assembly....693
      Inspection....697
    PORT BLOCK....700
      Removal And Installation....700
      Oil Cooler By–Pass Valve....700
      Hydraulic Oil Temperature Switch....700
      Charge Pressure By–Pass Valve....700
    OIL COOLER....701
      Removal and Installation....701
  DRIVE SYSTEM....703
    PARKING BRAKE....705
      Removal And Installation....705
      Disassembly And Assembly....705
    PARKING BRAKE DISC....706
      Removal and Installation....706
    TRACTION LOCK GUIDES....707
      Removal and Installation....707
    CHAINCASE FLUID....708
      Removing Oil From The Chaincase....708
    CHAINCASE COVERS....708
      Front Cover Removal And Installation....708
      Rear Cover Removal And Installation....708
    AXLE SEAL....709
      Removal And Installation....709
    AXLE, BEARINGS, AND SPROCKET....711
      Removal And Installation....711
    DRIVE CHAIN....715
      Removal....715
  MAIN FRAME....717
    SEAT BAR....719
      Removal And Installation....719
      Assembling Components....722
      Compression Spring Disassembly And Assembly....722
    OPERATOR CAB GAS CYLINDER....723
      Removal And Installation....723
      Disassembly And Assembly....723
    OPERATOR CAB....724
      Removal And Installation....724
    OPERATOR SEAT....727
      Removal And Installation....727
    REAR DOOR....728
      Removal And Installation....728
      Door Latch Adjustment....729
      Striker Removal And Installation (S/N 516313551 & Above) & (S/N 516415035 & Above)....730
      Striker Disassembly And Assembly (S/N 516313551 & Above) & (S/N 516415035 & Above)....730
      Adjusting The Striker (S/N 516313551 & Above) & (S/N 516415035 & Above) ....730
      Latch Removal And Installation (S/N 516313551 & Above) & (S/N 516415035 & Above)....731
    FUEL TANK....732
      Removal And Installation....732
      Fuel Level Sender....732
    BOB–TACH....733
      Removal And Installation....733
      Bob–Tach Lever And Wedge....735
    LIFT ARMS....737
      Removal and Installation....737
    REAR GRILL....741
      Removal And Installation....741
  ELECTRICAL SYSTEM....743
    ELECTRICAL SCHEMATICS....745
    TROUBLESHOOTING....777
    ELECTRICAL SYSTEM INFORMATION....778
      Description....778
      Fuse Location....778
      Relay Switches Location....778
    BATTERY....779
      Removal And Installation....779
    USING A BOOSTER BATTERY (JUMP STARTING)....780
      Procedure....780
    ALTERNATOR....781
      Removal And Installation....781
      Adjusting The Alternator Belt....781
      Description....782
      Tests....782
      Alternator Output Test....782
      Full Field Test....783
      Alternator Regulator Test....783
      Alternator Regulator Test With Voltmeter....783
      Parts Identification....784
      Pulley Removal And Installation....785
      Disassembly And Assembly....785
      Rotor Continuity Test....788
      Stator Continuity Test....789
      Rectifier Continuity (Diode) Test....790
      Brush Length....790
    STARTER....791
      Removal And Installation....791
      Checking The Starter In The Loader....791
      Parts Identification....792
      Disassembly....793
      Inspection And Repair....798
      No Load Test....801
      Assembly....802
    INSTRUMENT PANEL....809
      Removal And Installation....809
    FRONT LIGHTS....810
      Removal And Installation....810
  ENGINE SERVICE....811
    TROUBLESHOOTING....814
    ENGINE SPEED CONTROL....816
      Removal and Installation....816
      Disassembly....816
      Linkage Bar Removal And Installation....817
    RADIATOR....818
      Removal And Installation....818
    ENGINE MUFFLER....820
      Removal And Installation....820
    AIR CLEANER....820
      Removal And Installation....820
    ENGINE ....821
      Removal And Installation....821
    U–JOINT COUPLER....826
      Removal And Installation....826
      Disassembly and Assembly....826
    RUBBER DRIVE COUPLER....827
      Removal And Installation....827
      Disassembly....827
      Assembly....828
    FLYWHEEL ....830
      Removal And Installation....830
    FLYWHEEL HOUSING....831
      Flywheel Ring Gear....831
      Removal And Installation....831
    ENGINE MOUNTING BRACKETS....831
      Removal and Installation....831
    BLOWER FAN HOUSING....832
      Removal And Installation....832
    ENGINE COMPRESSION....833
      Checking....833
    GLOW PLUGS....834
      Checking....834
      Removal And Installation....835
    FUEL SHUT–OFF SOLENOID....836
      Removal And Installation....836
    FUEL LIFT PUMP....837
      Removal And Installation....837
    FUEL INJECTION PUMP....838
      Checking The Injection Pump....838
      Removal And Installation....839
      Timing The Injection Pump....841
    FUEL INJECTOR NOZZLES....842
      Removal and Installation....842
      Checking Fuel Injector Nozzles....843
    THERMOSTAT....844
      Removal And Installation....844
    WATER PUMP....844
      Removal And Installation....844
    TIMING GEAR CASE COVER....845
      Removal And Installation....845
    OIL PUMP....847
      Removal And Installation....847
    CRANKSHAFT FRONT SEAL....849
      Removal And Installation....849
    ENGINE SPEED CONTROL PLATE....851
      Removal And Installation....851
      Governor Spring Removal....851
      Start Spring Removal....851
      Idle Limit And Fuel Limit Adjustment....852
    EXHAUST MANIFOLD....852
      Removal And Installation....852
    VALVE COVER....853
      Removal And Installation....853
    ROCKER ARM....854
      Removal And Installation....854
    PUSH ROD....855
      Removal And Installation....855
    TAPPET....855
      Removal And Installation....855
    WATER FLANGE....856
      Removal And Installation....856
    CYLINDER HEAD....856
      Removal....856
      Installation....856
      Checking Piston Top Clearance....857
      Disassembly....858
      Assembly....858
      Servicing The Cylinder Head....859
      Combustion Chamber Removal And Installation....861
    IDLER GEAR....862
      Removal And Installation....862
    CAMSHAFT....863
      Removal And Installation....863
    FUEL CAMSHAFT....865
      Removal And Installation....865
    OIL PAN....867
      Removal And Installation....867
    GOVERNOR SHAFT....868
      Removal And Installation....868
    GOVERNOR FORK LEVER....871
      Removal And Installation....871
    PISTON....873
      Removal And Installation....873
      Checking The Piston And Connecting Rod....873
      Connecting Rod Alignment....874
      Piston Ring Gap....874
      Piston Ring Installation....874
      Connecting Rod Installation....875
      Checking Engine Cylinder Bore....875
    CRANKSHAFT....876
      Removal And Installation....876
      Checking Crankshaft Journal And Block Bearing....878
      Checking The Crankshaft Journal And Main Bearing....879
      Connecting Rod Journal....880
      Checking The End Play Of The Crankshaft....881
      Crankshaft Alignment....881
    ENGINE TIMING....882
      Installation....882
    TIMING GEAR BACKLASH....882
      Idler Gear And Crankshaft....882
      Idler Gear And Camshaft Gear....883
      Idler Gear And Fuel Camshaft Gear....883
      Fuel Camshaft Gear And Governor Shaft Gear....883
  SYSTEMS ANALYSIS....885
    BICS™ – BOBCAT INTERLOCK CONTROL SYSTEM....887
      BICS™ (With Press To Operate Button)....887
        Inspecting The BICS™ Controller (Engine STOPPED – Key ON)....887
        Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)....887
        nspecting The Seat Bar Sensor (Engine RUNNING)....887
        Inspecting The Traction Lock (Engine RUNNING)....887
        Inspecting The Lift Arm By–Pass Control....887
        Additional Inspection For Loaders With Advanced Hand Controls....887
        Troubleshooting Chart....888
      BICS™ (Without Press To Operate Button)....889
        Inspecting The BICS Controller (Engine STOPPED –Key ON)....889
        Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED–Key ON)....889
        Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)....889
        nspecting The Traction Lock (Engine RUNNING)....889
        Inspecting The Lift Arm By–Pass Control....889
        Maintenance....890
        Troubleshooting Chart....891
    BICS™ SYSTEM CONTROLLER....892
      Troubleshooting Guide....892
      Removal And Installation....893
    SEAT BAR SENSOR....894
      Troubleshooting Guide....894
      Seat Bar Sensor Test....895
      Removal And Installation....896
      BICS™ Controller Seat Bar Sensor Circuit Test....897
    SEAT SENSOR....898
      Troubleshooting Guide....898
      Seat Sensor Test....899
      Removal And Installation....900
      BICS™ Controller Seat Sensor Circuit Test....901
    TRACTION LOCK....902
      Troubleshooting Guide....902
      Removal and Installation....903
  SPECIFICATIONS....905
    LOADER SPECIFICATIONS....907
      Loader Dimensions....907
      Performance....907
      Controls....907
      Engine....907
      Hydraulic System....908
      Electrical....908
      Drive System....908
      Capacities....908
      Tires....908
    ENGINE SPECIFICATIONS....909
      Engine Compression....909
      Fuel Injection Nozzles....909
      Fuel Injection Pump....909
      Cylinder Head....909
      Valves....909
      Valve Springs....909
      Rocker Arms....909
      Camshaft....909
      Cylinders....910
      Piston Rings....910
      Pistons....910
      Crankshaft....910
      Oil Pump....910
      Thermostat....910
      Grinding Specifications for the Crankshaft....911
    TORQUE SPECIFICATIONS FOR LOADER....913
      Specifications....913
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....914
      Specifications....914
    METRIC TORQUE SPECIFICATIONS FOR BOLTS....915
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS....916
    DECIMAL AND MILLIMETER EQUIVALENTS....917
    U.S. TO METRIC CONVERSION....917
    HYDRAULIC CONNECTION SPECIFICATIONS....918
      O–ring Face Seal Connection....918
      Straight Thread O–ring Fitting....918
      Tubelines And Hoses....918
      Flare Fitting....918
      O–ring Flare Fitting....919
      Port Seal Fitting....921
  SERVICE MANUAL REVISIONS....923
    553-1....923
    553-2....925
    553-3....927
    553-4....929
6900785 (1-01) - 553 Operation & Maintenance Manual....931
  OPERATOR SAFETY WARNINGS....932
  CONTENTS....933
    BOBCAT COMPANY IS ISO 9001 CERTIFIED....934
    REGULAR MAINTENANCE ITEMS....934
  FOREWORD....935
    SERIAL NUMBER LOCATIONS....937
      LOADER SERIAL NUMBER....937
      ENGINE SERIAL NUMBER....937
    DELIVERY REPORT....937
    BOBCAT SKID STEER LOADER IDENTIFICATION....938
    OPTIONS AND ACCESSORIES....939
  SAFETY....941
    SAFETY INSTRUCTIONS FOR BOBCAT SKID–STEER LOADERS AND ATTACHMENTS....943
      SAFETY IS THE OPERATOR’S RESPONSIBILITY....943
      BEFORE OPERATING THE BOBCAT LOADER....944
      SAFE   OPERATION   NEEDS   A   QUALIFIED OPERATOR *....944
    FIRE PREVENTION....945
    MACHINE SIGNS (DECALS)....946
  OPERATING INSTRUCTIONS....949
    INSTRUMENT PANEL....951
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....952
      Lift Arm By–Pass Control....953
      Traction Lock Override....953
    ENGINE SPEED CONTROL....954
    PARKING BRAKE....954
    STEERING LEVERS....955
    STOPPING THE BOBCAT LOADER....955
    SEAT BAR RESTRAINT SYSTEM....956
    HYDRAULIC CONTROLS....958
      Foot Pedals....958
      Lift Arm Operation....958
      Lift Arm Float Position....958
      Tilt Operation....958
      Bucket Position Valve Operation (If Equipped)....958
      Auxiliary Hydraulics (If Equipped)....959
        Quick Couplers....959
      Relieving Hydraulic Pressure....960
    DAILY INSPECTION....961
    GETTING READY FOR OPERATION....962
    STARTING THE ENGINE....963
      Normal Starting....964
      Cold Temperature Starting....965
      Warming The Hydraulic/Hydrostatic System....965
    STOPPING THE ENGINE....965
    ATTACHMENTS AND BUCKETS....966
      Installing The Bucket Or Attachment....967
      Removing The Bucket Or Attachment ....968
    OPERATING PROCEDURES....969
      Filling The Bucket....970
      Emptying The Bucket....970
      Digging Into The Ground....971
      Leveling The Ground (Using Lift Arms In FloatPosition)....972
      Backfilling....972
    PARKING THE BOBCAT LOADER....973
    TRANSPORTING THE BOBCAT LOADER....973
    LIFTING THE LOADER....974
    TOWING THE LOADER....974
  PREVENTIVE MAINTENANCE....975
    MAINTENANCE SAFETY....976
    SERVICE SCHEDULE....977
    LIFT ARM SUPPORT DEVICE....978
      Engaging The Lift Arm Support Device....978
      Disengaging The Lift Arm Support Device....979
    OPERATOR CAB....980
      Raising The Operator Cab....980
      Lowering The Operator Cab....980
      Emergency Exits....981
    SEAT BAR RESTRAINT SYSTEM....982
      Inspecting The Seat Bar....982
      Maintaining The Seat Bar....982
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....983
      Inspecting The BICS™ Controller....983
      Inspecting The Seat Bar Sensor (Engine RUNNING)....983
      Inspecting The Traction Lock (Engine RUNNING)....983
      Inspecting The Lift Arm By–Pass Control....983
    REAR DOOR....984
      Adjusting The Latch ....984
    REAR GRILL....984
    AIR CLEANER SERVICE....985
    FUEL SYSTEM....986
      Fuel Specifications....986
      Filling The Fuel Tank....986
      Fuel Filter....986
      Removing Air From The Fuel System....987
    ENGINE LUBRICATION SYSTEM....988
      Checking Engine Oil....988
      Oil Chart....988
      Replacing Oil And Filter....988
    ENGINE COOLING SYSTEM....990
      Cleaning The Cooling System....990
      Checking The Coolant Level....990
      Replacing The Coolant....991
    ALTERNATOR BELT ADJUSTMENT....992
    ELECTRICAL SYSTEM....992
      Description....992
      Electrical System Maintenance....992
      Fuse Location....992
      Using A Booster Battery (Jump Starting)....993
      Removing And Installing The Battery....994
    HYDRAULIC/HYDROSTATIC SYSTEM....995
      Checking And Adding Fluid....995
      Replacing The Hydraulic/Hydrostatic Filter....996
      Replacing Hydraulic Fluid....996
    SPARK ARRESTOR MUFFLER....997
    TIRE MAINTENANCE....998
      Wheel Nuts....998
      Tire Rotation....998
      Tire Mounting....998
    FINAL DRIVE TRANSMISSION (CHAINCASE)....998
      Checking And Adding Oil....998
    LUBRICATING THE BOBCAT LOADER....999
    PIVOT PINS....1000
    BOB–TACH....1001
      Inspection And Maintenance....1001
    AUXILIARY CONTROL LOCKBOLT....1002
    U–JOINT LUBRICATION....1002
  SYSTEMS ANALYSIS....1003
    TROUBLESHOOTING THE ENGINE....1005
    TROUBLESHOOTING THE DRIVE SYSTEM....1006
    TROUBLESHOOTING THE HYDRAULIC SYSTEM....1007
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....1008
  MACHINE SIGN TRANSLATIONS....1009
    IMPORTANT - 6560573....1011
    WARNING - 6579510....1012
    SERVICE SCHEDULE - 6715563 ....1013
    WARNING - 6579528....1015
    DANGER - 6722302....1015
    WARNING - 6577754....1015
    DANGER - 6722301....1015
    DANGER - 6717343 ....1016
  SPECIFICATIONS....1017
    PERFORMANCE....1019
    CONTROLS....1019
    ENGINE....1019
    HYDRAULIC SYSTEM....1020
    ELECTRICAL....1020
    DRIVE SYSTEM....1020
    CAPACITIES....1020
    TIRES....1020
    FLOOR PRESSURE....1020
    BOBCAT COMPANY APPROVED ATTACHMENTS & ACCESSORIES....1021
    ADDITIONAL PUBLICATIONS....1023
  WARRANTY....1025
6901823 (1-05) - 553 Operation & Maintenance Manual....1027
  OPERATOR SAFETY WARNINGS....1029
  CONTENTS....1031
  FOREWORD....1033
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....1035
    REGULAR MAINTENANCE ITEMS....1035
    MOTOR OIL....1035
    SERIAL NUMBER LOCATIONS....1037
    LOADER SERIAL NUMBER....1037
    ENGINE SERIAL NUMBER....1037
    DELIVERY REPORT....1037
    BOBCAT LOADER IDENTIFICATION....1038
    FEATURES AND ACCESSORIES....1039
      Standard Items....1039
      Options and Accessories....1039
  SAFETY....1041
    SAFETY INSTRUCTIONS....1043
      Before Operation....1043
      Safe Operation Is The Operator’s Responsibility....1044
      Safe Operation Needs A Qualified Operator....1044
      Fire Prevention....1045
    MACHINE SIGNS (DECALS)....1046
  OPERATING INSTRUCTIONS....1049
    INSTRUMENT PANELS....1051
      Left, Right And Accessory Panels....1051
    BOBCAT INTERLOCK CONTROL SYSTEM (bics™)....1052
      Description....1052
      Lift Arm By-Pass Control....1052
      Traction Lock Override....1053
    ENGINE SPEED CONTROL....1053
      Operation....1053
    PARKING BRAKE (LATER MODELS)....1054
      Operation....1054
    PARKING BRAKE (EARLY MODELS)....1054
      Operation....1054
    STEERING LEVERS....1055
      Operation....1055
    STOPPING THE BOBCAT LOADER....1056
      Procedure....1056
    SEAT BAR RESTRAINT SYSTEM....1056
    HYDRAULIC CONTROLS....1058
      Foot Pedals....1058
      Bucket Position Valve Operation (If Equipped)....1058
      Quick Couplers....1059
      Relieving Hydraulic Pressure....1059
    DAILY INSPECTION....1060
      Daily Inspection and Maintenance....1060
    GETTING READY FOR OPERATION....1061
    STARTING THE ENGINE....1063
      Normal Starting....1063
      Cold Temperature Starting....1065
      Warming The Hydraulic/Hydrostatic System....1065
    STOPPING THE ENGINE....1065
    ATTACHMENTS AND BUCKETS....1066
      Choosing The Correct Bucket....1066
      Pallet Forks....1066
      Installing The Bucket or Attachment....1067
      Removing The Bucket Or Attachment....1069
    OPERATING PROCEDURE....1070
      Operating With A Full Bucket....1070
      Filling The Bucket....1071
      Emptying the Bucket....1071
      Digging Into The Ground....1072
      Leveling The Ground (Using Lift Arms In Float Position)....1072
      Backfilling....1072
    PARKING THE BOBCAT LOADER....1073
    TRANSPORTING THE BOBCAT LOADER....1074
      Loading Onto Transport Vehicle....1074
      Fastening To Transport Vehicle....1074
    LIFTING THE LOADER....1075
    TOWING THE LOADER....1075
  PREVENTIVE MAINTENANCE....1077
    MAINTENANCE SAFETY....1079
    SERVICE SCHEDULE....1081
      Chart....1081
    LIFT ARM SUPPORT DEVICE....1082
      Engaging The Lift Arm Support Device....1082
      Disengaging The Lift Arm Support Device....1083
    OPERATOR CAB....1084
      Description....1084
      Raising The Operator Cab....1084
      Lowering The Operator Cab....1085
      Emergency Exit....1086
    SEAT BAR RESTRAINT SYSTEM....1087
      Inspecting The Seat Bar....1087
      Maintaining The Seat Bar....1087
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....1088
      Inspecting The BICS Controller (Engine Stopped - Key ON)....1088
      Inspecting The Seat Bar Sensor (Engine RUNNING)....1088
      Inspecting The Traction Lock (Engine RUNNING)....1088
      Inspecting The Lift Arm By-Pass Control....1088
    REAR DOOR....1089
      Opening And Closing The Rear Door....1089
      Adjusting The Rear Door....1089
    REAR GRILL....1090
    AIR CLEANER SERVICE....1091
      Replacing Filter Elements....1091
    FUEL SYSTEM....1092
      Fuel Specifications....1092
      Filling The Fuel Tank....1092
      Fuel Filter....1093
      Removing Air From The Fuel System....1094
    ENGINE LUBRICATION SYSTEM....1095
      Checking Engine Oil....1095
      Oil Chart....1095
      Replacing The Oil And Filter....1096
    ENGINE COOLING SYSTEM....1097
      Cleaning The Cooling System....1097
      Checking The Coolant Level....1098
      Replacing The Coolant....1098
    ALTERNATOR BELT....1099
      Adjusting The Alternator Belt....1099
    ELECTRICAL SYSTEM....1100
      Description....1100
      Electrical System Maintenance....1100
      Fuse Location....1100
      Using A Booster Battery (Jump Starting)....1101
      Removing And Installing The Battery....1102
    HYDRAULIC / HYDROSTATIC SYSTEM....1104
      Checking And Adding Fluid....1104
      Replacing Hydraulic/Hydrostatic Filter....1105
      Replacing Hydraulic Fluid....1105
    SPARK ARRESTOR MUFFLER....1106
      Maintenance....1106
    TIRE MAINTENANCE....1107
      Wheel Nuts....1107
      Tire Rotation....1107
      Tire Mounting....1107
    FINAL DRIVE TRANSMISSION (CHAINCASE)....1108
      Checking And Adding Oil....1108
    LUBRICATING THE BOBCAT LOADER....1109
      Lubrication Locations....1109
    PIVOT PINS....1110
      Inspection And Maintenance....1110
    BOB-TACH....1111
      Inspection And Maintenance....1111
    AUXILIARY CONTROL LOCKBOLT....1112
    U-JOINT LUBRICATION....1112
  SYSTEM SETUP & ANALYSIS....1113
    TROUBLESHOOTING....1115
      Troubleshooting The Engine....1115
      Troubleshooting The Drive System....1116
      Troubleshooting The Hydraulic System....1116
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....1117
      Troubleshooting Chart....1117
  MACHINE SIGN TRANSLATIONS....1119
    WARNING (6579528)....1121
    WARNING (6577754)....1121
    IMPORTANT (6560573)....1122
    WARNING (6710358)....1122
    SERVICE SCHEDULE (6518398)....1123
    WARNING (6579510)....1124
    DANGER (6702301)....1125
    DANGER (6702302)....1125
    WARNING (6717343)....1126
  SPECIFICATIONS....1127
    LOADER SPECIFICATIONS....1129
      Machine Dimensions....1129
      Performance....1130
      Controls....1130
      Engine....1130
      Hydraulic System....1131
      Electrical....1131
      Drive System....1132
      Capacities....1132
    BOBCAT COMPANY APPROVED ATTACHMENTS AND ACCESSORIES....1133
      Buckets Available....1133
      Attachments....1134
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....1135
  WARRANTY....1137
6901824 (3-06) - 553 Service Manual....1139
  MAINTENANCE SAFETY....1141
  ALPHABETICAL INDEX....1143
  CONTENTS....1145
    FOREWORD....1146
    SAFETY INSTRUCTIONS....1149
      Fire Prevention....1151
    SERIAL NUMBER LOCATION....1153
      Loader Serial Number....1153
      Engine Serial Number....1153
    DELIVERY REPORT....1154
    BOBCAT LOADER IDENTIFICATION....1155
  SAFETY AND MAINTENANCE....1157
    LIFTING AND BLOCKING THE LOADER....1159
      Procedure....1159
    LIFT ARM SUPPORT DEVICE....1161
      Installing Lift Arm Support Device....1161
      Removing Lift Arm Support Device....1162
    OPERATOR CAB....1165
      Description....1165
      Raising The Operator Cab....1165
      Lowering The Operator Cab....1166
      Emergency Exit....1166
    TRANSPORTING THE BOBCAT LOADER....1169
      Procedure....1169
      Stopping The Bobcat Loader....1169
    TOWING THE LOADER....1173
      Procedure....1173
    REMOTE START....1175
      Procedure....1175
    SERVICE SCHEDULE....1177
      Chart....1177
    AIR CLEANER SERVICE....1179
      Replacing Filter Element....1179
    ENGINE COOLING SYSTEM....1181
      Cleaning The Cooling System....1181
      Checking The Coolant Level....1182
      Replacing The Coolant....1182
    FUEL SYSTEM....1185
      Fuel Specifications....1185
      Filling The Fuel Tank....1185
      Fuel Filter....1186
      Removing Air From The Fuel System....1187
    ENGINE LUBRICATION SYSTEM....1189
      Checking Engine Oil....1189
      Oil Chart....1189
      Replacing Oil And Filter....1189
    HYDRAULIC/HYDROSTATIC SYSTEM....1191
      Description....1191
      Checking And Adding Fluid....1191
      Replacing The Hydraulic/Hydrostatic Filter....1192
      Replacing Hydraulic Fluid....1192
    FINAL DRIVE TRANSMISSION (CHAINCASE)....1195
      Checking And Adding Oil....1195
    AUXILIARY CONTROL LOCKBOLT....1197
      Removal....1197
    BOB-TACH....1199
      Inspection And Maintenance....1199
    LUBRICATION OF THE BOBCAT LOADER....1201
      Procedure....1201
    TIRE MAINTENANCE....1203
      Wheel Nuts....1203
      Rotating....1203
      Mounting....1203
    SPARK ARRESTOR MUFFLER....1205
      Cleaning Procedure....1205
    PIVOT PINS....1207
      Procedure....1207
    SEAT BAR RESTRAINT SYSTEM....1209
      Description....1209
      Seat Bar Inspection....1209
      Seat Bar Maintenance....1209
    RUBBER COUPLER LUBRICATION....1211
      Procedure....1211
  HYDRAULIC SYSTEM....1213
    HYDRAULIC/HYDROSTATIC SCHEMATICS....1215
    HYDRAULIC SYSTEM INFORMATION....1217
      Tighten Procedures....1221
      Troubleshooting Chart....1221
    CYLINDER (LIFT)....1223
      Checking....1223
      Removal And Installation....1224
      Identification....1227
      Disassembly And Assembly....1228
    CYLINDER (TILT)....1231
      Checking....1231
      Removal And Installation....1231
      Identification....1233
      Disassembly And Assembly....1234
    MAIN RELIEF VALVE....1237
      Checking The Main Relief Valve Without Auxiliaries....1237
      Checking The Main Relief Valve With Auxiliaries....1238
      Removal and Installation....1239
    HYDRAULIC CONTROL VALVE....1241
      Removal And Installation....1241
      Identification Chart....1244
      Disassembly And Assembly....1245
      Load Check Valve....1245
      Main Releif Valve....1246
      Anti-Cavitation Check Valve....1247
      Port Relief Valve....1248
      Rubber Boot (Lift)....1249
      Rubber Boot (Tilt)....1249
      Rubber Boot (Aux.)....1249
      Lift Spool Detent....1250
      Tilt Centering Spring....1254
      Auxiliary Spool Detent....1255
      One Way Restrictors....1255
      Inspection....1256
      Spool Seal Installation....1257
    LIFT ARM BY-PASS CONTROL VALVE....1259
      Inspecting....1259
      Removal and Installation....1259
      Disassembly and Assembly....1260
    TILT LOCK VALVE....1261
      Removal And Installation....1261
      Disassembly and Assembly....1262
    HYDRAULIC PUMP....1263
      Check The Output Of The Hydraulic Pump....1263
      Removal And Installation....1265
      Identification....1267
      Disassembly And Assembly....1268
      Inspection....1270
    HYDRAULIC FILTER HOUSING....1271
      Removal and Installation....1271
    HYDRAULIC FLUID RESERVOIR....1273
      Removal and Installation....1273
  HYDROSTATIC SYSTEM....1275
    HYDROSTATIC SYSTEM INFORMATION....1277
      Troubleshooting Chart....1277
      Replenishing Valve Function....1278
    CONTROL PANEL....1279
      Removal and Installation....1279
    STEERING....1281
      Lever Removal and Installation....1281
      Lever Disassembly And Assembly....1282
      Linkage Removal And Installation....1282
      Pintle Lever Disassemby And Assembly....1284
      Linkage Neutral Adjustment....1286
    HYDROSTATIC MOTOR....1289
      Removal And Installation....1289
      Parts Identification....1291
      Disassembly And Assembly....1292
      Inspection....1299
      Timing The Hydrostatic Motor....1301
    PORT BLOCK....1303
      Removal And Installation....1303
      Oil Cooler By-Pass Valve....1303
      Hydraulic Oil Temperature Switch....1303
      Charge Pressure By-Pass Valve....1304
    HYDROSTATIC PUMP....1305
      Checking Charge Pressure....1305
      Removal And Installation....1306
      Drive Coupler Removal And Installation....1309
      Parts Identification....1310
      Disassembly And Assembly....1311
      Inspection....1315
    OIL COOLER....1319
      Removal and Installation....1319
  DRIVE SYSTEM....1321
    PARKING BRAKE....1323
      Disk Removal And Installation....1323
      Traction Lock Guides Removal And Installation....1324
    DRIVE COMPONENTS....1325
      Axle Seal Removal And Installation....1325
      Axle, Bearing, And Sprocket Removal And Installation....1327
      Chain Removal And Installation....1331
    CHAINCASE....1333
      Removing Oil From The Chaincase....1333
      Front Cover Removal And Installation....1333
      Rear Cover Removal And Installation....1334
  MAIN FRAME....1335
    SEAT BAR....1337
      Removal And Installation....1337
      Assembling Components....1340
      Compression Spring Disassembly And Assembly....1340
    OPERATOR CAB....1341
      Gas Cylinder Removal And Installation....1341
      Gas Cylinder Disassembly And Assembly....1342
      Removal And Installation....1342
    OPERATOR SEAT....1347
      Removal And Installation....1347
      Seat Belt Removal And Installation....1347
    BOB-TACH....1349
      Removal And Installation....1349
      Bob-Tach Lever And Wedge....1351
    LIFT ARM....1353
      Removal And Installation....1353
    REAR GRILL....1357
      Removal And Installation....1357
    REAR DOOR....1359
      Removal And Installation....1359
      Striker Removal and Installation....1360
      Striker Disassembly and Assembly....1360
      Adjusting The Striker....1360
      Latch Removal and Installation....1361
    FUEL TANK....1363
      Removal And Installation....1363
      Fuel Level Sender....1363
    CONTROL PEDALS....1365
      Removal And Installation....1365
      Pedal Adjustment....1365
      Pedal Interlock Linkage Removal And Installation....1366
      Pedal Interlock Linkage Adjustment....1367
      Crossbar Linkage Removal And Installation....1367
  ELECTRICAL SYSTEM....1369
    ELECTRICAL SCHEMATICS....1371
    ELECTRICAL SYSTEM INFORMATION....1374
      Troubleshooting....1376
      Description....1377
      Fuse Location....1377
      Relay Switches Location....1378
    BATTERY....1380
      Removal And Installation....1380
      Using A Booster Battery (Jump Starting)....1381
    ALTERNATOR....1384
      Removal And Installation....1384
      Adjusting The Alternator Belt....1384
      Description....1385
      Tests....1385
      Alternator Output Test....1386
      Full Field Test....1386
      Alternator Regulator Test....1387
      Alternator Regulator Test Using Voltmeter....1387
      Parts Identification....1388
      Pulley Removal And Installation....1389
      Disassembly And Assembly....1390
      Rotor Continuity Test....1392
      Stator Continuity Test....1393
      Rectifier Continuity (Diode) Test....1394
      Brush Length....1394
    STARTER....1396
      Removal And Installation....1396
      Checking The Starter In The Loader....1397
      Parts Identification....1398
      Disassembly....1399
      Inspection And Repair....1404
      No Load Test....1408
      Assembly....1409
    INSTRUMENT PANEL....1416
      Removal And Installation....1416
    LIGHTS....1418
      Front Removal And Installation....1418
    BICS™ SYSTEM CONTROLLER....1420
      Trouble Shooting Guide....1420
      Removal And Installation....1421
    BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON)....1424
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)....1424
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....1424
      Inspecting The Seat Bar Sensor (Engine RUNNING)....1424
      Inspecting The Traction Lock (Engine RUNNING)....1424
      Inspecting The Lift Arm By-Pass Control....1424
      Additional Inspection For Loaders With Advanced Hand Controls....1424
      Troubleshooting Chart....1425
    SEAT BAR SENSOR....1426
      Troubleshooting Guide....1426
      Seat Bar Sensor Test....1427
      Removal And Installation....1428
      BICS™ Controller Seat Bar Sensor Circuit Test....1430
    TRACTION LOCK....1432
      Troubleshooting Guide....1432
      Removal And Installation....1433
  ENGINE SERVICE....1436
    TROUBLESHOOTING....1438
      Chart....1438
    ENGINE SPEED CONTROL....1440
      Removal And Installation....1440
      Disassembly....1440
      Linkage Bar Removal And Installation....1441
    ENGINE SPEED CONTROL PLATE....1442
      Removal And Installation....1442
      Governor Spring Removal....1442
      Start Spring Removal....1442
      Idle Limit And Fuel Limit Adjustment....1443
    MUFFLER....1444
      Removal And Installation....1444
    AIR CLEANER....1446
      Removal And Installation....1446
    RADIATOR....1448
      Removal And Installation....1448
    BLOWER FAN HOUSING....1450
      Removal And Installation....1450
    ENGINE COMPONENTS AND TESTING....1452
      Compression Checking....1452
      Glow Plugs Checking....1453
      Glow Plugs Removal And Installation....1454
      Fuel Shut-Off Solenoid, Removal And Installation....1455
      Fuel Lift Pump Removal And Installation....1456
      Fuel Injection Pump, Checking....1456
      Fuel Injection Pump Removal And Installation....1457
      Timing The Injection Pump....1459
      Fuel Injector Nozzles Removal And Installation....1460
      Checking Fuel Injector Nozzles....1461
      Engine Timing Installation....1463
    ENGINE....1464
      Removal And Installation....1464
      Engine Mounting Brackets Removal And Installation....1468
    FLYWHEEL....1470
      Removal And Installation....1470
      Flywheel Ring Gear....1471
      Housing Removal And Installation....1471
    RECONDITIONING THE ENGINE....1472
      Thermostat Removal And Installation....1472
      Water Pump Removal And Installation....1472
      Timing Gear Case Cover Removal And Installation....1473
      Oil Pump Removal And Installation....1475
      Crankshaft Front Seal Removal And Installation....1477
      Exhaust Manifold Removal And Installation....1478
      Valve Cover Removal And Installation....1479
      Rocker Arm Removal And Installation....1480
      Push Rod Removal And Installation....1481
      Tappet Removal And Installation....1482
      Cylinder Head Removal And Installation....1482
      Checking Piston Top Clearance....1483
      Disassembly....1484
      Assembly....1484
      Servicing The Cylinder Head....1484
      Combustion Chamber Removal And Installation....1487
      Idler Gear Removal And Installation....1488
      Camshaft Removal And Installation....1489
      Fuel Camshaft Removal And Installation....1491
      Oil Pan Removal And Installation....1493
      Governor Shaft Removal And Installation....1494
      Governor Fork Lever Removal And Installation....1497
      Piston Removal And Installation....1498
      Checking The Piston And Connecting Rod....1499
      Connecting Rod Alignment....1500
      Pison Ring Gap....1500
      Piston Ring Installation....1501
      Connecting Rod Installation....1501
      Checking Engine Cylinder Bore....1502
      Crankshaft Removal And Installation....1502
      Checking Crankshaft Journal And Block Bearing....1505
      Checking The Crankshaft Journal And Main Bearing....1506
      Connecting Rod Journal....1507
      Checking the End Play Of The Crankshaft....1508
      Crankshaft Alignment....1508
      Idler Gear And Crankshaft....1509
      Idler Gear And Crankshaft Gear....1509
      Idler Gear And Fuel Camshaft Gear....1510
      Fuel Camshaft Gear And Governor Shaft Gear....1510
    RUBBER DRIVE COUPLER....1512
      Removal And Installation....1512
      Disassembly....1512
      Assembly....1513
    WATER FLANGE....1516
      Removal And Installation....1516
  SPECIFICATIONS....1518
    LOADER SPECIFICATIONS....1520
      Machine Dimensions....1520
      Performance....1521
      Controls....1521
      Engine....1521
      Hydraulic System....1522
      Electrical....1522
      Drive System....1523
      Capacities....1523
      Tires....1523
    ENGINE SPECIFICATIONS....1524
      Engine Compression....1524
      Fuel Injection Nozzles....1524
      Fuel Injection Pump....1524
      Cylinder Head....1524
      Valves....1524
      Valve Springs....1525
      Rocker Arms....1525
      Camshaft....1525
      Cylinders....1525
      Piston Rings....1526
      Pistons....1526
      Crankshaft....1526
      Oil Pump....1527
      Thermostat....1527
      Crankshaft Re-Grind Data....1528
    TORQUE SPECIFICATIONS FOR BOLTS....1530
      Torque For General SAE Bolts....1530
      Torque For General Metric Bolts....1531
    HYDRAULIC CONNECTION SPECIFICATIONS....1532
      O-ring Face Seal Connection....1532
      Straight Thread O-ring Fitting....1533
      Tubelines And Hoses....1533
      Flare Fitting....1533
      O-ring Flare Fitting....1534
      Port Seal Fitting....1536
    HYDRAULIC FLUID SPECIFICATIONS....1538
      Specifications....1538
    CONVERSIONS....1540
      Decimal And Millimeter Equivalents....1540
      U.S. To Metric Conversion....1540
  SMR....1542
    553-1....1542
6901824 (6-12) - 553 Service Manual....1544
  MAINTENANCE SAFETY....1546
  ALPHABETICAL INDEX....1548
  CONTENTS....1550
    FOREWORD....1551
    SAFETY INSTRUCTIONS....1554
      Fire Prevention....1556
    SERIAL NUMBER LOCATION....1558
      Loader Serial Number....1558
      Engine Serial Number....1558
    DELIVERY REPORT....1559
    BOBCAT LOADER IDENTIFICATION....1560
  SAFETY AND MAINTENANCE....1562
    LIFTING AND BLOCKING THE LOADER....1564
      Procedure....1564
    LIFT ARM SUPPORT DEVICE....1566
      Installing Lift Arm Support Device....1566
      Removing Lift Arm Support Device....1567
    OPERATOR CAB....1570
      Description....1570
      Raising The Operator Cab....1570
      Lowering The Operator Cab....1571
      Emergency Exit....1571
    TRANSPORTING THE BOBCAT LOADER....1574
      Procedure....1574
      Stopping The Bobcat Loader....1574
    TOWING THE LOADER....1578
      Procedure....1578
    REMOTE START....1580
      Procedure....1580
    SERVICE SCHEDULE....1582
      Chart....1582
    AIR CLEANER SERVICE....1584
      Replacing Filter Element....1584
    ENGINE COOLING SYSTEM....1586
      Cleaning The Cooling System....1586
      Checking The Coolant Level....1587
      Replacing The Coolant....1587
    FUEL SYSTEM....1590
      Fuel Specifications....1590
      Filling The Fuel Tank....1590
      Fuel Filter....1591
      Removing Air From The Fuel System....1592
    ENGINE LUBRICATION SYSTEM....1594
      Checking Engine Oil....1594
      Oil Chart....1594
      Replacing Oil And Filter....1594
    HYDRAULIC/HYDROSTATIC SYSTEM....1596
      Description....1596
      Checking And Adding Fluid....1596
      Replacing The Hydraulic/Hydrostatic Filter....1597
      Replacing Hydraulic Fluid....1597
    FINAL DRIVE TRANSMISSION (CHAINCASE)....1600
      Checking And Adding Oil....1600
    AUXILIARY CONTROL LOCKBOLT....1602
      Removal....1602
    BOB-TACH....1604
      Inspection And Maintenance....1604
    LUBRICATION OF THE BOBCAT LOADER....1606
      Procedure....1606
    TIRE MAINTENANCE....1608
      Wheel Nuts....1608
      Rotating....1608
      Mounting....1608
    SPARK ARRESTOR MUFFLER....1610
      Cleaning Procedure....1610
    PIVOT PINS....1612
      Procedure....1612
    SEAT BAR RESTRAINT SYSTEM....1614
      Description....1614
      Seat Bar Inspection....1614
      Seat Bar Maintenance....1614
    RUBBER COUPLER LUBRICATION....1616
      Procedure....1616
  HYDRAULIC SYSTEM....1618
    HYDRAULIC/HYDROSTATIC SCHEMATICS....1620
    HYDRAULIC SYSTEM INFORMATION....1624
      Tighten Procedures....1628
      Troubleshooting Chart....1628
    CYLINDER (LIFT)....1630
      Checking....1630
      Removal And Installation....1631
      Identification....1634
      Disassembly And Assembly....1635
    CYLINDER (TILT)....1638
      Checking....1638
      Removal And Installation....1638
      Identification....1640
      Disassembly And Assembly....1641
    MAIN RELIEF VALVE....1644
      Checking The Main Relief Valve Without Auxiliaries....1644
      Checking The Main Relief Valve With Auxiliaries....1645
      Removal and Installation....1646
    HYDRAULIC CONTROL VALVE....1648
      Removal And Installation....1648
      Identification Chart....1651
      Disassembly And Assembly....1652
      Load Check Valve....1652
      Main Releif Valve....1653
      Anti-Cavitation Check Valve....1654
      Port Relief Valve....1655
      Rubber Boot (Lift)....1656
      Rubber Boot (Tilt)....1656
      Rubber Boot (Aux.)....1656
      Lift Spool Detent....1657
      Tilt Centering Spring....1661
      Auxiliary Spool Detent....1662
      One Way Restrictors....1662
      Inspection....1663
      Spool Seal Installation....1664
    LIFT ARM BY-PASS CONTROL VALVE....1666
      Inspecting....1666
      Removal and Installation....1666
      Disassembly and Assembly....1667
    TILT LOCK VALVE....1668
      Removal And Installation....1668
      Disassembly and Assembly....1669
    HYDRAULIC PUMP....1670
      Check The Output Of The Hydraulic Pump....1670
      Removal And Installation....1672
      Identification....1674
      Disassembly And Assembly....1675
      Inspection....1677
    HYDRAULIC FILTER HOUSING....1678
      Removal and Installation....1678
    HYDRAULIC FLUID RESERVOIR....1680
      Removal and Installation....1680
  HYDROSTATIC SYSTEM....1682
    HYDROSTATIC SYSTEM INFORMATION....1684
      Troubleshooting Chart....1684
      Replenishing Valve Function....1685
    CONTROL PANEL....1686
      Removal and Installation....1686
    STEERING....1688
      Lever Removal and Installation....1688
      Lever Disassembly And Assembly....1689
      Linkage Removal And Installation....1689
      Pintle Lever Disassemby And Assembly....1691
      Linkage Neutral Adjustment....1693
    HYDROSTATIC MOTOR....1696
      Removal And Installation....1696
      Parts Identification....1698
      Disassembly And Assembly....1699
      Inspection....1706
      Timing The Hydrostatic Motor....1708
    PORT BLOCK....1710
      Removal And Installation....1710
      Oil Cooler By-Pass Valve....1710
      Hydraulic Oil Temperature Switch....1710
      Charge Pressure By-Pass Valve....1711
    HYDROSTATIC PUMP....1712
      Checking Charge Pressure....1712
      Removal And Installation....1713
      Drive Coupler Removal And Installation....1716
      Parts Identification....1717
      Disassembly And Assembly....1718
      Inspection....1722
    OIL COOLER....1726
      Removal and Installation....1726
  DRIVE SYSTEM....1728
    PARKING BRAKE....1730
      Disk Removal And Installation....1730
      Traction Lock Guides Removal And Installation....1731
    DRIVE COMPONENTS....1732
      Axle Seal Removal And Installation....1732
      Axle, Bearing, And Sprocket Removal And Installation....1734
      Chain Removal And Installation....1738
    CHAINCASE....1740
      Removing Oil From The Chaincase....1740
      Front Cover Removal And Installation....1740
      Rear Cover Removal And Installation....1741
  MAIN FRAME....1742
    SEAT BAR....1744
      Removal And Installation....1744
      Assembling Components....1747
      Compression Spring Disassembly And Assembly....1747
    OPERATOR CAB....1748
      Gas Cylinder Removal And Installation....1748
      Gas Cylinder Disassembly And Assembly....1749
      Removal And Installation....1749
    OPERATOR SEAT....1754
      Removal And Installation....1754
      Seat Belt Removal And Installation....1754
    BOB-TACH....1756
      Removal And Installation....1756
      Bob-Tach Lever And Wedge....1758
    LIFT ARM....1760
      Removal And Installation....1760
    REAR GRILL....1764
      Removal And Installation....1764
    REAR DOOR....1766
      Removal And Installation....1766
      Striker Removal and Installation....1767
      Striker Disassembly and Assembly....1767
      Adjusting The Striker....1767
      Latch Removal and Installation....1768
    FUEL TANK....1770
      Removal And Installation....1770
      Fuel Level Sender....1770
    CONTROL PEDALS....1772
      Removal And Installation....1772
      Pedal Adjustment....1772
      Pedal Interlock Linkage Removal And Installation....1773
      Pedal Interlock Linkage Adjustment....1774
      Crossbar Linkage Removal And Installation....1774
  ELECTRICAL SYSTEM....1776
    ELECTRICAL SCHEMATICS....1778
    ELECTRICAL SYSTEM INFORMATION....1782
      Troubleshooting....1784
      Description....1785
      Fuse Location....1785
      Relay Switches Location....1786
    BATTERY....1788
      Removal And Installation....1788
      Using A Booster Battery (Jump Starting)....1789
    ALTERNATOR....1792
      Removal And Installation....1792
      Adjusting The Alternator Belt....1792
      Description....1793
      Tests....1793
      Alternator Output Test....1794
      Full Field Test....1794
      Alternator Regulator Test....1795
      Alternator Regulator Test Using Voltmeter....1795
      Parts Identification....1796
      Pulley Removal And Installation....1797
      Disassembly And Assembly....1798
      Rotor Continuity Test....1800
      Stator Continuity Test....1801
      Rectifier Continuity (Diode) Test....1802
      Brush Length....1802
    STARTER....1804
      Removal And Installation....1804
      Checking The Starter In The Loader....1805
      Parts Identification....1806
      Disassembly....1807
      Inspection And Repair....1812
      No Load Test....1816
      Assembly....1817
    INSTRUMENT PANEL....1824
      Removal And Installation....1824
    LIGHTS....1826
      Front Removal And Installation....1826
    BICS™ SYSTEM CONTROLLER....1828
      Trouble Shooting Guide....1828
      Removal And Installation....1829
    BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON)....1832
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)....1832
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....1832
      Inspecting The Seat Bar Sensor (Engine RUNNING)....1832
      Inspecting The Traction Lock (Engine RUNNING)....1832
      Inspecting The Lift Arm By-Pass Control....1832
      Additional Inspection For Loaders With Advanced Hand Controls....1832
      Troubleshooting Chart....1833
    SEAT BAR SENSOR....1834
      Troubleshooting Guide....1834
      Seat Bar Sensor Test....1835
      Removal And Installation....1836
      BICS™ Controller Seat Bar Sensor Circuit Test....1838
    TRACTION LOCK....1840
      Troubleshooting Guide....1840
      Removal And Installation....1841
  ENGINE SERVICE....1844
    TROUBLESHOOTING....1846
      Chart....1846
    ENGINE SPEED CONTROL....1848
      Removal And Installation....1848
      Disassembly....1848
      Linkage Bar Removal And Installation....1849
    ENGINE SPEED CONTROL PLATE....1850
      Removal And Installation....1850
      Governor Spring Removal....1850
      Start Spring Removal....1850
      Idle Limit And Fuel Limit Adjustment....1851
    MUFFLER....1852
      Removal And Installation....1852
    AIR CLEANER....1854
      Removal And Installation....1854
    RADIATOR....1856
      Removal And Installation....1856
    BLOWER FAN HOUSING....1858
      Removal And Installation....1858
    ENGINE COMPONENTS AND TESTING....1860
      Compression Checking....1860
      Glow Plugs Checking....1861
      Glow Plugs Removal And Installation....1862
      Fuel Shut-Off Solenoid, Removal And Installation....1863
      Fuel Lift Pump Removal And Installation....1864
      Fuel Injection Pump, Checking....1864
      Fuel Injection Pump Removal And Installation....1865
      Timing The Injection Pump....1867
      Fuel Injector Nozzles Removal And Installation....1868
      Checking Fuel Injector Nozzles....1869
      Engine Timing Installation....1871
    ENGINE....1872
      Removal And Installation....1872
      Engine Mounting Brackets Removal And Installation....1876
    FLYWHEEL....1878
      Removal And Installation....1878
      Flywheel Ring Gear....1879
      Housing Removal And Installation....1879
    RECONDITIONING THE ENGINE....1880
      Thermostat Removal And Installation....1880
      Water Pump Removal And Installation....1880
      Timing Gear Case Cover Removal And Installation....1881
      Oil Pump Removal And Installation....1883
      Crankshaft Front Seal Removal And Installation....1885
      Exhaust Manifold Removal And Installation....1886
      Valve Cover Removal And Installation....1887
      Rocker Arm Removal And Installation....1888
      Push Rod Removal And Installation....1889
      Tappet Removal And Installation....1890
      Cylinder Head Removal And Installation....1890
      Checking Piston Top Clearance....1891
      Disassembly....1892
      Assembly....1892
      Servicing The Cylinder Head....1892
      Combustion Chamber Removal And Installation....1895
      Idler Gear Removal And Installation....1896
      Camshaft Removal And Installation....1897
      Fuel Camshaft Removal And Installation....1899
      Oil Pan Removal And Installation....1901
      Governor Shaft Removal And Installation....1902
      Governor Fork Lever Removal And Installation....1905
      Piston Removal And Installation....1906
      Checking The Piston And Connecting Rod....1907
      Connecting Rod Alignment....1908
      Pison Ring Gap....1908
      Piston Ring Installation....1909
      Connecting Rod Installation....1909
      Checking Engine Cylinder Bore....1910
      Crankshaft Removal And Installation....1910
      Checking Crankshaft Journal And Block Bearing....1913
      Checking The Crankshaft Journal And Main Bearing....1914
      Connecting Rod Journal....1915
      Checking the End Play Of The Crankshaft....1916
      Crankshaft Alignment....1916
      Idler Gear And Crankshaft....1917
      Idler Gear And Crankshaft Gear....1917
      Idler Gear And Fuel Camshaft Gear....1918
      Fuel Camshaft Gear And Governor Shaft Gear....1918
    RUBBER DRIVE COUPLER....1920
      Removal And Installation....1920
      Disassembly....1920
      Assembly....1921
    WATER FLANGE....1924
      Removal And Installation....1924
  SPECIFICATIONS....1926
    LOADER SPECIFICATIONS....1928
      Machine Dimensions....1928
      Performance....1929
      Controls....1929
      Engine....1929
      Hydraulic System....1930
      Electrical....1930
      Drive System....1931
      Capacities....1931
      Tires....1931
    ENGINE SPECIFICATIONS....1932
      Engine Compression....1932
      Fuel Injection Nozzles....1932
      Fuel Injection Pump....1932
      Cylinder Head....1932
      Valves....1932
      Valve Springs....1933
      Rocker Arms....1933
      Camshaft....1933
      Cylinders....1933
      Piston Rings....1934
      Pistons....1934
      Crankshaft....1934
      Oil Pump....1935
      Thermostat....1935
      Crankshaft Re-Grind Data....1936
    TORQUE SPECIFICATIONS FOR BOLTS....1938
      Torque For General SAE Bolts....1938
      Torque For General Metric Bolts....1939
    HYDRAULIC CONNECTION SPECIFICATIONS....1940
      O-ring Face Seal Connection....1940
      Straight Thread O-ring Fitting....1941
      Tubelines And Hoses....1941
      Flare Fitting....1941
      O-ring Flare Fitting....1942
      Port Seal Fitting....1944
    HYDRAULIC FLUID SPECIFICATIONS....1946
      Specifications....1946
    CONVERSIONS....1948
      Decimal And Millimeter Equivalents....1948
      U.S. To Metric Conversion....1948
  SMR....1950
    553-1....1950
    553-2....1952
6902827 (3-05) - 553 Operation & Maintenance Manual....1954
  OPERATOR SAFETY WARNINGS....1956
  CONTENTS....1958
  FOREWORD....1960
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....1962
    REGULAR MAINTENANCE ITEMS....1962
    MOTOR OIL....1962
    SERIAL NUMBER LOCATIONS....1964
    LOADER SERIAL NUMBER....1964
    ENGINE SERIAL NUMBER....1964
    DELIVERY REPORT....1964
    BOBCAT LOADER IDENTIFICATIONS....1965
    FEATURES AND ACCESSORIES....1966
      Standard Items....1966
      Options and Accessories....1966
      Attachments....1966
  SAFETY....1968
    SAFETY INSTRUCTIONS....1970
      Before Operation....1970
      Safe Operation Is The Operator’s Responsibility....1971
      Safe Operation Needs A Qualified Operator....1971
      Fire Prevention....1972
    MACHINE SIGNS (DECALS)....1973
  OPERATING INSTRUCTIONS....1976
    INSTRUMENT PANELS....1978
      Left, Right And Accessory Panels....1978
    BOBCAT INTERLOCK CONTROL SYSTEM (bics™)....1979
      Description....1979
      Lift Arm By-Pass Control....1979
      Traction Lock Override....1980
    ENGINE SPEED CONTROL....1980
      Operation....1980
    PARKING BRAKE....1981
      Operation....1981
    STEERING LEVERS....1981
      Operation....1981
    STOPPING THE BOBCAT LOADER....1982
      Procedure....1982
    SEAT BAR RESTRAINT SYSTEM....1982
    HYDRAULIC CONTROLS....1984
      Foot Pedals....1984
      Bucket Position Valve Operation (If Equipped)....1984
      Quick Couplers....1985
      Relieving Hydraulic Pressure....1985
    DAILY INSPECTION....1986
      Daily Inspection and Maintenance....1986
    GETTING READY FOR OPERATION....1987
    STARTING THE ENGINE....1989
      Normal Starting....1989
      Cold Temperature Starting....1991
      Warming The Hydraulic/Hydrostatic System....1991
    STOPPING THE ENGINE....1991
    ATTACHMENTS AND BUCKETS....1992
      Choosing The Correct Bucket....1992
      Pallet Forks....1992
      Installing The Bucket or Attachment....1993
      Removing The Bucket Or Attachment....1994
    OPERATING PROCEDURE....1995
      Operating With A Full Bucket....1995
      Filling The Bucket....1996
      Emptying the Bucket....1996
      Digging Into The Ground....1997
      Leveling The Ground (Using Lift Arms In Float Position)....1997
      Backfilling....1997
    PARKING THE BOBCAT LOADER....1998
    TRANSPORTING THE BOBCAT LOADER....1998
      Loading Onto Transport Vehicle....1998
      Fastening To Transport Vehicle....1999
    LIFTING THE LOADER....1999
    TOWING THE LOADER....2000
  PREVENTIVE MAINTENANCE....2002
    MAINTENANCE SAFETY....2004
    SERVICE SCHEDULE....2006
      Chart....2006
    LIFT ARM SUPPORT DEVICE....2007
      Engaging The Lift Arm Support Device....2007
      Disengaging The Lift Arm Support Device....2008
    OPERATOR CAB....2009
      Description....2009
      Raising The Operator Cab....2009
      Lowering The Operator Cab....2010
      Emergency Exit....2010
    SEAT BAR RESTRAINT SYSTEM....2012
      Inspecting The Seat Bar....2012
      Maintaining The Seat Bar....2012
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....2013
      Inspecting The BICS Controller (Engine Stopped - Key ON)....2013
      Inspecting The Seat Bar Sensor (Engine RUNNING)....2013
      Inspecting The Traction Lock (Engine RUNNING)....2013
      Inspecting The Lift Arm By-Pass Control....2013
    REAR DOOR....2014
      Opening And Closing The Rear Door....2014
      Adjusting The Rear Door....2014
    REAR GRILL....2015
    AIR CLEANER SERVICE....2015
      Replacing Filter Elements....2015
    FUEL SYSTEM....2016
      Fuel Specifications....2016
      Filling The Fuel Tank....2016
      Fuel Filter....2017
      Removing Air From The Fuel System....2018
    ENGINE LUBRICATION SYSTEM....2019
      Checking Engine Oil....2019
      Oil Chart....2019
      Replacing The Oil And Filter....2020
    ENGINE COOLING SYSTEM....2021
      Cleaning The Cooling System....2021
      Checking The Coolant Level....2022
      Replacing The Coolant....2022
    ALTERNATOR BELT....2023
      Adjusting The Alternator Belt....2023
    ELECTRICAL SYSTEM....2024
      Description....2024
      Electrical System Maintenance....2024
      Fuse Location....2024
      Using A Booster Battery (Jump Starting)....2025
      Removing And Installing The Battery....2026
    HYDRAULIC / HYDROSTATIC SYSTEM....2028
      Checking And Adding Fluid....2028
      Replacing Hydraulic/Hydrostatic Filter....2029
      Replacing Hydraulic Fluid....2029
    SPARK ARRESTOR MUFFLER....2030
      Maintenance....2030
    TIRE MAINTENANCE....2031
      Wheel Nuts....2031
      Tire Rotation....2031
      Tire Mounting....2031
    FINAL DRIVE TRANSMISSION (CHAINCASE)....2032
      Checking And Adding Oil....2032
    LUBRICATING THE BOBCAT LOADER....2033
      Lubrication Locations....2033
    PIVOT PINS....2034
      Inspection And Maintenance....2034
    BOB-TACH....2035
      Inspection And Maintenance....2035
    AUXILIARY CONTROL LOCKBOLT....2036
    RUBBER COUPLING LUBRICATION....2036
  SYSTEM SETUP & ANALYSIS....2038
    TROUBLESHOOTING....2040
      Troubleshooting The Engine....2040
      Troubleshooting The Drive System....2041
      Troubleshooting The Hydraulic System....2041
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)....2042
      Troubleshooting Chart....2042
  MACHINE SIGN TRANSLATIONS....2044
    SERVICE SCHEDULE (6734534)....2046
    DANGER (6702301)....2047
    WARNING (6579528)....2047
    DANGER (6702302)....2048
    WARNING (6577754)....2048
    IMPORTANT (6560573)....2049
    WARNING (6710358)....2049
    WARNING (6702255)....2050
    DANGER (6717343)....2050
    WARNING (6579510)....2051
    LIFT ARM SUPPORT DEVICE (6706558)....2052
  SPECIFICATIONS....2054
    LOADER SPECIFICATIONS....2056
      Machine Dimensions....2056
      Performance....2057
      Controls....2057
      Engine....2057
      Hydraulic System....2058
      Electrical....2058
      Drive System....2058
      Capacities....2058
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS....2059
  WARRANTY....2060
6903125 (2-06) - 553 Service Manual....2062
  MAINTENANCE SAFETY....2064
  ALPHABETICAL INDEX....2066
  CONTENTS....2068
    SAFETY INSTRUCTIONS....2072
      Fire Prevention....2074
    SERIAL NUMBER LOCATION....2076
      Loader Serial Number....2076
      Engine Serial Number....2076
    DELIVERY REPORT....2077
    BOBCAT LOADER IDENTIFICATION....2078
  SAFETY AND MAINTENANCE....2080
    LIFTING AND BLOCKING THE LOADER....2082
      Procedure....2082
    LIFT ARM SUPPORT DEVICE....2084
      Installing Lift Arm Support Device....2084
      Removing Lift Arm Support Device....2085
    OPERATOR CAB....2088
      Description....2088
      Raising The Operator Cab....2088
      Lowering The Operator Cab....2089
      Emergency Exit....2089
    TRANSPORTING THE BOBCAT LOADER....2092
      Procedure....2092
      Stopping The Bobcat Loader....2092
    TOWING THE LOADER....2094
      Procedure....2094
    REMOTE START....2096
      Procedure....2096
    SERVICE SCHEDULE....2098
      Chart....2098
    AIR CLEANER SERVICE....2100
      Replacing Filter Element....2100
    ENGINE COOLING SYSTEM....2102
      Cleaning The Cooling System....2102
      Checking The Coolant Level....2103
      Replacing The Coolant....2103
    FUEL SYSTEM....2106
      Fuel Specifications....2106
      Filling The Fuel Tank....2106
      Fuel Filter....2107
      Removing Air From The Fuel System....2108
    ENGINE LUBRICATION SYSTEM....2110
      Checking Engine Oil....2110
      Oil Chart....2110
      Replacing Oil And Filter....2110
    HYDRAULIC/HYDROSTATIC SYSTEM....2112
      Description....2112
      Checking And Adding Fluid....2112
      Replacing The Hydraulic/Hydrostatic Filter....2113
      Replacing Hydraulic Fluid....2113
    FINAL DRIVE TRANSMISSION (CHAINCASE)....2116
      Checking And Adding Oil....2116
    AUXILIARY CONTROL LOCKBOLT....2118
      Removal....2118
    BOB-TACH....2120
      Inspection And Maintenance....2120
    LUBRICATION OF THE BOBCAT LOADER....2122
      Procedure....2122
    TIRE MAINTENANCE....2124
      Wheel Nuts....2124
      Rotating....2124
      Mounting....2124
    SPARK ARRESTOR MUFFLER....2126
      Cleaning Procedure....2126
    PIVOT PINS....2128
      Procedure....2128
    SEAT BAR RESTRAINT SYSTEM....2130
      Description....2130
      Seat Bar Inspection....2130
      Seat Bar Maintenance....2130
    RUBBER COUPLER LUBRICATION....2132
      Procedure....2132
  HYDRAULIC SYSTEM....2134
    HYDRAULIC/HYDROSTATIC SCHEMATICS....2136
    HYDRAULIC SYSTEM INFORMATION....2138
      Tighten Procedures....2142
      Troubleshooting Chart....2142
    CYLINDER (LIFT)....2144
      Checking....2144
      Removal And Installation....2145
      Identification....2148
      Disassembly And Assembly....2149
    CYLINDER (TILT)....2152
      Checking....2152
      Removal And Installation....2152
      Identification....2154
      Disassembly And Assembly....2155
    MAIN RELIEF VALVE....2158
      Checking The Main Relief Valve Without Auxiliaries....2158
      Checking The Main Relief Valve With Auxiliaries....2159
      Removal and Installation....2160
    HYDRAULIC CONTROL VALVE....2162
      Removal And Installation....2162
      Identification Chart....2165
      Disassembly And Assembly....2166
      Load Check Valve....2166
      Main Releif Valve....2167
      Anti-Cavitation Check Valve....2168
      Port Relief Valve....2169
      Rubber Boot (Lift)....2170
      Rubber Boot (Tilt)....2170
      Rubber Boot (Aux.)....2170
      Lift Spool Detent....2171
      Tilt Centering Spring....2175
      Auxiliary Spool Detent....2176
      One Way Restrictors....2176
      Inspection....2177
      Spool Seal Installation....2178
    LIFT ARM BY-PASS CONTROL VALVE....2180
      Inspecting....2180
      Removal and Installation....2180
      Disassembly and Assembly....2181
    TILT LOCK VALVE....2182
      Removal And Installation....2182
      Disassembly and Assembly....2183
    HYDRAULIC PUMP....2184
      Check The Output Of The Hydraulic Pump....2184
      Removal And Installation....2186
      Identification....2188
      Disassembly And Assembly....2189
      Inspection....2191
    HYDRAULIC FILTER HOUSING....2192
      Removal and Installation....2192
    HYDRAULIC FLUID RESERVOIR....2194
      Removal and Installation....2194
  HYDROSTATIC SYSTEM....2196
    HYDROSTATIC SYSTEM INFORMATION....2198
      Troubleshooting Chart....2198
      Replenishing Valve Function....2199
    CONTROL PANEL....2200
      Removal and Installation....2200
    STEERING....2202
      Lever Removal and Installation....2202
      Lever Disassembly And Assembly....2203
      Linkage Removal And Installation....2204
      Pintle Lever Disassemby And Assembly....2206
      Linkage Neutral Adjustment....2208
    HYDROSTATIC MOTOR....2212
      Removal And Installation....2212
      Parts Identification....2214
      Disassembly And Assembly....2215
      Inspection....2222
      Timing The Hydrostatic Motor....2224
    PORT BLOCK....2226
      Removal And Installation....2226
      Oil Cooler By-Pass Valve....2226
      Hydraulic Oil Temperature Switch....2226
      Charge Pressure By-Pass Valve....2227
    HYDROSTATIC PUMP....2228
      Checking Charge Pressure....2228
      Removal And Installation....2229
      Drive Coupler Removal And Installation....2232
      Parts Identification....2233
      Disassembly And Assembly....2234
      Inspection....2238
    OIL COOLER....2242
      Removal and Installation....2242
  DRIVE SYSTEM....2244
    PARKING BRAKE....2246
      Disk Removal And Installation....2246
      Traction Lock Guides Removal And Installation....2247
    DRIVE COMPONENTS....2248
      Axle Seal Removal And Installation....2248
      Axle, Bearing, And Sprocket Removal And Installation....2250
      Chain Removal And Installation....2254
    CHAINCASE....2256
      Removing Oil From The Chaincase....2256
      Front Cover Removal And Installation....2256
      Rear Cover Removal And Installation....2257
  MAIN FRAME....2258
    SEAT BAR....2260
      Removal And Installation....2260
      Assembling Components....2263
      Compression Spring Disassembly And Assembly....2263
    OPERATOR CAB....2264
      Gas Cylinder Removal And Installation....2264
      Gas Cylinder Disassembly And Assembly....2265
      Removal And Installation....2265
    OPERATOR SEAT....2270
      Removal And Installation....2270
      Seat Belt Removal And Installation....2270
    BOB-TACH....2272
      Removal And Installation....2272
      Bob-Tach Lever And Wedge....2274
    LIFT ARM....2276
      Removal And Installation....2276
    REAR GRILL....2280
      Removal And Installation....2280
    REAR DOOR....2282
      Removal And Installation....2282
      Striker Removal and Installation....2283
      Striker Disassembly and Assembly....2283
      Adjusting The Striker....2283
      Latch Removal and Installation....2284
    FUEL TANK....2286
      Removal And Installation....2286
      Fuel Level Sender....2286
    CONTROL PEDALS....2288
      Removal And Installation....2288
      Pedal Adjustment....2288
      Pedal Interlock Linkage Removal And Installation....2289
      Pedal Interlock Linkage Adjustment....2290
      Crossbar Linkage Removal And Installation....2290
  ELECTRICAL SYSTEM....2292
    ELECTRICAL SCHEMATICS....2296
    ELECTRICAL SYSTEM INFORMATION....2294
      Troubleshooting....2299
      Description....2300
      Fuse Location....2300
      Relay Switches Location....2301
    BATTERY....2303
      Removal And Installation....2303
      Using A Booster Battery (Jump Starting)....2304
    ALTERNATOR....2307
      Removal And Installation....2307
      Adjusting The Alternator Belt....2307
      Description....2308
      Tests....2308
      Alternator Output Test....2309
      Full Field Test....2309
      Alternator Regulator Test....2310
      Alternator Regulator Test Using Voltmeter....2310
      Parts Identification....2311
      Pulley Removal And Installation....2312
      Disassembly And Assembly....2313
      Rotor Continuity Test....2315
      Stator Continuity Test....2316
      Rectifier Continuity (Diode) Test....2317
      Brush Length....2317
    STARTER....2319
      Removal And Installation....2319
      Checking The Starter In The Loader....2320
      Parts Identification....2321
      Disassembly....2322
      Inspection And Repair....2327
      No Load Test....2331
      Assembly....2332
    INSTRUMENT PANEL....2339
      Removal And Installation....2339
    LIGHTS....2341
      Front Removal And Installation....2341
    BICS™ SYSTEM CONTROLLER....2343
      Trouble Shooting Guide....2343
      Removal And Installation....2344
    BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON)....2347
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)....2347
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2347
      Inspecting The Seat Bar Sensor (Engine RUNNING)....2347
      Inspecting The Traction Lock (Engine RUNNING)....2347
      Inspecting The Lift Arm By-Pass Control....2347
      Additional Inspection For Loaders With Advanced Hand Controls....2347
      Troubleshooting Chart....2348
    SEAT BAR SENSOR....2349
      Troubleshooting Guide....2349
      Seat Bar Sensor Test....2350
      Removal And Installation....2351
      BICS™ Controller Seat Bar Sensor Circuit Test....2353
    TRACTION LOCK....2355
      Troubleshooting Guide....2355
      Removal And Installation....2356
  ENGINE SERVICE....2359
    TROUBLESHOOTING....2363
      Chart....2363
    ENGINE SPEED CONTROL....2365
      Removal And Installation....2365
      Disassembly....2365
      Linkage Bar Removal And Installation....2366
    ENGINE SPEED CONTROL PLATE....2367
      Removal And Installation....2367
      Governor Spring Removal....2367
      Start Spring Removal....2367
      Idle Limit And Fuel Limit Adjustment....2368
    MUFFLER....2369
      Removal And Installation....2369
    AIR CLEANER....2371
      Removal And Installation....2371
    RADIATOR....2373
      Removal And Installation....2373
    BLOWER FAN HOUSING....2375
      Removal And Installation....2375
    ENGINE COMPONENTS AND TESTING....2377
      Compression Checking....2377
      Glow Plugs Checking....2377
      Glow Plugs Removal And Installation....2378
      Fuel Shut-Off Solenoid, Removal And Installation....2379
      Fuel Lift Pump Removal And Installation....2380
      Fuel Injection Pump, Checking....2380
      Fuel Injection Pump Removal And Installation....2381
      Timing The Injection Pump....2383
      Fuel Injector Nozzles Removal And Installation....2384
      Checking Fuel Injector Nozzles....2385
      Breather Removal And Installation....2387
      Valve Clearance Adjustment....2387
    ENGINE....2389
      Removal And Installation....2389
      Engine Mounting Brackets Removal And Installation....2393
    FLYWHEEL....2395
      Removal And Installation....2395
      Flywheel Ring Gear....2396
      Housing Removal And Installation....2396
    RECONDITIONING THE ENGINE....2397
      Thermostat Removal And Installation....2397
      Water Pump Removal And Installation....2398
      Timing Gear Case Cover Removal And Installation....2398
      Oil Pump Removal And Installation....2400
      Checking Oil Pump....2401
      Crankshaft Front Seal Removal And Installation....2403
      Exhaust Manifold Removal And Installation....2404
      Valve Cover Removal And Installation....2405
      Rocker Arm Removal And Installation....2405
      Push Rod Removal And Installation....2407
      Cylinder Head Removal....2407
      Cylinder Head Installation....2408
      Tappet Removal And Installation....2408
      Checking Piston Top Clearance....2409
      Cylinder Head Disassembly....2410
      Cylinder Head Assembly....2410
      Servicing The Cylinder Head....2410
      Cylinder Head Surface Flatness....2411
      Cylinder Head Flaw....2411
      Valve And Valve Guide Checking....2412
      Valve Guide Replacement....2412
      Reconditioning The Valve And Valve Seat....2413
      Correcting The Valve Seat....2413
      Valve Spring....2414
      Idler Gear Removal And Installation....2415
      Camshaft Removal And Installation....2416
      Camshaft Height....2417
      Camshaft Oil Clearance....2417
      Camshaft Alignment....2418
      Camshaft Gear Removal And Installation....2418
      Fuel Camshaft Removal And Installation....2418
      Engine Timing Gear Alignment....2419
      Governor Shaft Removal And Installation....2420
      Governor Fork Lever Removal And Installation....2423
      Oil Pan Removal And Installation....2424
      Piston Removal....2426
      Piston Pin Removal And Installation....2427
      Checking The Piston And Connecting Rod....2427
      Connecting Rod Alignment....2428
      Connecting Rod Bushing Removal And Installation....2429
      Piston Ring Gap....2429
      Checking Engine Cylinder Bore....2430
      Piston Ring Installation....2430
      Connecting Rod Installation....2431
      Piston Installation....2431
      Crankshaft End Play....2432
      Crankshaft Removal And Installation....2432
      Crankshaft Disassembly And Assembly....2433
      Checking Crankshaft Number One Journal And Block Bearing....2434
      Checking The Crankshaft Journals And Main Bearings....2435
      Connecting Rod Journal....2437
      Crankshaft Alignment....2438
    RUBBER DRIVE COUPLER....2439
      Removal And Installation....2439
      Disassembly....2439
      Assembly....2440
    WATER FLANGE....2443
      Removal And Installation....2443
  SPECIFICATIONS....2445
    LOADER SPECIFICATIONS....2447
      Machine Dimensions....2447
      Performance....2448
      Controls....2448
      Engine....2448
      Hydraulic System....2449
      Electrical....2449
      Drive System....2450
      Capacities....2450
    ENGINE SPECIFICATIONS - KUBOTA D1105-B....2451
      Engine Compression....2451
      Fuel Injection Nozzles....2451
      Fuel Injection Pump....2451
      Cylinder Head....2451
      Valves....2451
      Valve Springs....2452
      Rocker Arms....2452
      Camshaft....2452
      Cylinders....2452
      Piston Rings....2453
      Pistons....2453
      Crankshaft....2453
      Oil Pump....2454
      Thermostat....2454
      Crankshaft Re-Grind Data....2455
    TORQUE SPECIFICATIONS FOR BOLTS....2457
      Torque For General SAE Bolts....2457
      Torque For General Metric Bolts....2458
    HYDRAULIC CONNECTION SPECIFICATIONS....2459
      O-ring Face Seal Connection....2459
      Straight Thread O-ring Fitting....2460
      Tubelines And Hoses....2460
      Flare Fitting....2460
      O-ring Flare Fitting....2461
      Port Seal Fitting....2463
    HYDRAULIC FLUID SPECIFICATIONS....2465
      Specifications....2465
    CONVERSIONS....2467
      Decimal And Millimeter Equivalents....2467
      U.S. To Metric Conversion....2467
  SMR....2469
    Revision No: 553-1....2469
6903125 (6-12) - 553 Service Manual....2471
  MAINTENANCE SAFETY....2473
  ALPHABETICAL INDEX....2475
  CONTENTS....2477
    SAFETY INSTRUCTIONS....2481
      Fire Prevention....2483
    SERIAL NUMBER LOCATION....2485
      Loader Serial Number....2485
      Engine Serial Number....2485
    DELIVERY REPORT....2486
    BOBCAT LOADER IDENTIFICATION....2487
  SAFETY AND MAINTENANCE....2489
    LIFTING AND BLOCKING THE LOADER....2491
      Procedure....2491
    LIFT ARM SUPPORT DEVICE....2493
      Installing Lift Arm Support Device....2493
      Removing Lift Arm Support Device....2494
    OPERATOR CAB....2497
      Description....2497
      Raising The Operator Cab....2497
      Lowering The Operator Cab....2498
      Emergency Exit....2498
    TRANSPORTING THE BOBCAT LOADER....2501
      Procedure....2501
      Stopping The Bobcat Loader....2501
    TOWING THE LOADER....2503
      Procedure....2503
    REMOTE START....2505
      Procedure....2505
    SERVICE SCHEDULE....2507
      Chart....2507
    AIR CLEANER SERVICE....2509
      Replacing Filter Element....2509
    ENGINE COOLING SYSTEM....2511
      Cleaning The Cooling System....2511
      Checking The Coolant Level....2512
      Replacing The Coolant....2512
    FUEL SYSTEM....2515
      Fuel Specifications....2515
      Filling The Fuel Tank....2515
      Fuel Filter....2516
      Removing Air From The Fuel System....2517
    ENGINE LUBRICATION SYSTEM....2519
      Checking Engine Oil....2519
      Oil Chart....2519
      Replacing Oil And Filter....2519
    HYDRAULIC/HYDROSTATIC SYSTEM....2521
      Description....2521
      Checking And Adding Fluid....2521
      Replacing The Hydraulic/Hydrostatic Filter....2522
      Replacing Hydraulic Fluid....2522
    FINAL DRIVE TRANSMISSION (CHAINCASE)....2525
      Checking And Adding Oil....2525
    AUXILIARY CONTROL LOCKBOLT....2527
      Removal....2527
    BOB-TACH....2529
      Inspection And Maintenance....2529
    LUBRICATION OF THE BOBCAT LOADER....2531
      Procedure....2531
    TIRE MAINTENANCE....2533
      Wheel Nuts....2533
      Rotating....2533
      Mounting....2533
    SPARK ARRESTOR MUFFLER....2535
      Cleaning Procedure....2535
    PIVOT PINS....2537
      Procedure....2537
    SEAT BAR RESTRAINT SYSTEM....2539
      Description....2539
      Seat Bar Inspection....2539
      Seat Bar Maintenance....2539
    RUBBER COUPLER LUBRICATION....2541
      Procedure....2541
  HYDRAULIC SYSTEM....2543
    HYDRAULIC/HYDROSTATIC SCHEMATICS....2545
    HYDRAULIC SYSTEM INFORMATION....2547
      Tighten Procedures....2551
      Troubleshooting Chart....2551
    CYLINDER (LIFT)....2553
      Checking....2553
      Removal And Installation....2554
      Identification....2557
      Disassembly And Assembly....2558
    CYLINDER (TILT)....2561
      Checking....2561
      Removal And Installation....2561
      Identification....2563
      Disassembly And Assembly....2564
    MAIN RELIEF VALVE....2567
      Checking The Main Relief Valve Without Auxiliaries....2567
      Checking The Main Relief Valve With Auxiliaries....2568
      Removal and Installation....2569
    HYDRAULIC CONTROL VALVE....2571
      Removal And Installation....2571
      Identification Chart....2574
      Disassembly And Assembly....2575
      Load Check Valve....2575
      Main Releif Valve....2576
      Anti-Cavitation Check Valve....2577
      Port Relief Valve....2578
      Rubber Boot (Lift)....2579
      Rubber Boot (Tilt)....2579
      Rubber Boot (Aux.)....2579
      Lift Spool Detent....2580
      Tilt Centering Spring....2584
      Auxiliary Spool Detent....2585
      One Way Restrictors....2585
      Inspection....2586
      Spool Seal Installation....2587
    LIFT ARM BY-PASS CONTROL VALVE....2589
      Inspecting....2589
      Removal and Installation....2589
      Disassembly and Assembly....2590
    TILT LOCK VALVE....2591
      Removal And Installation....2591
      Disassembly and Assembly....2592
    HYDRAULIC PUMP....2593
      Check The Output Of The Hydraulic Pump....2593
      Removal And Installation....2595
      Identification....2597
      Disassembly And Assembly....2598
      Inspection....2600
    HYDRAULIC FILTER HOUSING....2601
      Removal and Installation....2601
    HYDRAULIC FLUID RESERVOIR....2603
      Removal and Installation....2603
  HYDROSTATIC SYSTEM....2605
    HYDROSTATIC SYSTEM INFORMATION....2607
      Troubleshooting Chart....2607
      Replenishing Valve Function....2608
    CONTROL PANEL....2609
      Removal and Installation....2609
    STEERING....2611
      Lever Removal and Installation....2611
      Lever Disassembly And Assembly....2612
      Linkage Removal And Installation....2613
      Pintle Lever Disassemby And Assembly....2615
      Linkage Neutral Adjustment....2617
    HYDROSTATIC MOTOR....2621
      Removal And Installation....2621
      Parts Identification....2623
      Disassembly And Assembly....2624
      Inspection....2631
      Timing The Hydrostatic Motor....2633
    PORT BLOCK....2635
      Removal And Installation....2635
      Oil Cooler By-Pass Valve....2635
      Hydraulic Oil Temperature Switch....2635
      Charge Pressure By-Pass Valve....2636
    HYDROSTATIC PUMP....2637
      Checking Charge Pressure....2637
      Removal And Installation....2638
      Drive Coupler Removal And Installation....2641
      Parts Identification....2642
      Disassembly And Assembly....2643
      Inspection....2647
    OIL COOLER....2651
      Removal and Installation....2651
  DRIVE SYSTEM....2653
    PARKING BRAKE....2655
      Disk Removal And Installation....2655
      Traction Lock Guides Removal And Installation....2656
    DRIVE COMPONENTS....2657
      Axle Seal Removal And Installation....2657
      Axle, Bearing, And Sprocket Removal And Installation....2659
      Chain Removal And Installation....2663
    CHAINCASE....2665
      Removing Oil From The Chaincase....2665
      Front Cover Removal And Installation....2665
      Rear Cover Removal And Installation....2666
  MAIN FRAME....2667
    SEAT BAR....2669
      Removal And Installation....2669
      Assembling Components....2672
      Compression Spring Disassembly And Assembly....2672
    OPERATOR CAB....2673
      Gas Cylinder Removal And Installation....2673
      Gas Cylinder Disassembly And Assembly....2674
      Removal And Installation....2674
    OPERATOR SEAT....2679
      Removal And Installation....2679
      Seat Belt Removal And Installation....2679
    BOB-TACH....2681
      Removal And Installation....2681
      Bob-Tach Lever And Wedge....2683
    LIFT ARM....2685
      Removal And Installation....2685
    REAR GRILL....2689
      Removal And Installation....2689
    REAR DOOR....2691
      Removal And Installation....2691
      Striker Removal and Installation....2692
      Striker Disassembly and Assembly....2692
      Adjusting The Striker....2692
      Latch Removal and Installation....2693
    FUEL TANK....2695
      Removal And Installation....2695
      Fuel Level Sender....2695
    CONTROL PEDALS....2697
      Removal And Installation....2697
      Pedal Adjustment....2697
      Pedal Interlock Linkage Removal And Installation....2698
      Pedal Interlock Linkage Adjustment....2699
      Crossbar Linkage Removal And Installation....2699
  ELECTRICAL SYSTEM....2701
    ELECTRICAL SCHEMATICS....2705
    ELECTRICAL SYSTEM INFORMATION....2703
      Troubleshooting....2708
      Description....2709
      Fuse Location....2709
      Relay Switches Location....2710
    BATTERY....2712
      Removal And Installation....2712
      Using A Booster Battery (Jump Starting)....2713
    ALTERNATOR....2716
      Removal And Installation....2716
      Adjusting The Alternator Belt....2716
      Description....2717
      Tests....2717
      Alternator Output Test....2718
      Full Field Test....2718
      Alternator Regulator Test....2719
      Alternator Regulator Test Using Voltmeter....2719
      Parts Identification....2720
      Pulley Removal And Installation....2721
      Disassembly And Assembly....2722
      Rotor Continuity Test....2724
      Stator Continuity Test....2725
      Rectifier Continuity (Diode) Test....2726
      Brush Length....2726
    STARTER....2728
      Removal And Installation....2728
      Checking The Starter In The Loader....2729
      Parts Identification....2730
      Disassembly....2731
      Inspection And Repair....2736
      No Load Test....2740
      Assembly....2741
    INSTRUMENT PANEL....2748
      Removal And Installation....2748
    LIGHTS....2750
      Front Removal And Installation....2750
    BICS™ SYSTEM CONTROLLER....2752
      Trouble Shooting Guide....2752
      Removal And Installation....2753
    BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON)....2756
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)....2756
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2756
      Inspecting The Seat Bar Sensor (Engine RUNNING)....2756
      Inspecting The Traction Lock (Engine RUNNING)....2756
      Inspecting The Lift Arm By-Pass Control....2756
      Additional Inspection For Loaders With Advanced Hand Controls....2756
      Troubleshooting Chart....2757
    SEAT BAR SENSOR....2758
      Troubleshooting Guide....2758
      Seat Bar Sensor Test....2759
      Removal And Installation....2760
      BICS™ Controller Seat Bar Sensor Circuit Test....2762
    TRACTION LOCK....2764
      Troubleshooting Guide....2764
      Removal And Installation....2765
  ENGINE SERVICE....2768
    TROUBLESHOOTING....2772
      Chart....2772
    ENGINE SPEED CONTROL....2774
      Removal And Installation....2774
      Disassembly....2774
      Linkage Bar Removal And Installation....2775
    ENGINE SPEED CONTROL PLATE....2776
      Removal And Installation....2776
      Governor Spring Removal....2776
      Start Spring Removal....2776
      Idle Limit And Fuel Limit Adjustment....2777
    MUFFLER....2778
      Removal And Installation....2778
    AIR CLEANER....2780
      Removal And Installation....2780
    RADIATOR....2782
      Removal And Installation....2782
    BLOWER FAN HOUSING....2784
      Removal And Installation....2784
    ENGINE COMPONENTS AND TESTING....2786
      Compression Checking....2786
      Glow Plugs Checking....2786
      Glow Plugs Removal And Installation....2787
      Fuel Shut-Off Solenoid, Removal And Installation....2788
      Fuel Lift Pump Removal And Installation....2789
      Fuel Injection Pump, Checking....2789
      Fuel Injection Pump Removal And Installation....2790
      Timing The Injection Pump....2792
      Fuel Injector Nozzles Removal And Installation....2793
      Checking Fuel Injector Nozzles....2794
      Breather Removal And Installation....2796
      Valve Clearance Adjustment....2796
    ENGINE....2798
      Removal And Installation....2798
      Engine Mounting Brackets Removal And Installation....2802
    FLYWHEEL....2804
      Removal And Installation....2804
      Flywheel Ring Gear....2805
      Housing Removal And Installation....2805
    RECONDITIONING THE ENGINE....2806
      Thermostat Removal And Installation....2806
      Water Pump Removal And Installation....2807
      Timing Gear Case Cover Removal And Installation....2807
      Oil Pump Removal And Installation....2809
      Checking Oil Pump....2810
      Crankshaft Front Seal Removal And Installation....2812
      Exhaust Manifold Removal And Installation....2813
      Valve Cover Removal And Installation....2814
      Rocker Arm Removal And Installation....2814
      Push Rod Removal And Installation....2816
      Cylinder Head Removal....2816
      Cylinder Head Installation....2817
      Tappet Removal And Installation....2817
      Checking Piston Top Clearance....2818
      Cylinder Head Disassembly....2819
      Cylinder Head Assembly....2819
      Servicing The Cylinder Head....2819
      Cylinder Head Surface Flatness....2820
      Cylinder Head Flaw....2820
      Valve And Valve Guide Checking....2821
      Valve Guide Replacement....2821
      Reconditioning The Valve And Valve Seat....2822
      Correcting The Valve Seat....2822
      Valve Spring....2823
      Idler Gear Removal And Installation....2824
      Camshaft Removal And Installation....2825
      Camshaft Height....2826
      Camshaft Oil Clearance....2826
      Camshaft Alignment....2827
      Camshaft Gear Removal And Installation....2827
      Fuel Camshaft Removal And Installation....2827
      Engine Timing Gear Alignment....2828
      Governor Shaft Removal And Installation....2829
      Governor Fork Lever Removal And Installation....2832
      Oil Pan Removal And Installation....2833
      Piston Removal....2835
      Piston Pin Removal And Installation....2836
      Checking The Piston And Connecting Rod....2836
      Connecting Rod Alignment....2837
      Connecting Rod Bushing Removal And Installation....2838
      Piston Ring Gap....2838
      Checking Engine Cylinder Bore....2839
      Piston Ring Installation....2839
      Connecting Rod Installation....2840
      Piston Installation....2840
      Crankshaft End Play....2841
      Crankshaft Removal And Installation....2841
      Crankshaft Disassembly And Assembly....2842
      Checking Crankshaft Number One Journal And Block Bearing....2843
      Checking The Crankshaft Journals And Main Bearings....2844
      Connecting Rod Journal....2846
      Crankshaft Alignment....2847
    RUBBER DRIVE COUPLER....2848
      Removal And Installation....2848
      Disassembly....2848
      Assembly....2849
    WATER FLANGE....2852
      Removal And Installation....2852
  SPECIFICATIONS....2854
    LOADER SPECIFICATIONS....2856
      Machine Dimensions....2856
      Performance....2857
      Controls....2857
      Engine....2857
      Hydraulic System....2858
      Electrical....2858
      Drive System....2859
      Capacities....2859
    ENGINE SPECIFICATIONS - KUBOTA D1105-B....2860
      Engine Compression....2860
      Fuel Injection Nozzles....2860
      Fuel Injection Pump....2860
      Cylinder Head....2860
      Valves....2860
      Valve Springs....2861
      Rocker Arms....2861
      Camshaft....2861
      Cylinders....2861
      Piston Rings....2862
      Pistons....2862
      Crankshaft....2862
      Oil Pump....2863
      Thermostat....2863
      Crankshaft Re-Grind Data....2864
    TORQUE SPECIFICATIONS FOR BOLTS....2866
      Torque For General SAE Bolts....2866
      Torque For General Metric Bolts....2867
    HYDRAULIC CONNECTION SPECIFICATIONS....2868
      O-ring Face Seal Connection....2868
      Straight Thread O-ring Fitting....2869
      Tubelines And Hoses....2869
      Flare Fitting....2869
      O-ring Flare Fitting....2870
      Port Seal Fitting....2872
    HYDRAULIC FLUID SPECIFICATIONS....2874
      Specifications....2874
    CONVERSIONS....2876
      Decimal And Millimeter Equivalents....2876
      U.S. To Metric Conversion....2876
  SMR....2878
    Revision No: 553-1....2878
    Revision No: 553-2....2880
6904701 (5-07) - 553 Skid-Steer Loader Operation & Maintenance Manual....2882
  OPERATOR SAFETY WARNINGS....2884
  CONTENTS....2886
  FOREWORD....2888
    BOBCAT COMPANY IS ISO 9001:2000 CERTIFIED....2890
    REGULAR MAINTENANCE ITEMS....2890
    SERIAL NUMBER LOCATIONS....2891
      Loader Serial Number....2891
      Engine Serial Number....2891
    DELIVERY REPORT....2891
    LOADER IDENTIFICATION....2892
    FEATURES, ACCESSORIES AND ATTACHMENTS....2893
      Standard Items....2893
      Options and Accessories....2893
      Attachments....2894
      Buckets Available....2894
      Special Applications Kit....2895
      Special Applications Kit Inspection And Maintenance....2895
  SAFETY & TRAINING RESOURCES....2896
    SAFETY INSTRUCTIONS....2898
      Before Operation....2898
      Safe Operation Is The Operator’s Responsibility....2899
      Safe Operation Needs A Qualified Operator....2899
      Fire Prevention....2900
    MACHINE SIGNS (DECALS)....2901
    PUBLICATIONS AND TRAINING RESOURCES....2903
  OPERATING INSTRUCTIONS....2904
    INSTRUMENT PANEL IDENTIFICATION....2906
      Left Panel....2906
      Right Panel....2906
      Option And Field Accessory Panel....2907
      Cab Light....2907
    SEAT BAR RESTRAINT SYSTEM....2908
      Operation....2908
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2910
      Operation....2910
    LIFT ARM BYPASS CONTROL....2910
      Operation....2910
    TRACTION LOCK OVERRIDE....2911
      Operation....2911
    BACK-UP ALARM SYSTEM....2911
      Operation....2911
    ENGINE SPEED CONTROL....2912
      Operation....2912
    PARKING BRAKE....2912
      Operation....2912
    DRIVING AND STEERING THE LOADER....2913
      Operation....2913
    STOPPING THE LOADER....2913
      Using The Control Levers....2913
    HYDRAULIC CONTROLS....2914
      Description....2914
      Foot Pedals....2914
      Lift Arm Operation....2914
      Lift Arm Float Position....2914
      Tilt Operation....2914
      Hydraulic Bucket Positioning....2914
      Auxiliary Control Lockbolt....2915
      Auxiliary Hydraulics....2915
      Quick Couplers....2916
      Relieve Hydraulic Pressure (Loader And Attachment)....2916
    DAILY INSPECTION....2917
      Daily Inspection and Maintenance....2918
    PRE-STARTING PROCEDURE....2919
      Read Operating Material....2919
      Entering The Loader....2919
      Seat Adjustment....2919
      Seat Belt Adjustment....2920
      Seat Bar....2920
    STARTING THE ENGINE....2921
      Key Switch....2921
      Cold Temperature Starting....2922
      Warming The Hydraulic / Hydrostatic System....2922
    STOPPING THE ENGINE AND LEAVING THE LOADER....2923
      Procedure....2923
      Emergency Exit....2924
    ATTACHMENTS....2925
      Choosing The Correct Bucket....2925
      Pallet Fork....2925
      Installing And Removing The Attachment....2926
    OPERATING PROCEDURE....2929
      Inspect The Work Area....2929
      Operating With A Full Bucket....2929
      Operating With An Empty Bucket....2930
      Filling And Emptying The Bucket....2931
      Leveling The Ground Using Float....2932
      Digging And Filling A Hole....2932
    TOWING THE LOADER....2933
      Procedure....2933
    LIFTING THE LOADER....2934
      Single Point Lift....2934
    TRANSPORTING THE LOADER ON A TRAILER....2935
      Loading And Unloading....2935
      Fastening....2935
  PREVENTIVE MAINTENANCE....2936
    MAINTENANCE SAFETY....2940
    SERVICE SCHEDULE....2942
      Chart....2942
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2943
      Inspecting The BICS Controller (Engine Stopped - Key ON)....2943
      Inspecting The Seat Bar Sensor (Engine RUNNING)....2943
      Inspecting The Traction Lock (Engine RUNNING)....2943
      Inspecting The Lift Arm Bypass Control....2943
    SEAT BAR RESTRAINT SYSTEM....2944
      Description....2944
      Inspecting....2944
      Maintaining....2944
    SEAT BELT....2945
      Inspection and Maintenance....2945
    LIFT ARM SUPPORT DEVICE....2946
      Engaging....2946
      Disengaging....2947
    BACK-UP ALARM SYSTEM....2948
      Description....2948
      Inspecting....2948
      Adjusting Switch Position....2948
    OPERATOR CAB....2949
      Description....2949
      Raising....2949
      Lowering....2950
    REAR DOOR....2951
      Opening And Closing....2951
      Adjusting....2951
    REAR GRILL....2952
      Removing....2952
      Installing....2952
    CAB FILTERS....2952
      Cleaning And Maintenance....2952
    AIR CLEANER SERVICE....2953
      Replacing Filter Elements....2953
    FUEL SYSTEM....2954
      Fuel Specifications....2954
      Filling The Fuel Tank....2954
      Fuel Filter....2954
      Removing Air From The Fuel System....2955
    ENGINE LUBRICATION SYSTEM....2956
      Checking And Adding Engine Oil....2956
      Engine Oil Chart....2956
      Removing And Replacing Oil And Filter....2957
    ENGINE COOLING SYSTEM....2958
      Cleaning....2958
      Checking Level....2959
      Removing And Replacing Coolant....2959
    ALTERNATOR BELT....2961
      Belt Adjustment....2961
      Belt Replacement....2961
    ELECTRICAL SYSTEM....2962
      Description....2962
      Fuse And Relay Location / Identification....2962
      Battery Maintenance....2962
      Using A Booster Battery (Jump Starting)....2963
      Removing And Installing Battery....2964
    HYDRAULIC / HYDROSTATIC SYSTEM....2965
      Checking And Adding Fluid....2965
      Removing And Replacing Hydraulic / Hydrostatic Filter....2966
      Removing And Replacing Hydraulic Fluid....2966
    SPARK ARRESTOR MUFFLER....2967
      Cleaning Procedure....2967
    TIRE MAINTENANCE....2968
      Wheel Nuts....2968
      Rotating....2968
      Mounting....2968
    FINAL DRIVE TRANSMISSION (CHAINCASE)....2969
      Checking And Adding Oil....2969
      Removing And Replacing Oil....2969
    LUBRICATING THE LOADER....2970
      Lubrication Locations....2970
      Rubber Coupler Lubrication....2971
    PIVOT PINS....2972
      Inspection And Maintenance....2972
    BOB-TACH....2973
      Inspection And Maintenance....2973
    LOADER STORAGE AND RETURN TO SERVICE....2974
      Storage....2974
      Return to Service....2974
  SYSTEM SETUP & ANALYSIS....2976
    TROUBLESHOOTING....2978
      Troubleshooting The Engine....2978
      Troubleshooting The Hydrostatic / Drive System....2979
      Troubleshooting The Hydraulic System....2979
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2980
      Troubleshooting....2980
  MACHINE SIGN TRANSLATIONS....2982
    SERVICE SCHEDULE (6734534)....2984
    DANGER (6702301)....2987
    DANGER (6702302)....2987
    DANGER (6717343)....2987
    WARNING (6579528)....2988
    WARNING (6577754)....2988
    IMPORTANT (6560573)....2988
    WARNING (6579510)....2989
    WARNING (6710358)....2990
    WARNING (6733996)....2990
    WARNING (6737189)....2990
  SPECIFICATIONS....2992
    (553) LOADER SPECIFICATIONS....2994
      Dimensions....2994
      Performance....2995
      Controls....2995
      Engine....2995
      Hydraulic System....2996
      Electrical....2996
      Drive System....2996
      Capacities....2997
      Tires....2997
  WARRANTY....2998
6904705 (10-12) - 553 Skid-Steer Loader Service Manual....3004
  MAINTENANCE SAFETY....3006
  ALPHABETICAL INDEX....3008
  CONTENTS....3010
    FOREWORD....3011
    SAFETY INSTRUCTIONS....3014
      Fire Prevention....3016
    SERIAL NUMBER LOCATIONS....3018
      Loader Serial Number....3018
      Engine Serial Number....3018
    DELIVERY REPORT....3019
    LOADER IDENTIFICATION....3020
  SAFETY AND MAINTENANCE....3022
    LIFTING AND BLOCKING THE LOADER....3024
      Procedure....3024
    LIFT ARM SUPPORT DEVICE....3026
      Installing....3026
      Removing....3027
    OPERATOR CAB....3030
      Description....3030
      Raising....3030
      Lowering....3031
    TRANSPORTING LOADER ON A TRAILER....3032
      Loading And Unloading....3032
      Fastening....3032
    TOWING THE LOADER....3034
      Procedure....3034
    REMOTE START....3036
      Procedure....3036
    SERVICE SCHEDULE....3038
      Chart....3038
    AIR CLEANER SERVICE....3040
      Replacing Filter Elements....3040
    ENGINE COOLING SYSTEM....3042
      Cleaning....3042
      Checking....3043
      Removing And Replacing Coolant....3043
    FUEL SYSTEM....3046
      Fuel Specifications....3046
      Filling The Fuel Tank....3046
      Fuel Filter....3047
      Removing Air From The Fuel System....3047
    ENGINE LUBRICATION SYSTEM....3048
      Checking And Adding Engine Oil....3048
      Oil Chart....3048
      Removing And Replacing Oil And Filter....3049
    HYDRAULIC/HYDROSTATIC SYSTEM....3050
      Checking And Adding Fluid....3050
      Removing And Replacing The Hydraulic/Hydrostatic Filter....3050
      Removing And Replacing The Hydraulic/Hydrostatic Fluid....3051
    FINAL DRIVE TRANSMISSION (CHAINCASE)....3052
      Checking And Adding Oil....3052
      Removing Oil From Chaincase....3052
    AUXILIARY CONTROL LOCKBOLT....3054
      Procedure....3054
    BOB-TACH....3056
      Inspection And Maintenance....3056
    LUBRICATING THE BOBCAT....3058
      Lubrication Locations....3058
    TIRE MAINTENANCE....3060
      Wheel Nuts....3060
      Rotating....3060
      Mounting....3061
    SPARK ARRESTOR MUFFLER....3062
      Cleaning Procedure....3062
    PIVOT PINS....3064
      Inspection And Maintenance....3064
    SEAT BAR RESTRAINT SYSTEM....3066
      Inspection And Maintenance....3066
    RUBBER COUPLER LUBRICATION....3068
      Procedure....3068
    LOADER STORAGE AND RETURN TO SERVICE....3070
      Storage....3070
      Return to Service....3070
    STOPPING THE ENGINE AND LEAVING THE LOADER....3072
      Procedure....3072
      Emergency Exit....3073
  HYDRAULIC SYSTEM....3074
    HYDRAULIC/HYDROSTATIC SCHEMATICS....3076
    HYDRAULIC SYSTEM INFORMATION....3078
      Glossary Of Hydraulic / Hydrostatic Symbols....3078
      Troubleshooting Chart....3082
    CYLINDER (LIFT)....3084
      Testing....3084
      Removal And Installation....3085
      Parts Identification....3088
      Disassembly And Assembly....3089
    CYLINDER (TILT)....3092
      Testing....3092
      Removal And Installation....3092
      Parts Identification....3094
      Disassembly And Assembly....3095
    MAIN RELIEF VALVE....3098
      Description....3098
      Testing With Auxiliaries....3098
      Testing Without Auxiliaries....3100
      Removal and Installation....3101
    HYDRAULIC CONTROL VALVE....3102
      Description....3102
      BICS Valve Removal And Installation....3102
      Identification Chart....3105
      Disassembly And Assembly....3106
      Load Check Valve Removal And Installation....3106
      Main Relief Valve Removal And Installation....3107
      Anti-Cavitation Check Valve Removal And Installation....3108
      Port Relief Valve Removal And Installation....3109
      Rubber Boot (Lift) Removal And Installation....3110
      Rubber Boot (Tilt) Removal And Installation....3110
      Rubber Boot (Auxiliary) Removal And Installation....3110
      Lift Spool And Detent Removal And Installation....3111
      Tilt Spool Removal And Installation....3115
      Auxiliary Spool And Detent Removal And Installation....3116
      One Way Restrictors Removal And Installation....3119
      Spool Seal Installation....3120
    LIFT ARM BY-PASS CONTROL VALVE....3122
      Description....3122
      Testing....3122
      Removal And Installation....3122
      Disassembly And Assembly....3123
    TILT LOCK VALVE....3124
      Description....3124
      Testing....3124
      Removal And Installation....3124
      Disassembly And Assembly....3125
    HYDRAULIC PUMP....3126
      Description....3126
      Direct Pump Testing....3126
      Removal And Installation....3127
      Parts Identification....3129
      Disassembly And Assembly....3130
    HYDRAULIC/HYDROSTATIC FILTER....3132
      Description....3132
      Housing Removal And Installation....3132
      Housing Disassembly And Assembly....3133
    HYDRAULIC FLUID RESERVOIR....3134
      Description....3134
      Removal And Installation....3134
      Hydrauilc Fluid Screen....3135
    OIL COOLER....3136
      Description....3136
      Removal And Installation....3136
  HYDROSTATIC SYSTEM....3138
    HYDROSTATIC SYSTEM INFORMATION....3140
      Troubleshooting....3140
      Description....3141
    HYDROSTATIC MOTOR....3142
      Description....3142
      Removal And Installation....3142
      Parts Identification....3144
      Disassembly And Assembly....3145
      Timing....3153
    PORT BLOCK....3154
      Description....3154
      Removal And Installation....3154
      Oil Cooler By-Pass Valve Removal And Installation....3154
      Hydraulic Oil Temperature Switch Removal And Installation....3154
      Charge Pressure By-Pass Valve Removal And Installation....3155
    HYDROSTATIC PUMP....3156
      Description....3156
      Checking Charge Pressure....3156
      Removal And Installation....3157
      Drive Coupler Removal And Installation....3160
      Parts Identification....3162
      Disassembly And Assembly....3163
      Inspection....3167
  DRIVE SYSTEM....3170
    PARKING BRAKE....3172
      Description....3172
      Disk Removal And Installation....3172
      Traction Lock Guides Removal And Installation....3173
    DRIVE COMPONENTS....3176
      Description....3176
      Axle Seal Removal And Installation....3176
      Chain Removal And Installation....3182
    CHAINCASE....3184
      Description....3184
      Front Cover Removal And Installation....3184
      Rear Cover Removal And Installation....3184
  MAIN FRAME....3186
    SEAT BAR....3188
      Description....3188
      Removal And Installation....3188
      Disassembly And Assembly....3191
      Compression Spring Disassembly And Assembly....3191
    OPERATOR CAB....3192
      Gas Cylinder Removal And Installation....3192
      Gas Cylinder Disassembly And Assembly....3193
      Removal And Installation....3193
    OPERATOR SEAT....3198
      Removal And Installation....3198
      Seat Belt Removal And Installation....3198
    BOB-TACH....3200
      Description....3200
      Removal And Installation....3200
      Lever And Wedge Disassembly And Assembly....3202
    LIFT ARM....3204
      Removal And Installation....3204
    REAR GRILL....3208
      Removal And Installation....3208
    REAR DOOR....3210
      Removal And Installation....3210
      Striker Removal And Installation....3211
      Striker Disassembly And Assembly....3211
      Striker Adjustment....3211
      Latch Removal And Installation....3212
    FUEL TANK....3214
      Removal And Installation....3214
      Fuel Level Sender Removal And Installation....3214
    CONTROL PEDALS AND LINKAGES....3216
      Description....3216
      Removal And Installation....3216
      Pedal Adjustment....3216
      Pedal Interlock Linkage Removal And Installation....3217
      Pedal Interlock Linkage Adjustment....3218
      Crossbar Linkage Removal And Installation....3218
    CONTROL PANEL....3220
      Description....3220
      Removal And Installation....3220
    CONTROL LEVER....3222
      Description....3222
      Lever Removal And Installation....3222
      Lever Disassembly And Assembly....3223
      Linkage Removal And Installation....3224
      Pintle Lever Removal And Installation....3226
      Pintle Lever Disassemby And Assembly....3226
    WINDOW (REAR)....3232
      Removal....3232
      Installation....3232
    WINDOW (TOP)....3234
      Removal....3234
      Installation....3234
    WINDOW (SIDE)....3236
      Removal And Installation....3236
    WINDOW (FRONT DOOR)....3238
      Removal (Standard Window)....3238
      Installation (Standard Window)....3238
      Removal And Installation (Special Applications Window)....3240
  ELECTRICAL SYSTEM & ANALYSIS....3242
    ELECTRICAL SCHEMATICS....3244
    ELECTRICAL SYSTEM INFORMATION....3248
      Glossary Of Electrical Symbols....3248
      Description....3252
      Troubleshooting....3253
      Fuse And Relay Location And Identification....3254
    BATTERY....3256
      Removal And Installation....3256
      Using A Booster Battery (Jump Starting)....3257
    ALTERNATOR....3260
      Belt Adjustment....3260
      Charging System Inspection....3260
      Alternator Voltage Testing....3261
      Low Voltage Testing....3262
      High Voltage Testing....3262
      Removal And Installation....3263
      Parts Identification....3264
    STARTER....3266
      Testing....3266
      Removal And Installation....3267
      Parts Identification....3268
    INSTRUMENT PANELS....3270
      Left And Right Removal And Installation....3270
    LIGHTS....3272
      Front Removal And Installation....3272
      Rear Removal And Installation....3273
      Cab Light Removal And Installation....3274
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....3276
      Description....3276
      Inspecting The BICS System (Engine STOPPED - Key ON)....3276
      Inspecting The Seat Bar Sensor (Engine RUNNING)....3276
      Inspecting The Traction Lock (Engine RUNNING)....3276
      Inspecting The Lift Arm By-Pass Control....3276
      Troubleshooting Chart....3277
      Troubleshooting....3278
      Removal And Installation....3279
    SEAT BAR SENSOR....3280
      Description....3280
      Troubleshooting....3280
      Testing....3281
      Removal And Installation....3282
      Bobcat Interlock Control System (BICS) Circuit Test....3284
    TRACTION LOCK....3286
      Description....3286
      Troubleshooting....3286
      Removal And Installation....3287
  ENGINE SERVICE....3290
    ENGINE INFORMATION....3294
      Description....3294
      Specifications....3295
      Torque Values....3299
      Troubleshooting....3300
      Engine Removal And Installation....3302
      Engine Mount Replacement....3307
      Compression - Checking....3308
    ENGINE SPEED CONTROL....3310
      Removal And Installation....3310
      Linkage Bar Removal And Installation....3311
    ENGINE SPEED CONTROL PLATE....3312
      Removal And Installation....3312
      Governor Spring Removal....3312
      Start Spring Removal....3312
      Idle Limit And Fuel Limit Adjustment....3313
    MUFFLER....3314
      Removal And Installation....3314
    AIR CLEANER....3316
      Housing Removal And Installation....3316
    ENGINE COOLING SYSTEM....3318
      Cooling Fan Removal And Installation....3318
      Radiator Removal And Installation....3319
      Water Pump Removal And Installation....3322
      Thermostat Housing Removal And Installation....3322
      Thermostat Testing....3323
    LUBRICATION SYSTEM....3324
      Oil Pan Removal And Installation....3324
      Oil Pump Removal And Installation....3324
      Oil Pump Inspection....3324
      Engine Oil Pressure - Testing....3325
    FUEL SYSTEM....3326
      Fuel Camshaft Removal And Installation....3326
      Fuel Camshaft Governor Disassembly And Assembly....3327
      Fuel Shutoff Solenoid, Removal And Installation....3332
      Fuel Lift Pump Removal And Installation....3332
      Fuel Injection Pump, Checking....3333
      Fuel Injection Pump Removal And Installation....3333
      Injection Pump - Timing....3336
      Fuel Injector Removal And Installation....3337
      Fuel Injector Nozzle Pressure - Checking....3339
      Nozzle Spray Condition....3340
      Valve Seat Tightness....3340
    CYLINDER HEAD....3342
      Glow Plugs - Testing....3342
      Glow Plugs Removal And Installation....3342
      Closed Breather System - Checking....3343
      Valve Clearance Adjustment....3344
      Valve Timing - Checking....3344
      Exhaust Manifold Removal And Installation....3345
      Cylinder Head Removal And Installation....3345
      Cylinder Head Disassembly And Assembly....3346
      Cylinder Head - Servicing....3347
      Cylinder Head Top Clearance....3348
      Valve Guide And Valve Checking....3349
      Reconditioning The Valve And Valve Seat....3351
      Valve Springs....3352
      Valve Tappets....3353
      Rocker Arm And Shaft Removal And Installation....3353
      Rocker Arm And Shaft Disassembly And Assembly....3353
      Rocker Arm And Shaft - Checking....3354
    CRANKSHAFT AND PISTONS....3356
      Piston And Connecting Rod Removal And Installation....3356
      Piston And Connecting Rod - Servicing....3357
      Cylinder Bore Checking....3361
      Connecting Rod Alignment....3361
      Crankshaft And Bearing Removal And Installation....3362
      Crankshaft And Bearing - Servicing....3363
    CAMSHAFT AND TIMING GEARS....3370
      Timing Gearcase Cover Removal And Installation....3370
      Timing Gears Backlash - Checking....3372
      Idler Gear And Shaft Removal And Installation....3373
      Idler Gear And Shaft Servicing....3373
      Camshaft Removal And Installation....3374
      Camshaft Servicing....3375
      Camshaft Gear Removal And Installation....3376
      Engine Timing Gear Alignment....3376
    FLYWHEEL AND HOUSING....3378
      Flywheel Removal And Installation....3378
      Ring Gear Removal And Installation....3378
      Housing Removal And Installation....3379
    RUBBER DRIVE COUPLER....3380
      Removal And Installation....3380
      Disassembly And Assembly....3380
    WATER FLANGE....3384
      Removal And Installation....3384
  HEATER....3386
    HEATER SYSTEM....3388
      Description....3388
    REGULAR MAINTENANCE....3390
      Filter Element Removal And Installation....3390
      Heater Coil....3390
    TROUBLESHOOTING....3392
      Electric System....3392
      Heater Valve Not Opening Or Closing....3392
      Blower Motor Does Not Operate....3392
      Blower Motor Operates Normally, But Air Flow Is Insufficient....3392
    HEATER UNIT....3394
      Removal And Installation....3394
    HEATER COIL....3396
      Removal And Installation....3396
    HEATER FAN....3398
      Blower Removal And Installation....3398
      Disassembly And Assembly....3398
    HEATER MOTOR....3400
      Removal And Installation....3400
    RESISTOR....3402
      Removal And Installation....3402
      Checking....3402
    HEATER VALVE....3404
      Removal And Installation....3404
    HEATER SWITCH....3406
      Removal And Installation....3406
      Checking The Switch....3407
  SPECIFICATIONS....3408
    553 LOADER SPECIFICATIONS....3410
      Dimensions....3410
      Performance....3411
      Controls....3411
      Engine....3411
      Hydraulic System....3412
      Electrical....3412
      Drive System....3413
      Capacities....3413
      Tires....3413
    TORQUE SPECIFICATIONS FOR BOLTS....3414
      Torque For General SAE Bolts....3414
      Torque For General Metric Bolts....3415
    HYDRAULIC CONNECTION SPECIFICATIONS....3416
      O-ring Face Seal Connection....3416
      Straight Thread O-ring Fitting....3417
      Tubelines And Hoses....3417
      Flare Fitting....3417
      O-ring Flare Fitting....3418
      Port Seal Fitting....3420
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....3422
      Specifications....3422
    CONVERSIONS....3424
      Decimal And Millimeter Equivalents....3424
      U.S. To Metric Conversion Chart....3424
  SMR....3426
    553-1....3426
    553-2....3428
6904705 (3-06) - 553 Skid-Steer Loader Service Manual....3430
  MAINTENANCE SAFETY....3432
  ALPHABETICAL INDEX....3434
  CONTENTS....3436
    FOREWORD....3437
    SAFETY INSTRUCTIONS....3440
      Fire Prevention....3442
    SERIAL NUMBER LOCATIONS....3444
      Loader Serial Number....3444
      Engine Serial Number....3444
    DELIVERY REPORT....3445
    LOADER IDENTIFICATION....3446
  SAFETY AND MAINTENANCE....3448
    LIFTING AND BLOCKING THE LOADER....3450
      Procedure....3450
    LIFT ARM SUPPORT DEVICE....3452
      Installing....3452
      Removing....3453
    OPERATOR CAB....3456
      Description....3456
      Raising....3456
      Lowering....3457
    TRANSPORTING LOADER ON A TRAILER....3458
      Loading And Unloading....3458
      Fastening....3458
    TOWING THE LOADER....3460
      Procedure....3460
    REMOTE START....3462
      Procedure....3462
    SERVICE SCHEDULE....3464
      Chart....3464
    AIR CLEANER SERVICE....3466
      Replacing Filter Elements....3466
    ENGINE COOLING SYSTEM....3468
      Cleaning....3468
      Checking....3469
      Removing And Replacing Coolant....3469
    FUEL SYSTEM....3472
      Fuel Specifications....3472
      Filling The Fuel Tank....3472
      Fuel Filter....3473
      Removing Air From The Fuel System....3473
    ENGINE LUBRICATION SYSTEM....3474
      Checking And Adding Engine Oil....3474
      Oil Chart....3474
      Removing And Replacing Oil And Filter....3475
    HYDRAULIC/HYDROSTATIC SYSTEM....3476
      Checking And Adding Fluid....3476
      Removing And Replacing The Hydraulic/Hydrostatic Filter....3476
      Removing And Replacing The Hydraulic/Hydrostatic Fluid....3477
    FINAL DRIVE TRANSMISSION (CHAINCASE)....3478
      Checking And Adding Oil....3478
      Removing Oil From Chaincase....3478
    AUXILIARY CONTROL LOCKBOLT....3480
      Procedure....3480
    BOB-TACH....3482
      Inspection And Maintenance....3482
    LUBRICATING THE BOBCAT....3484
      Lubrication Locations....3484
    TIRE MAINTENANCE....3486
      Wheel Nuts....3486
      Rotating....3486
      Mounting....3487
    SPARK ARRESTOR MUFFLER....3488
      Cleaning Procedure....3488
    PIVOT PINS....3490
      Inspection And Maintenance....3490
    SEAT BAR RESTRAINT SYSTEM....3492
      Inspection And Maintenance....3492
    RUBBER COUPLER LUBRICATION....3494
      Procedure....3494
    LOADER STORAGE AND RETURN TO SERVICE....3496
      Storage....3496
      Return to Service....3496
    STOPPING THE ENGINE AND LEAVING THE LOADER....3498
      Procedure....3498
      Emergency Exit....3499
  HYDRAULIC SYSTEM....3500
    HYDRAULIC/HYDROSTATIC SCHEMATICS....3502
    HYDRAULIC SYSTEM INFORMATION....3504
      Glossary Of Hydraulic / Hydrostatic Symbols....3504
      Troubleshooting Chart....3508
    CYLINDER (LIFT)....3510
      Testing....3510
      Removal And Installation....3511
      Parts Identification....3514
      Disassembly And Assembly....3515
    CYLINDER (TILT)....3518
      Testing....3518
      Removal And Installation....3518
      Parts Identification....3520
      Disassembly And Assembly....3521
    MAIN RELIEF VALVE....3524
      Description....3524
      Testing With Auxiliaries....3524
      Testing Without Auxiliaries....3526
      Removal and Installation....3527
    HYDRAULIC CONTROL VALVE....3528
      Description....3528
      BICS Valve Removal And Installation....3528
      Identification Chart....3531
      Disassembly And Assembly....3532
      Load Check Valve Removal And Installation....3532
      Main Relief Valve Removal And Installation....3533
      Anti-Cavitation Check Valve Removal And Installation....3534
      Port Relief Valve Removal And Installation....3535
      Rubber Boot (Lift) Removal And Installation....3536
      Rubber Boot (Tilt) Removal And Installation....3536
      Rubber Boot (Auxiliary) Removal And Installation....3536
      Lift Spool And Detent Removal And Installation....3537
      Tilt Spool Removal And Installation....3541
      Auxiliary Spool And Detent Removal And Installation....3542
      One Way Restrictors Removal And Installation....3545
      Spool Seal Installation....3546
    LIFT ARM BY-PASS CONTROL VALVE....3548
      Description....3548
      Testing....3548
      Removal And Installation....3548
      Disassembly And Assembly....3549
    TILT LOCK VALVE....3550
      Description....3550
      Testing....3550
      Removal And Installation....3550
      Disassembly And Assembly....3551
    HYDRAULIC PUMP....3552
      Description....3552
      Direct Pump Testing....3552
      Removal And Installation....3553
      Parts Identification....3555
      Disassembly And Assembly....3556
    HYDRAULIC/HYDROSTATIC FILTER....3558
      Description....3558
      Housing Removal And Installation....3558
      Housing Disassembly And Assembly....3559
    HYDRAULIC FLUID RESERVOIR....3560
      Description....3560
      Removal And Installation....3560
      Hydrauilc Fluid Screen....3561
    OIL COOLER....3562
      Description....3562
      Removal And Installation....3562
  HYDROSTATIC SYSTEM....3564
    HYDROSTATIC SYSTEM INFORMATION....3566
      Troubleshooting....3566
      Description....3567
    HYDROSTATIC MOTOR....3568
      Description....3568
      Removal And Installation....3568
      Parts Identification....3570
      Disassembly And Assembly....3571
      Timing....3579
    PORT BLOCK....3580
      Description....3580
      Removal And Installation....3580
      Oil Cooler By-Pass Valve Removal And Installation....3580
      Hydraulic Oil Temperature Switch Removal And Installation....3580
      Charge Pressure By-Pass Valve Removal And Installation....3581
    HYDROSTATIC PUMP....3582
      Description....3582
      Checking Charge Pressure....3582
      Removal And Installation....3583
      Drive Coupler Removal And Installation....3586
      Parts Identification....3588
      Disassembly And Assembly....3589
      Inspection....3593
  DRIVE SYSTEM....3596
    PARKING BRAKE....3598
      Description....3598
      Disk Removal And Installation....3598
      Traction Lock Guides Removal And Installation....3599
    DRIVE COMPONENTS....3602
      Description....3602
      Axle Seal Removal And Installation....3602
      Chain Removal And Installation....3608
    CHAINCASE....3610
      Description....3610
      Front Cover Removal And Installation....3610
      Rear Cover Removal And Installation....3610
  MAIN FRAME....3612
    SEAT BAR....3614
      Description....3614
      Removal And Installation....3614
      Disassembly And Assembly....3617
      Compression Spring Disassembly And Assembly....3617
    OPERATOR CAB....3618
      Gas Cylinder Removal And Installation....3618
      Gas Cylinder Disassembly And Assembly....3619
      Removal And Installation....3619
    OPERATOR SEAT....3624
      Removal And Installation....3624
      Seat Belt Removal And Installation....3624
    BOB-TACH....3626
      Description....3626
      Removal And Installation....3626
      Lever And Wedge Disassembly And Assembly....3628
    LIFT ARM....3630
      Removal And Installation....3630
    REAR GRILL....3634
      Removal And Installation....3634
    REAR DOOR....3636
      Removal And Installation....3636
      Striker Removal And Installation....3637
      Striker Disassembly And Assembly....3637
      Striker Adjustment....3637
      Latch Removal And Installation....3638
    FUEL TANK....3640
      Removal And Installation....3640
      Fuel Level Sender Removal And Installation....3640
    CONTROL PEDALS AND LINKAGES....3642
      Description....3642
      Removal And Installation....3642
      Pedal Adjustment....3642
      Pedal Interlock Linkage Removal And Installation....3643
      Pedal Interlock Linkage Adjustment....3644
      Crossbar Linkage Removal And Installation....3644
    CONTROL PANEL....3646
      Description....3646
      Removal And Installation....3646
    CONTROL LEVER....3648
      Description....3648
      Lever Removal And Installation....3648
      Lever Disassembly And Assembly....3649
      Linkage Removal And Installation....3650
      Pintle Lever Removal And Installation....3652
      Pintle Lever Disassemby And Assembly....3652
    WINDOW (REAR)....3658
      Removal....3658
      Installation....3658
    WINDOW (TOP)....3660
      Removal....3660
      Installation....3660
    WINDOW (SIDE)....3662
      Removal And Installation....3662
    WINDOW (FRONT DOOR)....3664
      Removal (Standard Window)....3664
      Installation (Standard Window)....3664
      Removal And Installation (Special Applications Window)....3666
  ELECTRICAL SYSTEM & ANALYSIS....3668
    ELECTRICAL SCHEMATICS....3670
    ELECTRICAL SYSTEM INFORMATION....3673
      Glossary Of Electrical Symbols....3673
      Description....3677
      Troubleshooting....3678
      Fuse And Relay Location And Identification....3679
    BATTERY....3681
      Removal And Installation....3681
      Using A Booster Battery (Jump Starting)....3682
    ALTERNATOR....3685
      Belt Adjustment....3685
      Charging System Inspection....3685
      Alternator Voltage Testing....3686
      Low Voltage Testing....3687
      High Voltage Testing....3687
      Removal And Installation....3688
      Parts Identification....3689
    STARTER....3691
      Testing....3691
      Removal And Installation....3692
      Parts Identification....3693
    INSTRUMENT PANELS....3695
      Left And Right Removal And Installation....3695
    LIGHTS....3697
      Front Removal And Installation....3697
      Rear Removal And Installation....3698
      Cab Light Removal And Installation....3699
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....3701
      Description....3701
      Inspecting The BICS System (Engine STOPPED - Key ON)....3701
      Inspecting The Seat Bar Sensor (Engine RUNNING)....3701
      Inspecting The Traction Lock (Engine RUNNING)....3701
      Inspecting The Lift Arm By-Pass Control....3701
      Troubleshooting Chart....3702
      Troubleshooting....3703
      Removal And Installation....3704
    SEAT BAR SENSOR....3705
      Description....3705
      Troubleshooting....3705
      Testing....3706
      Removal And Installation....3707
      Bobcat Interlock Control System (BICS) Circuit Test....3709
    TRACTION LOCK....3711
      Description....3711
      Troubleshooting....3711
      Removal And Installation....3712
  ENGINE SERVICE....3715
    ENGINE INFORMATION....3719
      Description....3719
      Specifications....3720
      Torque Values....3724
      Troubleshooting....3725
      Engine Removal And Installation....3727
      Engine Mount Replacement....3732
      Compression - Checking....3733
    ENGINE SPEED CONTROL....3735
      Removal And Installation....3735
      Linkage Bar Removal And Installation....3736
    ENGINE SPEED CONTROL PLATE....3737
      Removal And Installation....3737
      Governor Spring Removal....3737
      Start Spring Removal....3737
      Idle Limit And Fuel Limit Adjustment....3738
    MUFFLER....3739
      Removal And Installation....3739
    AIR CLEANER....3741
      Housing Removal And Installation....3741
    ENGINE COOLING SYSTEM....3743
      Cooling Fan Removal And Installation....3743
      Radiator Removal And Installation....3744
      Water Pump Removal And Installation....3747
      Thermostat Housing Removal And Installation....3747
      Thermostat Testing....3748
    LUBRICATION SYSTEM....3749
      Oil Pan Removal And Installation....3749
      Oil Pump Removal And Installation....3749
      Oil Pump Inspection....3749
      Engine Oil Pressure - Testing....3750
    FUEL SYSTEM....3751
      Fuel Camshaft Removal And Installation....3751
      Fuel Camshaft Governor Disassembly And Assembly....3752
      Fuel Shutoff Solenoid, Removal And Installation....3757
      Fuel Lift Pump Removal And Installation....3757
      Fuel Injection Pump, Checking....3758
      Fuel Injection Pump Removal And Installation....3758
      Injection Pump - Timing....3761
      Fuel Injector Removal And Installation....3762
      Fuel Injector Nozzle Pressure - Checking....3764
      Nozzle Spray Condition....3765
      Valve Seat Tightness....3765
    CYLINDER HEAD....3767
      Glow Plugs - Testing....3767
      Glow Plugs Removal And Installation....3767
      Closed Breather System - Checking....3768
      Valve Clearance Adjustment....3769
      Valve Timing - Checking....3769
      Exhaust Manifold Removal And Installation....3770
      Cylinder Head Removal And Installation....3770
      Cylinder Head Disassembly And Assembly....3771
      Cylinder Head - Servicing....3772
      Cylinder Head Top Clearance....3773
      Valve Guide And Valve Checking....3774
      Reconditioning The Valve And Valve Seat....3776
      Valve Springs....3777
      Valve Tappets....3778
      Rocker Arm And Shaft Removal And Installation....3778
      Rocker Arm And Shaft Disassembly And Assembly....3778
      Rocker Arm And Shaft - Checking....3779
    CRANKSHAFT AND PISTONS....3781
      Piston And Connecting Rod Removal And Installation....3781
      Piston And Connecting Rod - Servicing....3782
      Cylinder Bore Checking....3786
      Connecting Rod Alignment....3786
      Crankshaft And Bearing Removal And Installation....3787
      Crankshaft And Bearing - Servicing....3788
    CAMSHAFT AND TIMING GEARS....3795
      Timing Gearcase Cover Removal And Installation....3795
      Timing Gears Backlash - Checking....3797
      Idler Gear And Shaft Removal And Installation....3798
      Idler Gear And Shaft Servicing....3798
      Camshaft Removal And Installation....3799
      Camshaft Servicing....3800
      Camshaft Gear Removal And Installation....3801
      Engine Timing Gear Alignment....3801
    FLYWHEEL AND HOUSING....3803
      Flywheel Removal And Installation....3803
      Ring Gear Removal And Installation....3803
      Housing Removal And Installation....3804
    RUBBER DRIVE COUPLER....3805
      Removal And Installation....3805
      Disassembly And Assembly....3805
    WATER FLANGE....3809
      Removal And Installation....3809
  HEATER....3811
    HEATER SYSTEM....3813
      Description....3813
    REGULAR MAINTENANCE....3815
      Filter Element Removal And Installation....3815
      Heater Coil....3815
    TROUBLESHOOTING....3817
      Electric System....3817
      Heater Valve Not Opening Or Closing....3817
      Blower Motor Does Not Operate....3817
      Blower Motor Operates Normally, But Air Flow Is Insufficient....3817
    HEATER UNIT....3819
      Removal And Installation....3819
    HEATER COIL....3821
      Removal And Installation....3821
    HEATER FAN....3823
      Blower Removal And Installation....3823
      Disassembly And Assembly....3823
    HEATER MOTOR....3825
      Removal And Installation....3825
    RESISTOR....3827
      Removal And Installation....3827
      Checking....3827
    HEATER VALVE....3829
      Removal And Installation....3829
    HEATER SWITCH....3831
      Removal And Installation....3831
      Checking The Switch....3832
  SPECIFICATIONS....3833
    553 LOADER SPECIFICATIONS....3835
      Dimensions....3835
      Performance....3836
      Controls....3836
      Engine....3836
      Hydraulic System....3837
      Electrical....3837
      Drive System....3838
      Capacities....3838
      Tires....3838
    TORQUE SPECIFICATIONS FOR BOLTS....3839
      Torque For General SAE Bolts....3839
      Torque For General Metric Bolts....3840
    HYDRAULIC CONNECTION SPECIFICATIONS....3841
      O-ring Face Seal Connection....3841
      Straight Thread O-ring Fitting....3842
      Tubelines And Hoses....3842
      Flare Fitting....3842
      O-ring Flare Fitting....3843
      Port Seal Fitting....3845
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....3847
      Specifications....3847
    CONVERSIONS....3849
      Decimal And Millimeter Equivalents....3849
      U.S. To Metric Conversion Chart....3849
  SMR....3851
    553-1....3851
    
Bobcat 553 Skid-Steer Loaders Repair Service Manuals