Bobcat 450, 453 Loader 6724259 (6-12) (Preview)
MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
– FOREWORD
– SAFETY INSTRUCTIONS
– SERIAL NUMBER LOCATIONS
– LOADER SERIAL NUMBER
– ENGINE SERIAL NUMBER
– DELIVERY REPORT
– BOBCAT SKID STEER LOADER IDENTIFICATION
– OPTIONS AND ACCESSORIES
PREVENTIVE MAINTENANCE
– SERVICE SCHEDULE
– LIFTING AND BLOCKING THE LOADER
— Procedure
– TRANSPORTING THE LOADER
— Procedure
– LIFTING THE LOADER
— Single Point Lift
– TOWING THE LOADER
– LIFT ARM SUPPORT DEVICE
— Engaging The Lift Arm Support Device
— Disengaging The Lift Arm Support Device
– OPERATOR CAB
— Description
— Emergency Exit
— Raising The Operator Cab
— Lowering The Operator Cab
– SEAT BAR RESTRAINT SYSTEM
— Seat Bar Inspection
— Seat Bar Maintenance
— Foot Pedal Clean Out
– AIR CLEANER SERVICE
— 450 Loader
— 453 Loader
– FUEL SYSTEM
— 450 Loader
— Fuel Specifications
— Filling The Fuel Tank
— Fuel Filter
— 453 Loader
— Fuel Specifications
— Filling the Fuel Tank
— Fuel Filter
— Removing Air From The Fuel System
– ENGINE LUBRICATION SYSTEM
— 450 Loader
— Replacing Oil And Filter
— 453 Loader
— Replacing Oil And Filter
– ENGINE COOLING SYSTEM
— 450 Loader
— Cleaning The Cooling System
— 453 Loader
— Checking The Coolant Level
— Cleaning The Cooling System
— Removing Coolant From The Cooling System
– ALTERNATOR BELT ADJUSTMENT (453)
– ELECTRICAL SYSTEM
— Description
– PIVOT PINS
– SPARK ARRESTOR MUFFLER
— Cleaning The Spark Arrestor Muffler
– HYDRAULIC/HYDROSTATIC SYSTEM
— Checking And Adding Fluid
— Replacing The Hydraulic/Hydrostatic Filter Element
— Removing The Hydraulic/Hydrostatic Fluid
– FINAL DRIVE TRANSMISSION (CHAINCASE)
— Checking And Adding Oil
– AUXILIARY CONTROL LOCKBOLT
– TIRE MAINTENANCE
— Wheel Nuts
— Tire Rotation
— Tire Inflation
– LUBRICATING THE LOADER
– BOB–TACH
– REMOTE START SWITCH
— Procedure
HYDRAULIC SYSTEM
– HYDRAULIC / HYDROSTATIC SCHEMATICS
– TROUBLESHOOTING
– HYDRAULIC SYSTEM INFORMATION
— Tighten Procedures
– LIFT CYLINDER(S)
— Removal and Installation
— Checking The Lift Cylinder For Internal Leakage
– TILT CYLINDER
— Removal And Installation
— Checking The Tilt Cylinder For Internal Leakage
– HYDRAULIC CYLINDERS
— Disassembly And Assembly
— Lift Cylinder Identification
– LIFT ARM BY–PASS BLOCK
— Removal And Installation
— Disassembly And Assembly
– HYDRAULIC CONTROL VALVE
— Checking The Main Relief Valve
— Main Relief Valve Removal And Installation
— Main Relief Valve Adjustment
— Removal And Installation
— Identification Chart
— Disassembly And Assembly
— Load Check Valve
— Main Relief Valve
— Anti–Cavitation Valve
— Rubber Boot
— Lift Spool Detent
— Tilt Centering Spring
— Auxiliary Spool Detent
— Spool Seal Installation
– HYDRAULIC PUMP
— Checking The Output Of The Hydraulic Pump
— Removal And Installation
— Disassembly And Assembly
— Parts Identification
– HYDRAULIC RESERVOIR
— Removal And Installation
– HYDRAULIC FILTER BLOCK
— Removal And Installation
— Disassembly And Assembly
— 450 Filter Block
— 453 Filter Block
– PEDAL INTERLOCK LINKAGE
— Removal And Installation
– CONTROL PEDALS
— Removal And Installation
— Pedal Adjustment
HYDROSTATIC SYSTEM
– TROUBLESHOOTING
– HYDROSTATIC SYSTEM INFORMATION
— Replenishing Valve Function
– CONTROL SHIELD AND STEERING LEVER PANELS
— Removal And Installation
– STEERING LEVERS AND STEERING LEVER PANELS
— Removal And Installation
– STEERING LEVERS
— Removal And Installation
— Disassembly And Assembly
– STEERING LINKAGE
— Adjustment
— Pintle Arm Removal And Installation
— Pintle Arm Disassembly And Assembly
– DRIVE BELT
— Removal And Installation
— 450 Loader
— 453 Loader
– HYDR0STATIC PUMP
— Checking Charge Pressure
— Removal And Installation
— 450 Loader
— 453 Loader
— Parts Identification
— Disassembly And Assembly
— Inspection
– TENSION PULLEY AND SPRING
– Removal And Installation
– HYDROSTATIC MOTOR
— Removal And Installation
— Parts Identification
— Disassembly
— Inspection
— Assembly
DRIVE SYSTEM
– PARKING BRAKE PEDAL
— Removal And Installation
— Disassembly And Assembly
– CHAINCASE FLUID
— Removing Oil From The Chaincase
– CHAINCASE COVER
— Removal And Installation
— Disassembly And Assembly
– PARKING BRAKE DISC
— Removal And Installation
– AXLE HUB
— Removal And Installation
– AXLE SEAL
— Removal And Installation
– AXLE, BEARINGS, AND SPROCKET
— Removing The Axle
— Removing And Installing The Axle Bearing
— Removing The Bearing Races
— Installing The Bearing Races
— Installing The Inner Bearing And Axle Sprocket
– DRIVE CHAINS
— Removal And Installation
MAIN FRAME
– SEAT BAR
— Gas Spring Removal And Installation
— Compressing The Gas Spring
— Seat Bar Removal And Installation
— Assembly
– OPERATOR CAB
— Removal And Installation
– OPERATOR CAB GAS CYLINDER
— Removal And Installation
– OPERATOR SEAT
— Removal And Installation
– BOB–TACH
— Removal
— Installation
— Seal Removal And Installation
— Lever And Wedge Removal
— Lever And Wedge Installation
– LIFT ARMS
— Removal And Installation
– FUEL TANK
— Removal And Installation
– REAR WINDOW
— Removal And Installation
– REAR DOOR
— Exhaust Pipe Removal And Installation
— Removal And Installation
ELECTRICAL SYSTEM
– ELECTRICAL SCHEMATICS
– TROUBLESHOOTING
— Chart
– ELECTRICAL SYSTEM INFORMATION
— Description
— Fuse Location
— Relay Switches Location – 453 Only
– BATTERY
— Removal And Installation
— Maintenance
– ALTERNATOR (450)
— Checking The Alternator Circuit (450)
— Replacing The Stator
– ALTERNATOR (453)
— Removal And Installation
— Adjusting The Alternator Belt
— Alternator Output Test
— Alternator Regulator Test
— Disassembly and Inspection – Parts Identification
— Stator Continuity Test
— Stator Ground Test
— Rotor Continuity Test
— Rotor Ground Test
— Rectifier Continuity (Diode) Test
— Assembly
– STARTER (453)
— Removal And Installation
— Checking The Starter
— Parts Identification
— Disassembly, Assembly And Inspection
– STARTER (450)
— Checking The Starter
— Removal And Installation
— Disassembly, Assembly And Inspection
– INSTRUMENT PANEL
— Removal And Installation
– FRONT LIGHTS (OPTIONAL)
— Removal And Installation
– REAR LIGHT (OPTIONAL)
— Removal And Installation
ENGINE SERVICE
– ENGINE SERVICE (450)
— TROUBLESHOOTING
— IGNITION SYSTEM
— Spark Plugs
— Ignition Module Air Gap
— Testing Ignition Module Primary
— Testing Ignition Module Secondary
— Valve & Tappet Clearance
— Compression Test
— CARBURETOR AND GOVERNOR
— Carburetor Adjustment On The Engine
— Main Fuel Adjustment
— Idle Fuel Adjustment
— Idle Speed Setting
— Shutdown Control Solenoid
— Governor And Adjustment
— Disassembly And Assembly
— ENGINE
— Removal And Installation
— Muffler Removal And Installation
— Intake Manifold Removal And Installation
— Breather and Valve Cover Removal And Installation
— Fuel Pump Removal And Installation
— ENGINE DISASSEMBLY
— Flywheel Removal And Installation
— Stator Removal and Installation
— Cylinder Head Removal
— Cylinder Barrel Removal
— Cylinder Barrel Inspection And Resizing
— Valve Removal And Installation
— Valve Guide Removal And Installation
— Valve Seat Insert Removal
— Valve Seat Insert Installation
— Valve Details
— Piston And Piston Rings
— Closure Plate
— Crankcase Halves
— Camshaft Removal
— Crankshaft Removal
— Connecting Rod Removal
— Governor Gear And Cross Shaft Removal
— Oil Pickup Removal
— OIl Pump Removal
— ENGINE ASSEMBLY
— Oil Pump Installation
— Cross Shaft And Governor Shaft Installation
— Connecting Rod Installation
— Crankshaft And Bearing Installation
— Tappets And Camshaft Installation
— Sealing The Crankcase
— Recommended Sealants
— Installing Camshaft Bore Plug
— Installing Crankcase Halves
— Front And Rear Seal Installation
— Filter Adapter Installation
— Installing Oil Pressure Relief Valve And Closure Plate
— Piston Installation
— Setting Valve To Tappet Clearance
— Cylinder Head Installation
– ENGINE SERVICE 453 (KUBOTA)
— TROUBLESHOOTING
— FUEL SYSTEM
— Replacing The Fuel Filter
— Removing The Air From The Fuel System
— Fuel Injection Pump
— Checking The Injection Pump
— Removing The Injection Pump
— Installing The Injection Pump
— Timing The Injection Pump
— Fuel Injector Nozzles
— Removing The Fuel Injector Nozzle
— Checking Fuel Injector Nozzles
— Installing The Fuel Injector Nozzle
— Checking Glow Plugs
— Engine Compression Test
— OIL COOLER & SHROUDING
— Removal And Installation
— RADIATOR
— Removal And Installation
— ENGINE SPEED CONTROL
— Adjustment
— Removal And Installation
— ENGINE
— Removal And Installation
— FLYWHEEL
— Removal And Installation
— FAN
— Removal And Installation
— CYLINDER HEAD
— Removing The Cylinder Head
— Disassembly Of The Cylinder Head
— Servicing The Cylinder Head
— Assembly Of The Cylinder Head
— Installing The Cylinder Head
— REPAIRING THE ENGINE
— Removing The Gearcase
— Removing The Timing Gear, Camshaft & Oil Pump
— Removing Pistons & Crankshaft
— Servicing The Timing Gear And Camshaft
— Servicing The Connecting Rods And Pistons
— Servicing The Crankshaft
— Servicing The Cylinder Liners
— Servicing The Oil Pump
— Servicing The Water Pump
— ASSEMBLY OF THE ENGINE
— Installing The Crankshaft
— Installing The Pistons
— Installing The Camshaft And Timing Gears
— Installing The Gearcase Cover
SYSTEMS ANALYSIS
– BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM)
— Inspecting The BICS™ System Controller (Engine STOPPED – Key ON)
— Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
— Inspecting The Traction Lock (Engine Running)
— Inspecting The Lift Arm By–Pass Control
— Maintenance
— Troubleshoot Chart
— Troubleshooting Guide
— BICS CONTROLLER
— TRACTION LOCK
— SEAT SENSOR
— SEAT BAR SENSOR
— LIFT LOCK BYPASS VALVE
– BICS™ SYSTEM CONTROLLER
— Removal And Installation
— Controller Test
– SEAT BAR SENSOR
— Removal And Installation
— Seat Bar Sensor Test
– SEAT SENSOR
— Removal And Installation
— Seat Sensor Test
– TRACTION LOCK
— Removal And Installation
– LIFT ARM BY–PASS BLOCK
— Removal And Installation
– LIFT AND TILT LOCK BY–PASS VALVE
— Disassembly And Assembly
SPECIFICATIONS
– 450 LOADER SPECIFICATIONS
— PERFORMANCE
— CONTROLS
— ENGINE
— HYDRAULIC SYSTEM
— ELECTRICAL
— DRIVE SYSTEM
— CAPACITIES
— TIRES
– ENGINE SPECIFICATIONS – 450 (KOHLER)
— Engine (General)
— Cylinder Bore
— Crankshaft
— Camshaft
— Connecting Rod
— Piston, Pin & Rings
— Valves, Guides & Tappet
— Oil Pump
— Engine Torque
– 453 LOADER SPECIFICATIONS
— PERFORMANCE
— CONTROLS
— ENGINE
— HYDRAULIC SYSTEM
— ELECTRICAL
— DRIVE SYSTEM
— CAPACITIES
— TIRES
– ENGINE SPECIFICATIONS – 453 (KUBOTA)
— Fuel Injector Nozzles
— Fuel Injection Pump
— Cylinder Head
— Valves
— Valve Springs
— Rocker Arms
— Camshaft
— Cylinders
— Piston Rings
— Pistons
— Crankshaft
— Oil Pump
— Thermostat
— Crankshaft Re–Grind Data
— Engine Torque
– TORQUE SPECIFICATIONS FOR BOLTS
— Torque For General SAE Bolts
— Torque For General Metric Bolts
– HYDRAULIC CONNECTION SPECIFICATIONS
— O–ring Face Seal Connection
— Straight Thread O–ring Fitting
— Tubelines And Hoses
— Flare Fitting
— O–ring Flare Fitting
— Port Seal Fitting
– HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
— Specifications
– DECIMAL AND MILLIMETER EQUIVALENTS
– U.S. TO METRIC CONVERSION
– GLOSSARY OF HYDRAULIC SYMBOLS
SERVICE MANUAL REVISIONS
– 450/453-1
– 450/453-2
– 450/453-3
– 450/453-4
– 450/453-5
– 450/453-6
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