Bobcat 453 Loader 6900363 (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
PREVENTIVE MAINTENANCE
– SERVICE SCHEDULE
– LIFTING AND BLOCKING THE LOADER
— Procedure
– TRANSPORTING THE LOADER
— Procedure
– TOWING THE LOADER
— Procedure
– LIFT ARM SUPPORT DEVICE
— Engaging The Lift Arm Support Device
— Disengaging The Lift Arm Support Device
– OPERATOR CAB
— Description
— Raising The Operator Cab
— Lowering The Operator Cab
— Emergency Exit
– SEAT BAR RESTRAINT SYSTEM
— Description
— Inspectng The Seat Bar
— Maintaining The Seat Bar
– AIR CLEANER SERVICE
— Replacing Filter Element
– FUEL SYSTEM
— Fuel Specifications
— Filling The Fuel Tank
— Fuel Filter
— Removing Air From The Fuel System
– ENGINE LUBRICATION SYSTEM
— Checking Engine Oil
— Oil Chart
— Replacing Oil and Filter
– ENGINE COOLING SYSTEM
— Checking The Coolant Level
— Cleaning The Cooling System
— Replacing the Coolant
– ALTERNATOR BELT
— Adjusting The Alternator Belt
– HYDRAULIC/HYDROSTATIC SYSTEM
— Checking And Adding Fluid
— Hydraulic/Hydrostatic Filter Replacement
— Replacing The Hydraulic/Hydrostatic Fluid
– SPARK ARRESTOR MUFFLER
— Cleaning Procedure
– TIRE MAINTENANCE
— Wheel Nuts
— Tire Rotation
— Tire Inflation
– FINAL DRIVE TRANSMISSION (CHAINCASE)
— Checking And Adding Oil
– AUXILIARY CONTROL LOCKBOLT
– LUBRICATING THE LOADER
— Procedure
– PIVOT PINS
– BOB–TACH
— Inspection And Maintenance
– REMOTE START SWITCH
— Procedure
HYDRAULIC SYSTEM
– HYDRAULIC SYSTEM INFORMATION
– HYDRAULIC / HYDROSTATIC SCHEMATICS
– TROUBLESHOOTING
— Chart
– LIFT CYLINDER(S)
— Checking The Lift Cylinders
— Removal And Installation
– TILT CYLINDER
— Checking The Tilt Cylinder
— Removal And Installation
– HYDRAULIC CYLINDERS
— Lift Cylinder Parts Identification
— Tilt Cylinder Parts Identification
— Disassembly And Assembly
– BICS™ BLOCK VALVE
— Removal And Installation
— Disassembly And Assembly
– MAIN RELIEF VALVE
— Checking The Main Relief Valve
— Checking The Main Relief Valve With Auxiliaries
— Removal And Installation
— Main Relief Valve Adjustment
– HYDRAULIC CONTROL VALVE
— 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
— Parts Identification
— Disassembly And Assembly
– HYDRAULIC RESERVOIR
— Removal And Installation
– HYDRAULIC FILTER BLOCK
— Removal And Installation
— Block Disassembly And Assembly
– PEDAL INTERLOCK LINKAGE
— Removal And Installation
– CONTROL PEDALS
— Removal and Installation
— Pedal Adjustment
HYDROSTATIC SYSTEM
– TROUBLESHOOTING
— Chart
– HYDROSTATIC SYSTEM INFORMATION
— Replenishing Valve Function
– CONTROL SHIELD 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
– HYDROSTATIC MOTOR
— Removal And Installation
— Parts Identification
— Disassembly
— Inspection
— Assembly
– DRIVE BELT
— Removal And Installation
– CHARGE PRESSURE
— Checking
– HYDROSTATIC PUMP
— Parts Identification
— Removal And Installation
— Disassembly And Assembly
— Inspection
– TENSION PULLEY AND SPRING
— Removal And Installation
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 CHAIN
– Removal And Installation
MAIN FRAME
– 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
– BATTERY
— Removal And Installation
— Servicing The Electrical System
— Using A Booster Battery (Jump Starting)
– ALTERNATOR
— Removal And Installation
— Adjusting The Alternator Belt
— Alternator Belt Removal And Installation
— Description
— Tests
— Alternator Output Test
— Full Field Test
— Alternator Regulator Test
— Alternator Regulator Test With Voltmeter
– STARTER
— Removal And Installation
— Checking The Starter In The Loader
— Parts Identification
— Disassembly
— Inspection And Repair
— No Load Test
— Assembly
– INSTRUMENT PANEL
— Removal And Installation
– FRONT LIGHTS (OPTIONAL)
— Removal And Installation
– REAR LIGHT (OPTIONAL)
— Removal And Installation
ENGINE SERVICE
– TROUBLESHOOTING
— Chart
– ENGINE SPEED CONTROL
— Adjustment
— Removal And Installation
– RADIATOR
— Removal And Installation
– RADIATOR MOUNTING BRACKET
— Removal And Installation
– FAN
— Removal And Installation
– FLYWHEEL
— Removal And Installation
– ENGINE MOUNTING BRACKET
— Removal And Installation
– VALVE CLEARANCE
— Ajustment
– FUEL INJECTION PUMP
— Checking The Injection Pump
— Removal
— Installation
— Timing Procedure
– FUEL INJECTOR NOZZLES
— Checking
— Removal
— Installation
– GLOW PLUGS
— Checking
– ENGINE COMPRESSION TEST
— Procedure
– ENGINE
— Removal And Installation
– CYLINDER HEAD
— Removal And Installation
— Inspection
— Top Clearance
– ROCKER ARM AND SHAFT
— Checking
– VALVE AND VALVE SPRINGS
— Valve Removal
— Checking Valve Spring
– VALVE GUIDE, VALVE AND VALVE SEAT
— Checking The Valve Guide
— Reconditioning The Valve And Valve Seat
– TIMING GEARCASE COVER
— Removal And Installation
– IDLER GEAR AND CAMSHAFT
— Removal And Installation
— Servicing The Idler Gear And Shaft
– TIMING GEARS
— Checking Backlash
– FUEL CAMSHAFT
— Removal And Installation
— Governor
– CRANKSHAFT GEAR
— Removal And Installation
– OIL PUMP
— Removal And Installation
— Oil Pump Service
— Checking Engine Oil Pressure
— Relief Valve
– PISTON AND CONNECTING ROD
— Removal And Installation
— Servicing The Piston And Connecting Rod
— Connecting Rod Alignment
– CRANKSHAFT AND BEARINGS
— Removal And Installation
— Inspection Of Crankshaft And Bearings
– CYLINDER BORE
— Inspection
– HYDRAULIC OIL COOLER AND SHROUDING
— Removal And Installation
– THERMOSTAT
— Removal And Installation
– WATER PUMP
— Removal And Installation
— Disassembly And Assembly
SYSTEMS ANALYSIS
– BICS™ (With Press To Operate Button)
— Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
— Inspecting The Seat Bar Sensor (Engine RUNNING)
— Inspecting The Traction Lock (Engine RUNNING)
— Inspecting The Lift Arm By–Pass Control
— Troubleshooting Chart
— Inspecting The BICSTM 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
– BICS™ SYSTEM CONTROLLER
— Troubleshooting Guide
— Removal And Installation
– SEAT BAR SENSOR
— Troubleshooting Guide
— Seat Bar Sensor Test
— Removal And Installation
— BICS™ Controller Seat Bar Sensor Circuit Test
– SEAT SENSOR
— Troubleshooting Guide
— Seat Sensor Test
— Removal And Installation
— BICS™ Controller Seat Sensor Circuit Test
– TRACTION LOCK
— Troubleshooting Guide
— Removal And Installation
SPECIFICATIONS
– SKID STEER LOADER SPECIFICATIONS
— PERFORMANCE
— CONTROLS
— ENGINE
— HYDRAULIC SYSTEM
— ELECTRICAL
— DRIVE SYSTEM
— CAPACITIES
— TIRES
— FLOOR PRESSURE
– ENGINE SPECIFICATIONS
— Engine
— Fuel Injector Nozzles
— Fuel Injection Pump
— Cylinder Head
— Valves
— Valve Springs
— Rocker Arms
— Camshaft
— Cylinders
— Piston Rings
— Pistons
— Crankshaft
— Oil Pump
— Thermostat
— ENGINE BOLT TORQUE
— Re–Grinding The Crankshaft
– 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
SERVICE MANUAL REVISIONS
– 453-1
– 453-2
– 453-3
– 453-4
– 453-5
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