Bobcat S550 B4ZD11001 & Up 7417391 (Preview)
MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrester Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT
Description
Installing
Removing
OPERATOR CAB
Description
Cab Door Sensor
Raising
Lowering
Special Applications Kit
Special Applications Kit Inspection And Maintenance
Forestry Door And Window Kit
Forestry Door And Window Kit Inspection And Maintenance
TRANSPORTING THE LOADER ON A TRAILER
Loading And Unloading
Fastening
TOWING THE LOADER
Procedure
REMOTE START TOOL KIT – MEL1563
Remote Start Tool – MEL1563
Service Tool Harness Communicator – MEL1566
Remote Start Procedure
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666
Description
Remote Start Tool (Service Tool) – 7022042
Loader Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
Remote Start Procedure
SERVICE SCHEDULE
Maintenance Intervals
ENGINE AIR CLEANER
Replacing Filters
ENGINE COOLING SYSTEM
Maintenance Platform
Cleaning
Checking And Adding Coolant
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filter
Replacing Fuel Pre-Filter
Replacing Main Fuel Filter
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic / Hydrostatic Fluid Chart
Removing And Replacing Hydraulic Fluid
Removing And Replacing Hydraulic / Hydrostatic Filter
Removing And Replacing Hydraulic Charge Filter
Replacing Reservoir Breather Cap
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Fluid
Removing And Replacing Fluid
BOB-TACH (HAND LEVER)
Inspection And Maintenance
BOB-TACH (POWER)
Inspection And Maintenance
LUBRICATING THE LOADER
Lubrication Locations
TIRE MAINTENANCE
Wheel Nuts
Rotating
Mounting
PIVOT PINS
Inspection And Maintenance
LOADER STORAGE AND RETURN TO SERVICE
Storage
Return To Service
STOPPING THE ENGINE AND LEAVING THE LOADER
Procedure
EMERGENCY EXIT
Rear Window Identification
Rear Window Removal (Latches)
Rear Window Removal (Rubber Cord)
External Access (Rear Window With Latches)
External Access (Rear Window With Rubber Cord)
Front Door
SEAT BELT
Inspection And Maintenance
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting
CYLINDER (LIFT)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (TILT)
Testing
Removal And Installation
Base End Pivot Pin Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BOB-TACH)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Description
Testing
Adjusting
Removal And Installation
HYDRAULIC CONTROL VALVE (STANDARD)
Description
Removal And Installation
Mount Bracket Removal And Installation
Identification Chart
Lift Load Check Valve Removal And Installation
Load Check Valve Removal And Installation (Tilt And Auxiliary)
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)
Port Relief Valve Removal And Installation
Plug Removal And Installation
Rubber Boot Removal And Installation
End Cap Block Removal And Installation
Lift Spool And Detent Removal And Installation
Tilt Spool Removal And Installation
Auxiliary Spool Removal And Installation
Auxiliary Solenoid Removal And Installation
Solenoid Removal And Installation
Lock Valve Removal And Installation
Lift Arm Bypass Orifice Removal And Installation
Main Relief Valve Removal And Installation
Check Valve Removal And Installation
HYDRAULIC CONTROL VALVE (SJC)
Description
Removal And Installation
Actuator Removal And Installation (In Loader)
Actuator Removal And Installation (Out Of Loader)
Identification Chart
Mount Bracket Removal And Installation
Lift Load Check Valve Removal And Installation
Load Check Valve Removal And Installation (Tilt And Auxiliary)
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)
Port Relief Valve Removal And Installation
Plug Removal And Installation
End Cap Block Removal And Installation
Lift Spool Removal And Installation
Lift Spool Disassembly And Assembly
Tilt Spool Removal And Installation
Auxiliary Spool Removal And Installation
Auxiliary Solenoid Removal And Installation
Solenoid Removal And Installation
Lock Valve Removal And Installation
Lift Arm Bypass Orifice Removal And Installation
Main Relief Valve Removal And Installation
Check Valve Removal And Installation
LIFT ARM BYPASS CONTROL VALVE
Description
Testing
Removal And Installation
Bracket Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP
Description
Pump Test At Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Removal And Installation
Hydraulic Pump Startup
Parts Identification
Disassembly And Assembly
HYDRAULIC PUMP (HIGH FLOW)
Description
Pump Test At Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Direct Pump Test (High Flow Section)
High Flow Relief Valve Adjustment
High Flow Relief Valve Removal And Installation
Solenoid Removal And Installation
Removal And Installation
Hydraulic Pump Startup
Parts Identification
Disassembly And Assembly
HYDRAULIC / HYDROSTATIC FILTERS
Description
Housing Removal And Installation
HYDRAULIC FLUID RESERVOIR
Description
Removal And Installation
Hydraulic Fluid Screen
OIL COOLER
Removal And Installation
BUCKET POSITION VALVE
Description
Removal And Installation
Solenoid Testing
Disassembly And Assembly
REAR AUXILIARY DIVERTER VALVE
Description
Solenoid Testing
Removal And Installation
Disassembly And Assembly
BOB-TACH (POWER) BLOCK
Description
Testing Relief Valve
Removal And Installation
Disassembly And Assembly
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Description
Removal And Installation
Disassembly And Assembly
AUTOMATIC RIDE CONTROL
Description
Removal And Installation
Checking The Pressure In The Accumulator
Adding Nitrogen To The Accumulator
HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Description
Troubleshooting
HYDROSTATIC DRIVE MOTOR
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
Description
Removal And Installation (Left Side)
Removal And Installation (Right Side)
Parts Identification
Disassembly
Assembly
HYDROSTATIC MOTOR CARRIER
Description
Shaft Seal Removal And Installation
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDROSTATIC MOTOR CARRIER (TWO-SPEED)
Description
Shaft Seal Removal And Installation
Removal And Installation
Parts Identification
Disassembly
Assembly
CHARGE PRESSURE
Description
Testing
Adjusting
Sender Removal And Installation (Earlier Models)
Sender Removal And Installation (Later Models)
HYDROSTATIC PUMP
Description
Removal And Installation
Hydrostatic Pump Startup
Replenishing / High Pressure Relief Valve Removal And Installation
Parts Identification (Left Half)
Parts Identification (Right Half)
Disassembly
Assembly
HYDROSTATIC PUMP (SJC)
Description
Port Locations And Gauge Installation
Removal And Installation
Hydrostatic Pump Startup
Parts Identification
High Pressure Relief And Bypass Valve
Charge Pressure Relief Valve
Disassembly And Assembly
Mechanical Neutral Adjustment
Hydraulic Controller Neutral Adjustment
DRIVE BELT
Belt Adjustment
Stop Adjustment
Belt Replacement
Tensioner Pulley Removal And Installation (Earlier Models)
Tensioner Pulley Disassembly And Assembly
Tensioner Pulley Removal And Installation (Later Models)
Tensioner Pulley Disassembly And Assembly
TWO-SPEED
Valve Block Removal And Installation
Valve Block Disassembly And Assembly
DRAIN MANIFOLD
Description
Drain Manifold Removal And Installation
DRIVE SYSTEM
BRAKE
Description
Disc Removal And Installation
DRIVE COMPONENTS
Description
Axle Seal Removal And Installation
Axle, Sprocket And Bearings Removal And Installation
Chain Removal And Installation
CHAINCASE
Description
Front Cover Removal And Installation
Center Cover Removal And Installation
Rear Cover Removal And Installation
MAINFRAME
SEAT BAR
Description
Removal And Installation
Disassembly And Assembly
Compression Spring Disassembly And Assembly
OPERATOR CAB
Gas Spring Removal And Installation
Gas Spring Bracket Disassembly And Assembly
Removal And Installation
OPERATOR SEAT
Removal And Installation
Seat Belt Removal And Installation (Retractable)
Seat Belt And Bracket Removal And Installation (Standard)
Seat Belt Bracket Removal And Installation
OPERATOR SEAT (SUSPENSION)
Removal And Installation
Slide Rail Removal And Installation
Seat Belt Removal And Installation
Lower Cushion Removal
Lower Cushion Installation
Back Cushion Removal And Installation
Shock Removal And Installation
3-Point Seat Belt Removal And Installation
BOB-TACH (HAND LEVER)
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
BOB-TACH (POWER)
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
LIFT ARMS
Stabilizer Bar Removal And Installation
REAR GRILLE
Removing
Installing
Shield Removal And Installation
REAR DOOR (TAILGATE)
Removal And Installation
Striker Removal And Installation
Striker Disassembly And Assembly
Striker Adjusting
Latch Removal And Installation
FUEL TANK
Removal And Installation
Fuel Level Sender Removal And Installation
CONTROL PEDALS AND LINKAGES
Description
Pedal Removal And Installation
Linkage Removal And Installation
Pedal (Adjusting)
Floor Pan Removal And Installation
CONTROL PANEL
Description
Removal And Installation
Disassembly And Assembly
Linkage Removal And Installation
Pintle Arm Disassembly And Assembly
Linkage Neutral (Adjusting)
Linkage Travel (Adjusting)
Shock Removal And Installation
CONTROL PANEL (SJC)
Description
Removal And Installation
CONTROL HANDLE / LEVER
Description
Lever Removal And Installation
Boot Removal And Installation
CONTROL HANDLE / LEVER (SJC)
Description
Joystick Testing
Joystick Removal And Installation
ACCESS PANEL (INSIDE)
Removal And Installation (Left)
Removal And Installation (Right)
ACCESS PANEL (INSIDE) (SJC)
Removal And Installation (Left)
Removal And Installation (Right)
WINDOW (REAR)
Rear Window Identification
Rear Window Removal (Latches)
Rear Window Removal (Rubber Cord)
External Access (Rear Window With Latches)
External Access (Rear Window With Rubber Cord)
Disassembly And Assembly (Latches)
WINDOW (TOP)
Removal And Installation
WINDOW (SIDE)
Removal And Installation
CAB DOOR
Description
Removal And Installation
Disassembly And Assembly
Aligning
Adjusting
Checking Operation
ARMREST
Description
Removal And Installation
Disassembly And Assembly
LEFT SIDE LOWER PANEL
Removal And Installation
Disassembly And Assembly
RIGHT SIDE LOWER PANEL
Removal And Installation
Disassembly And Assembly
HEADLINER
Removal And Installation
FAN DUCT PANELS
Removal And Installation
ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Standard Cab Harness Connectors
Deluxe Cab Harness Connectors
Mainframe Harness Connectors
Description
Troubleshooting
Fuse And Relay Location / Identification
Solenoid Testing
BATTERY
Removal And Installation
Battery Maintenance
Maintaining Battery Charge Level
Battery Service During Machine Storage
Battery Testing
Battery Charging
Using A Booster Battery (Jump Starting)
ALTERNATOR
Belt Adjustment
Belt Replacement
Charging System Inspection
Alternator Voltage Testing
Low Voltage Testing
High Voltage Testing
Removal And Installation
Parts Identification
STARTER
Testing
Removal And Installation
Parts Identification
INSTRUMENT PANEL IDENTIFICATION
Overview
Left Panel
Display Screen
Right Panel
Left Switch Panel
Right Switch Panel
Left Side Lower Panel
Right Side Lower Panel
Left Panel Removal And Installation
Right Panel Removal And Installation
Key Switch Disassembly And Assembly
Alarm Disassembly And Assembly
Left Switch Panel Removal And Installation
Right Switch Panel Removal And Installation
LIGHTS
Front Removal And Installation
Rear Removal And Installation
Cab Light Removal And Installation
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)
Description
Connector Identification
Removal And Installation
BOBCAT CONTROLLER (SJC) (DRIVE)
Description
Connector Identification
Removal And Installation
ENGINE CONTROL UNIT (ECU)
Description
Cleaning
Removal And Installation
DIAGNOSTIC SERVICE CODES
Viewing Service Codes
Service Codes List
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Description
Inspecting The BICS™ (Engine STOPPED – Key ON)
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
Inspecting The Seat Bar Sensor (Engine RUNNING)
Inspecting The Traction Lock And Parking Brake (Engine RUNNING)
Inspecting The Lift Arm Bypass Control
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)
Troubleshooting
SEAT BAR SENSOR
Description
Troubleshooting
Testing
Removal
Installation
Bobcat Interlock Control System (BICS™) Circuit Test
TRACTION LOCK
Description
Troubleshooting
Inspecting
ELECTRICAL / HYDRAULIC CONTROLS (MANUAL)
Identification Chart
Description
Identification Chart ACD Group 0
Identification Chart ACD Group 1
Identification Chart ACD Group 2
Identification Chart ACD Group 3
ELECTRICAL / HYDRAULIC CONTROLS (SJC)
Identification Chart
Description
Identification Chart ACD Group 0
Identification Chart ACD Group 1
Identification Chart ACD Group 2
Identification Chart ACD Group 3
SERVICE PC (LAPTOP COMPUTER)
Connecting Remote Start Tool (Service Tool)
CALIBRATION
Description
Actuator Testing
Lift And Tilt Calibration (SJC)
Hydrostatic Pump Calibration (SJC)
STEERING DRIFT COMPENSATION (OPERATOR MODE)
Description
Operation
STEERING DRIFT COMPENSATION (SERVICE MODE)
Description
Operation
CONTROL PANEL SETUP
Right Panel Setup (Deluxe Instrumentation Panel)
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)
Password Description
Changing The Owner Password
Changing The User Passwords
Password Lockout Feature
MAINTENANCE CLOCK
Description
Setup
Reset
BACK-UP ALARM SYSTEM
Description
Inspecting
Adjusting Switch Position
Troubleshooting (Standard)
Troubleshooting (Joystick)
Alarm Removal And Installation
Switch Removal And Installation
FRONT HORN
Removal And Installation
Troubleshooting
Troubleshooting (Joystick)
ENGINE SPEED CONTROL (HAND)
Removal And Installation
ENGINE SPEED CONTROL (FOOT)
Removal And Installation
Disassembly And Assembly
Foot Throttle Calibration
CAMSHAFT AND CRANKSHAFT POSITION SENSOR
Removal And Installation
MACHINE IQ
Description
Removal And Installation
Procedure
ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Sensor Location
Torque Values
Troubleshooting
Engine Removal And Installation
Engine Mount Replacement
Compression – Testing
Injector Signal – Testing
Injector Signal – Testing (In-Line)
DIESEL PARTICULATE FILTER (DPF) SYSTEM
Description
Removal And Installation
DPF Icons
DPF Regeneration Tables
Automatic Regeneration Operation
Forced Regeneration Operation
Forced Parked Regeneration Operation
Inhibit Mode Operation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Radiator / Oil Cooler Removal And Installation
Hydraulic Fan Description
Reversible Hydraulic Fan Description
Fan Duct Removal And Installation
Hydraulic Fan Motor Assembly Removal And Installation
Hydraulic Fan Motor Removal And Installation
Hydraulic Fan Motor Disassembly And Assembly
Blower Housing Removal And Installation
Water Pump Removal And Installation
Thermostat Housing Removal And Installation
Testing The Thermostat
LUBRICATION SYSTEM
Description
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Relief Valve Description
Oil Pump Relief Valve Removal And Installation
Oil Cooler Removal And Installation
Oil Filter Head Removal And Installation
Oil Cooler Bypass Description
Oil Cooler Bypass Removal And Installation
FUEL SYSTEM
Description
Fuel Filter Housing Removal And Installation
Fuel Lift Pump Removal And Installation
Transfer Pump / High Pressure Pump Removal And Installation
Fuel Temperature Sensor Removal And Installation
Fuel Cooler Removal And Installation
Fuel Recirculation Valve (FRV) Removal And Installation
Fuel Injector Removal And Installation
Injector Coding
CYLINDER HEAD
Glow Plugs Testing
Glow Plug Removal And Installation
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head Inspection
Cylinder Head Top Clearance
Valve Step Height
Valve Stem Height
Valve Guide
Valve
Valve Spring
Rocker Arm Shaft Disassembly And Assembly
Rocker Arm Shaft Inspection
Push Rod Inspection
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Inspection
Crankshaft Removal And Installation
Cylinder Block Inspection
Crankshaft Inspection
Connecting Rod Inspection
Engine Component Class
CAMSHAFT
Removal And Installation
Inspecting
GEARCASE
Gearcase Cover Removal And Installation
Gear Backlash
Gear Timing
Idle Gear Removal And Installation
Idle Gear Inspection
TURBOCHARGER
Description
Removal And Installation
Inspection
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
Removal And Installation
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Filters
Belt Adjustment
Belt Replacement
Air Conditioning Condenser
Air Conditioning Lubrication
Air Conditioning Service Chart
Evaporator / Heater Coil
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Does Not Operate At All, Or Operates Improperly
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
Temperature / Pressure Chart
Poor A/C Performance
HVAC Repair And Leaks
Electrical System
Engine Coolant Bypassing The Heater Valve
Heater Valve Not Opening Or Closing
SYSTEM CHARGING AND RECLAMATION
Refrigerant Identification
Reclamation And Charging With Recovery / Charging Unit
COMPRESSOR
Removal And Installation
Oil
Oil Check
CONDENSER
Removal And Installation
RECEIVER / DRIER
Receiver / Drier Removal And Installation
Pressure Switch Removal And Installation
Schrader® Valve Removal And Installation
EVAPORATOR / HEATER UNIT
Removal And Installation
THERMOSTAT
Description
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR COIL
Removal And Installation
HEATER COIL
Removal And Installation
BLOWER FAN
Removal And Installation
Disassembly And Assembly
HEATER VALVE
Removal And Installation
EVAPORATOR / HEATER COVER
Removing
Installing
SPECIFICATIONS
(S550) LOADER SPECIFICATIONS
Machine Dimensions
Performance
Engine
Drive System
Controls
Hydraulic System
Electrical System
Capacities
Tires
Environmental
Engine CO2 Emission Values
Temperature Range
TECHINCAL SERVICE GUIDE SPECIFICATIONS
Engine
Engine Torques
Cooling System
Loader Torques
Hydraulic / Hydrostatic System
Fuel Consumption
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
Straight Thread O-ring Fitting
Flare Fitting
Tubelines And Hoses
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart
SERVICE TOOLS REQUIRED
Remote Start Tools
Hydraulic Tools
Mainframe And Drive Tools
Electrical Tools
Engine Tools
HVAC Tools
ALPHABETICAL INDEX
Keep your Bobcat S550 running like a pro with this official service manual for machines B4ZD11001 & Up (Manual No. 7417391). Designed with technicians in mind, this manual dives deep into every essential system—from hydraulics and engine components to electrical schematics and troubleshooting charts. Whether you’re tackling routine maintenance or in-depth repairs, you’ll find crystal-clear instructions and detailed diagrams to guide your work confidently.
Built specifically for the S550 model, this manual isn’t just a generic guide—it’s tailored to match your machine’s unique build and performance needs. Ideal for workshop pros and hands-on owners alike, it’s your all-in-one reference for maximizing uptime and reducing guesswork. With this manual in hand, you’re not just maintaining a skid steer—you’re mastering it.
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