5 Service

5
Manual
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Bobcat Company or the products of
either.

S/N 513011001 & Above

Europe Only – S/N 513031001 & Above

3
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICSTM)
6724024 (6-12) Printed in U.S.A. © Melroe Company 1995

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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in th e manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.

CORRECT CORRECT CORRECT

B-10731a B-12365 B-7469

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG

B-11799 B-15231 B-15280

Have good ventilation when Disconnecting or loosening any Never work on l oader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by a n attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG

B-6590 B-6580 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on con tact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If a cid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well wit h
under pressure. It c an penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill f uel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & M aintenance Manual can be perform ed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW01-0805

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CONTENTS
PREVENTIVE
MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii. . . .
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v. . .
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii ...
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii. . .
BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii .. HYDRAULIC
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 ... SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 ....
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–1 ...
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–1....
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–1
.... HYDROSTATIC
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 .... SYSTEM
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–1 ....
BICS™/BOSS® SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–1 ...
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9–1....
DRIVE
SYSTEM

CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its MAIN
constituents are known to the State of California FRAME
to cause cancer, birth defects and other
reproductive harm.

ELECTRICAL
SYSTEM

ENGINE
SERVICE

BICS™/BOSS®
SYSTEM

SPECIFICATIONS

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FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

A general inspection of the following items must be made after the loader has had service or repair:

1. Check that the ROPS/FOPS 9. Enclosure door latches must

(Including sidescreens) is in open and close freely.
good condition and is not
modified.

2. Check that ROPS mounting 10. Bob–Tach wedges and

hardware is tightened and is linkages must function
Melroe approved. correctly and be in good
condition.

3. The seat belt must be correctly 11. Safety treads must in good
installed, functional and in condition.
good condition.

4. The seat bar and pedal 12. Check for correct function of
interlocks must be correctly indicator lamps (Optional on
adjusted, clean and lubricated. some models).

5. Machine signs must be legible 13. Check hydraulic fluid level,

and in the correct location. engine oil level and fuelsupply.

6. Steering levers and foot pedals 14. Inspect for fuel, oil or hydraulic
must return to neutral. fluid leaks.

7. Check for correct funtion of the 15. Lubricate the loader.

work lights.

8. The parking brake must 16. Check the condition of the

function correctly. battery and cables.

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17. Inspect the air cleaner for
damage or leaks. Check the
condition of the element.

18. Check the electrical charging

system.

19. Check tires for wear and

pressure.

20. Inspect for loose or broken

parts or connections.

21. Operate the loader and check

all functions.

22. Check for any field

modification not completed.

23. Check for correct function of

the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.

Recommend to the owner that all

necessary corrections be made
before the machine is returned to
service.

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SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual,
Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure
to follow instructions can cause injury or death.
W–2003–1289

The following publications provide information on the safe use and maintenance of the loader and attachments:

• The Delivery Report is used to assure that complete instructions have been given tothe new owner and that the machine
is in safe operating condition.

• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routin e
maintenance and service procedures. It is a part of the loader and must stay with the machine when
is sold.
it Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.

• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.

• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The handbook is available from your dealer in English edition or a combination English, French, German, Italia
n,
Dutch & Spanish edition.

• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.

• The Skid–Steer Loader Operator Training Course is available through your local dealer
. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish versions.

Warnings on the machine and in the This notice identifies procedures

manuals are for your safety. Failure to which must be followed to avoid
obey warnings can cause injury or damage to the machine.
death. I–2019–0284
W–2044–1285

Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see thi s
symbol follow the safety message to avoid personal injury or death.

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SAFETY INSTRUCTIONS (Cont’d)

• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicingthe loader. Safety glasses, hearing
protection or loader special application kits are required for some work. See your dealer for Melroe Safety equipmen t.

• Know where fire extinguishers and first aid kits are located and how to use them.
• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosiv
e
dust or gases.

• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent
a fire hazard and overheating.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace an
y
damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to chec
k
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuelorf
cleaning parts. Use commercial nonflammable solvents.

• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti–freeze.
• Do not use ether or starting fluids on this engine. It has glow plugs. These starting
aids can cause an explosion and injure
you or bystanders.

• Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or weldin
g
painted parts. Wear a dust mask when grinding painted parts. Toxic dust or gas can be produced.

• Stop the engine and let it cool before adding fuel. No smoking!
• Use the procedure in the Operation & Maintenance or Service Manuals for connecting the battery.
• Use the procedure in the Operation & Maintenance or Service Manuals for cleaning the spark arrestor muffler.
A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].

P–3705

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SERIAL NUMBER LOCATIONS

Always use the serial number of the loader when

A
requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a dif ferent procedure in doing a specific service
operation.

LOADER SERIAL NUMBER

The loader serial number plate is located on the inside of

the left upright, above the rear grill [A].

Explanation of loader Serial Number:

P–1670
XXXX XXXXX

Production Sequence (Series)

B
Model, Engine Version
1

ENGINE SERIAL NUMBER

The serial number (Item 1) [B] is located at the fuel
injection pump side on the engine block.

P–1671

DELIVERY REPORT C
The Delivery Report must be filled out by the dealer and
signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [C].

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553 BOBCAT LOADER IDENTIFICATION
SEAT BAR

UPRIGHTS
OPERATOR CAB
(ROPS & FOPS)

GRILL
LIFT ARM

LIFT
CYLINDER

REAR LIGHTS

REAR DOOR

TIRES*
FRONT LIGHTS

GRAB
HANDLES OPERATOR
SEAT

STEERING
LEVER
SEAT BELT

TILT CYLINDER
QUICK COUPLERS

SAFETY TREAD

BUCKET BUCKET STEPS B–14241

B–14239

* TIRES – The 553 Bobcat loader is base–equipped with flotation tires as shown.
BUCKET – Several different buckets and other attachments are available for the Bobcat loader .
ROPS, FOPS – Roll Over Protective Structure, per SAE J1040 and ISO 3471 and Falling Object Protective
Structure per SAE J1043 and ISO 3449 Level I. Level ll FOPS is available for protection from heavy falling
objects. The Bobcat loader is base–equipped with a standard operator cab as shown. An extra insulated cab
is available as an option (Reduced noise level).
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OPTIONS AND ACCESSORIES
All 553 Bobcat loaders are equipped with the following standard items:
Bob–Tach Seat Bar
Spark Arrestor Muffler Parking Brake
Lift Arm Support Device Gauges/Warning Lights
Operator Cab (W/ROPS & FOPS Approval) Bobcat Interlock Control System (BICS™)
Seat Belt
Below is a listing of the optional equipment which is available through your Bobcat loader dealer.

553
Tires
27 x 8:50–15, 4PR . . . . . . . . . . . . . . . . . . . . . . . . . Std.
27 x 8:50–15, 6 PR Heavy Duty . . . . . . . . . . . . . Opt.
Operator Cab
Sound Cab (85 dBa) . . . . . . . . . . . . . . . . . . . . . . . Opt. (Std. in Europe)
Deluxe Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opt.
Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA
Operating Lights (Front & Rear) . . . . . . . . . . . . . Opt. & FA
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA (Std. in Europe)
Back–Up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA
Heated Enclosed Cab . . . . . . . . . . . . . . . . . . . . . . Opt. & FA
Top Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA (Std. in Europe)
Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA (Std. in Europe)
Cab Enclosure Kit . . . . . . . . . . . . . . . . . . . . . . . . . FA
Vinyl Cab Enclosure . . . . . . . . . . . . . . . . . . . . . . . FA
Cover Kit (Pedals Area) . . . . . . . . . . . . . . . . . . . . FA (Std. in Europe)
Cover Kit (Hydraulic Reservoir Area) . . . . . . . . . FA
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Flasher Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Strobe or Rotating Beacon Light . . . . . . . . . . . . . FA
3’’ Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Special Applications Kit . . . . . . . . . . . . . . . . . . . . FA
Turn Signal Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA (Std. in Europe)
FOPS Level II Kit . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Hydraulics
Front Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . Opt. & FA (Std. in Europe)
Hydraulic Bucket Positioning . . . . . . . . . . . . . . . . Opt. & FA
Bucket Positioning On/Off . . . . . . . . . . . . . . . . . . FA
Other
Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . FA
Single Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Locking Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Radiator Screen Kit . . . . . . . . . . . . . . . . . . . . . . . . FA
Tool Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA (Std. in Europe)
Low Coolant Sensor Kit . . . . . . . . . . . . . . . . . . . . FA
Rental Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FA
Std. = Standard Equipment
Opt. = Factory Installed Option
FA = Field Accessory
NA = Not Available

Specifications subject to
change without notice

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553ServiceManual#6724024(S/N513011001&Above)–Contents

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PREVENTIVE MAINTENANCE
PREVENTIVE
Page MAINTENANCE
Number
AIR CLEANER SERVICE
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–10
..
ALTERNATOR BELT
Adjusting the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–18
..
ENGINE COOLING SYSTEM
Cleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–16
..
Checking the Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–16
..
Removing Coolant From the Cooling System . . . . . . . . . . . . . . . . . . . . 1–16 .
ENGINE LUBRICATION SYSTEM
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
...
Replacing Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
...
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking and Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–24
..
Removing Oil From the Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24 ..
FUEL SYSTEM
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 ...
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
....
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 ...
Removing Air From the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–13 .
HYDRAULIC/HYDROSTATIC SYSTEM
Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–20
..
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . .1–21 .
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–21
..
LIFT ARM SUPPORT DEVICE
Installing and Removing Lift Arm Support Device . . . . . . . . . . . . . . . . . .1–7
LIFTING AND BLOCKING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
....
LIFTING THE LOADER
Single Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–6
...
LUBRICATION OF THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–25
....
OPERATOR CAB
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
....
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–8 ...
Lowering the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–8 ..
Raising the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–8 ..
REMOTE START SWITCH
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27
....
SEAT BAR RESTRAINT SYSTEM
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 ...
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 ...
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
....
SERVICE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3
.....

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PREVENTIVE MAINTENANCE (Cont’d)
Page
Number
SPARK ARRESTOR MUFFLER
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22
...

TIRE MAINTENANCE
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
....
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
....
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
....

TOWING THE LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
....
TRANSPORTING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
....

USING A BOOSTER BATTERY (JUMP STARTING)

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19
....

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SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure to do so will result in excessivewear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.

Instructions are necessary before operating or servicing machine.

Read Operation Maintenance Manual, Handbook and signs (decals)
on machine. Follow warnings and instructions in the manual when
making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Failure to follow instructions
can cause injury or death.
W–2003–1289

SERVICE SCHEDULE HOURS

ITEM SERVICE REQUIRED 8–10 50 100 250 1000

Engine Oil Check the oil level and add oil as needed.
Engine Air Cleaner Replace the outer filter element only when the red ring shows in the
indicator window. Check for leaks and damaged components.
Engine Cooling System Clean debris from oil cooler, radiator & grill. Check coolant level in
recovery tank and add as needed.
Tires Check for damaged tires and correct air pressure.
Seat Belt, Seat Bar Check the condition of seat belt. Check the seat bar & pedal interlocks
for correct operation. Clean dirt and debris from moving parts.
Safety Signs and Safety Check for damaged signs (decals) and safety treads. Replace any
Tread signs or safety treads that are damaged or worn.
Indicator & Lights (Opt.) Check for correct operation of all indicators & lights.
Operator Cab Check the fastening bolts, washers & nuts. Check the condition of cab.
Lift Arms, Cyl., Bob–Tach Lubricate with multi–purpose lithium based grease.
Pivot Pins and Wedges
Engine Fuel Filter Remove the trapped water.
Bobcat Interlock Control Check BICS System Controller functions. Clean dirt, debris or objects
System (BICS™) from under or behind seat as required.
Battery Check cables & electrolyte level.
Hyd. Fluid, Hoses & Check fluid level & add as needed. Check for damage & leaks.
Tubelines Repair & replace as needed.
Control Pedals & Steering Check for correct operation. Repair or adjust as needed.
Wheel Nuts Check for loose wheel nuts & tighten to 105–1
15 ft.–lbs. (142–156 Nm)
torque.
Parking Brake Check operations & adjust as needed.
Alternator Belt Check tension & adjust as needed.
Final Drive Trans. Check fluid level and add as needed.
(Chaincase)
Engine Oil & Filter Replace oil & filter.
Spark Arrestor Muffler Clean the spark chamber.
Steering Lever Pivots Grease two fittings. Add oil to steering shaft.
U–Joint Grease three (3) fittings with correct grease.
Fuel Filter Replace filter element.
Hyd./Hydro. Reservoir Replace the reservoir breather cap and hydraulic/hydrostatic filter.
& Filter
Chaincase Replace the fluid.
Hyd. Reservoir Replace the fluid and filter.
Bobcat Interlock Control Check lift arm bypass control.
System (BICS™)

Check wheel nut torque every 8 hours for the first 24 hours.
Also replace hydraulic/hydrostatic filter element when the transmission warning light stays on for five minutes
after the fluid is at operating temperature.
Or every 12 months.

553 Loader
17 of 298 –1–3– Service Manual
PREVENTIVE MAINTENANCE
A

Instructions are necessary before operating or

servicing machine. Read Operation &
Maintenance Manuals, Handbook and signs
(decals) on machine. Follow warnings and
instructions in the manuals when making
repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or
service. Failure to follow instructions can
cause injury or death [A].
W–2003–1289

LIFTING AND BLOCKING THE LOADER B–7023

Procedure
Always park the loader on a level surface.

Put jackstands under the front axles and rear

corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W–2017–0286
B

Put a floor jack under the rear of the loader [B].

Lift the rear of the loader and install jackstands [B].

P–5824

Put the floor jack under the front of the loader [C].
Lift the front of the loader and put jackstands under the
C
loader frame.
NOTE: Make sure the jackstands do not touch the
tires.

P–5821

553 Loader
18 of 298 –1–4– Service Manual
TRANSPORTING THE LOADER
Procedure
A

Adequately designed ramps of sufficient

strength are needed to support the weight of
the machine when loading onto a transport
vehicle. Wood ramps can break and cause
personal injury.
W–2058–0494
B–2668

A loader with an empty bucket or no attachment must be

loaded backward onto the transport vehicle [A].
B
Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes [B].
Lower the bucket or attachment to the floor . Stop the
engine. Engage the parking brake. Install chains at the
front and rear loader as shown [B].
NOTE: Rear of the loader can be chained using the
upright slots or using the loop below the rear
door [B].
C–2563 C–7384

B–7383

P–4031

553 Loader
19 of 298 –1–5– Service Manual
LIFTING THE LOADER
Single Point Lift
A
1

AVOID INJURY OR DEATH

• Before lifting, check fasteners on single
point lift and operator cab.
• Assemble front cab fasteners as shown in
manual.
• Never allow riders in the cab or bystanders
within 15 feet (5 meters) while lifting the
machine.
W–2007–1285

The loader can be lifted with the single point lift which is
available as a kit from your Bobcat loader dealer.
Fasten the pins (Item 1) in the kit as shown in figure [A].
1
The single point lift, supplied by Melroe Company is
designed to safely lift and support the Bobcat loader.
TOWING THE LOADER
Procedure

B–7489

Never attempt to start the engine by pushing or

pulling. Hydrostatic pumps and motors will be
damaged. I–2001–1285

Do not push or pull the machine at more than

To prevent damage to the loader hydrostatic system, the 2 MPH (3,2 km/h) or for a distance of more than
loader must be towed only a short distance at slow speed.
(Example: Moving the loader onto a transport vehicle). 25 feet (7,6 meters) with the towing tool in
place. I–2017–0389
The towing chain (or cable) must be rated at 1–1/2 times
the weight of the loader. (See Specifications, Page 9–1.)
• Turn the key switch to ON and press the Traction
Lock Override button. Towing tool (MEL1220) must be
installed in the hydrostatic pump. (A
vailable from your
Bobcat dealer.)
• Tow the Bobcat at 2 MPH (3,2 km/hr.) or less for not
more than 25 feet (7,6 meters).
If the electrical system is not functioning, the brake
system must be disassembled to move the loader. Refer
to the Traction Lock Removal and Installation procedure
(Page 8–1).
STOPPING THE BOBCAT LOADER
When the steering levers are moved to the neutral
position, the hydrostatic transmission will act as aservice
brake and stop the loader.

553 Loader
20 of 298 –1–6– Service Manual
LIFT ARM SUPPORT DEVICE
Installing and Removing Lift Arm Support Device
A 1

Never work on a machine with the lift arms up

unless the lift arms are secured by a lift arm
support device. Failure to use an approved lift
arm support device can allow the lift arms or
attachment to fall and cause injury or death.
W–2059–0991
P–4008

Put jackstands under the rear corners of the loader.

Open the rear door of the loader and remove the lift arm
support device (Item 1) [A].

Both sets of fasteners at the front of the

operator cab (ROPS) must be assembled as
One person must be in the operator’s seat, with the seat shown in this Operation & Maintenance
belt fastened and seat bar lowered, until the lift arm Manual. Failure to secure ROPS correctly can
support device is installed [B]. cause injury or death.
W–2005–1089
Start the engine and raise the lift arms all the way up.
Have a second person install the lift arm support device
over the rod of one of the lift cylinders [B]. The lift arm
support device must be tight against the cylinder rod.
The 90° notch should be installed against the outer case
of the lift cylinder (See Inset). B
Lower the lift arms until the support device is held
between the lift arm and the lift cylinder.
Repeat the procedure used above to remove the lift arm
support device from the loader. MC–2201
OPERATOR CAB
Description
The Bobcat loader has an operator cab (ROPS and
FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer P–4040
if the operator cab has been damaged.

Never modify operator cab by welding,

grinding, drilling holes or adding attachments
unless instructed to do so by Melroe
Company. Changes to the cab can cause loss
of operator protection from rollover and falling
objects, and result in injury or death.
W–2069–1285

553 Loader
21 of 298 –1–7– Service Manual
OPERATOR CAB (Cont’d)
Emergency Exit
A
The front opening on the operator cab and rear window
provide exits.
To exit through the rear window , use the following
procedure:
Pull on the tag on the top of the rear window to remove the
rubber cord [A].

Push the rear window out of the rear of the operator cab.
P–0660
Exit through the rear of the operator cab [B].
ROPS/FOPS – Roll–Over Protection Structure per SAE
J1040 and ISO 3471 and Falling Object Protective
B
Structure per SAE J1043 and ISO 3449 Level I. Level II
is available.
Level I – Protection from falling bricks, small concrete
blocks, and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction site services.
Level II – Protection from falling tree, rocks; formachines
involved in site clearing, overhead demolition or forestry.
Raising the Operator Cab
Stop the loader on a level surface. Lower the lift arms. If P–7281
the lift arms must be up while raising the operator cab,
install the lift arm support device (Page 1–6).
C

Before the cab or the lift arms are raised for

service, jackstands must be put under the rear
corners of the frame. Failure to use jackstands
may allow the machine to tip backward
causing injury or death.
W–2014–1285

Remove the nut and plate (both sides) (Inset [C]).

P–1518 P–4032
Lift on the grab handle and bottom of the operator cab
slowly until the cab latching mechanism engages and the
cab is all the way up [C]. D
Lowering the Operator Cab
Pull down on the bottom of the operator cab until it stops
at the latching mechanism. Release the latching
mechanism and pull the cab all the way down [D].
Install the plate and nut (Inset [C]).
Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque
(Inset [C]).

P–7251

553 Loader
22 of 298 –1–8– Service Manual
SEAT BAR RESTRAINT SYSTEM
Description
A
The seat bar restraint system hasa pivoting seat bar with
arm rests and has spring loaded interlocks forthe lift and
tilt control pedals. The operator controls the use of the
seat bar. The seat bar in the down position helps to keep
the operator in the seat. The interlocks require the
operator to lower the seat bar in order to operate thefoot
pedal controls. When the seat bar is up, the lift and tilt
pedals are locked when returned to the neutral position.

P–3269 P–3270

AVOID INJURY OR DEATH B

The seat bar system must lock the lift and tilt
control pedals in neutral when the seat bar is
up. Service the system if pedals do not lock Clean
correctly.
W–2105–1285

Seat Bar Inspection

Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start the
engine.
Operate each foot pedal to check both the lift and tilt
functions. P–4002

Raise the lift arms until the bucket is about 2 feet (600
mm) off the ground. Raise the seat bar, try to move each
pedal. The pedals must be firmly locked in neutral
position. There must be no motion of the tilt
(bucket) or the
lift arms when the pedals are pushed.
Pull the seat bar down, lower the lift arms. Operate the lift
pedals. While the lift arms are going up, raise the seat bar
and the lift arms should stop.
Lower the seat bar , lower the lift arms and place the
bucket flat on the ground. Stop the engine. Raise the seat
bar and operate the foot pedals to be sure that the pedals
are firmly locked in the neutral position. Unbuckle the seat
belt.

Seat Bar Maintenance

See the Service Schedule Page 1–3 and on the loader for
correct service interval.
Clean any debris or dirt from the moving parts [A] & [B].
Inspect the linkage bolts and nuts for tightness. The
correct torque is 25–28 ft.–lbs. (34–38 Nm).
If the seat bar system does not function correctly, check
for free movement of each linkage part. Check for
excessive wear. Adjust pedal control linkage. Replace
parts that are worn or damaged. Use only genuine Melroe
replacement parts.

553 Loader
23 of 298 –1–9– Service Manual
AIR CLEANER SERVICE
Replacing Filter Element
A
See the Service Schedule Page 1–3 for the interval to
service the air cleaner system.
Check the air intake hose for damage. Check the air
cleaner housing for damage. Check to make sure all P–1688
1
connections are tight.
Replace the large (outer) filter element only when the red
ring shows in the window of the condition indicator (Item
1) [A].

NOTE: Push the button on the condition indicator

P–4009
(See Inset) and start the engine. If the red ring
does not show, do not replace the filter
element [A].
Service the air cleaner as follows:
B
Loosen the clamp (Item 1) [B] and remove the dust cover
(Item 2) [B].
1

P–4012

Remove the dust cup from the cover [C].

C

P–4014

Remove the wing nut from the large air filter element[D].
D

P–4011

553 Loader
24 of 298 –1–10– Service Manual
AIR CLEANER SERVICE (Cont’d)
Replacing Filter Element (Cont’d)
A
Remove the large air filter element [A].
NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Install the new filter element and tighten the wing nut.
Install the dust cover and tighten the wing nut.
Only replace the inner filter element under the following
conditions:
Replace the inner filter element every third time the
outer filter is replaced. P–4010

Replace the inner filter element when the red ring still
shows in the condition indicator window after the outer
filter is replaced. B
Remove the wing nut (Item 1) [B] and the inner filter
element.

1
P–4013

Record the operating hours of the loader on the decal

(Item 1) [C] inside the rear door. C

P–4007

553 Loader
25 of 298 –1–11– Service Manual
FUEL SYSTEM
Fuel Specifications A
Use only clean, high quality diesel fuel, Grade No. 1 or
Grade No. 2.
The following is one suggested blending guideline which
should prevent fuel gelling problems:
Temp. F°/C° No. 2 No. 1
+15o(–9o) o 100% 0%
Down to –20 /–29o 50% 50%
Below –20o/–29o 0% 100%
We recommend an operator contact their fuel supplier for
local recommendations.
Filling the Fuel Tank
P–4027

B WRONG

Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can
cause an explosion or fire. W–2063–0887

Remove the fuel fill cap [A].

Use a clean, approved safety container to add fuel of the
correct specifications. Add fuel only in an area that has
free movement of air and no open flames or sparks. NO
SMOKING [B]!
Install and tighten the fuel fill cap [A].
Fuel Filter B–6586

Always clean up spilled fuel or oil. Keep heat,

flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
combustibles can cause explosion or fire
which can result in injury or death.
W–2103–1285

See the Service Schedule Page 1–3 for the service

interval when to remove the water from the fuel filter.
Turn the fuel shut–off valve clockwise to shut–off the fuel
supply [C]. P–7023
Loosen the drain at the bottom of the filter element (See
Inset) [D] to drain the water from the filter.
Open the shut–off valve [C]. D
See the Service Schedule Page 1–3 for the service 1
interval when to replace the fuel filter.
Clean the area around the fuel filter . Close the shut–off
valve [C].
Use a wrench to loosen the fuel filter bolt (Item 2) [D].
Remove the water trap and fuel filter (Item 1) [D]. 2 P–7041
Replace the seals as needed.
Install the new filter element and water trap.
Tighten the fuel filter bolt.
Open the shut–off valve [C]. P–7042

553 Loader
26 of 298 –1–12– Service Manual
FUEL SYSTEM (Cont’d)
Removing Air From the Fuel System
A
After replacing the fuel filter element or when the fuel
tank
has run out of fuel, the air mustbe removed from the fuel
system before starting the engine.
Open the rear door. The engine must be cool.
Open the vent plug (Item 1) [A].

Operate the hand pump (Item 1) [B] until fuel flows from P–7042
the vent plug with no air bubbles.
Tighten the vent plug. B 1
Operate the hand pump until it feels solid [B].

Move the engine speed control to minimum RPM. Open

the valve (Item 1)[C] and squeeze thehand pump several
times. P–7046

Start the engine. When the engine runs smoothly, close

the valve (Item 1) [C].
C

Always clean up spilled fuel or oil. Keep heat,

flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around 1
combustibles can cause explosion or fire
which can result in injury or death.
W–2103–1285

P–7057

553 Loader
27 of 298 –1–13– Service Manual
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
A
Check the oil level every day.
Stop the engine and remove the dipstick [A].
Keep the oil level between the marks on the dipstick.
Use a good quality motor oil that meets API Service
Classification of CD or better (See Oil Chart).
Replacing Oil and Filter
See the Service Schedule Page 1–3 for the service
interval for replacing the engine oil and filter. P–1685

Use the following procedure to replace the oil and filter:

Run the engine until it is at operating temperature. Stop
B
the engine.
Open the rear door and remove the cap from the end of
the hose and drain the oil into a container [B].
Remove the filter (Item 1) [C].
Clean the filter housing surface. Put clean oil on the
gasket of the new filter install the filter and hand tighten.
Remove the oil filler cap [D].
Use a good quality motor oil that meets API Service
Classification of CD or better (See Oil Chart). P–1686

RECOMMENDED SAE VISCOSITY NUMBER

(LUBRICATION OILS FOR ENGINE CRANKCASE)
C°–34 –29 –23 –18 –13 –7 –1 +4 +10 +15 +21 +27 +32 +38 +43 +49 +54 +60
C
SAE 40 or 20W–50

SAE 10W–30

SAE 15W–40
1
SAE 5W–30

SAE 30W

SAE 20W–20

SAE 10W
P–4017
⎧°–30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140

TEMPERATURE RANGE ANTICIPATED BEFORE

NEXT OIL CHANGE D
(DIESEL: USE API CLASSIFICATION CD or BETTER)

Fill to capacity (See Specification Section, Page 9–1).

Start the engine and let it run for about 5 minutes. Check
for leaks at the filter. Check the oil level. Add oil until the
level is at the FULL mark on the dipstick. Install the oil filler
cap [D].
NOTE: DO NOT overfill the crankcase.

P–1689

553 Loader
28 of 298 –1–14– Service Manual
ENGINE LUBRICATION SYSTEM (Cont’d)
Replacing Oil and Filter (Cont’d)
A
Record the operating hours of the loader on the decal
(Item 1) [A] inside the rear door.

1
P–4007

553 Loader
29 of 298 –1–15– Service Manual
ENGINE COOLING SYSTEM
Check the cooling system every day to prevent
A
overheating, loss of performance or engine damage.
Checking the Coolant Level
Open the rear door.
The coolant recovery tank (Item 1) [A] must be at the
FULL COLD mark when engine is cool.
The loader is factory filled with propylene glycol mixture.
DO NOT mix propylene glycol with ethylene glycol.

NOTE: The loader is factory filled with propylene

P–4016
glycol coolant. DO NOT mix propylene glycol
with ethylene glycol.
Propylene Glycol B
Add premixed coolant; 47% water and 53% propylene
glycol to the recovery tank if the coolant level is low.
One gallon and one pint of propylene glycol mixed with
one gallon of water is the correct mixture of coolant to
provide a –34°F (–37°C) freeze protection.
Use a refractometer to check the condition of propylene
glycol in your cooling system.

P–1677

Wear safety glasses to prevent eye injury when C

any of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W–2019–1285

Cleaning the Cooling System

Open the rear door.
Remove the access panels at the blower housing [B].
P–4019
Remove the rear grill. (See Page 5–1.)
Use air pressure or water pressure to remove the debris
in the area of the radiator and oil cooler [C].
D
If debris is a problem, check with your dealer about the
special debris screens.
Removing Coolant From the Cooling System
Remove the rear grill. (See Page 5–1.) Remove the
radiator cap [D].

P–1678

553 Loader
30 of 298 –1–16– Service Manual
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