Service

Manual
S/N 516311001 & Above
S/N 516411001 & Above

EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICSTM)
6900450 (1–98) Printed in U.S.A. © Bobcat Company 1998

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Downloaded from www.Manualslib.com manuals search engine
 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 the 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 loader 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 an 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 contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can 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 fuel 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 & Maintenance Manual can be performed 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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Downloaded from www.Manualslib.com manuals search engine
 ALPHABETICAL INDEX
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . 1–1
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 3–1
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . 3–1
AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . 1–1 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
AXLE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 IDLER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
AXLE, BEARINGS, AND SPROCKET . . . . . . . . . . . . 4–1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . 1–1
BOBCAT INTERLOCK CONTROL LIFT CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 LIFT LOCK BY–PASS VALVE . . . . . . . . . . . . . . . . . . . . 2–1
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 9–1
BICS™ SYSTEM CONTROLLER . . . . . . . . . . . . . . . . 8–1 LUBRICATING OF THE BOBCAT LOADER . . . . . . . 1–1
BLOWER FAN HOUSING . . . . . . . . . . . . . . . . . . . . . . 7–1
BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
METRIC TORQUE SPECIFICATIONS
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
CHAINCASE COVERS . . . . . . . . . . . . . . . . . . . . . . . . 4–1
CHAINCASE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 OPERATOR CAB GAS CYLINDER . . . . . . . . . . . . . . . 5–1
CRANKSHAFT FRONT SEAL . . . . . . . . . . . . . . . . . . 7–1 OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
CROSSMEMBER LINKAGE . . . . . . . . . . . . . . . . . . . . 2–1
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
PARKING BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . 4–1
DECIMAL & MILLIMETER EQUIVALENTS . . . . . . . 9–1 PEDAL INTERLOCK LINKAGE . . . . . . . . . . . . . . . . . . 2–1
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 PORT BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
PUSH ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . 6–1
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
ENGINE COMPRESSION . . . . . . . . . . . . . . . . . . . . . . 7–1 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . 1–1 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . 1–1 REMOTE START SWITCH . . . . . . . . . . . . . . . . . . . . . . 1–1
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
ENGINE MOUNTING BRACKET . . . . . . . . . . . . . . . . 7–1 RUBBER DRIVE COUPLER . . . . . . . . . . . . . . . . . . . . . 7–1
ENGINE MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 9–1 SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . 7–1 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . 1–1
ENGINE SPEED CONTROL PLATE . . . . . . . . . . . . . 7–1 SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
ENGINE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SEAT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . 1–1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . 1–1 STANDARD TORQUE SPECIFICATIONS
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
FLYWHEEL HOUSING . . . . . . . . . . . . . . . . . . . . . . . . 7–1 STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
FRONT LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
FUEL CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . 1–1
FUEL INJECTION NOZZLES . . . . . . . . . . . . . . . . . . . 7–1
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . 7–1 TAPPET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
FUEL LIFT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
FUEL SHUT–OFF SOLENOID . . . . . . . . . . . . . . . . . . 7–1 TILT LOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TIMING GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . . 7–1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 TIMING GEAR CASE COVER . . . . . . . . . . . . . . . . . . . 7–1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TORQUE SPECIFICATIONS FOR LOADER . . . . . . . 9–1
GOVERNOR FORK LEVER . . . . . . . . . . . . . . . . . . . . 7–1 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . 1–1
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
GOVERNOR SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . . 1–1
TROUBLESHOOTING . . . . . . . . . . . . 2–1, 3–1, 6–1, 7–1
HYDRAULIC CONNECTION SPEC . . . . . . . . . . . . . . 9–1
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . 2–1 U.S. TO METRIC CONVERSION
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 2–1 U–JOINT COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
HYDRAULIC FILTER HOUSING . . . . . . . . . . . . . . . . 2–1 U–JOINT LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 1–1
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . 2–1 USING A BOOSTER BATTER (JUMP STARTING) . 6–1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . 2–1
HYDRAULIC/HYDROSTATIC FLUID WATER FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
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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
SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

SYSTEM
ANALYSIS

SPECIFICATIONS

553 Loader
i Service Manual
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 553 Loader
ii Service Manual
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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. The parking brake must

(Including sidescreens) is in function correctly.
good condition and is not
modified.

2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Melroe approved.

3. The seat belt must be correctly 11. Bob–Tach wedges and

installed, functional and in linkages must function
good condition. correctly and be in good
condition.

4. The seat bar and pedal 12. Safety treads must in good
interlocks must be correctly condition.
adjusted, clean and lubricated.

5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).

6. Machine signs must be legible WARNING 14. Check hydraulic fluid level,
and in the correct location. engine oil level and fuel supply.

7. Steering levers and foot pedals 15. Inspect for fuel, oil or hydraulic
must return to neutral. fluid leaks.

8. Check for correct function of 16. Lubricate the loader.

the work lights.

553 Loader
Revised Apr. 99 iii Service Manual
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 17. Check the condition of the
battery and cables.

18. Inspect the air cleaner for

damage or leaks. Check the
condition of the element.

19. Check the electrical charging

system.

20. Check tires for wear and

pressure.

21. Inspect for loose or broken

parts or connections.

22. Operate the loader and check

all functions.

23. Check for any field

modification not completed.

24. 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.

553 Loader
Revised Apr. 99 iv Service Manual
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 SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read and understand the 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. Untrained operators and failure to follow instructions can cause injury or death.
W–2003–0299

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 to the 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 routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. 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 an English edition or one of many other languages. See your
Bobcat dealer for more information on translated versions.

• 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 version.

• The Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and
correct service procedures for Bobcat Skid–Steer loaders.

• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

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

SI05–0299

553 Loader
v Service Manual
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 SAFETY INSTRUCTIONS (Cont’d)

• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing
protection or loader special applications kit are required for some work. See your dealer for Melroe Safety equipment.

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

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

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

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for
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 engines which have glow plugs. These starting aids can cause 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 welding
painted parts. Wear 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.
A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].

SI06–0398 P–3705

553 Loader
vi Service Manual
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 SERIAL NUMBER LOCATIONS
A
Always use the serial number of the loader when
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 different procedure in doing a specific service
operation.

LOADER SERIAL NUMBER

The loader serial number plate is located on the inside of

the operator cab, near the right steering lever.

Explanation of loader Serial Number:

P–10725
XXXX XXXXX

Production Sequence (Series)

B
Model, Engine Version

ENGINE SERIAL NUMBER

The serial number (Item 1) [B] is located below the
exhaust manifold near the front of the engine.
1

N–09931

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].

553 Loader
vii Service Manual
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 BOBCAT SKID STEER LOADER IDENTIFICATION
553ServiceManual(S/N516311001&Above)#6900450–ContentsSection

SEAT BAR
OPERATOR CAB
(ROPS & FOPS)
UPRIGHTS

GRILL
LIFT ARM

LIFT
CYLINDER

◊ REAR LIGHTS

REAR DOOR

◊ FRONT LIGHTS * TIRES

OPERATOR
GRAB SEAT
HANDLES
STEERING
LEVER

SEAT BELT

TILT CYLINDER

◊ QUICK
COUPLERS

BUCKET SAFETY TREAD

BUCKET STEPS
B–15064
B–15065

◊ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)

* 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,Falling Object Protective Structure, per SAE J1040 and ISO
3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level II is available. The
Bobcat loader is base–equipped with a standard operator cab as shown. Extra insulated cab is available as
an option (Reduced noise level).
553 Loader
viii Service Manual
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 PREVENTIVE MAINTENANCE
PREVENTIVE
Page MAINTENANCE
Number
AIR CLEANER SERVICE
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
ALTERNATOR BELT
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19

AUXILIARY CONTROL LOCKBOLT

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28
BOB–TACH
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27

ENGINE COOLING SYSTEM

Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
ENGINE LUBRICATION SYSTEM
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15

FINAL DRIVE TRANSMISSION (CHAINCASE)

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24
FUEL SYSTEM
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14

HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21

LIFT ARM SUPPORT DEVICE

Disengaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
LIFTING AND BLOCKING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

LUBRICATING OF THE BOBCAT LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–25

OPERATOR CAB
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9

Continued On Next Page 553 Loader

Revised Apr. 99 –1–1– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 PREVENTIVE MAINTENANCE (Cont’d)
Page
Number
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26
REMOTE START SWITCH
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–29

SERVICE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
SEAT BAR RESTRAINT SYSTEM
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
SPARK ARRESTOR MUFFLER
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22

STOPPING THE BOBCAT LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
TIRE MAINTENANCE
Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
TOWING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

TRANSPORTING THE LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
U–JOINT LUBRICATION
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28

553 Loader
Revised Apr. 99 –1–2– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear 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 and understand the 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–2003–1298

ITEM SERVICE REQUIRED 8–10 50 100 200 250 500 1000

Engine Oil Check the oil level and add oil as needed.
Engine Air Filter Replace the outer filter element only when the red ring shows in the
and Air System 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 and Seat Bar and Check the condition of seat belt. Check the seat bar & pedal inter–
Control Interlocks locks for correct operation. Clean dirt & 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 Arm and Bob–Tach Lubricate with multi–purpose lithium based grease.
Pivot Pin and Wedges
Engine Fuel Filter Remove the trapped water.
Bobcat Interlock Control Check BICS™ System Controller functions. Clean dirt, debris or
System (BICSTM) objects from under or behind seat as required.
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 105–115 ft.–lbs.
(142–156Nm) torque.
Parking Brake Check operation of the brake.
Alternator Belt Check tension & adjust as needed.
Final Drive Trans. Check fluid level and add as needed.
(Chaincase)
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections & electrolyte level. Add distilled water
as needed.
Engine Oil & Filter Replace oil & filter. Use CD or better grade oil and Melroe filter.
Fuel Filter Replace filter element.
Steering Lever Pivots Grease two fittings. Add oil to steering shaft.
U Joint Grease three (3) fittings with correct grease.
Hyd./Hydros Filter Replace the filter element.
Hyd Reservoir Breather Cap Replace the reservoir breather cap.
Engine Valves Check and adjust the engine valve clearance.
Hyd./Hydros. Reservoir Replace the hydraulic/hydrostatic fluid.
Chaincase Replace the fluid.
Bobcat Interlock Control Check the lift arm by–pass 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
Revised Mar. 02 –1–3– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 A

Instructions are necessary before operating or

servicing machine. Read and understand the
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–2003–1298

LIFTING AND BLOCKING THE LOADER

Procedure
B–07023
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
Lift the rear of the loader and install jackstands [B].

P–10938

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

P–10917

553 Loader
Revised Apr. 99 –1–4– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 TOWING THE LOADER
Procedure
To prevent damage to the loaders hydrostatic system, the
loader must be towed only a short distance at slow speed. Never attempt to start the engine by pushing or
(Example: Moving the loader onto a transport vehicle). pulling. Hydrostatic pumps and motors will be
damaged.
I–2001–1285
Relief valve release tool set MEL1220 is available from
your dealer. Tool must be installed before towing. Do not push or pull the machine at more than
2 MPH (3,2 km/h) or for a distance of more than
Raise the operator cab. (See Raising The Operator Cab 25 feet (7,6 meters) with the towing tool in
Page 1–9 for the correct procedure.) place.
I–2017–0389
Clean the area around the hydrostatic pumps.
Remove the high pressure relief valve from one side of
each hydrostatic pump [A] and install the relief valve
tubes. Install the plugs and tighten.
Lower the operator cab. (See Lowering The Operator Cab
A
Page 1–9.)
The towing chain (or cable) must be rated at 1 and 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.
• 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, contact your E–01457
Bobcat loader dealer. (Part of the brake system must be B–06924
disassembled to move the loader.)

553 Loader
Revised Apr. 99 –1–5– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 TOWING 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

SUPPORT P–10732
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [A].
The rear of the trailer must be blocked or supported [A]
when loading or unloading the loader to prevent the front
B
end of the trailer from raising up.
Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving Both Sides
during sudden stops or when going up and down slopes
[B].
• Lower the bucket or attachment to the floor.
• Stop the engine.
P–10731
• Engage the parking brake.
• Install chains at the front and rear of the loader as
shown [B].

P–10730

STOPPING THE BOBCAT LOADER

When the steering levers are moved to the neutral
position, the hydrostatic transmission will act as a service
brake and stop the loader.

P–10726

P–10728

553 Loader
Revised Apr. 99 –1–6– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 LIFT ARM SUPPORT DEVICE
A

P–10706

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved B
lift arm support device. Failure to use an
approved lift arm support device can allow the 1
lift arms or attachment to fall and cause injury
or death. W–2059–0598

Engaging The Lift Arm Support Device

Maintenance and service work can be done with the lift
arms lowered. If the lift arms are raised for service, use
the following procedure:
Put jackstands under the rear corners of the loader frame.
Remove any attachment before raising the lift arms. P–10703
Disconnect the spring from the approved lift arm support
device retaining pin (Item 1) [A]. Hold onto the lift arm
support device (Item 2) [A] and remove the retaining pin. C
Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring (Item 1) [B] to the lift arm
support device so there will be no interference with the
support device engagement.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine. Loaders without seat
sensors Press the green PRESS TO OPERATE Button.
1
Raise the lift arms, until the lift arm support (Item 1) [C]
device drops onto the lift cylinder rod.
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine. P–10708
Raise the seat bar and move foot pedals (or hand
controls) until both lock.
Install pin (Item 1) [D] into the rear of the lift arm support
device below the cylinder rod.
D

Service lift arm support device if damaged or if

parts are missing. Using a damaged lift arm 1
support or with missing parts can cause lift
arms to drop causing injury or death.
W–2271–1197
P–10701

553 Loader
Revised Apr. 99 –1–7– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 LIFT ARM SUPPORT DEVICE (Cont’d)
A
Disengaging The Lift Arm Support Device
Remove the pin from the lift arm support device.
Connect the spring (Item 1) [A] from the lift arm support
device to the bracket below the lift arms.
With the operator in the seat, seat belt fastened and seat 1
bar lowered, start the engine.
Loaders without seat sensors press the green PRESS TO
OPERATE Button.
Raise the lift arms a small amount and the spring will lift
the support device off the lift cylinder rod. P–10702

Lower the lift arms and stop the engine.

Raise the seat bar and move pedals until both lock.
B
Disconnect the spring from the bracket.

Raise the support device into storage position and insert

pin (Item 1) [B] through lift arm support device and
bracket.
Connect spring to pin.
1

P–10706

553 Loader
Revised Apr. 99 –1–8– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 OPERATOR CAB
The Bobcat loader has an operator cab (ROPS and
A
FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer
if the operator cab has been damaged.
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 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 trees, rocks; for
machines involved in site clearing, overhead demolition P–10724 P–10723
or forestry.

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

Raising The Operator Cab

P–09773 P–10719
Stop the loader on a level surface. Lower the lift arms.
Stop the engine. If the lift arms must be up while raising
the operator cab, install the lift arm support device. (See
LIFT ARM SUPPORT DEVICE Page 1–7.)
Put jackstands under the rear corners of loader (Inset)
[B].
Loosen the nut (both sides) at the corner of the operator
cab [A]. Before the cab or the lift arms are raised for
Remove the nut and plate (both sides) [A]. service, jackstands must be put under the rear
corners of the frame. Failure to use jackstands
Lift on the grab handle and bottom of the operator cab can allow the machine to tip backward causing
slowly until the cab latching mechanism engages and the injury or death.
cab is all the way up [B]. W–2014–0895

Lowering The Operator Cab

Pull down on the bottom of the operator cab until it stops
at the latching mechanism. Release the latching
mechanism [C] and pull the cab all the way down.
Install the plate and nut (both sides) [A]. C
Tighten the nuts [A] to 40–50 ft.–lbs. (54–68 Nm) torque.

Both sets of fasteners at the front of the

operator cab (ROPS) must be assembled as
shown in this Operation & Maintenance
Manual. Failure to secure ROPS correctly can
cause injury or death.
W–2005–1089
P–10715 P–10713

553 Loader
Revised Apr. 99 –1–9– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 OPERATOR CAB (Cont’d)
A
Emergency Exit
The front opening on the operator cab and rear window
provide exits.
Rear Window (If Equipped):
• 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–00660
Exit through the rear of the operator cab [B].

P–10722

Front Door: (if equipped)

C
NOTE: When an Operator Cab Enclosure Kit is
installed, the window of the front door can be
used as an emergency exit. [C]
Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [C].

P–09216

Push the window out with your foot [D]. D

Exit through the front door.

P–09217

553 Loader
Revised Apr. 99 –1–10– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SEAT BAR RESTRAINT SYSTEM
Description
A
The seat bar restraint system has a pivoting seat bar with
arm rests and has spring loaded interlocks for the lift and
tilt control pedals. Clean
(Both Sides)
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 the foot pedal controls.
When the seat bar is up, the lift and tilt pedals are locked
when returned to the NEUTRAL POSITION.
P–10361

AVOID INJURY OR DEATH

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
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. Loaders without seat sensors press the green Clean
PRESS TO OPERATE Button.
(Both Sides)
Operate each foot pedal to check both the lift and tilt
functions.
Raise the lift arms until the bucket is about 2 feet (600
mm) off the ground.
Raise the seat bar. Try to move each foot 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. Loaders without seat sensors
press the green PRESS TO OPERATE Button. 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 P–10717
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
Revised Apr. 99 –1–11– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 AIR CLEANER SERVICE
Replacing Filter Element
A
1
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–10749
connections are tight.
Replace the large (outer) filter element only when the red
ring shows in the window (Item 1) [A] of the condition
indicator.
NOTE: Push the button on the condition indicator
(See Inset) and start the engine. If the red ring P–10747
does not show, do not replace the filter
element [A].
B 1
Disengage the clamps (Item 1) and remove the dust
cover (Item 2) [B].

2
Outer Element:
P–10733
Pull the outer filter element from the air cleaner housing
[C].
C
NOTE: Make sure all sealing surfaces are free of dirt
and debris.

Install a new outer element.

Install the dust cover and fasten the clamps.

Inner Element:
Only replace the inner filter element under the following
conditions [D]:
P–10734
• Replace the inner filter element every third time the
outer filter is replaced.
• Replace the inner filter element when the red ring still D
shows in the condition indicator window after the outer
filter is replaced.
Pull the inner filter element from the air cleaner housing.

NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Install the new inner element.

Record the operating hours of the loader on the decal

inside the rear door. P–10729

553 Loader
Revised Apr. 99 –1–12– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 FUEL SYSTEM
Fuel Specifications
A
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1.
The following is one suggested blending guideline which
should prevent fuel gelling problems:
Temp. F°/C° No. 2 No. 1
1
+15o(–9o) 100% 0%
Down to –20o/–29o 50% 50%
Below –20o/–29o 0% 100%
We recommend an operator contact their fuel supplier for P–10710
local recommendations.
Filling The Fuel Tank

Always clean up spilled fuel or oil. Keep heat,

flames, sparks or lighted tobacco away from
fuel and oil. Failure to use care around
Stop and cool the engine before adding fuel. combustibles can cause explosion or fire
NO SMOKING! Failure to obey warnings can which can result in injury or death.
cause an explosion or fire. W–2063–0887 W–2103–1285

Remove the fuel fill cap (Item 1) [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 1
See the SERVICE SCHEDULE Page 1–3 for the service
interval when to remove the water from the fuel filter and
to replace the fuel filter.

Remove Water:
Shut–off the fuel supply (Item 1) [B] (turn clockwise).
Loosen the drain at the bottom of the filter element (Item P–10714
1) [C] to drain the water from the filter.
Open the shut–off valve [B]. C
Replacing Filter:
Clean the area around the fuel filter.
Close the shut–off valve (Item 1) [B].
2
Remove the fuel filter element (Item 2) [C].
Install the new filter element.
Tighten the fuel filter. 1

Open the shut–off valve [B]. P–10678

553 Loader
Revised Apr. 99 –1–13– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 FUEL SYSTEM (Cont’d)
Removing Air From The Fuel System
A 3
After replacing the fuel filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
system before starting the engine.

Open the rear door.

Open the vent plug (Item 1) [A] on top of the fuel filter
head.

Operate the hand pump (Item 2) [A] until fuel flows from
the vent plug with no air bubbles.
P–10679

Tighten the vent plug.

Operate the hand pump (Item 1) [A] until it feels solid.

Move the engine speed control to minimum RPM. Open

the valve (Item 3) [A] and squeeze the hand pump several
times.
Start the engine.
When the engine runs smoothly, close the valve (Item 3)
[A].

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

Close the rear door.

P–10675

2
1

P–10678

553 Loader
Revised Apr. 99 –1–14– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE LUBRICATION SYSTEM
Checking Engine Oil
A
Check the engine oil level every day before starting the
engine for the work shift.
Open the rear door and remove the dipstick (Item 1) [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 below).
Install the dipstick and close the rear door.
Oil Chart P–10680
RECOMMENDED SAE VISCOSITY NUMBER
C° (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
–40 –34 –29 –23 –18 –13 –7 –1 +4 +10 +15 +21 +27 +32 +38 +43 +49

SAE 40W or 20W–50 1

SAE 10W–30

SAE 15W–40

SAE 30W

* SAE 5W–30
SAE 20W–20

SAE 10W P–10687

SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

–40 –30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120
B
F°
TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CD, CF4, CG4 )
* Can be used ONLY when available with appropriate diesel rating.

Replacing Oil And Filter

See the SERVICE SCHEDULE Page 1–3 for the service
interval for replacing the engine oil and filter.
Run the engine until it is at operating temperature.
Stop the engine.
Open the rear door.
2
Remove the cap (Item 1) [B] from the end of the hose and
drain the oil into a container. Dispose of used oil in an
environmentally safe manner.
Remove the filter (Item 2) [B].
Clean the filter housing surface.
Put clean oil on the gasket of the new filter. Install the filter
and hand tighten.
Install the cap on the drain hose and tighten.
1
P–10689

553 Loader
Revised Apr. 99 –1–15– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE LUBRICATION SYSTEM (Cont’d)
Replacing Oil And Filter (Cont’d)
A
Remove the oil fill cap (Item 1) [A].
Use a good quality motor oil that meets API Service 1
Classification of CD or better. (See Oil Chart Page 1–15.)
Fill to capacity. (See SPECIFICATIONS 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 fill cap (Item 1) [A].
P–10677
NOTE: DO NOT overfill the crankcase.

Record the operating hours of the loader on the decal

inside the rear door.
Close the rear door before operating the loader.

P–10689

553 Loader
Revised Apr. 99 –1–16– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE COOLING SYSTEM
Cleaning The Cooling System
A
Check the cooling system every day to prevent
overheating, loss of performance or engine damage.

Wear safety glasses to prevent eye injury when

any of the following conditions exist:
• When fluids are under pressure. P–10749

• Flying debris or loose material is present.

• Engine is running
• Tools are being used. B
W–2019–1285

Open the rear door.

Remove the access panel from the blower housing (Item
1) [A].
Remove the rear grill. (See REAR GRILL Page 5–1)
Use air pressure or water pressure to remove the debris
in the area of the radiator and oil cooler [B].
Install the rear grill and close the rear door.
P–10743
Checking The Coolant Level
Open the rear door. C
The coolant recovery tank (Item 1) [C] must be at the
FULL COLD mark when engine is cool.

Propylene Glycol
NOTE: The loader is factory filled with propylene
glycol coolant. DO NOT mix propylene glycol 1
with ethylene glycol.
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 P–10760
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.
Close the rear door before operating the loader.

553 Loader
Revised Apr. 99 –1–17– Service Manual
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 ENGINE COOLING SYSTEM (Cont’d)
Replacing The Coolant
A
Open the rear door.
1
Remove the rear grill. (See REAR GRILL Page 5–1.)
Remove the radiator cap (Item 1) [A].

Connect a hose to the coolant drain valve (Item 1) [B] or P–10744

use a funnel to keep coolant from getting into the engine
compartment.
Open the valve and drain all the coolant into a container.
B
Close the valve.
Fill the radiator with premixed coolant and install the
radiator cap. (See Checking the Coolant Level Page 1–17
for premix recommendations.)

Fill the coolant recovery tank 1/3 full with premixed 1

coolant (Item 1) [C].
Check the radiator cap for correct pressure rating or
overheating can result. P–10687

Check for leaks in the cooling system. Check for worn or

damaged hoses, clamps or radiator. Check for loose or
worn water pump belt. C
Replace damaged parts immediately to prevent leaks and
overheating.
Install the radiator cap and the rear grill and close the rear
door.

P–10760
AVOID ENGINE DAMAGE
Always use the correct ratio of water to anti-
freeze.
Too much antifreeze reduces cooling system
efficiency and may cause serious premature
engine damage.
Too little antifreeze reduces the additives
which protect the internal engine compo-
nents; reduces the boiling point and freeze
protection of the system.
Always add a premixed solution. Adding full
strength concentrated coolant can cause seri-
ous premature engine damage.
I–2124–0497

553 Loader
Revised Apr. 99 –1–18– Service Manual
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 ALTERNATOR BELT
Adjusting The Alternator Belt
A
1
Stop the engine.
Open the rear door.
Remove the engine belt shield. 2

Loosen the mounting bolt (Item 1) and adjustment bolt

(Item 2) [A].
P–10682

P–10689

Move the alternator to set the belt tension at 5/16 inch (8

mm) movement between pulleys with 15 pounds (67 N)
B
of force [B].
Tighten the adjustment bolt and mounting bolt.
Install the engine belt shield.
Close the rear door.

P–10681

553 Loader
Revised Apr. 99 –1–19– Service Manual
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 HYDRAULIC/HYDROSTATIC SYSTEM
A
Description
1
The hydraulic and hydrostatic systems use the same
hydraulic fluid reservoir.
The system has an engine driven pump that supplies fluid
to the control valve, lift and tilt cylinders.
Fluid also goes from the control valve to the hydrostatic
transmission pumps to provide charge pressure and
cooling.
A filter is installed on the right side of the engine
compartment. This filter cleans the fluid for the
hydrostatic transmission. P–10693

The oil cooler is under the radiator. The oil cooler cools the
hydraulic fluid before it returns to the hydrostatic pump. B
Checking And Adding Fluid
Use only recommended fluid in the hydraulic/hydrostatic
system. (See SPECIFICATIONS Page 9–1.)
1
Put the loader on a level surface.
Lower the lift arms and put the attachment flat on the
ground.
Stop the engine.
Hydraulic fluid must show in the sight gauge (Item 1) [A].
P–10697
Remove the filler cap (Item 1) [B].
Add fluid to the reservoir until it shows in the sight gauge
[A].
Install the filler cap [B].

553 Loader
Revised Apr. 99 –1–20– Service Manual
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 HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)
Replacing The Hydraulic/Hydrostatic Filter
A
See the SERVICE SCHEDULE Page 1–3 for the correct
service interval to replace the filter.
Stop the engine. Open the rear door. 1
Clean the area around the filter housing and remove the
filter element (Item 1) [A].
Clean the surface where the filter seal contacts the filter
housing.
Lubricate the rubber gasket with grease. Install the filter
element and hand tighten.
P–10685
Operate the loader and check for leaks at the filter.
Check fluid level in the reservoir and add as needed. B
Close the rear door.

Replacing Hydraulic Fluid

See the SERVICE SCHEDULE Page 1–3 for the service 1
interval to replace the fluid. Replace the fluid if it becomes
contaminated and after any major repairs.
Remove the filler cap (Item 1) [B].
Remove the screen (Item 1) [C].
Wash the screen in clean solvent. Install the screen in the
hydraulic reservoir. P–10697

Remove the fluid from the hydraulic reservoir. (See Page

2–1.) C
Remove the filter element.
Install a new filter element. (See procedure above.)
Add hydraulic/hydrostatic fluid to the reservoir. (See 1
SPECIFICATIONS Page 9–1 for the correct fluid.) DO
NOT fill above the sight glass.
Install the filler cap.
Close the rear door.
Operate the loader.
Stop the engine. P–10695

Check the fluid level and add as needed.

AVOID INJURY OR DEATH

Never service or adjust the machine when the
engine is running unless instructed to do so
in the manual.
W–2012–0497

553 Loader
Revised Apr. 99 –1–21– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SPARK ARRESTOR MUFFLER
A
Cleaning Procedure
See the SERVICE SCHEDULE Page 1–3 for correct
service interval to clean the spark arrestor muffler.
Do not operate the loader with a defective exhaust
system.

P–10692
This loader is factory equipped with a U.S.D.A.
Forestry Service approved spark arrestor
muffler. It is necessary to do maintenance on
this spark arrestor muffler to keep it in working
condition. The spark arrestor muffler must be
serviced by dumping the spark chamber every
100 hours of operation.
If this machine is operated on flammable forest,
brush or grass covered land, it must be
equipped with a spark arrestor attached to the
exhaust system and maintained in working
order. Failure to do so will be in violation of
California State Law, Section 4442 PRC.
Make reference to local laws and regulations for
spark arrestor requirements.
I–2022–0595

Stop engine and allow the muffler to cool

before cleaning the spark chamber. Wear safety
goggles. Failure to obey can cause serious
injury.
W–2011–1285

When an engine is running in an enclosed area,

fresh air must be added to avoid concentration
of exhaust fumes. If the engine is stationary,
vent the exhaust outside. Exhaust fumes
contain odorless, invisible gases which can kill
without warning.
W–2050–1285

Stop the engine. Open the rear door.

Cover the battery with a fire retardant material.
Remove the plug (Item 1) [A] at the bottom of the muffler.
Start the engine.
Have a second person (wearing safety goggles) hold a
block of wood over the outlet of the muffler (with the
engine running) for about 10 seconds.
Stop the engine and install the plug.
Close the rear door.
553 Loader
Revised Apr. 99 –1–22– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 TIRE MAINTENANCE
Wheel Nuts
A
See the SERVICE SCHEDULE Page 1–3 for the service
interval to check the wheel nuts. The correct torque is
105–115 ft.–lbs. (142–156 Nm) [A].
Tire Rotation
Check the tires regularly for wear, damage and pressure.
(See SPECIFICATIONS Page 9–1 for the correct tire
pressure.)
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [B]. P–10704

It is important to keep the same size tires on each side of

the loader to avoid excessive wear. If different sizes are
used, each tire will be turning at a different rate and cause
B
excessive wear. The tread bars of all the tires must face
the same direction.
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before
operating the loader.
Tire Mounting
Tires are to be repaired only by an authorized person
using the proper procedures and safety equipment. Tires
and rims must always be checked for correct size before
mounting. Check rim and tire bead for damage. C–01965

The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire, avoid excess pressure
which can rupture the tire and cause serious injury or
death. During inflation of the tire, check the tire pressure
frequently to avoid over–inflation.
Inflate tires to the MAXIMUM pressure shown on the side Do not inflate tires above specified pressure.
wall of the tire. DO NOT mix brands of tires used on the Failure to use correct tire mounting procedure
same loader. can cause an explosion which can result in
injury or death.
W–2078–1285

Inflate tires to the MAXIMUM pressure shown

on the sidewall of the tire. DO NOT mix brands
of tires used on the same loader.
I–2057–0794

553 Loader
Revised Apr. 99 –1–23– Service Manual
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 FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
A
The chaincase contains the final drive sprockets and
chains and uses the same type of oil as the
hydraulic/hydrostatic system. (See SPECIFICATIONS
Page 9–1.)
Drive the loader on a level surface. Stop the engine.
1
Remove the plug (Item 1) [A] from the front of the
chaincase housing.
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
P–10699
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.

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Revised Apr. 99 –1–24– Service Manual
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 LUBRICATING THE BOBCAT LOADER
553ServiceManual#6900450–PreventiveMaintenanceSectionPart1of2

A
Procedure
Lubricate the Bobcat loader as specified in the SERVICE 1
SCHEDULE Page 1–3 for the best performance of the
loader.
Record the operating hours each time you lubricate the
Bobcat loader.
Always use a good quality lithium based multi–purpose
grease when you lubricate the loader. Apply until extra
grease shows.
Lubricate the following locations on the loader:
P–10694

1. Rod End Lift Cylinder (both sides) [A].

B
2. Base End Lift Cylinder (both sides) [B].

P–10698

3. Lift Arm Pivot Pin (both sides) [C]. C

C 3

P–10700
P–10698

4. Base End Tilt Cylinder [D].

D
4

P–10758

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Revised Apr. 99 –1–25– Service Manual
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 LUBRICATING THE BOBCAT LOADER (Cont’d)
Procedure (Cont’d)
A
5
5. Rod End Tilt Cylinder [A].

6. Bob–Tach Pivot Pin (both sides) [A]. 6 7

7. Bob–Tach Wedge (both sides) [A].

P–10696

8. 250 Hours: Steering Lever Shaft Bearings two [B]

B
(The opposite end is lubricated under the cab.).
Put oil in the hole of the cross shaft where the right 8
and left steering shafts meet under the cab.

P–10709

PIVOT PINS
C
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [C].
Check that the lock nuts are tightened to 18–20 ft.–lbs.
(24–27 Nm) torque.
1

P–10698

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Revised Apr. 99 –1–26– Service Manual
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 BOB–TACH
Inspection And Maintenance
A
Move the Bob–Tach levers to engage the wedges [A]. 1
The levers and wedges must move freely. N–17033

The wedges must extend through the holes in the

attachment mounting frame (Item 1) [A].

N–17031
Bob–Tach wedges must extend through the
holes in attachment. Levers must be fully
down and locked. Failure to secure wedges
can allow attachment to come off and cause B
injury or death.
W–2102–0588

The spring loaded wedge (Item 1) [A] must contact the

lower edge of the hole in the attachment (Item 1) [B] and
[C].
If the wedge does not contact the lower edge of the hole
[B] and [C], the attachment will be loose and can come
off the Bob–Tach.
1

N–17034

C Bob–Tach
Wedge

Wedge Must Contact

Lower Edge Of Hole
In The Attachment

Inspect the mounting frame on the attachment and the

Bob–Tach, linkages and wedges for excessive wear or
damage [D]. Replace any parts that are damaged, bent,
D
or missing. Keep all fasteners tight.

Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.
Lubricate the wedges (See SERVICE SCHEDULE, Page
1–3 and LUBRICATION OF THE BOBCAT LOADER,
Page 1–25.)

TS–01062

553 Loader
Revised Apr. 99 –1–27– Service Manual
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 AUXILIARY CONTROL LOCKBOLT
A
Removal
The auxiliary control has a lockbolt (Item 1) [A] that must
be removed to use the optional auxiliary hydraulics.
Raise the operator cab. (See Page 1–9.)
1
Remove the nut and bolt (Item 1) [A] at the right hand
steering lever.
Lower the operator cab. (See Page 1–9.)

P–10754

U–JOINT LUBRICATION B
Procedure
See the SERVICE SCHEDULE Page 1–3 for the correct
service interval to lubricate the U–joint grease fittings
(three) (Item 1) [B].
Raise the operator cab. (See Page 1–9.)
Use the special U–joint grease (P/N 6599719) for correct 1
lubrication for the U–joint.
Lower the operator cab. (See Page 1–9.)

P–10727

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Revised Apr. 99 –1–28– Service Manual
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 REMOTE START SWITCH
Procedure
A
The tool listed will be needed to do the following
procedure:
MEL1429 B – Remote Start Switch
The Remote Start Switch is required when the service
technician is adjusting the steering linkage, checking the
hydraulic/hydrostatic system.
Lift and block the loader. (See Page 1–4.)
1
P–07101

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
lift arm support device. Failure to use an
approved lift arm support device can allow the P–10965
lift arms or attachment to fall and cause injury
or death. W–2059–0598
C
Raise the lift arms and install an approved lift arm support
device. (See Page 1–7.)
Raise the operator cab. (See Page 1–9.) 1

NOTE: On current model loaders, the connector on

the BICS harness is round (7–pin) connector,
not a rectangular (8–pin) connector. Use the
adapter harness (Item 1) [A] to connect the
remote start switch to the loader harness.
Disconnect the operator cab wire harness (Item 1) [B]
from the engine wire harness.
1
Connect the remote start switch to the engine harness
connectors (Item 1) [C].

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

P–10966

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Added Apr. 99 –1–29– Service Manual
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 REMOTE START SWITCH (Cont’d)
553ServiceManual#6900450–PreventiveMaintenanceSectionPart2of2

A
Procedure (Cont’d) 1
Put the traction lock override switch (Item 1) [A] in the ON
position so the traction function is locked. The wheels are
not able to turn.
Turn the key to the right and start the engine.

P–04713

Move the traction lock override switch (Item 1) [B] to the

OFF position so the traction function is unlocked. The
wheels are now able to turn.
B
1
The auxiliary mode switch (Item 2) [B] is used to turn the
front auxiliary quick couplers ON and OFF during relief
pressure and flow tests.

2
B–04714

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Added Apr. 99 –1–30– Service Manual
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 1
(5–1–98)
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 (5–1–98)
2

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 3
(5–1–98)

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Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC SYSTEM
Page
Number
CONTROL PEDALS
Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–45
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–45 HYDRAULIC
SYSTEM
CROSSMEMBER LINKAGE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–48
HYDRAULIC CONTROL VALVE
Anti–Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
Auxiliary Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31
Lift Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23
One Way Restrictors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25
Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32
Tilt Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30
HYDRAULIC CYLINDER
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
Lift Cylinder Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
Tilt Cylinder Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
HYDRAULIC FILTER HOUSING
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–44
HYDRAULIC FLUID RESERVOIR
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39
HYDRAULIC PUMP
Checking The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . 2–33
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–37
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–38
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–36
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–35
HYDRAULIC SYSTEM INFORMATION
Tighten Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
LIFT LOCK BY–PASS VALVE
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–41
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–40

Continued On Next Page

553 Loader
Revised Apr. 99 –2–1– Service Manual
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 HYDRAULIC SYSTEM (Cont’d)
Page
Number
LIFT CYLINDER(S)
Checking The Lift Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Left Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Right Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
Left Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
Right Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6

MAIN RELIEF VALVE

Checking The Main Relief Valve With Auxiliaries . . . . . . . . . . . . . . . . . . 2–16
Checking The Main Relief Valve Without Auxiliaries . . . . . . . . . . . . . . . . 2–15
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17

PEDAL INTERLOCK LINKAGE

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–47
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46
TILT CYLINDER
Checking The Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9

TILT LOCK VALVE

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–43
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42

TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 9)
UNLESS OTHERWISE SPECIFIED.

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–2–2– Service Manual
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 TROUBLESHOOTING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel
only. Check for correct function after adjustments,
repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

PROBLEM CAUSE

The hydraulic system will not operate. 1, 2, 3, 5, 8

The transmission warning light comes ON when hydraulics are
operating. 1, 3

Slow hydraulic system action. 1, 3, 4, 6, 8

Hydraulic action is not smooth. 1, 4, 5, 6, 7

Lift arms go up slowly at full engine RPM. 1, 3, 4, 6, 7, 8, 9

The lift arms or Bob–Tach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11

KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.

2. The pedal linkage is disconnected.

3. The hydraulic pump has damage.

4. The pedal linkage is not adjusted correctly.

5. Relief valve is not at the correct pressure.

6. Suction leak on the inlet side of the hydraulic pump.

7. Fluid is cold. Wrong viscosity fluid. (See Section 9.)

8. Using the loader for more than its rated capacity.

9. Internal leak in the lift cylinder(s).

10. External leak from the lift cylinder(s).

11. Damaged lift spool.

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 HYDRAULIC SYSTEM INFORMATION

When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888

Tighten Procedures
To tightening the hydraulic fittings, tubelines etc.,
See Section 9. – Hydraulic Connection
Specifications, for the correct procedure and torque.

Hydraulic fluid escaping under pressure can

have sufficient force to enter a person’s body
by penetrating the skin. This can cause serious
injury and possibly death if proper medical
treatment by a physician familiar with this
injury is not received immediately.
W–2145–0290

553 Loader
Revised Apr. 99 –2–4– Service Manual
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 LIFT CYLINDERS
Checking The Lift Cylinder(s)
A
Stop the engine.
2
Pull the lift arm by–pass control and move the lift pedal to
release the hydraulic pressure.
Raise the seat bar.
Check only one cylinder at a time. 1
Left Lift Cylinder
At the engine compartment, disconnect the lift cylinder
base end hose (Item 1) [A] from the hydraulic tubeline P–10837
(Item 2) [A].
Install a plug in the tubeline (Item 1) [B] and tighten. B
Lower the seat bar and start the engine, be sure the
parking brake is engaged.
Push the top (toe) of the lift pedal. 1
If there is leakage from the lift cylinder base end hose,
remove the lift cylinder for repair. (See Page 2–6.)

P–10836

Right Lift Cylinder

C
Remove the loader battery. (See Page 6–1.)
Disconnect the lift cylinder base end hose (Item 1) [C]
from the hydraulic tubeline.
1
Install a plug in the tubeline (Item 2) [C] and tighten.
2
Install the battery and connect the battery cables,
negative cable last.
Lower the seat bar and start the engine, be sure the
parking brake is engaged.
Push the top (toe) of the lift pedal. P–10839

If there is leakage form the lift cylinder base end hose,

remove the lift cylinder for repair. (See Page 2–6.)

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 LIFT CYLINDERS (Cont’d)
Removal And Installation
A
Right Lift Cylinder
Raise the lift arms, and have a second person put
jackstands under the Bob–Tach.
Stop the engine. Pull up on the lift arm by–pass control
and move the lift pedal to release the hydraulic pressure,
until the Bob–Tach rests on the jackstands [A].
Raise the seat bar.
Place jackstands under the rear of the loader. (See Page
1–1.) P–10884

Raise the operator cab. (See Page 1–1.)

B
Remove the retainer bolt (Item 1) [B] and nut from the rod
end pivot pin.
5
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque.
Remove the rod end pivot pin (Item 2) [B] from the 4
cylinder.
1 3
Remove the retainer bolt (Item 3) [B] nut and spacer from
the lift arm support device. 2
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque. P–10856

Remove the lift arm support device retaining pin (Item 4)

[B].
C
Remove the lift arm support device (Item 5) [B].
1
Remove the battery. (See Page 6–1.)
2
At the engine compartment disconnect the lift cylinder rod
end hose (Item 1) [C] from the tubeline.
Disconnect the lift cylinder base end hose (Item 2) [C]
from the tubeline. Cap and plug all hoses and tubelines.

P–10839

Remove the retainer bolt (Item 1) [D] and nut from the
base end pivot pin. D
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque.
Remove the base end pivot pin (Item 2)[D].
1
Remove the lift cylinder from the loader.

P–10874

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–2–6– Service Manual
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 LIFT CYLINDERS (Cont’d)
Removal and Installation (Cont’d)
A
Left Lift Cylinder
Raise the lift arms, and have a second person put
jackstands under the Bob–Tach.
Stop the engine. Pull up on the lift arm by–pass control
and move the lift pedal to release the hydraulic pressure,
until the Bob–Tach rests on the jackstands [A].
Raise the seat bar.
Place jackstands under the rear of the loader. (See Page
1–1.) P–10884

Raise the operator cab. (See Page 1–1.)

Remove the retainer bolt (Item 1) [B] and nut from the rod
B
end pivot pin.
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque.
1
Remove the rod end pivot pin (Item 2) [B] from the
cylinder.

P–10878

At the engine compartment disconnect the lift cylinder

base end hose (Item 1) [C]. C
Disconnect the lift cylinder rod end hose (Item 2) [C]. Cap
and plug all hoses and tubelines.
2

P–10837

Remove the retainer bolt (Item 1) [D] and nut from the D
base end pivot pin.
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque. 1

Remove the base end pivot pin (Item 2) [D] from the
cylinder.
2
Remove the lift cylinder from the lift arm.

P–10875

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 TILT CYLINDER
Checking The Tilt Cylinder
A
Remove the attachment from the Bob–Tach.
2
Retract the tilt cylinder (Item 1) [A]. 1
NOTE: The Bob–Tach is disconnected from the tilt
cylinder for photo clarity purposes only.

Stop the engine and raise the seat bar.

P–10844

Hydraulic fluid escaping under pressure can

have sufficient force to enter a person’s body
by penetrating the skin. This can cause serious
injury and possibly death if proper medical
treatment by a physician familiar with this
injury is not received immediately.
W–2145–0290

Disconnect the hose (Item 2) [A] from the base end of the
tilt cylinder.
Install a plug in the hose and tighten the plug.
Lower the seat bar and start the engine, be sure the
parking brake is engaged.
Push the bottom (heel) of the tilt pedal.
If there is leakage from the open port of the tilt cylinder,
remove the cylinder for repair. (See Page 2–9.)

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 TILT CYLINDER (Cont’d)
Removal And Installation
A
Remove the attachment from the Bob–Tach.
1
Roll the Bob–Tach fully out with the lift arms slightly
raised.
Stop the engine.
Pull up on the lift arm by–pass and lower the Bob–Tach
onto blocks [A].
Raise the seat bar.
Place jackstands under the rear of the loader. (See Page P–10896
1–1.)
Remove the retainer bolt (Item 1) [A] and nut from the tilt
cylinder rod end pivot pin.
B
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque.
Remove the pivot pin (Item 1) [B] from the tilt cylinder. 1

NOTE: Do not use a hammer and punch on the end

of the pivot pin with the lubrication fitting.
Damage can occur to the lubrication fitting.

P–05827

Retract the tilt cylinder to prevent damage to the rod

during removal [C]. C
Disconnect the rod and base end hoses (Items 1) [C] from 1
the tilt cylinder.
1

P–10844

Remove the retainer bolt and nut (Item 1) [D] from the
base end pivot pin.
D
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque.

P–10877

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 TILT CYLINDER (Cont’d)
Removal And Installation (Cont’d)
A
Remove the base end pivot pin (Item 1) [A] from the tilt
cylinder.
Remove the tilt cylinder from the loader.
1

P–10880

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 HYDRAULIC CYLINDER
Lift Cylinder Identification

1. Case 9. O–ring
2. Piston 10. O–ring
3. Head 11. Washer
4. Rod 12. Seal
5. Spacer 13. Seal
6. O–ring 14. Plug
7. Nut 15. O–ring
8. Ring 16. Tube

2
4
*7
14
15
6
13
16
12
1
14 3

15
11

10

* Tighten to 180 ft.–lbs. (244 Nm) torque. TS–01097

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 HYDRAULIC CYLINDER (Cont’d)
Tilt Cylinder Identification

1. Cylinder 10. Seal

2. Case 11. Seal
3. Nut 12. Rod
4. Piston 13. Seal
5. Seal 14. Tube
6. O–ring 15. Clamp
7. O–ring 16. Bolt
8. Washer 17. Nut
9. Head

MC–01688

10

16 11

14 1

12
2
7
15

8 13
3
13
17 19
4

MC–01688

* Tighten to 400 ft.–lbs. (542 Nm) torque C–02808

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 HYDRAULIC CYLINDER (Cont’d)
A
Disassembly And Assembly
Use the following tools to disassemble and assemble the
cylinder:
MEL1074 – O–ring Seal Hook
MEL1396 – Seal Installation Tool
MEL1033 – Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench

NOTE: The lift cylinder will be used to represent

repair for both lift and tilt cylinders. The
cylinders internal components are similar.
P–07429
The differences are listed below.

Tilt rod diameter is larger.

Piston relief area is slightly different. B 4
No spacer in the tilt cylinder.
Higher torque for the tilt rod nut. 2 3

Hold the hydraulic cylinder over a drain pan and move the 1
rod in and out slowly to remove the fluid from the cylinder.
Put the base end of the cylinder in a vise.
Use a spanner wrench to loosen the head [A].

Remove the head and the rod assembly from the cylinder
[B].
Put the rod end in a vise. P–07428

Remove the nut (Item 1) [B], piston (Item 2) [B], spacer

(Item 3) [B] and head (Item 4) [B]. C 3
Installation: Lift: Tighten the nut to 180 ft.–lbs. (244 Nm)
torque.
Tilt: Tighten the nut to 600 ft.–lbs. (813 Nm) 2
torque.
1

Remove the seal (Item 1) [C] and O–ring (Item 2) [C] from
the piston (Item 3) [C].

P–07430

Remove the thick O–ring (Item 1) [D] and the back–up

washer (Item 2) [D] from the groove in the head. Remove
the thin O–ring (Item 3) [D].
D

2
1

P–07422

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Revised Mar. 02 –2–13– Service Manual
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 HYDRAULIC CYLINDER (Cont’d)
A
Disassembly And Assembly (Cont’d)
Remove the wiper seal (Item 1) [A], and the rod seal (Item
2) [A].
Remove the O–ring (Item 3) [A] from the rod seal. 2
Wash the cylinder parts in solvent and air dry them. 3 1
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
Always install new O–rings and seals during assembly.
Lubricate all O–rings and seals with hydraulic oil during P–07426
installation.

Install the new seal on the tool and slowly stretch it until
B
it fits the piston [B].
Allow the seal to stretch for 30 seconds before installing
it on the piston.
Use a ring compressor to compress the seal to the correct
size. Leave the piston in the compressor for about three
minutes.

P–07424

Install the rod seal on the rod seal tool [C].

C
NOTE: During installation the O–ring side of the seal
must be toward the inside of the cylinder.
Rotate the handles to collapse the rod seal.

P–07427

Install the rod seal in the head [D].

D
Install the wiper seal with the wiper toward the outside of
the head.

P–07425

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 MAIN RELIEF VALVE (Cont’d)
Checking the Main Relief Valve Without Auxiliaries
A
1
The tools listed will be needed to do the following
procedure:
1
MEL10003 – Hydraulic Tester
MEL10006 – Hydraulic Test Kit
Stop the engine.
Lift and block the loader. (See Page 1–1.)
Disconnect the hydraulic hoses (Item 1) [A] from the tilt
cylinder.
P–10844
Connect the hydraulic tester to the tilt cylinder hoses.
Have a second person in the operator seat, with seat bar
in down position.

The hydraulic tester must be in the fully open

position before you start the engine.
I–2024–0284

Start the engine and run at idle RPM.

Push the tilt pedal at the top (toe) or bottom (heel) until the
hydraulic tester shows the correct fluid flow through the
flow meter.
Increase the engine RPM to maximum.
There should be 8.5 GPM (32 L/min.) free flow.
Turn the restrictor control, on the tester, to increase the
pressure until the main relief valve opens.
The correct pressure is 2000 PSI (13790 kPa).
Stop the engine.
Replace or adjust the main relief valve. (See Page 2–17.)

When an engine is running in an enclosed

area, fresh air must be added to avoid
concentration of exhaust fumes. If the engine
is stationary, vent the exhaust outside.
Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W–2050–1285

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 MAIN RELIEF VALVE (Cont’d)
Checking The Main Relief Valve With Auxiliaries
A
NOTE: The following procedure is for checking the
main relief valve only. Use this procedure
when it is known that the hydraulic pump is
in good working condition. If the hydraulic 2
pump is not working correctly, refer to
checking the output of the hydraulic pump
Page 2–34.

The tools listed will be needed to do the following

procedure:
MEL10003 – Hydraulic Tester 1
P–05933
MEL10006 – Hydraulic Test Kit
Lift and block the loader. (See Page 1–1.)
B
Connect the IN port of the hydraulic tester to the bottom
(female) quick coupler (Item 1) [A] on the loader.
’
Connect the OUT port of the hydraulic tester to the top
(male) quick coupler (Item 2) [A] on the loader.

The hydraulic tester must be in the fully open P–10750

position before you start the engine.
I–2024–0284

Remove the auxiliary hydraulics lock bolt. (See Page

1–1.)
Put jackstands under the front axles and rear
Start the engine and run at low idle RPM. Push the right corners of the frame before running the engine
steering lever all the way to the right to engage the front for service. Failure to use jackstands can allow
auxiliary hydraulics detent [B]. the machine to fall or move and cause injury or
death.
Increase the engine speed to full RPM. Watch the flow W–2017–0286
meter on the hydraulic tester to make sure the flow is
correct.
There should be 8.5 GPM (32 L/min.) free flow
The correct pressure for the main relief valve is 2000 PSI
(13790 kPa).
If the relief valve pressure is not correct, stop the engine.
Adjust or replace the main relief valve. (See Page 2–17.)
When the test is complete, move the steering lever back
to center to disengage the front auxiliary hydraulics. When the engine is running during service, the
steering levers must be in neutral and the
parking brake engaged. Failure to do so can
cause injury or death.
W–2006–0284

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 MAIN RELIEF VALVE (Cont’d)
Removal And Installation
A
Raise the operator cab. (See Page 1–1.)
Clean the area around the control valve. Loosen and
remove the main relief valve (Item 1) [A].
Installation: Tighten the main relief valve to 35–40 1
ft.–lbs. (47–54 Nm) torque.

When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888

NOTE: The engine has been removed for clarity only.

It does not need to be removed to remove the
main relief valve.

Adjustment
If the main relief pressure is not correct, it needs to be
adjusted. P–07071

An adjusting screw is located on the end of the main relief

valve (Item 1) [A].
B
Remove the end cap (Item 1) [B] from the main relief
valve. O–ring
Turn the adjusting screw in (increase pressure) or out
(decrease pressure) until the correct main relief pressure
2000 PSI (13790 kPa) is obtained.
If the correct pressure can not be obtained, remove the
main relief valve from the the main control valve. (See 1
procedure above.)
Remove the O–rings and backup washers from the main
relief valve [B]. Backup
B–06764
Clean the main relief valve in clean solvent. Use air
pressure to dry the valve.
Install new O–rings and backup washers. Install the main
relief valve (Item 1) [B] and tighten. Readjust the main
relief valve to the correct setting.
NOTE: If the correct pressure can not be obtained
after cleaning and readjusting the main relief
valve, replace the relief valve. Also check the
pressure of the new relief valve.

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 HYDRAULIC CONTROL VALVE
Removal And Installation
A 1

P–05943

B
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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–2059–0598

Lift and block the loader. (See Page 1–1.)

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.) Stop the engine. 1

Pull up on the lift arm bypass control and move the lift P–05942
pedal to release the hydraulic pressure. Raise the seat
bar.
Raise the operator cab. (See Page 1–1.)
C
Remove the control panel from the loader. (See Page
3–1.)
Thoroughly clean the control valve area.
Disconnect the lift (Item 1) [A], tilt (Item 2) [A] and
auxiliary spool (Item 3) [A] linkages from the control
valve.
Disconnect the control valve inlet hose (Item 1) [B] which
comes from the hydraulic pump. 1
Disconnect and remove the two tubelines (Item 1) [C] that P–05946
are routed over the control valve which come from the lift
lock valve.
Disconnect the front (rod end) tubeline (Item 1) [D] from
D
the lift section of the control valve.

P–05948

553 Loader
Revised Apr. 99 –2–18– Service Manual
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 HYDRAULIC CONTROL VALVE (Cont’d)
Removal And Installation (Cont’d)
A
2
Disconnect the front (rod end) tubeline (Item 1) [A] from
the tee fitting on the tilt section of the control valve.

NOTE: The tee fitting located in this port is capped

because it is not equipped with an optional
bucket position valve. If the loader has a
bucket position valve, disconnect the
tubeline from this fitting. 1
Disconnect the return tubeline (Item 2) [A] which tees into
the fitting located on the inlet port of the control valve.
P–05949

Disconnect the rear (base end) tubeline (Item 1) [B] from

the lift section of the control valve. B
1

P–05950

Disconnect the rear (base end) tubeline (Item 1) [C] from

the tee fitting of the tilt section of the control valve. C
NOTE: The tee fitting located in this port is capped 1
because it is not equipped with an optional
bucket position valve. If the loader has a
bucket position valve, disconnect the
tubeline from this fitting.

P–05951

Disconnect the two tubelines (Item 1) [D] from the

auxiliary section of the control valve. D
Disconnect the tubelines (Item 2) [D] from the outlet port 1
of the control valve.

P–05947

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–2–19– Service Manual
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 HYDRAULIC CONTROL VALVE (Cont’d)
Removal And Installation (Cont’d)
A
1
Remove the two mounting bolts (Item 1) [A] from the
control valve.
Installation: Tighten the mounting bolts to 17 ft.–lbs. (23
Nm) torque.
Remove the control valve from the loader.
Use the reverse removal procedure to install the hydraulic
control valve.

P–05953

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Revised Mar. 02 –2–20– Service Manual
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 HYDRAULIC CONTROL VALVE (Cont’d)
A G1 G3
Identification Chart
F1
Item 553
G2
A1 Lift Cylinder Rod End
F2
A2 Tilt Cylinder Rod End
(Internal Restrictor .110’’)
A3 Auxiliary Coupler (Female)
B1 Lift Cylinder Base End
(Internal Restrictor .125’’) B1 B2 B3

B2 Tilt Cylinder Base End

B3 Auxiliary Coupler (Male) C1 C2 C3

C1 Lift Load Check INLET

C2 Tilt Load Check A1 A2 A3

OUTLET
C3 Auxiliary Load Check
D1 Lift Spool
D2 Tilt Spool
D3 Auxiliary Spool E1
E1 Plug D1 D2 D3
B–06283
F1 Relief Valve
F2 Anti–Cav. Check Valve
G1 Lift Detent
G2 Tilt Centering Spring
G3 Auxiliary Detent

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 HYDRAULIC CONTROL VALVE (Cont’d)
Disassembly and Assembly
A
Refer to CONTROL VALVE Identification Chart Page 1
2–21 for the correct location of the parts.

When repairing hydrostatic and hydraulic

systems, clean the work area before P–07263
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system. B
I–2003–0888

Mark each valve section and spool so that the parts will
be returned to their original bore during assembly.
Use bolts to fasten the control valve to a work bench for
easier disassembly and assembly.
Load Check Valve 2
1
Loosen the load check plug (Item 1) [A] (C port). See
CONTROL VALVE Identification Chart Page 2–21. 3
P–07265
Assemble: Always use new O–ring. Tighten the plug to
35–40 ft.–lbs. (47–54 Nm) torque.

Remove the load check plug (Item 1) [B], spring (Item 2)

[B], and load check valve (Item 3) [B].

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 HYDRAULIC CONTROL VALVE (Cont’d)
Main Relief Valve
A
Loosen the main relief valve (Item 1) [A].
Assembly: Always use new O–rings and back–up
washers. Tighten to 35–40 ft.–lbs. (47–54 Nm) torque.

1
P–07267

Remove the main relief valve (Item 1) [B] from the control
valve. B

1
P–07268

Remove the O–ring (Item 1) [C], back–up washer (Item

2) [C], glide ring (Item 3) [C] and O–ring (under the glide C
ring) from the main relief valve. 1
2 3

P–07262

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 HYDRAULIC CONTROL VALVE (Cont’d)
Anti–Cavitation Check Valve
A
Loosen the anti–cavitation check valve (Item 1) [A].
1
Assembly: Always use new O–rings and backup
washers. Tighten to 35–40 ft.–lbs. (47–54 Nm) torque.
NOTE: The anti–cavitation check valve is located in
the control valve (F2 port). See CONTROL
VALVE Identification Chart, Page 2–21.

P–07271

Remove the anti–cavitation check valve (Item 1) [B] from

the control valve. B
Remove the O–ring (Item 2) [B].
2
Remove the O–ring (Item 3) [B] and backup washer.

1 3

P–07270

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 HYDRAULIC CONTROL VALVE (Cont’d)
553ServiceManual(S/N516311001&Above)#6900450– HydraulicSystemSectionPart1of2

Rubber Boot
A
Remove the two screws (Item 1) [A] from the rubber boot
retainer.
Assembly: Tighten the screws to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.

1
P–07264

Remove the rubber boot (Item 1) [B] and boot retainer

(Item 2) [B].
B
Remove the O–ring retainer plate (Item 3) [B] and O–ring
(Item 4) [B]. 2
Assembly: Use a new O–ring (Item 4) [B] for assembly. 1

4
3

P–07273

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–2–25– Service Manual
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 HYDRAULIC CONTROL VALVE (Cont’d)
Lift Spool Detent
A
The tool listed will be needed to do the following
procedure:
MEL1278 – Detent Tool
2
The lift spool detent (Item 1) [A] is located next to the main
relief valve (Item 2) [A].

1 P–07271

Remove the two screws (Item 1) [B] from the detent cap
(Item 2) [B].
B
Remove the snap ring (Item 3) [B] and washer (Item 4)
[B]. 2

The detent assembly has small springs and

balls. Do not lose these parts during 1 3
disassembly and assembly.
4
I–2012–0284 P–07272

Remove the detent cap (Item 1) [C]. C

Wrap a clean rag around the detent sleeve (Item 2) [C] to
prevent losing the two detent balls.
NOTE: The detent sleeve (Item 2) [C] is longer than
the detent sleeve located on the auxiliary
spool. DO NOT switch the sleeves from one
spool to the other.
2

P–07276

Remove the detent sleeve (Item 1) [D], two detent balls

(Item 2) [D], and detent spring (Item 3) [D]. D
Remove the rubber boot assembly from the control valve
(linkage side). (See Page 2–25 for the correct procedure.)

3
2

1
P–07275

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 HYDRAULIC CONTROL VALVE (Cont’d)
Lift Spool Detent (Cont’d)
A
3
Remove the spool assembly (Item 1) [A] back–up washer
(Item 2) [A], and spool seal (Item 3) [A] from the control
valve.

1
P–07274
Put the linkage end of the spool assembly (Item 1) [B] in
a vise.
Install MEL1285 Spring Compressor Tool (Item 1) [B] on
B
the spring assembly.
Loosen the detent adapter [B].
1

The detent assembly has small springs and

balls. Do not lose these parts during
disassembly and assembly.
I–2012–0284 P–07306

Wrap a clean rag around the assembled detent adapter C

(Item 1) [C] and adapter retainer (Item 2) [C].
2
Remove the detent adapter (Item 1) [C] from the adapter
retainer (Item 2) [C]. 1
Remove the detent spring (Item 3) [C] and detent balls
(Item 4) [C]. 6
Remove the centering spring (Item 5) [C] and end cap 5
(Item 6) [C] from the spool. 3

P–07280

Lift Spool Only: Remove the stud from the end of the
spool [D]. D

P–07278

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 HYDRAULIC CONTROL VALVE (Cont’d)
A
Lift Spool Detent (Cont’d) 2
Removal of the plastic plug [A]:
• Make a center point in the plug using a 3/16 inch drill.
• Drill a hole all the way through the plug using a 7/64
inch tap drill.
1
• Turn a 6–62 tap into the plug. Pull the tap and plug out
of the spool. BE CAREFUL, do not break the tap. 0.60’’
(15,2 mm)
• Clean all the debris from the inside of the spool bore.
Assembly: Install the new plastic plug (Item 1) [A] and B–09973
O–ring (Item 2) [A]. Install the stud and leave 0.60 inch
(15,2 mm) past the end of the spool [A].
NOTE: DO NOT USE LOCTITE ON THE STUD
B
THREADS. DO NOT EXCEED 70 in.–lbs. (8 1
Nm) torque during stud installation. Excess
torque may cause spool distortion resulting
in sticky spool operation.

NOTE: Put grease on all detent component surfaces

before assembly. 2
Install the detent balls and spring into the detent adapter
(Item 1) [B]. Hold the detent balls in position with the tool
and install the detent adapter into the end cap (Item 2) 3
[B].

NOTE: The detent cap (Item 3) [B] shown, is used for P–07282
support during assembly.
Install the spool seal and back–up washer on the spool.
(See Page 2–32 for correct installation procedure for the C
spool seal.)
Use MEL1285 Compression Spring Tool and install the
centering spring retainer, centering spring, and detent 1
adapter/end cap assembly on the spool. (See Page 2–27
for correct installation sequence of these parts.)
Tighten the detent adapter (Item 1) [C] to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.

P–07306

Remove the spool (Item 1) [D] from the control valve. The
spool seal (Item 2) [D] will remain seated in the spool D
chamber after the spool is removed.
Remove the spool seal (Item 2) [D] from the control valve.
Assembly: Lubricate the spool seal and install the spool
seal (Item 2) [D] on the spool as shown. Push the spool
seal into the control valve. Be sure the spool seal is evenly
installed against the seat in the spool chamber.
2

P–07277

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 HYDRAULIC CONTROL VALVE (Cont’d)
Lift Spool Detent (Cont’d)
A
Install the spool assembly (Item 1) [A] in the control valve.

P–07274

Hold the detent balls and spring in position with the tool
[B].
B

P–07283

Install the detent sleeve over the balls and into position
[C].
C

P–07285

D
Install the detent cap (Item 1) [D].
Install the washer and snap ring [D].
Install the mounting bolts [D].
Tighten the mounting bolts to 90–100 in.–lbs. (10,2–11,3
Nm) torque.

1 P–07271

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 HYDRAULIC CONTROL VALVE (Cont’d)
Tilt Centering Spring
A
Remove the end cap mounting screws (Item 1) [A].
Assembly: Tighten the mounting screws to 90–100
in.–lbs. (10,2–11,3 Nm) torque.
Remove the spool end cap (Item 2) [A]. 2
Remove the spool and centering spring assembly from
the control valve [A]. 1
Assembly: If the centering spring bolt is removed, tighten 1
it to 90–100 in.–lbs. (10,2–11,3 Nm) torque.
P–07284
Put grease on all the center spring component parts.
Always use a new spool seal.
B
Auxiliary Spool Detent
Remove the two mounting screws (Item 1) [B] from the
detent cap (Item 2) [B].
5
Remove the snap ring (Item 3) [B] and washer (Item 4)
[B]. 2
Remove the detent cap (Item 2) [B]. 1
Refer to the Lift Spool Detent Page 2–26 for the correct
removal and disassembly procedures. These procedures 1 4
are the same for the Auxiliary Spool Detent.
3 P–07287
NOTE: The detent sleeve (Item 5) [B] is shorter than
the detent sleeve on the lift spool. DO NOT
switch the sleeves from one spool to the
other.

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 HYDRAULIC CONTROL VALVE (Cont’d)
One Way Restrictors
A
A one way restrictor is located in the lift section (Item 1)
[A] (B1 Port) of the control valve. 1

P–07267

Remove the fitting (Item 1) [B] and remove the restrictor

(Item 2) [B].
B
The restrictor size is 0.125 inch (3,175 mm).

2
1

P–07269

There is also a one way restrictor located in the tilt section

(Item 1) [C] (A2 Port) of the control valve. C
1

Remove the tee fitting (Item 1) [D] and remove the

restrictor (Item 2) [D].
P–07263
The restrictor size is 0.110 inch (2,794 mm).
Inspection
D
Check the spools for wear or scratches.
Check that the spools are not loose in their bore. 2
1
Check that the centering springs are not broken.
Check that the load check valve seats are not worn.
Check the load check poppets for damage.
Check the rubber boots and retainers that they are not
worn or damaged.
Replace the parts as needed. P–07266

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 HYDRAULIC CONTROL VALVE (Cont’d)
Spool Seal Installation
A
To install new spool seals when the centering spring (tilt
spool) or the detent assembly (lift spool) are not removed
from the spool, use the following procedure:
Check the seal surface area (in the control valve) for rust,
corrosion, scratches, etc. Correct any irregularities
before continuing. 1
Install the back–up washer on the spool.
Put plastic material on the valve spool [A].
Put clean oil on the spool seal. Install the spool seal (Item CD–15080
1) [A] on the spool being careful not to damage the seal
on the sharp edges.
Remove the plastic material.
B
Install the spool into the control valve.
Slide the linkage end spool seal (Item 1) [B] over the
rubber boot groove.
Be careful not to damage the spool seal.

P–07277

Install the O–ring (Item 1) [C] and O–ring retainer plate

(Item 2) [C]. C
Install the rubber boot retainer (Item 3) [C] and rubber
boot (Item 4) [C]. 3
Install the two mounting screws and tighten to 90–100 4
in.–lbs. (10,2–11,3 Nm) torque.
Continue assembling the control valve.
1
2

P–07273

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 HYDRAULIC PUMP
Checking The Output Of The Hydraulic Pump
A
The tools listed will be needed to do the following
procedure:
MEL1429 B – Remote Start Switch
MEL10003 – Hydraulic Tester
MEL10006 – Hydraulic Test Kit
1
NOTE: The relief pressure must be per specification
before the output test is performed. 2

P–10930

B 1 2
Put jackstands under the front axles and rear
corners of the frame before running the engine IN
for service. Failure to use jackstands can allow OUT
the machine to fall or move and cause injury or
death.
W–2017–0286

Lift and block the loader. (See Page 1–1.)

P–07102

The hydraulic tester must be in the fully open

position before you start the engine.
I–2024–0284
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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–2059–0598

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Connect the remote start switch. (See Page 1–1.)
Disconnect the OUTLET hose (Item 1) [A] from the
hydraulic pump. Connect the OUTLET hose (Item 1) [B]
from the tester to the hose (Item 1) [A].
Connect the INLET hose (Item 2) [B] from the tester to the
OUTLET fitting (Item 2) [A] on the hydraulic pump.

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 HYDRAULIC PUMP (Cont’d)
Checking The Output Of The Hydraulic Pump
A
(Cont’d)
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the hydraulic fluid to 140° F (60° C) by turning the
restrictor control on the tester to about 1000 PSI (6895
kPa). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (GPM) at full
RPM.
P–10750
Push the right steering lever all the way to the right
(detent) [A] to engage the auxiliary hydraulics
(attachment must be disconnected from the front
auxiliary couplers). The fluid pressure will go over main
relief. If the pressure does not go over, adjust the main
relief valve. (See Page 2–15 or 2–16.) Record the highest
pressure (PSI) and flow (GPM). The high pressure flow
must be at least 80% of free flow.

HIGH PRESSURE FLOW (GPM)

%= X 100
FREE FLOW (GPM)

A low percentage indicates a failed pump.

*Refer to specifications (Section 9) for system relief
pressure, RPM, and hydraulic pump capacity (GPM).

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 HYDRAULIC PUMP (Cont’d)
Removal And Installation
A

2
1

P–10930

B
1
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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–2059–0598

Lift and block the loader. (See Page 1–1.)

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Stop the engine and raise the seat bar. P–10932

Raise the operator cab. (See Page 1–1.)

C
Drain the hydraulic reservoir. (See Page 2–39.)
Disconnect the inlet hose (Item 1) [A] from the hydraulic
pump.
Disconnect the outlet hose (Item 2) [A] from the hydraulic
pump.
Remove the two mounting bolts (Item 1) [B] from the
hydraulic pump.
2
Installation: Tighten the hydraulic pump mounting bolts 1
to 25–28 ft.–lbs. (34–38 Nm) torque.
Remove the hydraulic pump from the hydrostatic pump. P–07112

Remove and inspect the shaft coupler (Item 1) [C] from

the hydraulic pump shaft.
Remove the O–ring (Item 2) [C] from the hydraulic pump
mounting flange.
Installation: Install a new O–ring on the hydraulic pump
mounting flange.
Always clean up spilled fuel or oil. Keep heat,
Use the reverse removal procedure to install the hydraulic flames, sparks or lighted tobacco away from
pump. 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 Page 2–37 for correct assembly and disassembly
procedures for the hydraulic pump.

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 HYDRAULIC PUMP (Cont’d)
Parts Identification

6
3
7

4
8

12

10
11

C–02733

MODEL: 553

Ref. Description
1 BOLT
2 HOUSING
3 PIN, dowel
4 GEAR, idler
5 GEAR, drive
6 PLATE, wear
7 DIAPHRAGM
8 GASKET
9 SEAL
10 SPRING
11 BALL
12 PLATE, front

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 HYDRAULIC PUMP (Cont’d)
A
Disassembly And Assembly

When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system. B–05937
I–2003–0888

Put the hydraulic pump in the vise. B

Put a mark across the housing of the pump for correct
assembly [A].
Remove the four bolts from the pump [B].
Assembly: Tighten the bolts to 25–28 ft.–lbs. (33–38
Nm) torque.

B–05938

Remove the pump from the vise. Hold the pump in both
hands and hit the shaft against a block of wood to
separate the pump housing [C].
C

B–05940

Remove the housing from the end of the pump [D]. D

B–05945

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 HYDRAULIC PUMP (Cont’d)
Disassembly And Assembly (Cont’d)
A
Remove the pump gears [A].

P–05946

Remove the wear plate (Item 1) [B]. B 1

Remove the gaskets and seal from the pump housing
(Item 2) [B].

B–05947

Remove the spring and steel ball from the pump housing
[C]. C
NOTE: Make sure to mark the port where the spring
and ball are removed. The ball and spring
need to be installed in the pressure side of
the pump. There can not be a direct pressure
port connected to the seal area on the
pressure side of the pump.
Assembly: Always use new O–rings, gaskets and seals
when assembling the hydraulic pump.
Inspection
Clean and dry all the parts. B–05950

Inspect the gears as follows:

1. Inspect both the drive and idler gear shafts at the D

bearing points and seal area for rough surfaces
and wear.
2. Check the face of the gears for wear.

Check for wear on the face of the wear plate (Item 1) [B].
If the wear is more than 0.0015 inch (0,038 mm) from one
side to the other, the plate must be replaced.
Check the housing in the gear area for wear.
Replace the parts as needed.

B–04426

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 HYDRAULIC FLUID RESERVOIR
Removal And Installation
A
Place jackstands under the rear corners of the loader.
(See Page 1–1.) 2
3

P–05935

B
1
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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 3
or death. W–2059–0598 2

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
P–05937
Raise the operator cab. (See Page 1–1.)
Disconnect the return tubeline (Item 1) [A] from the
hydraulic reservoir (Item 2) [A].
Attach a hose to the fitting on the bottom of the hydraulic
reservoir and drain the fluid into a container.
A fluid transfer pump may also be used to drain the
reservoir from the fluid fill location (Item 1) [B] if available.
Be sure to remove the fluid fill screen from the fill hole.
Remove the wiring harness clamp (Item 3) [A] from the
loader frame.
Remove the mounting bolt (Item 2) [B] and plate from the
left side of the hydraulic reservoir mounting strap.
Remove the wiring harness mounting bracket (Item 3) [B]
and pull the wiring away from the hydraulic reservoir.
Remove the hydraulic reservoir from the loader.
Use the reverse removal procedure to install the hydraulic
reservoir.

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Revised Apr. 99 –2–39– Service Manual
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 LIFT LOCK BY–PASS VALVE
Removal And Installation
A

P–04034

B
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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 1
or death. W–2059–0598

Place jackstands under the rear corners of the loader.

(See Page 1–1.)
2
Raise the loader lift arms and install an approved lift arm
support device. (See Page 1–1.)
P–05929
Raise the loader operator cab. (See Page 1–1.)
Drain the hydraulic fluid reservoir. (See Page 2–39.) C
The lift lock bypass valve (Item 1) [A] is located under the
right side of the control panel.
Remove the engine speed control. (See Page 7–1.) This
procedure is optional.
1
Remove the control panel. (See Page 3–1.) This
procedure is optional.
If you choose not to remove the engine speed control and
control panel, the lift arm by–pass control knob (Item 1)
[B] will need to be removed from the control panel.
Hold the bypass control knob (Item 1) [B] and loosen the P–05941
jam nut on the by–pass valve shaft.
Remove the bypass control knob and jam nut from the
valve shaft.
Remove the rubber washer (Item 2) [B].
Disconnect the four tubelines from the lift lock by–pass
valve (Item 1) [C].

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Revised Apr. 99 –2–40– Service Manual
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 LIFT LOCK BY–PASS VALVE (Cont’d)
Removal And Installation (Cont’d)
A
2
Remove the two mounting bolts and nuts (Item 1) [A] from 1
the lift lock by–pass valve.
1
Installation: Tighten the two mounting bolts and nuts to
180–200 in.–lbs. (21–23 Nm) torque.
Remove and replace the by–pass valve mounting bracket
(Item 2) [A] if necessary.
Installation: Tighten the valve bracket mounting bolts to
190–240 in.–lbs. (22–27 Nm) torque.
Reverse the removal procedure to install the lift lock P–05944
by–pass valve in the loader.
Refer to Page 8–1 for lift arm by–pass control inspection
procedure.
B

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. 2
W–2103–1285
P–04096

Disassembly and Assembly

Remove the by–pass valve (Item 1) [B] from the valve
block. Inspect the by–pass valve for damage and replace
if necessary.
Remove the check valve (Item 2) [B] from the valve block.
Inspect the check valve for damage and replace if
necessary.
Inspect the hydraulic fittings on the valve block for
damage and replace if necessary.

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 TILT LOCK VALVE
Removal And Installation
A

1
P–07052

B
Never work on a machine with the lift arms up 1
unless the lift arms are secured by an approved
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–2059–0598

Place jackstands under the rear corners of the loader.

(See Page 1–1.)
2
P–07053
Raise the loader lift arms and install an approved lift arm
support device. (See Page 1–1.)
Raise the loader operator cab. (See Page 1–1.)
Drain the hydraulic fluid reservoir. (See Page 2–39.)
Remove the battery from the loader. (See Page 6–1.)
The tilt lock valve (Item 1) [A] is located at the engine
AVOID INJURY OR DEATH
Do not modify the electrical wiring connected
compartment on the right side of the loader frame. to the tilt lock valve solenoid. Service work for
the tilt lock valve should be performed by a
Disconnect the five tubelines connected to the tilt lock qualified technician. Use only genuine Melroe
valve [A]. parts if repair to the BICS™is necessary.
Remove the Do Not Modify sta–strap (P/N 6665527) from W–2166–0195
the electric solenoid connector (Item 1) [B].
Installation: Install a new Do Not Modify sta–strap (P/N
6665527) on the electric solenoid connector (Item 1) [B].
Disconnect the solenoid connector (Item 1) [B].
Remove the two mounting bolts (Item 2) [B] and nuts from
the tilt lock valve.
Installation: Tighten the two mounting bolts to 180–200
in.–lbs. (21–23 Nm) torque.
When repairing hydrostatic and hydraulic
Remove the tilt lock valve. systems, clean the work area before
disassembly and keep all parts clean. Always
Reverse the removal procedure to install the tilt lock use caps and plugs on hoses, tubelines and
valve. ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888

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Revised Apr. 99 –2–42– Service Manual
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 TILT LOCK VALVE (Cont’d)
A
Disassembly And Assembly
Remove the solenoid mounting nut (Item 1) [A], solenoid
(Item 2) [A] and solenoid valve (Item 3) [A] from the tilt
lock valve.

3 1

P–04115

Remove the check valve (Item 1) [B] from the lift lock
valve. B
Assembly: Tighten the solenoid mounting nut to 80–90
in.–lbs. (9–10 Nm) torque.
Inspect the solenoid valve, check valve and hydraulic
fittings for damage or wear. Replace if necessary.
Refer to Page 8–1 for lift arm by–pass control inspection
procedure.

1
P–04114

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 HYDRAULIC FILTER HOUSING
Removal And Installation
A
1
Stop the engine and open the rear door.
Remove the rear grill (Item 1) [A]. (See Page 5–1.)

P–10747

Disconnect the wires from the charge pressure switch

(Item 1) [B]. B
3
Remove the mounting bolt (Item 2) [B] holding the loader
wiring harness clip and lower the harness out of the way.
Remove the two mounting bolts (Item 3) [B] from the filter
housing.
Installation: Tighten the filter housing mounting bolts to 2
25–28 ft.–lbs. (34–38 Nm) torque.

P–10941

Pull the filter housing (attached to the hoses) out of the C

rear compartment [C].
Disconnect the hoses (Item 1) [C] from the filter housing
and remove the filter housing. 1
Replace the filter housing if necessary.
Use the reverse removal procedure to install the filter
housing and filter.

P–10946

553 Loader
Revised Apr. 99 –2–44– Service Manual
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 CONTROL PEDALS
Removal And Installation
A
1
Remove the bolt (Item 1) [A] and nut from the pedal
linkage.
Installation: Tighten the mounting bolt and nut to 25–28
ft.–lbs. (34–38 Nm) torque.
Check the rubber bushing in the pedal for wear and
replace if necessary.

P–05923

Remove the two mounting bolts (Item 1) [B] from the

pedal mounting bracket.
B 1

Remove the pedal assembly from the loader.

Use the reverse removal procedure to install the control
pedal.
Pedal Adjustment
After installing the pedal, it needs to be adjusted correctly.
Clearance is needed under the rear of the control pedal.
Adjust the pedal so the valve spool will travel full stroke,
without the rear of the control pedal making contact with P–05924
the floor panel.

AVOID INJURY OR DEATH

Adjust locking tabs on control linkage so that
lift and tilt control pedals or (Mechanical Hand
controls) are locked in neutral when the seat
bar is up.
W–2104–0199

NOTE: See Page 2–47 for the correct procedure to

adjust the pedal interlock linkage.

553 Loader
Revised Apr. 99 –2–45– Service Manual
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 PEDAL INTERLOCK LINKAGE
Removal And Installation
A
Remove the two interlock mounting nuts (Item 1) [A] and
two plastic washers.
Installation: Tighten the interlock nut to 80–90 in.–lbs.
(9–10 Nm) torque.
Remove the interlock (Item 2) [A].

P–05927

Remove the two plastic washers (Item1) [B] located

between the interlock and the fender.
B
Remove the two mounting bolts (Item 2) [B] from the
fender.

1
2

P–05932

553 Loader
–2–46– Service Manual
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 PEDAL INTERLOCK LINKAGE (CONT’D)
Removal And Installation (Cont’d)
A
1
Installation: During installation, be sure to keep the
interlock pressed against the loader frame so the plastic
washers (Item 1) [A] do not fall off the collar of each
interlock mounting nut. If the washer does not sit correctly
over the collar on the mounting nut, it will become wedged
between the fender and the mounting nut when the
mounting nut is tightened.

P–04049

Adjustment B

2
1
AVOID INJURY OR DEATH
Adjust locking tabs on control linkage so that
lift and tilt control pedals or (Mechanical Hand
controls) are locked in neutral when the seat
bar is up.
W–2104–0199
P–05928

Check the pedal interlock linkage (Item 1) [B] so it moves

freely with the seat bar lowered.
Make sure the locking tab (Item 2) [B] on the control pedal
linkage is centered in the slot of the pedal interlock and
locks both control pedals with the seat bar raised.
If the tab is not centered, loosen the mounting nuts on the
locking tab and center the locking tab in the slot of the
pedal interlock.
Installation: Tighten the locking tab mounting nuts and
bolts to 25–28 ft.–lbs. (34–38 Nm) torque.
The locking tab should fit into the slot of the pedal interlock
as shown [B], when adjusted correctly.

553 Loader
Revised Apr. 99 –2–47– Service Manual
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 CROSSMEMBER LINKAGE
553ServiceManual(S/N516311001&Above)#6900450–HydraulicSystemSectionPart2of2

A
Removal And Installation 1

P–05984

B
Never work on a machine with the lift arms up 1
unless the lift arms are secured by an approved
lift arm support device. Failure to use an 2
approved lift arm support device can allow the
lift arms or attachment to fall and cause injury
or death. W–2059–0598

Place jackstands under the rear corners of the loader.

(See Page 1–1.)
Raise the lift arms and install an approved lift arm support
device. P–05980

Remove the hydrostatic pump assembly from the loader.

(See Page 3–1.) C 1
Remove the mounting bolt (Item 1) [A] and nut from the
from the connection point of the lift pedal linkage and the
crossmember linkage.
Installation: Tighten the linkage mounting bolt and nut to
25–28 ft.–lbs. (34–38 Nm) torque.

Remove the mounting bolt (Item 1) [B] from the pivot

bushing plate (Item 2) [B].
Installation: If the pivot bushing plate is worn or
damaged, remove the two mounting bolts and nuts from P–05943
the plate and replace it. Tighten the mounting bolts and
nuts to 25 ft.–lbs. (34 Nm) torque.

Disconnect the crossmember linkage (Item 1) [C] from

the spool on the hydraulic control valve.
Remove the crossmember linkage from the loader.
Use the reverse removal procedure to install the
crossmember linkage.

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Revised Apr. 99 –2–48– Service Manual
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 HYDROSTATIC SYSTEM
Page
Number
CONTROL PANEL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

HYDROSTATIC MOTOR
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13 HYDROSTATIC
Timing The Hydrostatic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24 SYSTEM

HYDROSTATIC PUMP
Checking Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31
Drive Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–35
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–30
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26

HYDROSTATIC SYSTEM INFORMATION

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
OIL COOLER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–39

PORT BLOCK
Charge Pressure By–pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38
Hydraulic Oil Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38
Oil Cooler By–Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38

STEERING LEVERS
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6

STEERING LINKAGE
Pintle Lever Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3–10
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
Steering Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11

TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 9)
UNLESS OTHERWISE SPECIFIED.

553 Loader
–3–1– Service Manual
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 553 Loader
–3–2– Service Manual
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 TROUBLESHOOTING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures
must be done by authorized Bobcat Service Personnel
only.
Check for correct function after adjustments,
repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

PROBLEM CAUSE

No drive on one side, in one direction. 1, 2, 3, 4, 5, 19

No drive on one side in both directions. 2, 3, 5, 6, 7, 8

The loader does not move in a straight line. 2, 3, 4, 6, 7, 8, 10, 19

The hydrostatic system is overheating. 4, 11, 12, 13, 14, 15

The oil light comes ON. 16, 17, 18

KEY TO CORRECT THE CAUSE

1. The hydrostatic system has a fluid leak.

2. The steering linkage needs adjustment.
3. The high pressure replenishing valve(s) are defective.
4. The shuttle valve in the hydrostatic motor has a defect.
5. The balance plate in the hydrostatic motor seals are defective.
6. The hydrostatic pumps have a defect.
7. The final drive chain is broken.
8. The hydrostatic motor has a defect.
9. The tires do not have the correct tire pressure.
10. The tires are not the same size.
11. The hydraulic fluid is not at the correct level.
12. The oil cooler has a restriction. (Externally or Internally.)
13. The temperature sending switch is not operating correctly.
14. The control valve is not operating correctly.
15. The loader is not being operated at the correct RPM.
16. The sender has a defective.
17. There is low charge pressure.
18. The charge relief has a defect.
19. Steering lever is obstructed.

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–3–3– Service Manual
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 HYDROSTATIC SYSTEM INFORMATION
A
CHARGE OIL

When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and Valve Moves for Charge
ports to keep dirt out. Dirt can quickly damage Oil Replacement
the system.
I–2003–0888 FUNCTION 1

Replenishing Valve Function

The functions of the replenishing valves are:
1. To give replacement fluid to the low pressure side
of the hydrostatic circuit. Replacement fluid is
needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling;
Function 1 [A].
2. To keep high pressure fluid out of the low pressure
side of the hydrostatic circuitry; Function 2 [A].
Valve Stays on Seat to
Hold High Pressure for Drive
FUNCTION 2
B–02804

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–3–4– Service Manual
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 CONTROL PANEL
A 3 1
Removal And Installation

3
2
3

P–10920

B 1
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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 1
or death. W–2059–0598
1
Lift and block the loader. (See Page 1–1). 1
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.) P–10919

Remove the engine speed control. (See Page 7–1.)

Loosen the jam nut on the bypass control knob (Item 1)
[A].
Remove the control knob (Item 1) [A], jam nut and rubber
washer (Item 2) [A].
Put jackstands under the front axles and rear
Remove the hand grip from each steering lever 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.
NOTE: Use air pressure under each grip to make W–2017–0286
removal easier.

Remove the four mounting bolts (Item 3) [A] from the right
side of the control panel.
Remove the four mounting bolts (Item 1) [B] from left side
of the control panel.
Installation: Tighten the mounting bolts to 25–28 ft.–lbs.
(34–38 Nm) torque.
Slide the panel up over the steering levers and remove it
from the loader.
NOTE: Use a small amount of liquid soap on each
rubber boot to make removal of the control
panel easier.
Reverse the removal procedure to install the control
panel.

553 Loader
Revised Apr. 99 –3–5– Service Manual
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 STEERING LEVERS
Removal And Installation
A

Put jackstands under the front axles and rear

corners of the frame before running the engine 1
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W–2017–0286
Never work on a machine with the lift arms up P–10931
unless the lift arms are secured by an approved
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 B
or death.
W–2059–0598

1
P–05983
Lift and block the loader. (See Page 1–1.)
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.) C
Raise the operator cab. (See Page 1–1.)
Remove the engine speed control. (See Page 7–1.) 2
Remove the control panel from the loader. (See Page
3–5.)
Remove the mounting bolt (Item 1) [A] and nut from the
steering linkage (both sides) to disconnect the linkage 1
from the steering levers.
Disconnect the auxiliary control linkage (Item 1) [B] from
the right steering lever.
Installation: Tighten the mounting bolt to 80–90 in.–lbs. P–05939
(9–10 Nm) torque.
Remove the right side steering shaft bearing (Item 1) [C].
Installation: Tighten the two bearing mounting bolts to
D
180–200 in.–lbs. (21–23 Nm) torque. Use the grease
fitting (Item 2) [C] to lubricate the bearing. 2
1
Remove the two mounting bolts from the left side steering
shaft bearing (Item 1) [D].
Installation: Tighten the two bearing mounting bolts to
180–200 in.–lbs. (21–23 Nm) torque. Use the grease
fitting (Item 2) [D] to lubricate the bearing.
Remove the steering levers assembly from the loader.

P–05982

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Revised Apr. 99 –3–6– Service Manual
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 STEERING LEVERS (Cont’d)
Disassembly And Assembly
A
Slide the left steering lever assembly off the shaft of the
right steering lever assembly [A].
2
Check the plastic bushings (Item 1) [A] for damage or
wear and replace if necessary.
Assembly: Lightly lubricate the steering shaft before
assembly.
Install the washer (Item 2) [A] on the shaft.
1
Install the two plastic bushings (Item 1) [A] in each end
of the left side lever assembly. P–05987

Slide the left side steering lever assembly onto the right
side lever assembly.

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–3–7– Service Manual
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 STEERING LINKAGE
A
Removal And Installation 2

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
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 1
or death. W–2059–0598 P–09683

Lift and block the loader. (See Page 1–1.)

B
Raise the lift arms and install an approved lift arm support 1
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)

NOTE: The steering linkage/hydrostatic pump

assembly has been removed from the loader
to show the steering linkage removal and
installation more clearly. The steering
linkage can be removed from the loader with
the assembly installed in the loader.
P–09684
Remove the right and left steering linkages (Item 1) [A]
from the pintle bars (Item 2) [A].
Remove the mounting nut (Item 1) [B] from the centering
C 2.4’’ Compressed
(51 mm) Length
spring assembly.
Inspect the centering spring assembly (Item 1) [C] and
replace any damaged or worn parts.
Installation: When installing the centering spring, the
compressed length of the spring should be 2.4 inches (51
mm) [C].

P–05968

Remove the two high pressure hose fittings (Item 1) [D]

from the hydrostatic pumps. D

1
P–09685

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Revised Apr. 99 –3–8– Service Manual
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 STEERING LINKAGE (Cont’d)
Removal And Installation (Cont’d)
A
Remove the four mounting bolts (Item 1) [A] from each
adjustment bar on the centering bar.
Remove the two adjustment bars from the centering bar.

P–09686

NOTE: Both holes (Item 1) [B] for the front pump

adjustment bar are slotted for adjustment B
purposes. Only the top hole (Item 2) [B] for 2
the rear pump is slotted. When adjusting the
steering linkage to neutral, adjust the pintle
lever on the rear pump first. See Page 3–11 for
correct steering neutral adjustment
procedure.

P–09687

Remove the centering bar (Item 1) [C] from the pintle

levers (Item 2) [C]. C 2
See Page 3–10 for pintle lever disassembly and
assembly if necessary.

P–09688

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–3–9– Service Manual
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 STEERING LINKAGE (Cont’d)
Pintle Lever Disassembly And Assembly
A
Remove the pintle lever retainer (Item 1) [A] and the two
plastic washers 4
NOTE: There is only one plastic washer (which is
slotted), located on the rear hydrostatic
pump for mounting the centering bar.
Remove the pintle lever mounting bolt (Item 2) [A].
Installation: Tighten the mounting bolt to 180–200
in.–lbs. (21–23 Nm) torque.
2
Slide the pintle lever off the keyed shaft (Item 3) [A] of the
hydrostatic pump. 3
Check the pivot bushing (Item 4) [A] for the steering
linkage.
1

P–05976

If worn or damaged, place the pintle bar in a vice to

remove the pivot bushing for the steering linkage [B]. B
Use a 1 inch socket (Item 1) [B] and a 9/16 inch socket
(Item 2) [B] (both 1/2 inch drive), and press out the pivot
bushing.
1

P–05974

Check the pivot bushing mounting hole (Item 1) [C] for C

wear or damage and replace the pintle lever if necessary.

1
P–05977

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–3–10– Service Manual
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 STEERING LINKAGE (Cont’d)
Pintle Lever Disassembly And Assembly (Cont’d)
A
3
Installation: Use 7/8 inch socket (Item 1) [A] and a 3/4
inch socket (Item 2) [A] (both 1/2 inch drive), to press a
new pivot bushing into the pintle lever. 1
The lobes (Item 3) [A] may also become worn or
damaged. 2

Place the pintle lever in a vise as shown [B].

Remove the lobe mounting bolts (Item 1) [B].
Installation: Install new lobes in the pintle lever and P–05973
tighten the mounting bolts to 180–200 in.–lbs. (21–23
Nm) torque.
Steering Neutral Adjustment
B
1

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
P–05972

C
2

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
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–2059–0598

Lift and block the loader. (See Page 1–1.) 1

Raise the loader and install an approved lift arm support

device. (See Page 1–1.) P–09689

Raise the operator cab. (See Page 1–1.)

Connect the remote start switch (MEL1429). (See Page
D
1
1–1.)
NOTE: Both holes (Item 1) [C] for the front pump
adjustment bar are slotted for the steering
neutral adjustment procedure. Only the top
hole (Item 2) [C] for the rear pump adjustment
bar is slotted for the steering neutral
adjustment procedure. Begin the steering
neutral adjustment procedure with the rear
pump.
Loosen the pivot bolt (Item 1) [D] on the rear pump pintle
lever to eliminate any tension between the lever and the
steering linkage. P–09690

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Revised Apr. 99 –3–11– Service Manual
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 STEERING LINKAGE (Cont’d)
Steering Neutral Adjustment (Cont’d)
A
Loosen the pivot bolt (Item 1) [A] on the left side steering
lever to eliminate any tension between steering linkage
and the steering lever.
Use the remote start switch and start the engine, move
the engine speed control to low idle.

1
P–09691

Loosen the two mounting bolts (Item 1) [B] on the

adjustment bar for the rear pump pintle lever. B
Move the left steering lever until the left side tires do not
move (neutral position).

1
P–07095

Move the adjustment bar (Item 1) [C] so it touches the

bottom and top lobe (Item 2) [C] of the pintle lever at the
same time. C
Be sure the wheels do not turn and stay in the neutral
position.
2
Tighten the adjustment bar mounting bolts to 25–28 1
ft.–lbs. (34–38 Nm) torque.
Test the left steering lever by moving the lever forward
and backward. Let the steering lever return to the neutral
position.
If the wheels do not stop turning in neutral position,
readjust the adjustment bar against the lobes of the pintle
lever. P–07097

Repeat the procedure until the wheels stop turning

(neutral position) and the steering lever is in the neutral
position.
After the left side linkage is complete, tighten the pivot
bolts on the pintle lever and steering lever linkages.
Tighten the locknuts on each linkage to 25–28 ft.–lbs.
(34–38 Nm) torque.
Repeat the complete procedure for the right side steering
linkage.

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–3–12– Service Manual
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 HYDROSTATIC MOTOR
Removal And Installation
A

P–05994

B 1
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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–2059–0598

Lift and block the loader. (See Page 1–1.)

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.) P–05993

Remove the front and rear wheels from the side which the
motor is located. (See Page 1–1.) C
Remove the control panel. (See Page 3–5.)
Remove the center cover and brake solenoid. (See Page
4–1.)
Remove the four mounting bolts (Item 1) [A] from the
motor cover (Item 2) [A] and remove the cover from the
loader.
1
Installation: Tighten the motor cover mounting bolts to
25–28 ft.–lbs. (34–38 Nm) torque.
Mark the two drive hoses (Item 1) [B] to ensure correct
installation. P–05991

Disconnect the two drive hoses (Item 1) [B] from the

hydrostatic motor. D
Disconnect the case drain hose (Item 1) [C] from the drive
motor.

Use coated electrical wire to support the sprocket, chains

and brake disc [D].

The wire will keep the assembly from falling down and will
also make drive motor installation easier.

P–07001

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Revised Apr. 99 –3–13– Service Manual
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 HYDROSTATIC MOTOR (Cont’d)
Removal And Installation (Cont’d)
A
1
Remove the four mounting bolts (Item 1) [A] from the
drive motor.
Installation: Tighten the mounting bolts to 65–70 ft.–lbs.
(89–94 Nm) torque.

P–05997

Remove the drive motor from the loader [B]. B

Reverse the removal procedure to install the drive motor
in the loader.

P–05999

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 HYDROSTATIC MOTOR (Cont’d)
Parts Identification

MODEL: 109–1269–006 4 11
Splined Shaft 9 3
5 10
6 7 8

5
3 12
1

13
4
21 2
20 19
14
15

16 24
18 17
24

23 22

22 26
25
30 22

28 27

29

34

33
31 32
D–01678

MODEL: 553

Ref. Description Ref. Description

1 PLUG 19 PLATE, balancing
2 O–RING 20 VALVE
3 SHUTTLE 21 PLATE, valve
4 SPRING 22 O–RING
5 POPPET 23 SHAFT
6 PLUG 24 O–RING
7 O–RING 25 GEROLER
8 HOUSING 26 SHAFT
9 PISTON 27 HOUSING, bearing
10 O–RING 28 SEAL
11 PLUG 29 SHAFT & BEARING
12 BOLT 30 SEAL, shaft
13 BOLT 31 SEAL, dust
14 O–RING 32 BOLT
15 SPRING 33 WASHER
16 O–RING 34 COVER, front
17 SEAL, outer
18 SEAL, inner

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–3–15– Service Manual
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 HYDROSTATIC MOTOR (Cont’d)
Disassembly And Assembly
A
NOTE: The illustrations may differ slightly from the
motor that you are working on, but the
procedure is the same.

The tools listed will be needed to do the following

procedure:
MEL1187 – Socket
MEL1015 – Seal Tool

B–05117

B
When repairing hydrostatic and hydraulic
systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888

Shaft
Put a mark across the motor sections for correct
assembly [A].
Remove the four bolts from the motor [B]. B–05118

Assembly: Tighten the bolts to 50 ft.–lbs. (68 Nm)

torque.
C
Lift the valve housing straight up [C]. If done carefully, the
springs and balance plate will stay on the valve.

NOTE: See Page 3–24 for the correct installation of

the housing and the balance plate.

B–05120

Remove the large and small O–rings [D].

D

B–05126

553 Loader
–3–16– Service Manual
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 HYDROSTATIC MOTOR (Cont’d)
Disassembly And Assembly (Cont’d)
A
Remove the plug at the valve housing [A].

B–05127

Remove the spring, shuttle and poppet [B]. B

B–05128

Use a punch, remove the poppet, spring, O–ring, shuttle

and plug [C]. C

B–05129

Remove the two springs from the balance plate [D].

D

B–05124

553 Loader
–3–17– Service Manual
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 HYDROSTATIC MOTOR (Cont’d)
Disassembly And Assembly (Cont’d)
A
Remove the inner seal from the balance plate [A].
Assembly: Put grease on the inner seal and install as
shown [A].
Balance
Plate Outer
Outer Seal
Seal

Pin B–08733
Inner Seal Pin B–03046

Remove the outer seal from the balance plate [B]. B

Assembly: Put grease on the outer seal and install as
shown [B].
NOTE: See Page 3–24 for timing the motor when
installing the valve, valve drive and geroler.

Balance Outer
Outer Plate Seal
Seal

Pin B–08732
Inner Seal Pin B–03046

Remove the valve [C].

C

Shaft

B–05134

Remove the valve plate [D].

D

Shaft

B–05123

553 Loader
–3–18– Service Manual
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 HYDROSTATIC MOTOR (Cont’d)
Disassembly And Assembly (Cont’d)
A
Remove the valve drive [A].

Shaft

B–05122

Remove the geroler [B]. B

Make sure the rollers are kept in the geroler.

Shaft

B–05121

Remove the drive shaft [C].

C

Shaft

B–05119

Remove the O–rings (large and small) from the bearing

housing [D]. D

B–05125

553 Loader
–3–19– Service Manual
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 HYDROSTATIC MOTOR (Cont’d)
Disassembly And Assembly (Cont’d)
A
Remove the eight bolts at the bearing housing [A].
Assembly: Use MEL1187 to tighten the bolts to 20
ft.–lbs. (27 Nm) torque.

B–03042

Shaft

B–05132

Remove the mounting flange from the housing [B]. B

Shaft

B–05133

Use a press, remove the shaft and bearing assembly [C].

C
NOTE: If there is any wear or damage to the shaft or
bearing assembly, you must replace the
complete unit.

Shaft

B–05135

Remove the seal from the bearing housing [D].

D

B–05140

553 Loader
Revised Mar. 02 –3–20– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 HYDROSTATIC MOTOR (Cont’d)
Disassembly And Assembly (Cont’d)
A
Assembly: Put the bearing housing on a smooth surface 1
with the largest opening up [A]. Take the largest diameter
half of the seal tool and lubricate the inside.
Install the seal tool MEL1015 (Item 1) [A] into the bearing
housing.
Install the shaft face seal (with the inside edge up) into the
seal tool.

B–05138

Install the small diameter of the seal tool and push the
B
seal into position [B].

B–05137

Press the shaft and bearing assembly into the bearing C Shaft
housing [C].
Be careful not to damage the shaft seal. Turn the shaft
several times to make sure that the shaft turns freely.

B–05136

MODEL: 109–1052–005 D
Remove the backup washer and seal from the mounting
flange [D].
Assembly: Use the correct size seal driver tool and install
the backup washer.

B–05142

B–05141

553 Loader
Revised Mar. 02 –3–21– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 HYDROSTATIC MOTOR (Cont’d)
Disassembly And Assembly (Cont’d)
A
Remove the dust seal from the mounting flange [A].

B–06769

Remove the shaft seal and brass backup ring [B].

B

B–06768

Assembly: Use the correct size seal driver tool and install
the shaft seal the dust seal [C] & [D].
C
NOTE: Always use new O–rings, gaskets and seals
when assembling the hydrostatic motor.

B–06770

B–06771

553 Loader
–3–22– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 HYDROSTATIC MOTOR (Cont’d)
Inspection
A
Clean all the parts in solvent and use air pressure to dry
them. DO NOT use cloth or paper because small pieces
of material can get into the system and cause damage.
Before the motor is assembled, check the following items:
Check the geroler roller and rotor for wear and scratches
[A]. B–06392

NOTE: Put all the rollers back in their position.

B–06394

Check the valve plate for scratches [B].

B

B–06390

B–06391

Check the balance plate for scratches [C].

C
Check the valve drive and main drive for wear.

B–06389

Check the end plate surface for scratches [D]. D

B–06388

553 Loader
–3–23– Service Manual
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 HYDROSTATIC MOTOR (Cont’d)
A
Inspection (Cont’d)
Assembly: When installing the balance plate in the end
housing, put your finger through the hole and hold it in
position until the housing is in position [A].

B–08690

Rotate Valve Clockwise

Timing The Hydrostatic Motor B 1/2 Tooth to Engage Spline
The timing of the motor controls the direction of rotation
of the drive shaft of the motor. The timing parts are as Anyone of 6 Ports
follows: Open to Outside of Valve 4

1. Geroler (Item 1) [B]. Largest Opening

Valve
2. Valve Drive (Item 2) [B].

3. Valve Plate (Item 3) [B].

4. Valve (Item 4) [B].

Find the largest opening between the geroler star and the
geroler ring and mark the outside of the geroler ring at that Case Drain
point [B]. Hole (2)
Align the two drain holes and the three pressure holes in Valve Plate
the geroler ring with the same holes in the mounting
flange and install the geroler assembly.
2
3
Install new O–rings.
Valve Drive
Install the valve drive [B]. 1
Pressure
Relief Hole (3)
Align the drain hole in the valve plate with the drain hole
in the geroler. Install the valve plate with the O–ring Geroler
toward the geroler. Make sure the slot opening of the Ring
valve plate is in alignment with the largest opening of the Geroler
geroler. Star

Install the valve plate [B]. C–02384

Install the valve on the valve plate. Make alignment with
one of the side openings with the mark on the geroler.
Turn the valve clockwise a small amount until the teeth
on the valve drive engage.
Continue with the rest of the assembly procedure.

553 Loader
–3–24– Service Manual
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 HYDROSTATIC PUMP
553ServiceManual(S/N516311001&Above)#6900450–HydrostaticSystemSectionPart1of2

A
Checking Charge Pressure
1
The tools listed are needed to complete the following
procedure:
MEL1173 – Test Kit

Put jackstands under the front axles and rear

corners of the frame before running the engine P–10930
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W–2017–0286 B
Lift and block the loader. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Connect the remote start switch to the loader. (See Page
1–1.)
Remove the plug (Item 1) [A] located on the inlet tubeline
of the front hydrostatic pump.
Connect a pressure gauge to the fitting where the plug
was removed [B].
P–07253
Start the engine and increase the speed to 2500 RPM.
The charge pressure should be 55–85 PSI (379–586
kPa). This is the minimum acceptable level without any
C 2
use of the hydraulic/hydrostatic functions.
If the pressure is not correct, check the charge pressure
by–pass valve (Item 1) [C] located in the port block (Item
2) [C].
Remove the charge pressure by–pass valve. (See Page
3–38.)
Inspect and clean the by–pass valve or install a new 1
bypass valve in the port block. Repeat the charge
pressure test.
If the test still shows the incorrect pressure, refer to the P–10931
troubleshooting chart. (See Page 3–3.) Other problems
may exist that are causing the charge pressure to be
incorrect.

553 Loader
–3–25– Service Manual
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 HYDROSTATIC PUMP (Cont’d)
Removal And Installation
A
2

P–10929

B
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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–2059–0598

Lift and block the loader. (See Page 1–1.) 1

2
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
P–10930
Raise the operator cab. (See Page 1–1.)
Remove the engine speed control. (See Page 7–1.)
C
Remove the control panel from the loader. (See Page
3–5.)
Drain the hydraulic fluid from the reservoir. (See Page
2–1.) 2

Disconnect the two charge inlet hoses (Items 1 & 2) [A] 1

from the hydrostatic pump assembly.
Remove the inlet hose (Item 1) [B] from the hydraulic
pump.
Remove the outlet hose (Item 2) [B] from the hydraulic
pump. P–10931

Disconnect the steering linkage bars (Items 1 & 2) [C]

from the steering levers.
D
Disconnect the two high pressure hoses (Items 1 & 2) [D]
from the front and rear (right side) hydrostatic pumps.
1
Be sure to mark each hose for correct installation.

2
P–09694

553 Loader
Revised Apr. 99 –3–26– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 HYDROSTATIC PUMP (Cont’d)
A
Removal And Installation (Cont’d)
Disconnect the two high pressure hoses (Items 1 & 2) [A]
from the front and rear (left side) hydrostatic pumps.
Be sure to mark each hose for correct installation.

1 2

P–09692

Remove the mounting bolt (Item 1) [B] washers, and nut

from the left side of the hydrostatic pump mount. B
Installation: Tighten the mounting bolt to 65–70 ft.–lbs.
(89–94 Nm) torque.

P–09693

Remove the mounting bolt (Item 1) [C] washers, and nut

from the right side of the hydrostatic pump mount. C
Installation: Tighten the mounting bolt to 65–70 ft.–lbs.
(89–94 Nm) torque.
1

P–05961

Remove the two mounting bolts (Item 1) [D] from the rear
pump and pump assembly mounting plate.
D
Installation: Tighten the mounting bolts to 25–28 ft.–lbs. 1
(34–38 Nm) torque.

P–05962

553 Loader
–3–27– Service Manual
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 HYDROSTATIC PUMP (Cont’d)
Removal And Installation (Cont’d)
A
Install a chain hoist securely around the hydrostatic pump 1
assembly.
Slide the pump drive (Item 1) [A] out of the u–joint drive
coupler (Item 2) [A].
Installation: Grease the pump drive coupler and the
inside of the u–joint coupler for easier installation. 2

Remove the hydrostatic pump assembly from the loader.

Reverse the removal procedure to install the hydrostatic
pump assembly in the loader. P–05964

If the rear pump mount (Item 1) [B] is removed, be sure

to note the location and amount of shim washers (Item 1)
B
[C] between the pump mount and the loader frame on
each side of the pump mount.

P–05963

NOTE: A total of four shim washers (Item 1) [C] can

be used per side on the rear pump mount to C
align the splined shaft of the hydrostatic
pump with the u–joint coupler on the engine.
Refer to the loader parts manual for the
correct shim part number and specifications.
1 1

S/N 516313345 & Above & 516414608 & Above

P–07075
NOTE: The 553 loaders listed above are factory
equipped with a rubber drive coupler. A kit is
available to install a rubber drive coupler on
loaders with earlier serial numbers. D

It is not necessary to remove the pump mount when

removing the hydrostatic pump.
Remove the nuts and bolts (Item 1) [D] from the pump
flange and mount.
The hydrostatic pump removal procedure is the same as 1
shown on the previous pages.

P–24641

553 Loader
Revised Mar. 02 –3–28– Service Manual
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 HYDROSTATIC PUMP (Cont’d)
Drive Coupler Removal And Installation
A
Remove the hydrostatic pump assembly from the loader.
(See Page 3–26.)
The drive coupler (Item 1) [A] is located on the shaft of the
rear hydrostatic pump.

P–05975

Remove the drive coupler mounting bolt (Item 1) [B] and

washer (Item 2) [B] from the hydrostatic pump shaft. Be
B
careful to not damage the splines on the coupler.
Installation: Apply (LOCTITE #242) adhesive to the 3
drive coupler mounting bolt, tighten the mounting bolt to
25–28 ft.–lbs. (34–37 Nm) torque.
2
Remove the drive coupler (Item 3) [B] from the keyed
pump shaft. 1

Inspect the key (Item 4) [B] for wear or damage and

replace if necessary. 4
Reverse the removal procedure to install the drive
coupler. P–05978

553 Loader
–3–29– Service Manual
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 HYDROSTATIC PUMP (Cont’d)
Parts Identification

REAR FRONT
Drive End Hydraulic Pump End

37
37 18
18 16
16 10 11 17
10 11 17 12
12 13 36
13 15 14
14

35
7 8 21 22
21 54
54 22
56
6 10
5 34 9 14
34 9 14 10 2 19
2 19 1 24 13
1 13 26 20
24 20
26 27 28
27 23
23 28 25
25 29
29

32 33
34
32 33 24
34 3031 23
24
3031 23

E–01408 E–01406

MODEL: 553

Ref. Description Ref. Description

1 RING, retaining 20 O–RING
2 SEAL 21 COVER
3 WASHER 22 COVER
4 RING, retaining 23 PLUG
5 RACE 24 O–RING
6 BEARING, thrust 25 SPRING
7 KEY 26 VALVE, relief
8 SHAFT, drive 27 PLATE, back
9 BEARING 28 BOLT
10 SCREW 29 BOLT
11 COVER 30 GASKET
12 SEAL 31 BEARING
13 WASHER 32 DOWEL
14 BEARING 33 SEAT
15 HOUSING 34 SPRING
16 KEY 35 SHAFT, drive
17 PLATE, yoke 36 HOUSING
18 ROTATING GROUP 37 PLATE, valve wear
19 BEARING

553 Loader
–3–30– Service Manual
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 HYDROSTATIC PUMP (Cont’d)
Disassembly And Assembly
A
NOTE: The illustrations may differ slightly from the
hydrostatic pump you are working on, but
the procedure is the same.

The tool listed will be needed to do the following

procedure:
MEL1219–4 – Torx Socket

B–06057

B
When repairing hydrostatic and hydraulic
systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888

NOTE: Before you begin the disassembly

procedure, remove the hydraulic pump from
the unit.

Remove the bolt and splined gear from the pump shaft B–06058
[A]. (See Page 3–29.)
Remove the charge tubeline between the two pumps [B].
C
Remove the two bolts which fasten the two pumps
together [C].
Assembly: Tighten the bolts to 25–28 ft.–lbs. (34–38
Nm) torque.
Separate the pumps and remove the coupler.

B–06060

Remove the plugs at the high pressure replenishing

valves [D]. D

B–08842

553 Loader
–3–31– Service Manual
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 HYDROSTATIC PUMP (Cont’d)
Disassembly And Assembly (Cont’d)
A
Remove the high pressure replenishing valves [A].

B–08844

NOTE: The hydrostatic pump front and rear pump

internal parts are the same. Keep all the parts
for one pump separated from the parts for the
B
other pump.

Remove the four bolts from the center section [B].

Assembly: Tighten the bolts to 17–21 ft.–lbs. (23–28
Nm) torque.

B–06062

Remove the center section [C]. C

B–06063

Remove the rotating group [D]. D

Put your hand under the rotating group and turn the pump
housing around so the rotating group will slide into your
hand.

B–06064

553 Loader
–3–32– Service Manual
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 HYDROSTATIC PUMP (Cont’d)
Disassembly And Assembly (Cont’d)
A
Remove the snap ring from the rear housing [A].
Hit the shaft on a block of wood to remove the bearing and
shaft [A].

B–06072

B–06071

Remove the seal and backup washer from the shaft [B]. B

B–06073

Remove the bolts at the cover of the long pintle shaft [C].
C
Remove the pintle cover.

B–06065

Remove the seal and washer [D].

D

B–06067

553 Loader
–3–33– Service Manual
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 HYDROSTATIC PUMP (Cont’d)
Disassembly And Assembly (Cont’d)
A
Remove the pintle shaft bearing [A].
Assembly: When installing the bearing, make sure the
numbered side of the bearing is toward the outside.

B–06066

Remove the screws and cover from the short pintle shaft
[B].
B

B–06068

Remove the washer and O–ring from the shaft [C].

C

B–06069

Remove the bearing and bearing race from the shaft [D].
D
Assembly: When installing the race, make sure that the
chamfer side of the race is toward the cam plate.

B–06070

553 Loader
–3–34– Service Manual
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 HYDROSTATIC PUMP (Cont’d)
Disassembly And Assembly (Cont’d)
A
Remove the cam plate from the housing [A].

B–06074

Inspection B
NOTE: Keep all the parts for one pump separated
from the parts for the other pump.

Clean all the parts in solvent and use air pressure to dry
them. DO NOT use cloth or paper because small pieces
of material can get into the system and cause damage.
Inspect the input drive shafts, bearings and races for wear
and damage to the shaft splines [B] & [C].
The bearings in the center section and housing, only have
to be removed if they are loose and show wear. Use a
press to remove and replace the bearings. B–08859

B–06075

Inspect the flat surface of the sections. The finish must be

smooth and free of grooves. If the grooves can be felt on D
the finished surfaced with a fingernail, replace the part
[D].

B–06076

553 Loader
–3–35– Service Manual
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 HYDROSTATIC PUMP (Cont’d)
Inspection (Cont’d)
A
Inspect the camplate for wear. The finish must be smooth
and free of grooves. If the grooves can be felt with a
fingernail, replace the camplate [A].

B–06079

Inspect the rotating group as follows:

Check each piston in its bore. The piston must move
B
freely.
Check the pins for wear or damage [B].
All the pins must be the same length and must not be bent.
Check the spherical washer for sharp edges, wear or
scratches [B].

B–08860

Check the piston shoe for scratches [C].

C

B–06077

Check the end play of each piston assembly [D]. Measure

the thickness of each shoe. All shoes must be within
0.001 inch (0,025 mm) of each other [D]. D This Dimension Must be Maintained on All
Nine Shoes Within 0.001’’ (0,0254 mm)

Piston

Shoe
Shoe Must Swivel
Smoothly on Ball
End Play Must Not
Exceed .003’’ (0,076 mm)
A–01850

553 Loader
–3–36– Service Manual
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 HYDROSTATIC PUMP (Cont’d)
A
Inspection (Cont’d)
Check the flat surface of the piston block for being smooth
and free of scratches [A].
Inspect the shoe plate for wear or cracks. If there is any
defect in the rotating group, the complete unit must be
replaced.
DO NOT use sandpaper or a file to remove scratches.

NOTE: Always use new O–rings, gaskets and seals

when assembling the hydrostatic pumps.
B–06078

553 Loader
–3–37– Service Manual
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 PORT BLOCK
Removal And Installation
A 4

Drain the hydraulic fluid from the reservoir. (See Page

1–1.)
Disconnect the two hydrostatic motor case drain hoses 3
(Item 1) [A] from the tee fitting on the port block.
Disconnect the charge inlet hose (Item 2) [A] from the 5
port block.
Disconnect the wire (Item 3) [A] from the hydraulic fluid 2
temperature switch. 1
P–05954

Disconnect the inlet and outlet hoses (Item1) [B] from the
port block. B 2
Disconnect the return tubeline (Item 2) [B] from the port
block.
Remove the mounting bolt (Item 3) [B] from the port block
and remove the port block from the loader.
Reverse the removal procedure to install the port block in
the loader.
Oil Cooler By–Pass Valve
3

The oil cooler by–pass valve is located in the return 1

tubeline port (Item 2) [B] of the port block.
P–05945
Disconnect the tubeline and remove the fitting from the
port.
Check the poppet and spring for damage or wear and
replace if necessary.
Hydraulic Oil Temperature Switch
To replace the hydraulic oil temperature switch (Item 4)
[A], disconnect the wire (Item 3) [A] from the switch and
remove the switch from the port block.
Charge Pressure By–Pass Valve
The charge pressure by–pass valve (Item 5) [A] is
located under the hydraulic oil temperature switch in the
port block.
Remove the hydraulic oil temperature switch (Item 4) [A]
to access the charge pressure by–pass valve.
Remove the plug (Item 5) [A] from the port block.
Check the spring and poppet for damage or wear and
replace if necessary.
Replace the O–ring on the plug.

553 Loader
–3–38– Service Manual
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 OIL COOLER
Removal and Installation
A
1
Remove the loader radiator. (See Page 7–1).
Remove the mounting bolts (Item 1) [A] and remove the
hydraulic oil cooler from the housing.
Reverse the removal procedure to install the radiator in
the loader.

P–10964

553 Loader
–3–39– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 553ServiceManual(S/N516311001&Above)#6900450–HydrostaticSystemSectionPart2of2

553 Loader
–3–40– Service Manual
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 DRIVE SYSTEM
Page
Number
AXLE SEAL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7

AXLE, BEARINGS, AND SPROCKET

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9
CHAINCASE COVERS
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
CHAINCASE FLUID
Removing Oil From The Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
DRIVE
DRIVE CHAIN SYSTEM
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–13
PARKING BRAKE
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

PARKING BRAKE DISC

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
Brake Disc Guide Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 4–5

553 Loader
–4–1– Service Manual
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 553 Loader
–4–2– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 PARKING BRAKE
A
Removal And Installation

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved 1
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–2059–0598 P–05925

Lift and block the loader. (See Page 1–1.) B

Raise the loader lift arms and install an approved lift arm 1
support device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.)
Remove the control panel. (See Page 3–1.)
Remove the two mounting bolts (Item 1) [A] from the
brake pedal mounting bracket.
Installation: Tighten the mounting bolts to 25–28 ft.–lbs.
(34–38 Nm) torque.
Disconnect the brake switch connector (Item 1) [B] from P–05988
the BICS™ harness.
Remove the parking brake assembly from the loader. C 5
Reverse the removal procedure to install the parking
brake assembly in the loader. 6

Disassembly And Assembly

Loosen and remove the mounting bolt (Item 1) [C] and nut 1
from the spring mounting bracket (Item 2) [C]. 4
Remove the brake pedal spring (Item 3) [C] from the
spring mounting bracket (Item 2) [C] and from the brake
pedal mounting bracket (Item 4) [C]. 2
3
P–04189
Remove the two mounting bolts, washers, and nuts (Item
5) [C] from the brake pedal sensor.
Remove the harness mounting clamp (Item 1) [D] from D
the pedal mounting bracket (Item 4) [C]. 1

Remove the sensor harness from the pedal mounting

bracket.
Remove the pedal mounting bolt (Item 6) [C], plastic
spacers, and bushing nut from the brake pedal.
Remove the pedal from the pedal mounting bracket.
Photo [D] shows the parking brake disassembled to
identify the existing parts of the brake assembly.

P–04156

553 Loader
Revised Apr. 99 –4–3– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 PARKING BRAKE DISC
A
Removal and Installation 1

1
P–05997

B
1
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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–2059–0598

Install jackstands under the rear of the loader. (See Page

1–1.)
Raise the loader lift arms and install an approved lift arm P–13134
support device. (See Page 1–1.)
Stop the engine.
C
Raise the loader operator cab. (See Page 1–1.)
Remove the engine speed control. (See Page 7–1.)
Remove the control panel from the loader. (See Page
3–1.)
Remove the traction lock assembly. (See Page 8–1.)
Remove the rear chaincase cover. (See Page 4–6.)
Remove the front chaincase cover. (See Page 4–6.)
Remove the hydrostatic motor cover.(See Page 3–1.) P–13136

Loosen the four mounting nuts (Item 1) [A] from the

hydrostatic motor, and slide the motor out on the
mounting bolts to allow for clearance between the drive
shafts.
Installation: Tighten the mounting nuts to 65–70 ft.–lbs.
(89–94 Nm) torque.
Use snap ring pliers with 90° tips to remove the outer snap
ring (Item 1) [B].
Slide the brake disk off the cluster sprocket and remove
through the front chain case cover [C].

553 Loader
Revised Apr. 99 –4–4– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 TRACTION LOCK GUIDES
A
Removal and Installation
1 2

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
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–2059–0598 P–13239

Install jackstands under the rear of the loader. (See Page

1–1.) B 1
Raise the loader lift arms and install an approved lift arm
support device. (See Page 1–1.)
Stop the engine. 2 2
Raise the loader operator cab.(See Page 1–1.)
Remove the engine speed control. (See Page 7–1.)
Remove the control panel from the loader. (See Page
3–1.)
Remove the traction lock assembly. (See Page 8–1.)
P–13235
Remove the rear chaincase cover. (See Page 4–6.)

NOTE: Before removing the traction lock guides

(Items 1&2) [A], use the vent (Item 1) [B] as a
reference for the rear of the chaincase cover.
Mark the traction lock guides for left and right
and also mark the guides for front and rear.
This must be done for proper installation of
the guides and to allow for the correct
positioning of the shaft assembly in the
guides.

Remove the four mounting bolts (Item 2) [B] from the

traction lock guides and remove the guides.
Installation: Put a bead of polyurethane caulk around
each mounting hole between the chaincase cover and the
traction lock guides. Put liquid adhesive (LOCTITE #242)
on the threads of the traction lock guide bolts. Tighten to
65–70 ft.–lbs. (88–95 Nm) torque.
Inspect the traction lock guides for damage or wear and
replace if necessary.
Reverse the removal procedure to install the traction lock
guides.

553 Loader
Revised Apr. 99 –4–5– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 CHAINCASE FLUID
A
Removing Oil From The Chaincase
To drain the oil from the chaincase, remove the plug (Item
1) [A] located in the front of the chaincase.

1
P–10917

Use a transfer pump as shown [B] and remove the oil

from the chaincase into a container. B
Installation: Add oil to the chaincase in the same location
as shown in [B]. (See SPECIFICATIONS Page 9–1.)

NOTE: An alternate method to remove or add oil to

the chaincase would be through the front or
rear chaincase cover.

P–05823
CHAINCASE COVERS
Front Cover Removal And Installation C
Remove the control panel. (See Page 3–1.)
Remove the parking brake from the front cover (Item 1)
[C]. (See Page 4–3.) 1
Remove the eight mounting bolts (Item 2) [C] from the
front cover.
Installation: Apply liquid adhesive (LOCTITE #242) to
each mounting bolt and tighten the bolts to 190–240 2
in.–lbs. (22–27 Nm) torque.
Remove the gasket from the chaincase and inspect for
damage. Replace if necessary. P–05995

Rear Cover Removal And Installation D

Remove the control panel. (See Page 3–1.)
Remove the traction lock assembly from the rear cover
(Item 1) [D]. (See Page 8–1.)
Remove the ten mounting bolts (Item 2) [D] from the rear 1
cover.
Installation: Apply liquid adhesive (LOCTITE #242) to 2
each mounting bolt and tighten the mounting bolts to
190–240 in.–lbs. ( 22–27 Nm) torque.
Remove the gasket from the chaincase and inspect for
damage. Replace if necessary. P–05989

553 Loader
–4–6– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 AXLE SEAL
A
Removal And Installation
The tools listed are needed for the following procedure: 2
Axle Hub Puller Tool
Slide Hammer
MEL1469 – Seal Driver Tool
MEL1242 – Power Ram (may be used if desired)
NOTE: The front axle seal is shown in this 1
procedure. This procedure is the same for
the rear axle.

Lift and block the loader. (See Page 1–1.)

2
P–07002

Remove the front wheel from the loader.

Installation: Tighten the wheel mounting nuts to B
105–115 ft.–lbs. (142–156 Nm) torque.
Loosen the axle hub mounting bolt (Item 1) [A]. 1
Remove the axle hub mounting bolt (Item 1) [A] and 2
washer from the axle.
Installation: Tighten the axle hub mounting bolt to the
following specifications:
2.0 inch length bolt 575–625 ft.–lbs. (780–845 Nm)
torque.
2.25 inch length bolt 775–825 ft.–lbs. (1051–1119 Nm)
torque.
P–07003
Remove two of the wheel mounting studs (Item 2) [A]
(180° opposite from each other).
Use a wheel mounting nut on each stud and remove the
two studs with a hammer.
Installation: Support the flange of the axle hub and install
the two studs with a hammer. Use a hydraulic press for
this procedure if available.
Install the puller tool (Item 1) [B] on the axle hub.
Use a driver tool (Item 2) [B] to center the threaded rod
of the puller on the axle.

NEVER STAND IN–LINE OF THE HUB WHEN

REMOVING A HUB FROM AN AXLE. The hub
has a tapered fit on the axle end and can come
off the axle with great force and cause serious
injury.
W–2186–0395

Use a wrench on the threaded rod of the puller and

remove the axle hub from the axle.

553 Loader
Revised Apr. 99 –4–7– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 AXLE SEAL (Cont’d)
Removal And Installation (Cont’d)
A
Remove the key (Item 1) [A] from the axle.

P–07000

Drill a small hole in the axle seal [B]. B

Install a slide hammer (Item 1) [B] with a screw tip end in
the drilled hole on the seal.
NOTE: More than one hole may need to be drilled in
the seal before the seal can be removed from
the axle tube.

Remove the axle seal.

1
P–07004

Installation: MEL1469 seal driver tool is necessary for

the installation procedure. C
Clean the seal area and inspect the shaft for wear.
NOTE: If the shaft is damaged or worn, an axle repair
sleeve kit is available from Melroe Parts in
Chicago.
Put the new axle seal over the axle and into the axle tube.
Install MEL1469 seal driver tool over the end of the axle
and against the seal [C].
Hit the seal driver tool with a hammer [C].
P–07007

Drive the seal (Item 1) [D] into the axle tube until the seal
tool is against the axle tube. D 1
If installed correctly, the axle seal is slightly recessed from
the edge of the axle tube after installation is complete.
Reverse the removal procedure to install the axle hub and
wheel on the loader.

P–07015

553 Loader
–4–8– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 AXLE, BEARINGS, AND SPROCKET
A
Removal And Installation
The tools listed are needed for the following procedure:
MEL1242 – Power Ram
MEL1202B – Axle Bearing Service Set

NOTE: The procedure shown is for removing the

front axle, bearings, and sprocket. This
procedure can also be used to remove the
rear axle, sprocket, and bearings from the 1
loader.

P–05995

B
Never work on a machine with the lift arms up
unless the lift arms are secured by an approved
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–2059–0598

Lift and block the loader. (See Page 1–1.)

1
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.) P–07006

Remove the control panel. (See Page 3–1.)

Remove the front chaincase cover (Item 1) [A] from the
C
loader. (See Page 4–6.)
Remove the axle sprocket mounting bolt (Item 1) [B].
Installation: Apply liquid adhesive (LOCTITE #242) to
the axle sprocket mounting bolt and tighten to 220–245 1
ft.–lbs. (300–330 Nm) torque.
Remove the fluid from the chaincase. (See Page 4–6.)
Remove the axle hub. (See Page 4–7.)
Install the MEL1242 Power Ram (Item 1) [C] between the
sprockets as shown. P–07005

Install a spacer (the same diameter as the end of the axle

shaft), between the power ram and the axle shaft [C]. D
Push the axle out until the power ram is tight against the
sprocket. Add a thicker spacer and push the axle again. 2 1
Repeat the procedure until the axle is free from the
sprocket and inner bearing.
Remove the drive chain from the sprocket (Item 1) [D]
and remove the sprocket from the chaincase.
Remove the inner bearing (Item 2) [D] and remove the
axle from the axle tube. (See Page 4–10 for outer bearing
removal from the axle.)
Installation: Grease both axle bearings before installing
them. P–07011

553 Loader
Revised Apr. 99 –4–9– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 AXLE, BEARINGS, AND SPROCKET (Cont’d)
Removal And Installation (Cont’d)
A
A bearing puller (Item 1) [A] is needed for the following 1
procedure:
Put the axle/outer bearing assembly in the bearing puller
as shown and put in the hydraulic press [A].
Be sure the bearing puller makes good contact with the
inner race of the bearing and press the bearing off the
mounting surface of the axle.
Be sure to hold onto the axle during removal as it will slide
freely along the axle shaft after removal from the bearing
mounting surface and until the bearing contacts the spline P–04170
on the shaft.
Press the splined end of the axle free from the bearing
[B].
B

P–04171

Installation: A piece of round tube (Item 1) [C] is needed

to install the bearing on the axle shaft. The tube needs to C
measure approximately 1/2 inch (12,7 mm) to 1 inch (25,4 4
mm) in length. The inside diameter of the tube should not 3
be under 1.8 inches (45,7 mm) and the outside diameter
should not be over 2.1 inches (50,3 mm),
A bearing puller (Item 2) [C] is also needed to install the 1
bearing on the axle.
Put the tube (Item 1) [C] on the bearing puller (Item 2) [C].
Put the bearing (Item 3) [C] on the tube as shown. 2
Put the spline end of the axle shaft (Item 4) [C] in the
bearing and press the bearing onto the axle. P–04169

Be sure to hold onto the axle during installation. It will slide

freely along the axle shaft after the spline end has passed
through the bearing and until it reaches the bearing D
mounting surface on the axle.
When the bearing reaches the bearing mounting surface,
continue the installation until the bearing is fully seated
[D].

P–04175

553 Loader
–4–10– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 AXLE, BEARINGS, AND SPROCKET (Cont’d)
A
Removal And Installation (Cont’d)
Use the tools provided in the MEL1202B Axle Bearing
Service Set for bearing cup removal and installation. A
slide hammer is also necessary for this procedure.
Use the long rod and bearing cup tool to remove the inner
bearing cup [A].
Hit the long rod with a hammer to remove the bearing cup
from the axle tube [A].

P–07009

To remove the outer bearing cup, put the bearing cup tool
(Item 1) [B] on the slide hammer. B
Leave the bearing cup tool loose until the tool is installed
inside the tube [B].
After the bearing cup tool is inside the axle tube, pull the
tool against the bearing cup and tighten the nut (Item 2)
[B] on the tool.

1
2

P–07008

Use the slide hammer and remove the bearing cup from
the axle tube [C]. C

P–07012

553 Loader
–4–11– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 AXLE, BEARING, AND SPROCKET (Cont’d)
A
Removal And Installation (Cont’d)
1
Use the bearing cup installation tools (Item 1) [A] and
(Item 1) [B] and the long threaded rod (Item 2) [B] from
the service set to install the inner and outer bearing cups.
Put the inner bearing cup in the axle tube (Item 2) [A].
Put the installation tool (Item 1) [A] in the axle tube.
Install the long threaded rod (Item 2) [B] into the axle tube 3
and through the installation tool (Item 1) [A]. 2

Secure the tool to the threaded rod with a nut (Item 3) [A].
P–07014
Put the installation tool (Item 1) [B] in the axle tube with
the threaded rod through the hole in the tool.
Secure the tool to the threaded rod with a nut [B].
B
Hold the inside nut (Item 3) [A] with a wrench and tighten
the outside nut as shown in photo [B].
Tighten the nut until the bearing cup is seated.

P–07013

To install the outer bearing cup, use the short rod and the
bearing cup tool used for removing the bearing cups. C
Put the bearing cup tool on the short rod.
Put the bearing cup in the axle tube and put the tool into
the tube over the bearing cup [C].
Hit the short rod with a hammer until the bearing cup is
seated inside the axle tube.

P–07010

553 Loader
–4–12– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 DRIVE CHAIN
A
Removal
2 1

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
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–2059–0598 P–07011

Lift and block the loader. (See Page 1–1.)

Raise the loader lift arms and install an approved lift arm
B
support device. (See Page 1–1.) 1

Raise the loader operator cab. (See Page 1–1.)

Drain the fluid from the chaincase. (See Page 4–6.)
Remove the engine speed control. (See Page 7–1.)
Remove the control panel. (See Page 3–1.)
Remove the traction lock assembly. (See Page 8–1.)
Remove the front and rear chaincase covers. (See Page
4–6.) P–05992

Remove the front axle (Item 1) [A] and sprocket (Item 2)

[A]. (See Page 4–9.) C
NOTE: Only the front axle and sprocket need to be
removed to replace the front drive chain.
When replacing the rear drive chain, remove
both front and rear axles and sprockets.

Remove the parking brake disc (Item 1) [B]. (See Page

4–4.)
Remove the front (or rear) drive chain from the chaincase.
The tool listed is needed for the following procedure:
MEL1037 – Chain Link Tool B–13504

Installation: If an old chain is repaired, a connector link

must be used to connect the chain together.
Use MEL1037 Chain Link Tool and #80 chain adapter.
Secure the tool and put the connector link in the tool as
shown [C].
Turn the threaded rod of the tool and press the connector
link together on the chain [C]. Tighten the threaded rod of
the chain link tool to 180 ft.–lbs. (244 Nm) torque.

553 Loader
Revised Apr. 99 –4–13– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 553ServiceManual(S/N516311001&Above)#6900450–DriveSystemSection

553 Loader
–4–14– Service Manual
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 MAIN FRAME
Page
Number
BOB–TACH
Bob–Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–19
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17

FUEL TANK
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16

LIFT ARMS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–21
OPERATOR CAB
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

OPERATOR CAB GAS CYLINDER

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7
MAIN
OPERATOR SEAT FRAME
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11
REAR DOOR
Adjusting The Striker (S/N 516313551 & Above And
516415035 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
Door Latch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
Latch Removal And Installation (S/N 516313551 & Above And
516415035 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–15
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12
Striker Disassembly And Assembly (S/N 516313551 & Above And
516415035 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
Striker Removal And Installation (S/N 516313551 & Above And
516415035 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
REAR GRILL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–25
SEAT BAR
Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . 5–6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 9)
UNLESS OTHERWISE SPECIFIED.

Revised Mar. 02 553 Loader

–5–1– Service Manual
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 Revised Mar. 02
553 Loader
–5–2– Service Manual
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 SEAT BAR
A
Removal And Installation
Lower the seat bar (Item 1) [A] so the compression
springs (Item 2) [A] will be in a down position.
1

2 2

P–10907

Loosen the adjustment lock nut (Item 1) [B] (both sides). B

P–09542

Turn the bolt (Item 1) [C] into the clevis five turns (both
sides).
C
Installation: When properly adjusted the clearance
distance between the bolt head (Item 1) [C] and the seat 1
bar tab (Item 2) [C] is 1/16 inch (1,58 mm). 2
Tighten the adjustment lock nut (Item 3) [C] to the clevis.
Repeat above installation procedure for other side. 3
1/16inch
NOTE: This adjustment must be made with the seat (1.58mm)
bar locked down in operating position.

P–09542

Remove the retaining pin (Item 1) [D] and clevis pin (both
sides). D

P–09541

553 Loader
–5–3– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SEAT BAR (Cont’d)
Removal And Installation (Cont’d)
A
Disconnect the wiring harness connector (Item 1) [A] (left
side). 1

Remove the seat bar mounting bolt (Item 2) [A] (both

sides).
2
Remove the sensor mounting bolt (Item 3) [A] (left side).

3
P–09548

Installation: Make sure the two tabs (Item 1) [B] are

located in the slot on the operator cab. B

P–09547

Installation: Tighten the mounting bolt and nut (Item 1)

[C] to 180 – 200 in.–lbs. (21 – 23 Nm) torque. C

P–09554

To protect the paint on the operator cab from getting

scratched, install cardboard (Item 1) [D] on the right side. D
1
Wrap tape around the left pivot end of the seat bar.
Wrap tape around the cab grab handle (Item 2) [D] and
the front edge of the cab (Item 3) [D].

P–10913

553 Loader
–5–4– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SEAT BAR (Cont’d)
A
Removal And Installation (Cont’d) 2
Position the seat bar in the recess on the left side of the 3 1
cab (Item 1) [A]. Position the left side pivot end of the seat
bar between the cab and the grab handle (Item 2) [A].
Lift straight up on the right side (Item 3) [A] of the seat bar.

P–10911

Continue to lift on the right side of the seat bar and allow
the left side of the seat bar to rotate between the cab and
B 1
the grab handle (Item 1) [B].

P–10909

Lift the right side of the seat bar until it clears the right side
screen of the cab [C]. C

P–10908

Remove the left side of the seat bar pivot from between
the cab and grab handle and remove the seat bar from the D
cab [D].
Reverse the above procedure to install the seat bar into
the operator cab.

P–10912

553 Loader
–5–5– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SEAT BAR (Cont’d)
A 6
3
1
Assembling Components
4
Assemble the parts as shown for the left side of the seat
bar pivot assembly [A]:
Mounting Bolt (Item 1)
Washer (Item 2)
Keyed Plastic Bushing (Item 3)
Magnetic Bushing Assembly (Item 4) 2
Sensor Mounting Nut (Item 5)
Sensor Bracket (Item 6)
Sensor Mounting Bolt (Item 7) 8
9 5
Pivot Bushing (Item 8) 7
Mounting Bolt (Item 9)
P–09555

Assemble the parts as shown for the right side of the seat
bar pivot assembly [B]: B 3
2
Mounting Bolt (Item 1) 1
Pivot Bushing (Item 2)
Mounting Bracket (Item 3)
Keyed Plastic Bushing (Item 4)
Washer (Item 5)
Mounting Bolt (Item 6)
6 5 4

P–09551

Compression Spring Disassembly And Assembly

Loosen the lock nut (Item 1) [C] and turn the bolt (Item 2)
C
[C] out of the clevis.
Assembly: Adjust the compression spring as shown on
Page 5–3. 2

P–09542

Disassemble and assemble the seat bar compression

spring and parts as shown in Fig. [D]: D 2
1
Pin (Item 1)
Retaining Pin (Item 2)
Clevis (Item 3)
Lock Nut (Item 4)
Washer (Item 5) 3
Spring (Item 6)
Bushing (Item 7) 4
Bolt (Item 8)
5
8
6

7
P–09586

553 Loader
–5–6– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 OPERATOR CAB GAS CYLINDER
A
Removal And Installation

Cylinder contains high pressure gas. Do not

open. Opening cylinder can release rod and
cause injury or death.
W–2113–0288

P–10902
Remove the operator cab stop (Item 1) (both sides) [A].

NOTE: Be careful not to break the rear window when

the cab is raised after the cab stops are
removed.
B
Raise the operator cab slowly (See Page 1–1), to release
the tension on the gas cylinder (Item 1) [B].
3 2
Remove the retaining pin (Item 2) [B] from the gas
cylinder clevis pin.
Remove the retaining pin and plastic spacer (Item 3) [B]
to disconnect the base end of the gas cylinder from the
operator cab. 1

Installation: Move the cab slightly back or forth to align

the base end of the gas cylinder with the operator cab
mounting bracket, when installing the clevis pin, plastic P–05859
spacer and retaining pin [B].
Remove the retaining pin (Item 1) [C] from the clevis pin
(Item 2) [C] on the rod end of the gas cylinder.
C
Remove the clevis pin (Item 2) [C] to disconnect the rod
end of the gas cylinder from the mounting bracket (Item
3) [C].
Remove the bracket mounting bolts and replace the 1
mounting bracket (Item 3) [C] if it is worn or damaged.
Reverse the removal procedure to install a gas cylinder.
2
Disassembly And Assembly
Remove the clevis (Item 1) [D] and washer (Item 2) [D] 3
from the end of the gas cylinder. P–07023

Remove the gas cylinder from the outer housing.

Installation: Install a replacement cylinder inside the D
cylinder housing.
Apply a small amount of liquid adhesive (LOCTITE #242)
on the threads of the cylinder rod [D].
2
Reinstall the washer and clevis on the cylinder rod [D]. 1

P–01008

553 Loader
–5–7– Service Manual
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 OPERATOR CAB
Removal And Installation
A
Block the rear of the loader. (See Page 1–1.)
1
Remove the operator cab stop (Item 1) [A] (both sides).

P–10902

Install a lifting strap on both operator cab lift handles [B]. B

Fasten the lifting strap to a chain hoist [B].
Raise the loader operator cab. (See Page 1–1.)

NOTE: Be careful when raising the operator cab. The

cab will tilt farther back with the cab stops
removed. If the cab is equipped with a rear
window, the window could be damaged if not
careful.

P–10900

Remove the retaining pin (Item 1) [C] clevis pin and

spacer from the gas cylinder (Item 2) [C] (both sides). C
Keep the other end of the gas cylinder fastened to the
loader and put the cylinder on the fender of the loader.
1

P–05859

553 Loader
–5–8– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 OPERATOR CAB (Cont’d)
A
Removal And Installation (Cont’d) 1 2
Disconnect the operator cab harness (Item 1) [A] and
BICS™ harness (Item 2) [A].
Disconnect the operator cab ground wire (Item 3) [A] from
the loader frame. 3
Use the chain hoist to lower the operator cab back on the
fenders of the loader frame.

P–10905

Install the operator cab holddown plate and nut [B] to

prevent the cab from sliding forward. It is not necessary
to tighten the nut all the way on the plate.
B

P–01518

Remove the operator cab mounting bolt (Item 1) [C] and

nut (both sides).
C

P–10904

Raise the back of the cab and install the bolt (Item 1) [D]
in the cab mount as shown. D
Install the nut (Item 2) [D] on the mounting bolt.
Install a second lifting strap around the two rear cab
mounts as shown in [D].
2

P–10906

553 Loader
–5–9– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 OPERATOR CAB (Cont’d)
Removal And Installation (Cont’d)
A
Fasten the lifting straps to the chain hoist [A].
Remove the holddown nut and plate from each side of the
operator cab.
Raise the operator cab off the loader frame.
Lower the cab to the floor and remove the chain hoist from
the cab.
Reverse the removal procedure and install a new
operator cab on the loader if necessary.

P–10901

553 Loader
–5–10– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 OPERATOR SEAT
A
Removal And Installation
Use the following procedure to remove the operator seat
from the operator cab: 2
Place jackstands under rear of the loader. (See Page
1–1.)
Raise the operator cab. (See Page 1–1.)
Locate the operator seat sensor (Item 1) [A] on the 1
bottom of the seat pan.

P–05863

Disconnect the seat sensor connector (Item 1) [B] and

remove the seat sensor assembly. (See Page 8–1.)
B
Remove the three seat mounting nuts (Item 2) [A] and
washers from the operator seat mounting studs.
Lower the operator cab and remove the operator seat 1
from the cab.

P–10903

NOTE: There are two spacers (Item 1) [C] located

between seat track and the seat pan on each
front mounting stud. Be sure not to lose the
C
spacers when removing the seat.
3
Remove the seat spring (Item 2) [C] from under the right
seat track when removing the operator seat.

1
1
P–03996

Installation: Install the seat spring (Item 1) [D] with the

bend of the seat spring in the position shown. D Operator
Seat
Inspect the seat adjustment track (Item 3) [C].
Seat
1 Spring
Remove the mounting bolt from each end of the track and
replace the adjustment track if necessary.
Seat
Reverse the removal procedure to install the operator Pan
seat.

MC–02043

553 Loader
–5–11– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 REAR DOOR
A
Removal And Installation
The following tools are necessary to remove the rear
door:
Two Lifting Straps
Chain Hoist
Place jackstands under the rear of the loader. (See Page 1
1–1.)
Stop the loader engine and open the rear door.
Disconnect the rear light harness (Item 1) [A] from the
rear door if so equipped. P–10915

Remove the rear lights from the door.

B
Install one lifting strap (Item 1) [B] through the top hole on
the right side of the rear door.
Connect the lifting strap to the chain hoist [B].
Install the second lifting strap (Item 2) [B] through the top
hole on the left side of the rear door.
Connect the lifting strap to the chain hoist [B].

1
2

P–10914

553 Loader
–5–12– Service Manual
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 REAR DOOR (Cont’d)
A
Removal And Installation (Cont’d)
Remove the two hinge pins (Item 1) [C] from the upper 1
and lower hinges on the rear door.
Remove the door from the loader.
Reverse the removal procedure to install the rear door.

Door Latch Adjustment

AVOID INJURY P–10910

Never service or adjust the machine when the

engine is running unless instructed to do so in
the manual. B
W–2012–0290

The door latch (Item 1) [B] can be adjusted side to side

and up/down for alignment with the door latch
mechanism.

1
P–10735

The door latch mechanism (Item 1) [C] can be adjusted

backward and forward for alignment with the door catch.
C
Close the rear door before operating the loader.
1

P–10669

553 Loader
–5–13– Service Manual
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 REAR DOOR (Cont’d)
Striker Removal And Installation (S/N 516313551 &
A
Above) & (516415035 & Above) 1

Remove the two striker mount bolts (Item 1) [A].

Remove the striker assembly from the loader.

Striker Disassembly And Assembly (S/N 516313551 &

Above) & (516415035 & Above)
2
Remove the lock nut (Item 2) [A] to remove the bolt and
bushings. 1
P–31126

Check the parts for wear and replace as needed [B]. B

P–31320
Adjusting The Striker (S/N 516313551 & Above) &
(516415035 & Above)
Loosen the two striker assembly mount bolts (Item 1) [C}. C
1
Align the striker assembly in the center of the mounting
holes.
Tighten the striker assembly, top mount bolt only, until it
will hold the striker assembly in the center of the mounting
slots.
Shut the rear door. (This will align the striker assembly to
the correct position.)
Open the rear door.
1
Tighten both striker mount bolts (Item 1) [C]. P–31126

Close the rear door.

553 Loader
–5–14– Service Manual
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 REAR DOOR (Cont’d)
Latch Removal And Installation (S/N 516313551 &
A
Above) & (516415035 & Above)
Reconnect the spring (Item 1) [A] from the tailgate.
Remove the bolt and nut (Item 2) [A] from the door latch.
2

P–31125

Remove the spring (Item 1) [B] from the door handle. B

Remove the spring (Item 2) [B] from the door latch.
Remove the door latch (Item 3) [B] from the lever. 3

P–31127

Remove the lever (Item 1) [C} from the rear door.

C

P–31128

553 Loader
–5–15– Service Manual
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 FUEL TANK
A 1
Removal And Installation
3
Raise the operator cab. (See Page 1–1.)
Disconnect the fuel supply hose (Item 1) [A] from the fuel
tank.
2 4
The fuel supply hose is connected to the shutoff drain
(Item 1) [B] located under the fuel tank on the right side
of the loader.
Disconnect the fuel return hose (Item 2) [A] from the fuel
tank.
The fuel return hose is connected to the return tubeline on P–10918
the fuel injectors.
Disconnect the two wires from the fuel level sender (Item
3) [A].
B

P–07023

Remove the mounting bolt (Item 1) [C] from fuel tank

retaining strap (Item 2) [C].
C
1
Remove the fuel tank from the loader.
2
If the fuel tank is being replaced due to damage, remove
the remaining fuel from the tank and put into an approved
fuel container.
Reverse the removal procedure to install the fuel tank.

Fuel Level Sender

To replace the fuel level sender, disconnect the two wires
(Item 3) [A] from the fuel sender. P–10916

Remove the five mounting screws (Item 4) [A] from the

fuel sender.
Remove the fuel level sender from the fuel tank.
Inspect the sender and replace if necessary.
Reverse the removal procedure to install the fuel level
sender in the fuel tank.

Revised Mar. 02 553 Loader

–5–16– Service Manual
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 BOB–TACH
Removal And Installation
A
Tilt the Bob–Tach forward, so it is parallel to the floor.
Lower the Bob–Tach onto the floor [A].

P–10852

Remove the retainer bolt (Item 1) [B] from the pivot pin. B
Installation: Tighten the retainer bolt to 18–20 ft.–lbs.
(24–27 Nm) torque.

P–04601

Remove the rod end pivot pin (Item 1) [C]. C

P–03915

D
Remove the tilt cylinder rod end.
Remove the seals (Item 1) [D].

P–03911

Revised Mar. 02 553 Loader

–5–17– Service Manual
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 BOB–TACH (Cont’d)
A
Removal And Installation (Cont’d)
Installation: Use two pieces of shim stock (light
cardboard), install the rod end of the tilt cylinder into the
Bob–Tach [A].
Be careful not to damage the seals during installation.
NOTE: Removal procedure is shown for the right
side. Left side procedure is the same.

P–03910

Remove the grease fitting (Item 1) [B] from the Bob–Tach

frame for the pivot pin (both sides). B
NOTE: The pivot pin grease fitting must be removed
to prevent the pivot pin from being locked in
the Bob–Tach frame. 1
2
Loosen the bolt (Item 2) [B] at the Bob–Tach pivot pin.
Installation: Tighten the bolt to 190 ft.–lbs. (260 Nm)
torque.
Strike the head of the bolt (Item 2) [B] to push the pivot
pin into the Bob–Tach frame.
Remove the bolt (Item 2) [B] and spacer. P–10843
Use a punch to push the pivot pin all the way into the
Bob–Tach frame.
C
Slowly back the loader away to remove the Bob–Tach
frame [C].
Remove the seal dust cup (Item 1) [C].

1
P–10849

Remove the rubber seal (Item 1) [D].

D

P–10850

Revised Mar. 02 553 Loader

–5–18– Service Manual
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 BOB–TACH (Cont’d)
A
Removal And Installation (Cont’d)
Install the Bob–Tach mounting bolt (Item 1) [A] into the
pivot pin (Item 2) [A]. Remove the pivot pin from the
Bob–Tach frame.
Check for wear and damage. Replace the pivot pins as
needed.
NOTE: Use tapered ream MEL1233 to clean the
tapered hole in the lift arms. The tapered hole 3
must be clean and free of debris to provide a 1 2
good contact surface for the pivot pin.
P–10851

Installation: Push the pivot pin (Item 2) [A] into the

Bob–Tach frame. Position the end of the pin flush with the
end of the Bob–Tach bushing (Item 3) [A].
B

Use a long bolt (Item 1) [B] to install through the lift arms
into the pivot pin, to pull the pivot pin into the lift arms.
1
Reverse the removal procedure to install the Bob–Tach

P–10853

C
Bob–Tach Lever And Wedge
Use the following procedure to remove and install the
Bob–Tach lever (Item 1) [C], spring and wedge.

P–10847

D
Remove the lever mounting nut (Item 1) [D], washer (Item
2) [D] and spring (Item 3) [D].
Installation: Tighten the nut to 25–28 ft.–lbs. (34–38 Nm)
torque.

3
1 2
P–03928

Revised Mar. 02 553 Loader

–5–19– Service Manual
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 BOB–TACH (Cont’d)
Bob–Tach Lever And Wedge (Cont’d)
A
Remove the Bob–Tach lever (Item 1) [A].

P–03924

Use a punch and hammer, remove the roll pin (Item 1) [B]
from the Bob–Tach wedge and spring, bolt and clevis
B
assembly. 1

Remove the spring, bolt and clevis assembly (Item 2) [B].

P–10846

Remove the wedge (Item 1) [C] from the Bob–Tach

frame. C
Always replace bent or broken wedges.
1

P–10845

If the bolt (Item 1) [D], handle pivot (Item 2) [D], spring

(Item 3) [D] or clevis (Item 4) [D] are damaged, put the D
assembly in the vise. Loosen and remove the bolt (Item
1) [D] with a 5/16 inch allen wrench.
Replace the worn or damaged parts as needed.
1
Reverse the removal procedure to install the Bob–Tach
Lever and Wedge. 2
3

P–10848

Revised Mar. 02 553 Loader

–5–20– Service Manual
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 LIFT ARMS
A
Removal and Installation
Remove the attachment from the Bob–Tach.
Remove the Bob–Tach from the loader. (See Page 5–15.)
Stop the engine. Pull up on the lift arm by–pass control
and move the lift pedal to release the hydraulic pressure,
until the boom arms rest on blocks [A].
Raise the seat bar.
Install jackstands under the rear of the loader. (See Page
1–1.)
P–10854
Raise the operator cab. (See Page 1–1.)
Remove the retainer bolt (Item 1) [B] and nut from the rod
end pivot pin.
B
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque. 5
Remove the rod end pivot pin (Item 2) [B] from the
cylinder.
4
Remove the retainer bolt (Item 3) [B] nut and spacer from
the lift arm support device. 1 3
Installation: Tighten the retainer bolt and nut to 18–20 2
ft.–lbs. (24–27 Nm) torque.
Remove the lift arm support device retaining pin (Item 4) P–10856
[B].
Remove the lift arm support device (Item 5) [B]. C
Remove the tubeline mounting brackets (Item 1) [C] from
the tilt cylinder tubelines.

P–10841

Remove the tilt cylinder tubeline mounting bracket (Item

1) [D]. D

1
P–10842

Revised Mar. 02 553 Loader

–5–21– Service Manual
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 LIFT ARMS (Cont’d)
A
Removal And Installation (Cont’d) 1
Remove the mounting bolt and nut from the tilt cylinder
pivot pin (Item 1) [A].
Installation: Tighten the mounting bolt and nut to 80–90
in.–lbs (9–10 mm).

P–10882

Remove the pivot pin (Item 1) [B] from the tilt cylinder. B 1
Lower the tilt cylinder with attached tubelines to the floor.

P–10883

Remove the mounting bolts (Item 1) [C] from the auxiliary

hydraulic coupler mounting bracket.
C

P–10711

Remove the mounting bolt and nut from the lift arm pivot
pin (Item 1) [D] (left side). D
Installation: Tighten the mounting bolt and nut to 80–90
in.–lbs. (9–10 Nm) torque.
Remove the rod end pivot pin (Item 2) [D] from the left
side lift cylinder.
2

P–10878

Revised Mar. 02 553 Loader

–5–22– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 LIFT ARMS (Cont’d)
Removal And Installation (Cont’d)
A
Remove the left side tubeline mounting brackets (Item 1)
[A].

P–10876

Position the lifting straps and chains securely to the lift

arms and to the overhead chain hoist [B]. B
Raise the chain hoist to support the weight of the lift arms.

P–10886

Remove the retainer bolt (Item 1) [C] and nut from the lift
arm pivot pins (both sides). C
Installation: Tighten the mounting bolt and nut to 80–90
in.–lbs. (9–10 Nm) torque.
Remove the lift arm pivot pin (Item 2) [C] (both sides).

P–10879

Revised Mar. 02 553 Loader

–5–23– Service Manual
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 LIFT ARMS (Cont’d)
A
Removal And Installation (Cont’d)
Remove the lift arms from the loader [A].
Slowly move the lift arms clear of the loader and lower
them on the floor.
Reverse the removal procedure to install the lift arms.

P–10885

Revised Mar. 02 553 Loader

–5–24– Service Manual
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 REAR GRILL
A
Removal And Installation 1
Stop the loader engine and open the rear door of the
loader.
The grill (Item 1) [A] has four mounting bolts (Item 2) [A].
Remove the four mounting bolts (Item 2) [A] from the grill.
2
Installation: Tighten the mounting bolts to 180–200
in.–lbs. (21–23 Nm) torque.
Remove the grill from the loader.
P–10747

Revised Mar. 02 553 Loader

–5–25– Service Manual
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 553ServiceManual(S/N516311001&Above)#6900450–MainFrameSection

Revised Mar. 02 553 Loader

–5–26– Service Manual
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 ELECTRICAL SYSTEM
Page
Number
ALTERNATOR
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
Alternator Regulator Test With Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
Brush Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Full Field Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8

BATTERY
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5

ELECTRICAL SYSTEM INFORMATION

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
Relay Switches Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 ELECTRICAL
SYSTEM
FRONT LIGHTS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–36

INSTRUMENT PANEL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–35

STARTER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28
Checking The Starter In The Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–19
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–27
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–18
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–17

TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
USING A BOOSTER BATTER (JUMP STARTING)
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE

STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 9)
UNLESS OTHERWISE SPECIFIED.

553 Loader
–6–1– Service Manual
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 553 Loader
–6–2– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 TROUBLESHOOTING
The following troubleshooting chart is provided for
assistance in locating and correcting problems. Many of
the recommended procedures must be done by
authorized Bobcat Service Personnel only.

Instructions are necessary before operating or

servicing machine. Read and understand the
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. Untrained operators and
failure to follow instructions can cause injury
or death. W–2003–0199

PROBLEM CAUSE

Battery will not take a charge. 1, 2, 3, 4, 5

Alternator will not charge. 1, 2, 5

Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE

1. Alternator belt is loose or damaged.

2. Battery connections are dirty or loose.

3. Battery is damaged.

4. The ground connection is not making a good contact.

5. The alternator is damaged.

6. The engine is locked.

7. The starter is damaged.

8. The wiring or the solenoid is damaged.

9. Check the fuses.

Revised Mar. 02
553 Loader
–6–3– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ELECTRICAL SYSTEM INFORMATION
Description
A
1
The loader has a 12 volt, negative ground alternator
charging system. The electrical system is protected by 2
fuses (Item 1) [A] located in the engine compartment. The
fuses will protect the electrical system when there is an
electrical overload. The reason for the overload must be
found before starting the engine again. 2

Fuse Location
The electrical system for loaders is protected by seven
fuses located in the fuse block (Item 1) [A].
P–10748

Remove the fuse block cover to access the fuses [B].

B

P–10674

The decal located on the alternator belt shield specifies

the fuse sizes used in the various electrical circuits [C].
C
Relay Switches Location
The loader engine harness has relay switches (Item 2) [A]
located next to the fuses.
There are five relay switches (Item 2) [A] for the circuitry
on the loader.
The relay switches are for the starter, switch power, glow
plug, brake and fuel shut off.
Replace a relay switch if the switch is malfunctioning.
Refer to the engine electrical wiring diagram at the
beginning of this section for correct wiring connections. 6707786

553 Loader
–6–4– Service Manual
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 BATTERY
Removal And Installation
A

Batteries contain acid which burns eyes and

skin on contact. Wear goggles, protective
clothing and rubber gloves to keep acid off
body.
In case of acid contact, wash immediately with P–10838
water. In case of eye contact get prompt medical
attention and wash eye with clean, cool water
for at least 15 minutes. B 1
If electrolyte is taken internally drink large
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention.
W–2065–1296

Open the rear door.

Disconnect the negative (–) battery cable (Item 1) [A].
Remove the battery holddown clamp (Item 1) [B].

P–10835

Disconnect the positive (+) cable (Item 1) [C]. C 1

Remove the battery from the loader.

P–10840

Always clean the terminals and cable ends when

installing a new battery [D]. D
Do not touch any metal parts with the battery terminals.
Connect and tighten the battery cables. Connect the
negative (–) cable last to prevent sparks.
Inspect the battery holddown to be sure that it is in good
condition. If it is cracked or broken, replace it.
Close the rear door.

P–09590 P–09589

553 Loader
–6–5– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 USING A BOOSTER BATTERY (JUMP STARTING)
A
Procedure

2
4

Damage to the alternator can occur if:

• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a
fast charger or when welding on the loader
(Remove both cables from the battery).
P–10690
• Extra battery cables (booster cables) are
connected wrong.
I–2023–1285

If it is necessary to use an extra battery to start the engine,

BE CAREFUL! There must be one person in the
operator’s seat and one person to connect and
disconnect the battery cables. 1
The key switch must be OFF.
3
The battery must be 12 volt.
Connect the end of the first cable to the positive terminal
(+) of the booster battery (Item 1) [A]. Connect the other
end of the same cable to the loader battery positive (+)
terminal (Item 2) [A]. P–10691

Connect the end of the second cable to the negative

terminal (–) of the booster battery (Item 3) [A]. Connect
the other end of second cable to the engine ground (Item
4) [A].
Keep the cables away from moving parts.
Start the engine.
After the engine has started, remove the ground cable
connected to the engine first.
Remove the cable connected to the loader battery.

Batteries contain acid which burns eyes and Keep arcs, sparks, flames and lighted tobacco
skin on contact. Wear goggles, protective away from batteries. When jumping from
clothing and rubber gloves to keep acid off booster battery make final connection
body. (negative) at engine frame.

In case of acid contact, wash immediately with Do not jump start or charge a frozen or damaged
water. In case of eye contact get prompt medical battery. Warm battery to 60°F. (16°C.) before
attention and wash eye with clean, cool water connecting to a charger. Unplug charger before
for at least 15 minutes. connecting or disconnecting cables to battery.
Never lean over battery while boosting, testing
If electrolyte is taken internally drink large or charging.
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention. Battery gas can explode and cause serious
W–2065–1296 injury. W–2066–1296

553 Loader
–6–6– Service Manual
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 ALTERNATOR
Removal And Installation
A
1
Stop the loader engine and open the rear door. 1
Remove the negative (–) cable at the battery.
Remove the mounting bolts (Item 1) [A] from the
alternator belt shield.
1 1
Installation: Tighten the mounting bolts to 180–200
in.–lbs. (21–23 Nm) torque.
Remove the belt shield.
P–10746

Remove the red wires (Item 1) [B] at the alternator. B

Disconnect the wiring harness connector (Item 2) [B]. 2
1

P–10940

Loosen the adjustment bolt (Item 1) [C].

C 1
Remove the alternator belt.
Remove the adjustment bolt (Item 1) [C].
Remove the mounting bolt (Item 2) [C] and nut.
Remove the alternator.

2
Adjusting The Alternator Belt
Stop the engine and open the rear door.
P–10682
Remove the alternator belt shield.
Loosen the alternator mounting bolt (Item 2) [C].
D
Loosen the adjustment bolt (Item 1) [C].

Move the alternator until the belt has 5/16 inch (8 mm)
movement [D] at the middle of the belt span with 15 lbs.
(67 N) of force.
Tighten the adjustment bolt and mounting bolt.
Reinstall the alternator belt shield.

P–10681

553 Loader
–6–7– Service Manual
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 ALTERNATOR
A 1
Description
3
The output terminal (Item 1) [A].
4 2
The battery or power sensing terminal (Item 2) [A].
The ignition terminal (Item 3) [A].
Open terminal not used in the loader harness (Item 4) [A].
Access hole for full field test (Item 5) [A].

Tests 5
P–10018 P–10023
Perform the following alternator tests in this order:
Alternator Output Test: Tests the alternator and regulator
output.
B
1
Full Field Test: Tests the maximum amperage output of
the alternator.
Alternator Regulator Test: Tests the regulator voltage
output.

Alternator Output Test

Lift and block the loader. (See Page 1–1.)
Check battery and battery connections. (See Page 6–6.)
P–10940
Disconnect the negative (–) cable from the battery.

Disconnect the red wire (Item 1) [B] from the alternator.

C
Connect that wire to the negative (–) side of the ammeter
(Item 1) [C].
Connect the positive (+) side of the ammeter to the output
terminal at the alternator (Item 2) [C].
Reconnect the negative (–) cable to the battery.
Start the engine and run at full RPM.
The ammeter reading should be between 35 and 40
amps.
1
2
If the ammeter reading is less than 35 amps do the full
field test.

When an engine is running in an enclosed

area, fresh air must be added to avoid
concentration of exhaust fumes. If the engine
is stationary, vent the exhaust outside.
Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W–2050–1285

P–10951

553 Loader
–6–8– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ALTERNATOR (Cont’d)
Full Field Test
A
Start the engine and run at full RPM.
1
Place a small screw driver in the test port (Item 1) [A] to
provide a ground to the alternator case. This will give
maximum amperage output from the alternator.
NOTE: The Full Field Test should only last long
enough to get ammeter reading to prevent
damage to the alternator.
The ammeter reading should be above 35 amps.
If the ammeter reading is low, repair or replace the P–10021
alternator.

When an engine is running in an enclosed

area, fresh air must be added to avoid
concentration of exhaust fumes. If the engine
is stationary, vent the exhaust outside.
Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W–2050–1285

Alternator Regulator Test

Disconnect the fuel stop solenoid connector.
1
Turn the lights on (if equipped) and crank the engine for
30 seconds to discharge the battery.
Connect the fuel stop solenoid connector. 2

Start the engine and run at full RPM.

The ammeter reading should be around 35 amps and
slowly decrease with alternator output.
If ammeter reading is low or does not decrease with time,
replace the alternator’s regulator.
Disconnect the negative (–) cable from the battery.
Reconnect the alternator wires.
P–10952
Reconnect the negative (–) cable from the battery.

NOTE: The alternator regulator test can also be run

using a voltmeter.
Alternator Regulator Test With Voltmeter
Connect the positive (+) voltmeter lead to the positive (+)
battery terminal (Item 1) [B].
Connect the negative (–) voltmeter lead to the negative
(–) battery terminal (Item 2) [B].
Start the engine and run at full RPM.
The voltmeter should read between 13.9 and 14.7 volts.
If the voltmeter reading is not within this range, replace
the alternator’s regulator.
553 Loader
–6–9– Service Manual
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 ALTERNATOR (Cont’d)
Parts Identification

1. Nut 10. Rotor Assy. 19. Regulator

2. Pulley 11. Bearing 20. Screw
3. Spacer 12. Cover 21. Brush
4. Frame Assy. 13. Frame End 22. Spring
5. Stud 14. Nut 23. Screw
6. Bearing 15. Insulator 24. Screw
7. Plate 16. Nut 25. Seal
8. Screw 17. Bolt 26. Brush
9. Screw 18. Rectifier 27. Cover
28. Bolt 10

9 12

5 7
11
6
4

27

3
24

1 16 25
26 28

15

23
14 22

21
13
20

19
17 18

C–03456

553 Loader
–6–10– Service Manual
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 ALTERNATOR (Cont’d)
A
Pulley Removal And Installation
Remove the alternator from the loader. (See Page 6–7.)
1
Wrap a V–belt in the alternator pulley and clamp the pulley
into a vise as shown [A]. Do not over tighten vise.
Using a box end wrench (Item 1) [B] (22 mm) loosen and
remove the nut (Item 1) [A] while the pulley shaft (Item 2) 2
[A] is held firmly with a 6–point socket (Item 2) [B] (10
mm).

P–10048
NOTE: A six point box end wrench should be used,
a twelve point box end wrench may damage
the corners of the nut. B

P–10050

Assembly: Tighten the pulley nut [C] as shown to 70–94

ft.–lbs. (94–127 Nm) torque.
C

P–09794

Disassembly And Assembly D

Remove the three screws (Item 1) [D], the nut and 2
insulator (Item 2) [D] and remove the end cover (Item 3)
[D].
1
3

P–10020

553 Loader
–6–11– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ALTERNATOR (Cont’d)
A 1 2
Disassembly And Assembly (Cont’d)
Remove the two screws (Item 1) [A] and remove the
1
brush holder (Item 2) [A].

P–10031

Remove the three screws (Item 1) [B] and remove the

regulator (Item 2) [B].
B 1

NOTE: The lengths of the screws are different, and 2

must be marked prior to disassembly. If the
wrong screw is used damage to the
alternator may occur.
1

P–10032

C
Loosen the four screws (item 1) [C] that hold the rectifier 1
lead wires. Unwrap and straighten the rectifier lead wires
from the screws, and lift the rectifier (Item 2) [C] from the
stator. 1
1

2
1

P–10033

D
Remove the two bolts (Item 1) [D] and two nuts (Item 2) 1 2
[D].

2 1

P–10034

553 Loader
–6–12– Service Manual
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 ALTERNATOR (Cont’d)
Disassembly And Assembly (Cont’d)
A
Using a puller (Item 1) [A], remove the rear housing as
shown in Fig. [A].

P–10035

Support the alternator housing (Item 1) [B] on blocks.

B 2 1
With the nut (Item 2) [B] on the pulley shaft, tap the rotor
out of the bearing. A press may be needed if the bearing
is stuck to the rotor shaft.

NOTE: Care should be used not to damage the fan,

slip ring, etc.

P–10037

C
1
Remove the four screws (Item 1) [C] and remove the
retainer plate (Item 2) [C].

1
P–10036

553 Loader
–6–13– Service Manual
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 ALTERNATOR (Cont’d)
Disassembly And Assembly (Cont’d)
A
Support the alternator housing (Item 1) [A] on blocks, and
press the bearing from the housing. 1

P–10039

Assembly: Press a new bearing in the housing [B].

B

P–10040
Remove the bearing (Item 1) [C] from the rotor shaft,
using a puller (Item 2) [C].
C 1
NOTE: A vise with padded jaws may be used to
secure the rotor assembly. Do not over
tighten the vise.

2
P–10042

D
Rotor Continuity Test
Touch the probes to the slip rings [D].
The ohmmeter should read approximately 2.9 ohms.

If there is no continuity, replace the rotor.

P–10043

553 Loader
–6–14– Service Manual
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 ALTERNATOR (Cont’d)
A
Rotor Continuity Test (Cont’d) 1
Check the continuity across the slip rings (Item 1) [A] to
the core of the rotor (Item 2) [A] with an ohmmeter.
If there is continuity, replace the rotor.
2

P–13179

‘
Measure the slip ring shaft [B].
B
Standard measurement is 0.57 inches (14,45 mm)
allowable limit is 0.55 inches (14,0 mm).
Check the slip ring for stained or rough surfaces, use fine
sandpaper to clean shaft.

P–10041
Stator Continuity Test
Check the continuity across each of the four leads of the
C
stator coil with an ohmmeter [C].
If there is no continuity, replace the stator.

P–13177

Check the continuity across each stator coil lead to the

core (Frame Assembly) with an ohmmeter [D]. D
If it has continuity, replace it.

P–13178

553 Loader
–6–15– Service Manual
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 ALTERNATOR (Cont’d)
‘
Rectifier Continuity (Diode) Test A
Test 1: Touch the positive (+) test probe (Item 1) [B] to the
positive terminal. Touch the negative (–) test probe (Item 2 1
2) [B] to the P1, P2, P3 and P4 terminals. There should
be no reading.
P1
Test 2: Reverse the positions of the test probes from Test
1, there should be reading.
P2

P4
P3
P–10046

Test 3: Touch the positive (+) test probe (Item 1) [C] to the B
ground terminals, touch the (–) negative test probe (Item
2) [C] to the P1, P2, P3 and P4 terminals. There should
be be a reading.
2 1
Test 4: Reverse the positions of the test probes from test
3, there should be no reading. P1

P2

P4 P3
P–10047

C
Brush Length
Measure the length of the brush protruding from the brush
holder [D].
Standard measurement is 0.41 inches (10,5 mm)
allowable limit is 0.18 inches (4,5 mm).

P–10044

553 Loader
–6–16– Service Manual
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 STARTER
A
Removal And Installation
Stop the engine and open the rear door.
1
Remove the battery from the loader. (See Page 6–5.) 2
Make note of the wiring connections on the starter to
ensure correct installation.
Remove the rubber cover from the solenoid terminal 4 3
(Item 1) [A] and remove the solenoid wire.
Remove the rubber cover from the positive (+) starter
terminal (Item 2) [A] and remove the positive (+) wires
from the starter. P–10944

Remove the starter mounting nut (Item 3) [A] and

negative (–) cables. B 1
Remove the mounting bolt (Item 4) [A] from the starter
support bracket, and remove the bracket from the starter.
Remove the starter mounting nuts (Item 1 & 2) [B].
Remove the starter.
Installation: Tighten the starter mounting bolts to 25–28
ft.–lbs. (34–38 Nm) torque.

P–10943

Checking The Starter In The Loader C

NOTE: The starter is removed from the loader for
clarity.
2
The key switch must be in the OFF position.
The battery must be at full charge.
The cable connections on the battery must be clean and
tight.
1
Connect a jumper wire between battery terminal (Item 1)
[C] and the solenoid terminal (Item 2) [C].
If the starter turns but does not turn the engine, the starter P–09975
drive has a defect.

Connect a jumper wire between the battery terminal (Item

D
1) [D] and the motor terminal (Item 2) [D].
If the starter turns, the defect is in the solenoid.
If the starter does not turn, the starter is defective.

2
1

P–09976

553 Loader
–6–17– Service Manual
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 STARTER
Parts Identification

1. Bearing
2. Armature 7
3. Bearing
4. Frame 5 8 9
5. Brush Spring 6
6. Brush Holder
7. Cover
8. Bolt 4
9. Bolt 11. Cover
10. Bolt 12. Gasket
3 13. Switch
2 14. Nut
15. Washer
16. Nut
17. Washer
18. Roller
19. Retainer
20. Idler Gear

1 10

15 12
14 11

16

18 17 13
19
20

16
23 14
22
15
21

36

35 21. Ball
34 22. Spring
23. Housing
24. Screw
33 25. Washer
32 26. O–ring
26 27. Housing
25 29
31 28. O–ring
24 29. Snap Ring
30 30. Collar
29 31. Pinion Gear
28 32. Spring Seat
33. Spring
34. Clutch
35. Spring
27 36. Pinion Shaft

D–02297

553 Loader
–6–18– Service Manual
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 STARTER (Cont’d)
Disassembly
A 2

Remove the cable (Item 1) [A] from the magnetic switch.

Mark the frame and magnetic switch (Item 2) [A] for ease
of assembly.
1

N–15019

Remove the bolts (Item 1) [B].

B

1
1

N–15020

Remove the frame (Item 1) [C] from the magnetic switch.

C

1
N–15021

Remove the screws (Item 1) [D] from the brush cover

(Item 2) [D]. D
Remove the cover (Item 2) [D].

1
N–15022

553 Loader
–6–19– Service Manual
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 STARTER (Cont’d)
Disassembly (Cont’d)
A
Using a needle nose pliers, pull the brush springs (Item
1) [A] back and remove the brushes (Item 2) [A]. 2

NOTE: The brushes are non–replaceable, If the

brushes are worn order a new brush holder
(for the negative brushes) and yolk (for the
positive brushes). 1
Remove the brush holder (Item 3) [A] from the end of the
armature.
3
N–15023

Remove the armature (Item 1) [B] from the frame.

B
1

N–15024

Remove the bearings (Item 1) [C] from both ends of the

armature.
C

1 1
N–15025

Remove the bolts (Item 1) [D] from the starter housing.

D

1 1

N–15026

553 Loader
–6–20– Service Manual
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 STARTER (Cont’d)
A
Disassembly (Cont’d)
Remove the starter housing (Item 1) [A] from the
magnetic switch housing.

1
N–15027

Remove the ball (Item 1) [B] from the pinion shaft. B

1
N–15028

Remove the idler gear (Item 1) [C], rollers (Item 2) [C] and
retainer (Item 3) [C]. C 3

N–15029

In order to remove the snap ring from the pinion shaft, a

tube 0.605 inches (15,4 mm) in diameter by 2.0 inches D
(50,8 mm) in length is needed [D].

N–15042

553 Loader
–6–21– Service Manual
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 STARTER (Cont’d)
Disassembly (Cont’d)
A
Install the tube (Item 1) [A] in the over running clutch.

1
N–15045

Press down on the starter carrier (Item 1) [B] to extend

the pinion shaft. Press down on the pinion (Item 2) [B]. B
Press the collar (Item 3) [B] down to gain access to the
snap ring.

1
2

N–15046

Remove the snap ring (Item 1) [C].

C

N–15047

Remove the collar (Item1) [D], pinion (Item 2) [D], spring

(Item 3) [D], and spring seat (Item 4) [D]. D
3
2
4 1

N–15053

553 Loader
–6–22– Service Manual
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 STARTER (Cont’d)
Disassembly (Cont’d)
A
Remove the pinion shaft (Item 1) [A] and spring (Item 2)
[A] from the starter drive.

1 2

N–15033

Remove the over running clutch (Item 1) [B].

B

N–15034

Remove the O–ring (Item 1) [C] from the starter housing.

C

N–15035

Remove the spring (Item 1) [D] from the magnetic switch.

D

N–15030

553 Loader
–6–23– Service Manual
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 STARTER (Cont’d)
A
Disassembly (Cont’d)
Remove the bolts (Item 1) [A] from the magnetic switch
cover.

1
1

N–15031

Remove the cover (Item 1) [B], gasket (Item 2) [B] and

switch (Item 3) [B]. B

3 2 1

N–15032

Inspection And Repair

Inspect the brush cover for discoloration, indicating the
C
starter has been overheated.
Inspect the pinion teeth for wear and damage.
Armature Short–Circuit Test: Use a growler tester, put the
armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [C]. A short circuited armature causes the blade
to vibrate and be attracted to the core. An armature which
is short–circuited must be replaced.

B–14455

Armature Winding Ground Test: Use a circuit tester, touch

one probe to a commutator segment and the other probe D
to the armature core [D]. There should be no continuity.
If there is continuity, the armature is grounded and must
be replaced.

N–15036

553 Loader
–6–24– Service Manual
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 STARTER (Cont’d)
553ServiceManual(S/N516311001&Above)#6900450–ElectricalSystemSectionPart1of2

Inspection And Repair (Cont’d)

A
Armature Winding Continuity Test: Use a circuit tester,
touch the probes to two commutator segments [A]. There
must be continuity at any point. If there is no continuity,
the winding is open–circuited, replace the armature.

N–15037

Commutator Run–Out Test: Check the commutator

run–out as shown in [B].
B
Service Limit – 0.020 inch (0,4 mm)
If the commutator exceeds the service limit, repair as
needed.

B–14458

Measure the segment mica depth (Item 1) [C].

C
Service Limit – 0.008 inch (0,2 mm)
If it is worn, replace the armature. 1

Check the commutator surface for burned spots which

usually indicates an open–circuit, and correct it using
#400 sand paper.

B–14460

Check the field windings for wear and damage.

D
Check all the connections for clean and tight solder joints.
Field Winding Ground Test: Use a circuit tester, touch one
probe to the field winding end of the brush and the other
probe to the surface of the frame [D]. There should be no
continuity. If there is continuity, the field windings are
grounded.
Replace the field windings.

N–15039

553 Loader
–6–25– Service Manual
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 STARTER (Cont’d)
Inspection And Repair (Cont’d)
A
Field Windings Continuity Test: Use a circuit tester, touch
one probe to the wire and the other probe to the brush [A].
There must be continuity. If there is no continuity, the field
windings are open–circuited. Replace the yoke if the field
windings have an open circuit.

N–15040

Inspect the brushes for wear and damage. B

Replace the brush holder or yoke assembly if the brushes
are worn or damaged.
Check brush springs, for damage or rust. Replace as
needed.
Brush Holder Insulation Test: Use a circuit tester, touch
one probe to the positive brush holder plate and the other
probe to the holder plate [B]. There should be no
continuity. If there is continuity, replace or repair.

N–15059

Inspect the over running clutch (Item 1) [C], it must rotate

freely in the direction of the starter rotation and lock in the
opposite rotation. C
1

N–15043

553 Loader
–6–26– Service Manual
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 STARTER (Cont’d)
A 50
Inspection And Repair (Cont’d)
C
The following tests should be done without the armature
assembly.
M.T. . . Main Terminal to which the main cable from the
battery is connected.
C . . . . . C–Terminal to which the wire from the field
windings is connected.
M.T.
50 . . . . 50–Terminal to which the wire from the starting
switch or stator relay is connected.
B–14471
NOTE: Each test should be performed a short time
(3 to 5 seconds) to prevent the magnetic
switch winding from burning. Each test
should be performed with 12 volts. B 50

Pull–In Test: Connect the wires as shown in [A]. When C

connecting Terminal C and M.T. are closed, the pinion
should engage.

Hold–In Test: With the same conditions as in the pull–in

test, open the connecting Terminal C [B]. The pinion
should remain in the engaged position.

M.T.

B–14470

Return Test: With the same conditions as in the hold–in

test, open the connecting Terminal 50 [C]. The pinion C 50
should return immediately.
C

M.T.

B–14469

No Load Test
D Ammeter
The following test should be done after reassembling the
starter:
50
M.T.
Clamp the starter in a vise. Using a 12 volt battery and
ammeter, connect the positive wire of the battery, and the C
ammeter to the 50 terminal [D]. Connect the negative
wire to the starter body. Using a jumper wire, connect the
50 terminal to the main terminal.
The starter should show smooth and steady rotation
immediately after the pinion is engaged, it should draw
less than the specified current.
Service Limit – 220 Amp. Maximum Draw Starter
B–14440

553 Loader
–6–27– Service Manual
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 STARTER (Cont’d)
Assembly
A
Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running
clutch, and idler gear rollers. 1 2 3
Install the switch plunger (Item 1) [A], gasket (Item 2) [A]
and cover (Item 3) [A] on the switch housing.

N–15032

Install the bolts (Item 1) [B].

B

1
1

N–15031

Install the spring (Item 1) [C] on the magnetic switch.

C

N–15030

Install the O–ring (Item 1) [D] in the starter housing.

D

N–15035

553 Loader
–6–28– Service Manual
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 STARTER (Cont’d)
A
Assembly (Cont’d)
Install the over running clutch (Item 1) [A] in the starter
housing.
1

N–15034

Install the spring (Item 1) [B] and pinion shaft (Item 2) [B]
in the over running clutch. B

1 2

N–15033

In order to install the pinion and snap ring on the pinion

shaft, a tube (Item 1) [C] 0.605 inch (15,4 mm) in diameter
by 2.0 inches (50,8 mm) in length is needed.
C
1

N–15042

Install the tube (Item 1) [D] in the over running clutch.

D

1
N–15044

553 Loader
–6–29– Service Manual
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 STARTER (Cont’d)
A
Assembly (Cont’d)

Place the starter drive on the bench, and press down on 1

the starter drive housing.

Install the spring seat (Item 1) [A] on the pinion shaft.

N–15054

Install the spring (Item 1) [B].

B
1

N–15055

Install the pinion (Item 1) [C].

C
1

N–15056

Install the collar (Item 1) [D].

D 1

N–15057

553 Loader
–6–30– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 STARTER (Cont’d)
A
Assembly (Cont’d)
1
Install the snap ring (Item 1) [A]. Pull the collar (Item 2)
[A] over the snap ring. 2

N–15047

With the pinion shaft extended, extend and release the

pinion (Item 1) [B]. The pinion must return to the fully re- B
tracted position.

N–15058

Install the rollers (Item 1) [C] in the retainer.

C

N–15041

Install the roller/retainer assembly (Item 1) [D] on the

starter housing.
D 1

Install the idler gear (Item 2) [D] over the roller/retainer

assembly.

N–15029

553 Loader
–6–31– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 STARTER (Cont’d)
A
Assembly (Cont’d)

Install the ball (Item 1) [A] in the pinion shaft.

1
N–15028

Install the starter drive (Item 1) [B] on the magnetic

switch. B

1
N–15027

Install the two bolts (Item 1) [C]. Tighten the bolts to

60–104 in.–lbs. (7–12 Nm) torque. C

1 1

N–15026

Install the bearings (Items 1 & 2) [D] on both ends of the

armature. D

1 2
N–15025

553 Loader
–6–32– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 STARTER (Cont’d)
A
Assembly (Cont’d) 1
Install the armature (Item 1) [A] in the magnetic switch
housing.

N–15048

Install the new O–rings (Item 1) [B] on both ends of the

frame. B

N–15050

Install the frame (Item 1) [C] over the armature.

NOTE: Make sure the tab (Item 2) [C] on the frame is

C
aligned with the slot in the magnetic switch
housing.

N–15049

Install the brush holder (Item 1) [D] on the armature.

D
Using a needle nose pliers, pull the spring (Item 2) [D]
back and install the brushes (Item 3) [D].
3

1
N–15051

553 Loader
–6–33– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 STARTER (Cont’d)
A
Assembly (Cont’d)

Install the brush cover and screws (Item 1) [A].

N–15052

Install the thru bolts (Item 1) [B]. Tighten the bolts to

60–104 in.–lbs. (7–12 Nm) torque. B

1
1

N–15020

Install the cable (Item 1) [C] on the terminal. Tighten the

terminal nut to 4–7 ft.–lbs. (5–9 Nm) torque. C

N–15019

553 Loader
–6–34– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 INSTRUMENT PANEL
A
Removal And Installation
Pry the rubber light mount loose from the operator cab
(both sides) [A].

P–03995

Lower the light from the operator cab and locate the
instrument panel mounting bolts (Item 1) [B] (both sides). B
Remove the mounting bolts (Item 1) [B]. 1
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels.

P–03955

Pull the left instrument panel down and disconnect the

wire harness connectors from the panel. Remove the
panel [C].
C

P–03951

Repeat steps [A] and [B]. Pull the right instrument panel
down and disconnect the wire harness connectors from D
the panel. Remove the panel [D].
Reverse the removal procedure to install the instrument
panel.

P–03953

553 Loader
–6–35– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 FRONT LIGHTS
553ServiceManual(S/N516311001&Above)#6900450–ElectricalSystemSectionPart2of2

Removal And Installation

A
The front lights are mounted in the upper corners of the
operator cab [A].

P–03956

Pry the rubber light mount free from the operator cab [B]. B

P–03995

Pull the light down and remove the mounting bolts (Item
1) [C] from the instrument panel. C
Disconnect the front light connector from the instrument 1
panel. Remove the front light from the operator cab.
Reverse the removal procedure to install the front light.

P–03955

553 Loader
–6–36– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE SERVICE Page
Number
AIR CLEANER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10

BLOWER FAN HOUSING

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–22
CAMSHAFT
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–53

CRANKSHAFT
Checking Crankshaft Journal And Block Bearing . . . . . . . . . . . . . . . . . . 7–68
Checking The Crankshaft Journal And Main Bearing . . . . . . . . . . . . . . . 7–69
Checking The End Play Of The Crankshaft . . . . . . . . . . . . . . . . . . . . . . . 7–71
Connecting Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–70
Crankshaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–71
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–66

CRANKSHAFT FRONT SEAL

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39

CYLINDER HEAD
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–48
Checking Piston Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–47
Combustion Chamber Removal And Installation . . . . . . . . . . . . . . . . . . . 7–51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–46
Servicing The Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–49

ENGINE
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11 ENGINE
SERVICE
ENGINE COMPRESSION
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23

ENGINE MOUNTING BRACKET

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21
ENGINE MUFFLER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10

ENGINE SPEED CONTROL

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6
Linkage Bar Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6

ENGINE SPEED CONTROL PLATE

Governor Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
Idle Limit And Fuel Limit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–42
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
Start Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41

ENGINE TIMING
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–72

EXHAUST MANIFOLD
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–42
Continued On Next Page
553 Loader
Revised Mar. 02 –7–1– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE SERVICE (Cont’d)
Page
Number
FLYWHEEL
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–20

FLYWHEEL HOUSING
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21
FUEL CAMSHAFT
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–55

FUEL INJECTION NOZZLES

Checking the Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32

FUEL INJECTION PUMP

Checking the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–28
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–29
Timing the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–31

FUEL LIFT PUMP

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–27
FUEL SHUT–OFF SOLENOID
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–26

GLOW PLUGS
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–24
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–25

GOVERNOR FORK LEVER

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–61

GOVERNOR SHAFT
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–58

IDLER GEAR
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–52
OIL PAN
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–57

OIL PUMP
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–37
PISTON
Checking Engine Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–65
Checking The Piston And Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . 7–63
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–64
Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–65
Piston Ring Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–64
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–64
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–63

Continued On Next Page

553 Loader
Revised Mar. 02 –7–2– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE SERVICE (Cont’d)
Page
Number
PUSH ROD
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–45

RADIATOR
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
ROCKER ARM
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–44

RUBBER DRIVE COUPLER

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–17

TAPPET
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–45
THERMOSTAT
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34

TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
TIMING GEAR BACKLASH
Fuel Camshaft Gear And Governor Shaft Gear . . . . . . . . . . . . . . . . . . . . 7–73
Idler Gear And Crankshaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–72
Idler Gear And Camshaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–73
Idler Gear And Fuel Camshaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–73

TIMING GEAR CASE COVER

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35

U–JOINT COUPLER
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–16
VALVE COVER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–43
WATER FLANGE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–46

WATER PUMP
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34

553 Loader
Revised Mar. 02 –7–3– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 TROUBLESHOOTING
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most common.
Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM CAUSE

Slow cranking speed. 1, 2, 3, 4

Engine will not start. 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 30,

31, 32

Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 23, 28,
30, 31, 32

No power for engine. 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 30,

31, 32
Engine is mis–firing. 8, 9, 10, 11, 12, 13, 14, 16, 18, 19, 20, 24, 25, 27, 28, 30, 31, 32

Too much fuel consumption. 11, 13, 14, 16, 18, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32
Black exhaust. 11, 13, 14, 16, 18, 19, 19, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32

Blue/white exhaust. 4, 16, 18, 19, 20, 24, 26, 30, 32, 33, 34, 44, 54

Low oil pressure. 4, 35, 36, 37, 38, 39, 41, 42, 43, 56
Engine knocking. 9, 14, 16, 18, 19, 22, 25, 27, 28, 30, 32, 34, 35, 44, 45, 57

Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 25, 27, 28, 29, 32, 34, 44, 57

Vibration. 13, 14, 20, 24, 25, 28, 29, 32, 44, 47
High oil pressure. 4, 37, 40

Overheating. 11, 13, 14, 16, 18, 19, 23, 24, 44, 46, 48, 49, 50, 51, 52, 55

Too much crankcase pressure. 24, 30, 32, 33, 44, 53

Poor compression. 11, 19, 24, 27, 28, 30, 31, 32, 33, 45, 57

Start and stop. 10, 11, 12

553 Loader
–7–4– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 TROUBLESHOOTING (Cont’d)

KEY TO CORRECT THE CAUSE

1. Battery capacity low. 30. Worn cylinder bores.
2. Bad electrical connections. 31. Worn valve and seats.
3. Faulty starter motor. 32. Broken, worn or sticking piston rings.
4. Incorrect grade of oil. 33. Worn valve stems or guides.
5. Low cranking speed. 34. Overly full air cleaner.
6. Fuel tank empty. 35. Worn or damaged bearings.
7. Faulty stop control operation. 36. Not enough oil in the crankcase.
8. Plugged fuel line. 37. Gauge is not correct.
9. Plugged fuel lift pump. 38. Oil pump worn.
10. Plugged fuel filter. 39. Pressure relief valve is open.
11. Restriction in the air cleaner. 40. Pressure relief valve is sticking closed.
12. Air in the fuel system. 41. Broken relief valve spring.
13. Faulty fuel injection pump. 41. Faulty suction pipe.
14. Faulty fuel injectors. 43. Plugged oil filter.
15. Incorrect use of the glow plugs. 44. Piston seizure.
16. Glow plugs not working. 45. Incorrect piston height.
17. Broken fuel injection pump drive. 46. Damaged fan.
18. Incorrect fuel pump timing. 47. Faulty engine mounting.
19. Incorrect valve timing. 48. Faulty thermostat.
20. Poor compression. 49. Restriction in water jacket.
21. Plugged fuel tank vent. 50. Loose fan belt.
22. Incorrect type or grade of fuel. 51. Plugged radiator.
23. Exhaust pipe restriction. 52. Faulty water pump.
24. Cylinder head gasket leaking. 53. Plugged breather pipe.
25. Overheating. 54. Valve stem seals damaged.
26. Cold running. 55. Coolant level low.
27. Incorrect tappet adjustment. 56. Plugged oil pump pipe strainer.
28. Sticking valves 57. Broken valve spring.
29. Incorrect high pressure tubelines.
553 Loader
–7–5– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE SPEED CONTROL
A
Removal and Installation

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
lift arm support device. Failure to use an 1
approved lift arm support device can allow the
lift arms or attachment to fall and cause injury
or death. W–2059–0598 P–05929

Block the rear of the loader. (See Page 1–1.) B

Raise the lift arms and install an approved lift arm support
device (Page 1–1).
Raise the operator cab. (See Page 1–1.)
Remove the two mounting bolts (Item 1) [A] and nuts from
the speed control mounting bracket.
Installation: Tighten the mounting bolts and nuts evenly
until the speed control lever moves back and forth at a 1
comfortable tension.

Pull the speed control away from the loader frame and P–05934
disconnect the speed control rod (Item 1) [B] from the
control.
Installation: Be sure to install the control rod in the C
bottom hole of the speed control.

Installation: Install the stop bracket (Item 1) [C] in the 1

same location. It is necessary for the front and rear stop
on the bracket to be located correctly.
Reverse the removal procedure to install the engine 2
speed control.
Disassembly
Loosen the two control lever mounting bolts (Item 2) [A]
and remove the mounting nuts (Item 2) [C]. P–04068

Assembly: Do not lubricate the engine speed control.

Replace any worn or damaged parts if necessary.

553 Loader
Revised Apr. 99 –7–6– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE SPEED CONTROL (Cont’d)
Linkage Bar Removal And Installation
A

1 2

Never work on a machine with the lift arms up

unless the lift arms are secured by an approved
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–2059–0598 P–07077

Install jackstands under the rear of the loader. (See Page B

1–1.)
Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Stop the engine.
Open the rear door.
1
Remove the radiator/oil cooler assembly. (See Page
7–8.)
Remove the engine from the loader. (See Page 7–11.)
P–07075
Remove the blower fan housing from the loader. (See
Page 7–19.)
The engine speed control linkage bar (Item 1) [A] is
located between the hydrostatic pump assembly and the
blower fan housing.

Remove the mounting nut (Item 1) [B] from the linkage

bar pivot point.
Installation: Tighten the pivot mounting nut to 180–200
in.–lbs. (21–23 Nm) torque.
Lower the linkage bar and remove the two washers.
Disconnect the bar from the engine speed control rod
(Item 2) [A] and remove the linkage bar.
Reverse the removal procedure to install the linkage bar.

553 Loader
Revised Apr. 99 –7–7– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 RADIATOR
A
Removal And Installation
1
Stop the engine and allow the engine to cool.
Install jackstands under the rear of the loader.(See Page
1–1.)
Raise the loader operator cab. (See Page 1–1.)
Drain the hydraulic oil reservoir. (See Page 2–1.)
Lower the operator cab after the hydraulic reservoir is
drained.
P–10747

B 2

Do not remove radiator cap when the engine is 1

hot. You can be seriously burned.
W–2070–1285

Open the rear door.

Remove the rear grill (Item 1) [A]. (See Page 5–1.)
3
Drain the coolant from the radiator. (See Page 1–1.)
Remove the mounting bolt (Item 1) [B] from the rear
radiator shield and the air cleaner element indicator P–10749
bracket.
Move the air cleaner indicator.
C
Remove the mounting bolt (Item 2) [B] from the rear
radiator shield and remove the shield.
Remove the mounting bolts (Item 3) [B] from the blower
housing access panel and remove the panel.
3
Remove the hose clamp (Item 1) [C] and remove the
radiator hose.
1
Remove the tubeline (Item 2) [C] from the oil cooler. Cap
and plug the lines. 2

Remove the mounting bolt (Item 3) [C] from the rear of the
radiator. P–10962

Remove the hose clamp (Item 1) [D] and remove the D

radiator hose.
Remove the tubeline (Item 2) [D] from the oil cooler. Cap
and plug the lines. 3 1
Remove the mounting bolt (Item 3) [D] from the rear of the
radiator. 2

P–10961

553 Loader
–7–8– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 RADIATOR (Cont’d)
Removal And Installation (Cont’d)
A 2

Remove the overflow hose (Item 1) [A] from the radiator

fill neck and remove it with the overflow bottle.
Remove the three mounting nuts (Item 2) [A] from the 2 1
radiator housing. 2

Installation: Tighten the mounting nuts to 180–200

in.–lbs. (21–23 Nm) torque.

P–10963

Remove the radiator/oil cooler and housing assembly

(Item 1) [B] from the loader. B
Remove the two front radiator mounting bolts (Item 2) [B]
from the housing.
Installation: Tighten the mounting bolts to 180–200 2 2
in.–lbs. (21–23 Nm) torque.
Remove the radiator from the housing.
Reverse the removal procedure to install the radiator in
the loader.

1
P–10964

When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888

553 Loader
–7–9– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE MUFFLER
Removal And Installation
A
Stop the engine and allow the engine and muffler to cool.
Open the rear door.
1
Remove the mounting bolts and nuts (Item 1) [A] from the
muffler support bracket and remove the bracket. 1

Installation: Tighten the mounting bolt and nut to 25–28

ft.–lbs. (34–38 Nm) torque.

P–10945

Remove the four mounting bolts (Item 1) [B] from the

muffler. B 1
Installation: Tighten the mounting nuts to 190–240
in.–lbs. (21–27 Nm) torque.
Remove the muffler from the loader.
1
Reverse the removal procedure to install the muffler.

P–10939

AIR CLEANER
Removal And Installation C
Stop the engine and open the rear door.
Remove the hose (Item 1) [C] from the air cleaner that is
connected to the intake manifold on the engine.
1

P–10733

Remove the two mounting bolts (Item 1) [D] from the air
cleaner.
D 1
Remove the air cleaner from the loader.
Reverse the removal procedure to install the air cleaner.
1

P–10947

553 Loader
–7–10– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE
Removal And Installation
A
4

P–10969

Never work on a machine with the lift arms up

B
unless the lift arms are secured by an approved
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 1
or death. W–2059–0598

Lift and block the loader. (See Page 1–1.)

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1).
Drain the coolant from the engine cooling system. (See P–10971
Page 1–1.)
Drain the hydraulic oil reservoir. (See Page 2–1). C
Lower the operator cab after the hydraulic reservoir is 2
drained.
Remove the radiator and oil cooler. (See Page 7–8).
Shut off the fuel supply at the fuel tank. (See Page 5–1).
Disconnect the engine speed control linkage (Item 1) [A]
from the throttle linkage on the engine.
1
Disconnect the fuel shut–off solenoid connector (Item 2)
[A] from the engine harness.
Disconnect the mounting bolt (Item 3) [A] from the engine
wiring harness clamp. P–10967

Disconnect the hose clamp (Item 4) [A] from the air intake
hose and remove the hose from the engine. D
Remove the hose clamp (Item 1) [B] from the fuel return
hose and remove the hose from the engine. Cap and plug
the fuel line and hose. 1
Remove the mounting bolts (Item 1) [C] from the
fuse/relay mounting bracket.
Remove the hose clamp (Item 2) [C] from the fuel supply
hose and remove the hose from the filter. Cap and plug
the lines and hoses.
Make note of the fuel supply hose routing and remove the
hose clamp (Item 1) [D] from the hose.
Remove the battery from the loader. (See Page 6–1). P–10684

553 Loader
Revised Apr. 99 –7–11– Service Manual
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 ENGINE (Cont’d)
Removal And Installation (Cont’d)
A
Make note of the wiring connections on the starter, for
proper installation. 1

Remove the solenoid wire (Item 1) [A]. 2

Remove the positive (+) wires (Item 2) [A] from the
starter.
3
Remove the negative (–) wires (Item 3) [A] from the
starter.

P–10944

Disconnect the wire (Item 1) [B] from the engine oil

pressure switch.
B
1

P–10687

Disconnect the engine harness connector (Item 1) [C]

from the the rear tail light harness.
C
Disconnect the engine harness connector (Item 2) [C]
from the charge pressure switch.
Remove the bolt (Item 3) [C] from the engine harness
clamp.

P–10941

553 Loader
–7–12– Service Manual
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 ENGINE (Cont’d)
Removal And Installation (Cont’d)
A 2
Disconnect the positive (+) wires (Item 1) [A] from the 1
alternator.
Disconnect the wiring harness connector (Item 2) [A].

P–10940

Disconnect the wire (Item 1) [B] from the coolant

temperature sensor.
B 3

Remove the wire (Item 2) [B] from the engine glow plugs.
Remove the bolt (Item 3) [B] from the engine harness
clamp.

2 1

P–10677

Remove the two engine mounting bolts (Item 1) [C], nuts,

and washers from the left side engine mounting brackets. C
Tighten the engine mounting bolts to 65–70 ft.–lbs.
(88–95 Nm) torque.
1

P–10968

553 Loader
–7–13– Service Manual
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 ENGINE (Cont’d)
A
Removal And Installation (Cont’d)
Remove the two engine mounting bolts (Item 1) [A], nuts,
and washers from the right side engine mounting 1
brackets.
Tighten the engine mounting bolts to 65–70 ft.–lbs.
(88–95 Nm) torque.

P–10994

P–10970

Attach a chain with a hook on each end, to each lift eye

B
on the engine.
Lift the engine slowly with the chain hoist until the rear
engine mounts clear the rear lip of the loader frame [B].
Pull the engine out of the engine compartment [B].
Be sure the front engine mounts clear the rear lip of the
loader frame as the engine is removed.
Replace the engine mounts if they are worn or damaged.

P–10972

553 Loader
–7–14– Service Manual
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 ENGINE (Cont’d)
A
Removal And Installation (Cont’d)
Installation: Reverse the removal procedure to install
the engine in the loader.
With another person place the engine in the loader frame
as shown in [A]. 1

With one person to align the U–joint coupler on the engine

with the splined drive shaft on the hydrostatic pump. The
second person using a socket wrench (Item 1) [A] on the
crankshaft pulley nut, turn the engine.
Turn the engine with the wrench and push forward until
the engine and hydrostatic pump slide together. P–13141

Use a punch to align the engine mounts with the mounting

holes in the loader frame.
Check engine mounting bolts for wear and replace as
needed.
Tighten the engine mounting bolts to 65–70 ft.–lbs.
(88–95 Nm) torque.

553 Loader
–7–15– Service Manual
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 U–JOINT COUPLER
Removal And Installation
A
NOTE: For procedures requiring the use of LOCTITE 1
adhesive, thoroughly clean and dry affected
parts before the application of LOCTITE. 3

Remove the hydrostatic pump assembly from the loader. 2

(See Page 3–1.)
Remove the four mounting bolts (Item 1) [A] from the
u–joint coupler assembly (Item 2) [A].
Assembly: Apply (LOCTITE #242) liquid adhesive and P–07079
tighten the mounting bolts to 180–200 in.–lbs. (21–23
Nm) torque.
Remove the coupler assembly from the coupler mounting B
flange (Item 3) [A].
2
Assembly: If the coupler assembly mounting flange
needs to be replaced, apply (LOCTITE #242) liquid
adhesive to the four mounting bolts and tighten to 25–28
ft.–lbs. (34–38 Nm) torque. 1
3
Disassembly and Assembly
Remove the four mounting bolts (Item 1) [B] from the first
spider (Item 2) [B] of the u–joint coupler assembly.
Assembly: Apply (LOCTITE #242) liquid adhesive and
P–07085
tighten the mounting bolts to 180–200 in.–lbs. (21–23
Nm) torque.

NOTE: Be sure to align the three grease fittings (Item C

3) [B] on the same side of the assembly.
1
Remove the spider coupling (Item 1) [C] from the second
spider of the assembly.

P–07088

D
Remove the four mounting bolts (Item 1) [D] from the
second spider (Item 2) [D] from the hydrostatic pump
coupler (Item 3) [D]. 2

Assembly: Apply LOCTITE #242 liquid adhesive and

tighten the mounting bolts to 180–200 in.–lbs. (21–23
Nm) torque. 1

P–07091

Revised Mar. 02 553 Loader

–7–16– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 RUBBER DRIVE COUPLER
A
Removal And Installation 2
Remove the steering linkage bolts (Item 1) [A] from the
pintle levers. remove the nuts, washers, and bolts (Item 2) 1
[A] from the hydrostatic pump mounting bracket.
1

2
P–24645

Move the hydrostatic pump assembly (Item 1) [B] forward

and to the side enough to remove the rubber coupler. B
1
Installation: Apply (LOCTITE 242) liquid adhesive to the
bolts and tighten to 25–30 ft.–lbs. (34–40 Nm) torque.

P–24635

Remove the mounting bolts (Item 1) [C]. C

1
Installation: Tighten the bolts to 40–45 ft.–lbs. (54–61 1
Nm) torque.

P–31710
Disassembly
Remove the six bolts (Item 1) [D] from the rubber elements. D
Remove the splined flange (Item 2) [D]. 2

P–31017
Revised Dec. 01
553 Loader
–7–17– Service Manual
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 RUBBER DRIVE COUPLER (Cont’d)
A
Disassembly (Cont’d)
2
Remove the bolts (Item 1) [A] and the spacer (Item 2) [A]
from the rubber element. Remove the bolts (Item 3) [A]
securing the rubber element to the splined flange.

3 3

P–31016

Remove the bolts (Item 1) [B] securing the rubber element

to the flywheel flange.
B
1
Check the condition of all parts and replace as needed.
1

P–31014

Assembly
NOTE: Too much oil in the holes for the bolt heads can
C
cause premature failure.
NOTE: If existing bolts are to be used during
assembly, clean the bolt threads and apply
liquid adhesive (LOCTITE 242) to the bolts. 1
New bolts are pre–coated with thread 1
adhesive.

Place the flywheel flange on a raised surface and install the

four bolts (Item 1) [C].

P–31013

Apply a light amount of oil to the bolt head areas on the D

rubber couplers before installing the bolts [D].
NOTE: Too much oil in the holes for the bolt heads can
cause premature failure.

P–31015
Revised Mar. 02 553 Loader
–7–18– Service Manual
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 RUBBER DRIVE COUPLER (Cont’d)
A
Assembly (Cont’d)
Install the rubber element on the flywheel flange [A].
1
Apply (LOCTITE #242) liquid adhesive to the bolts (Item 1) 1
[A] and tighten to 25–30 ft.–lbs. (34–40 Nm) torque.

P–31014
Install the rubber element on the splined flange [B].
Apply (LOCTITE #242) liquid adhesive to the bolts (Item 1)
[B] and tighten to 25–30 ft.–lbs. (34–40 Nm) torque.
B 2
Install the spacer (Item 2) [B] in the rubber coupler.
Apply (LOCTITE #242) liquid adhesive to the bolts (Item 3)
[B]. DO NOT fully tighten the bolts in the spacer at this time.
1 1

P–31016

Install the splined flange (Item 1) [C] and spacer on the

flywheel flange.
C
1
Apply (LOCTITE #242) liquid adhesive to the bolts (Item 2)
[C]. Thread the bolts into the spacer. DO NOT fully tighten
the bolts in the spacer at this time.

P–31017

Place the assembly in a bench vise and tighten the vise

until the spacer contacts both flanges [D].
D
Tighten the bolts (Item 1) [D] into the spacer to 25–30
ft.–lbs. (34–40 Nm) torque.

1 1

P–31018
Revised Mar. 02
553 Loader
–7–19– Service Manual
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 FLYWHEEL
Removal And Installation
A
Remove the engine from the loader. (See Page 7–11.)
1 1
Remove the four mounting bolts (Item 1) [A] from the
u–joint drive coupler assembly and remove.
Installation: Apply (LOCTITE #242) liquid adhesive to 1
the mounting bolts and tighten to 40–45 ft.–lbs. (54–61 1
Nm) torque.

P–10996

Remove the four mounting bolts (Item 1) [B] from the

rubber drive coupler assembly and remove.
B
Installation: Apply (LOCTITE #242) liquid adhesive to 1
the bolts and tighten to 40–45 ft.–lbs. (54–61 Nm) torque. 1

P–31812

Remove the four mounting bolts (Item 1) [C] from the

blower fan. C
Installation: Apply (LOCTITE #242) liquid adhesive to
the mounting bolts and tighten to 25–28 ft.–lbs. (34–38 1
1
Nm) torque.
Remove the blower fan (Item 2) [C] from the engine 2
flywheel.

1
1

P–10997

Remove the six flywheel mounting bolts (Item 1) [D] from

the flywheel. D
1
Installation: Apply (LOCTITE #242) liquid adhesive to
the mounting bolts and tighten to 40–43 ft.–lbs. (54–59
Nm) torque.
1
Remove the flywheel from the crankshaft. 1

Reverse the removal procedure to install the flywheel on

the engine crankshaft.
1
1
1

P–10995

553 Loader
Revised Mar. 02 –7–20– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 FLYWHEEL HOUSING
Flywheel Ring Gear
A 1

The ring gear (Item 1) [A] is installed on the flywheel with

and interference fit. To remove the ring gear, heat the ring
gear enough to expand the gear. Hit the ring gear evenly
around the gear to remove it from the flywheel.
Clean the outer surface of the flywheel thoroughly so the
new ring gear will fit smoothly onto the flywheel.
Clean the new ring gear and heat it to a temperature of
450° –500° (232° – 260° C).
Fit the ring gear on the flywheel and be sure the gear is
seated correctly. P–10999

Removal And Installation

Remove the engine from the loader. (See Page 7–11.)
B 2

Remove the flywheel from the engine. (See Page 7–20.)

Remove the starer. (See Page 6–1.) 2 2
Remove the four mounting bolts (Item 1) [B] from the
engine mounting brackets.
Remove the six mounting bolts (Item 2) [B] and remove
the flywheel housing from the engine. 1 1
2
ENGINE MOUNTING BRACKETS 1 1

Removal and Installation P–10998

Remove the engine from the loader. (See Page 7–11.)

Support the engine with a chain hoist. C
Remove the two mounting bolts (Item 1) [C] from the fuel
filter mounting bracket and move the mounting bracket 3
and fuel filter assembly. 3
Remove the four mounting nuts (Item 2) [C] & [D] and
bolts from the engine flywheel housing. 1
Remove the mounting bolts (Item 3) [C] & [D] and remove
the engine mounting brackets from the engine.
2

P–13110

3 3

P–13111

553 Loader
Revised Mar. 02 –7–21– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 BLOWER FAN HOUSING
Removal And Installation
A
Remove the engine from the loader. (See Page 7–11.)
Remove the mounting nut (Item 1) [A] from the top of the
blower fan housing.
1

P–07036

Remove the fastener (Item 1) [B] from the bottom of the

blower housing. B
NOTE: The hole (Item 2) [B] located at the bottom of
the blower housing should be kept clean. 2
The hole will keep moisture or residue from
collecting in the bottom of the housing.

P–07068

Remove the fastener (Inset) [C] from the blower fan

housing. Use a hammer and punch to remove the center C
bullet from the outer fastener.
Installation: Install the outer fastener in the hole in the
bottom of the housing and through the hole in the loader
frame. Put the bullet into the outer fastener and punch the P–07078
bullet into the outer fastener to spread the fastener. Install
the bullet into the fastener so the two parts are flush with
each other.
Remove the blower fan housing from the loader.

P–07067

553 Loader
Revised Mar. 02 –7–22– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE COMPRESSION
Checking
A
The tools listed will be needed to do the following
procedure: 1
MEL10630 – Engine Compression Kit
MEL1546 – Compression Test Adapter
Warm the engine.
Clean the area around the fuel injection pump and the fuel
injectors thoroughly.
Remove the fuel injector nozzles from the engine. (See P–13123
Page 7–29.)
Install the compression adapter (Item 1) [A] in the
cylinder head .
B
Connect the compression gauge to the adapter [B].
Turn the engine with the starter at 200 to 300 RPM. Run
the test for each cylinder two times at 5 to 10 seconds
each time and take the average reading.
The correct compression for the engine is 412–469 PSI
(2840,7–3233,8 kPa) with no more than 10% difference
between the cylinders.

P–13124

553 Loader
Revised Mar. 02 –7–23– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 GLOW PLUGS
Checking
A
Disconnect the engine harness wire and glow plug
connecting strap (Item 1) [A].
1

P–13101

Use an ohmmeter to check the glow plugs [B]. B

P–13102

Touch one probe to the end of the glow plug and the other
probe to the body of glow plug [C]. C
The reading must be 0.9 ohms. If the resistance is infinite,
the coil of the glow plug is broken and must be replaced.
Repeat the procedure for each glow plug.
Replace each glow plug as needed. (See Page 7–22.)

P–13106

553 Loader
Revised Mar. 02 –7–24– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 GLOW PLUGS (Cont’d)
Removal And Installation
A
Disconnect the negative (–) cable from the battery.
Disconnect the engine harness wire (Item 1) [A] from the
glow plug.
1

P–10677

Remove the nuts (Item 1) [B] from the top of each glow
plug.
B
Remove the glow plug connecting strap (Item 2) [B].
1 1 1

P–13101

Loosen and remove the glow plugs (Item 1) [C]. C

Installation: Tighten the glow plugs to 5–10 ft.–lbs.
(6,8–13,6 Nm).

P–13104

Photo [D] shows the glow plug assembly removed from

the engine. Inspect the glow plugs and replace when D
necessary.

P–04307

553 Loader
Revised Mar. 02 –7–25– Service Manual
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 FUEL SHUT–OFF SOLENOID
A
Removal And Installation
Disconnect the engine wiring harness (Item 1) [A] from
the fuel shut–off solenoid.
1

P–10969

Remove the two mounting bolts (Item 1) [B] from the fuel
shut–off solenoid.
B 1

P–13108

Remove the solenoid from the engine [C] and replace if

needed. C

P–13109

553 Loader
Revised Mar. 02 –7–26– Service Manual
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 FUEL LIFT PUMP
A
Removal And Installation
1
Remove the fuel lines (Items 1) [A] from the fuel lift pump.

P–13103

Remove the two mounting nuts (Item 1) [B] from the lift
pump and remove the pump from the engine.
B

1
1

P–13107

553 Loader
Revised Mar. 02 –7–27– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 FUEL INJECTION PUMP
553ServiceManual(S/N516311001&Above)#6900450–EngineServiceSectionPart1of3

Checking The Injection Pump

A
The injection pump contains parts which have a very 3
close tolerance and its operation has a direct effect on the
performance of the engine. Be sure to clean the area
around the injection pump and injectors before removal
to prevent contamination from dirt.

2
1
P–13138
Diesel fuel or hydraulic fluid under pressure
can penetrate skin or eyes, causing serious
injury or death. Fluid leaks under pressure may
not be visible. Use a piece of cardboard or wood
to find leaks. Do not use your bare hand. Wear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention from a physician
familiar with this injury.
W–2072–0496

The tools listed will be needed to do the following

procedure:
MEL1237 – Adapter Fuel Line
MEL1173A – Pressure Gauge
To check the initial discharge pressure, remove the high
pressure tubelines from the fuel injection pump. (See
Page 7–26.)
Connect a pressure gauge (Item 1) [A] to the long leg of
the test tubeline (Item 2) [A] and tighten.
Connect the short leg of the tubeline to the fitting at the
fuel injection pump (Item 3) [A].
Rotate the engine, with the starter, to increase the
pressure 1990–2133 PSI (13721–14707 kPa). Align the
plunger with T.D.C.
With the pressure at 1990–2133 PSI (13721–14707 kPa),
it should hold this for 5 seconds or more.
If the time is less than the allowable limit, replace the
injection pump.

553 Loader
Revised Mar. 02 –7–28– Service Manual
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 FUEL INJECTION PUMP (Cont’d)
A 1
Removal And Installation
Stop the engine and open the rear door.
Let the engine cool and clean the area around the
injection pump and injectors thoroughly.
Disconnect the high pressure fuel lines (Item 1) [A] from
the fuel injectors.

NOTE: Hold the banjo fitting nuts (Item 2) [A] when 2

removing or tightening the high pressure 2
fuel lines.
P–13101
Installation: Tighten the high pressure fuel line nuts to
18–25 ft.–lbs. (24–33 Nm).
B
Disconnect the high pressure fuel lines (Item 1) [B] from
the injection pump. 1

NOTE: Hold the delivery valve holder nuts (Item 2)

[B] when removing or tightening the high
pressure fuel lines.

Installation: Tighten the high pressure fuel line nuts to

18–25 ft.–lbs. (24–33 Nm).

2
P–13105

Remove the high pressure fuel lines (Item 1) [C] from the
engine. C
1
Remove the fuel shut–off solenoid (Item 2) [C]. (See
Page 7–23.)

P–13119

Remove the six mounting bolts (Item 1) [D] from the

intake manifold. Remove the intake manifold from the D
engine. 1
1
1
Installation: Replace the manifold gasket. Tighten the
mounting bolts to 16–20 ft.–lbs. (22–27 Nm) torque. 1

1
1

P–13126

Revised Mar. 02 553 Loader

–7–29– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 FUEL INJECTION PUMP (Cont’d)
Removal And Installation (Cont’d)
A
Disconnect the fuel inlet hose (Item 1) [A] from the
injection pump.
Remove the four mounting bolts (Item 2) [A] from the top
of the injection pump. 2
2
Installation: Tighten the mounting bolts to 16–20 ft.–lbs.
(22–27 Nm) torque. 1

P–13127

Remove the injection pump from the engine [B].

B

P–13129

Installation: The fuel rack pin (Item 1) [B] on the injection

pump must be aligned with the notch (Item 1) [C] located C
inside the injection pump chamber. Use the throttle lever 2
(Item 2) [C] on the side of the injection pump chamber to
align the notch.

P–13128

Install the shim(s) (Item 1) [D] on the injection pump

mounting surface. Refer to the timing the injection pump D
Page 7–28 for information on number of shims used.
Install the injection pump in the engine.

P–13130

Revised Mar. 02 553 Loader

–7–30– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 FUEL INJECTION PUMP (Cont’d)
A
Timing The Injection Pump

Do not attempt to maintain or adjust unless

you are trained and have the correct
equipment.
I–2028–0289

Timing the injection pump is done by changing the P–13132

number of shims between the injection pump and the
injection pump mounting surface.
Disconnect the high pressure fuel lines from the injection
B
pump and the injectors. (See Page 7–29.)
Remove the fuel injectors. (See Page 7–29.)
Remove the fuel shut–off solenoid. (See Page 7–23.)
Install a short plastic tube (Item 1) [A] in the number one 1
cylinder port of the injection pump. The tube should fit
tight in the port and point upward.
Move the fuel lever on the injection pump to full fuel
position (or full throttle).
Turn the flywheel counterclockwise until fuel flows from P–10895
the delivery valve holder and into the plastic tube.
Continue rotating the engine slowly until the start of fuel
rise in the plastic tube (Item 1) [A].
C
At this point look at the timing mark (located on the
flywheel) for proper alignment (Item 1) [B]. When the
timing mark is aligned as shown the timing is correct for
the injection pump, which is 18°–20° degrees B.T.D.C.
Add or subtract shim(s) (Item 1) [C] as needed to adjust
the fuel delivery timing.
1
Shims are available in thickness of 0.20 mm, 0.25 mm
and 0.30 mm. Combine these shims for adjustments.

Addition of shim(s) (0.0020 inch, 0.05 mm) delays the

injection timing by approximately 0.5 degree. P–13130

Reduction of shim(s) (0.0020 inch, 0.05 mm) advances

the injection timing by approximately 0.5 degree.

Revised Mar. 02 553 Loader

–7–31– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 FUEL INJECTOR NOZZLES
A 1

Diesel fuel or hydraulic fluid under pressure

can penetrate skin or eyes, causing serious
injury or death. Fluid leaks under pressure may
not be visible. Use a piece of cardboard or wood
to find leaks. Do not use your bare hand. Wear 2
safety goggles. If fluid enters skin or eyes, get 2
immediate medical attention from a physician
familiar with this injury. P–13101
W–2072–0496

These are some engine problems caused by damaged

injector nozzles.
B
1
• The engine is hard to start or will not start.
• Engine operation is not smooth.
• The engine will not idle correctly.
• Bad engine performance.
• The engine exhaust smoke is black, white or blue.
Remove the injector nozzles from the engine and test the
injectors only after engine performance shows that there
may be damage.
Removal and Installation
2
Stop the engine and open the rear door.
P–13105
Let the engine cool and clean the area around the
injection pump and injectors thoroughly.
Disconnect the high pressure fuel lines (Item 1) [A] from
C
the fuel injectors.
NOTE: Hold the banjo fitting nuts (Item 2) [A] when
removing or tightening the high pressure
fuel lines.

Installation: Tighten the high pressure fuel line nuts to

18–25 ft.–lbs. (24–33 Nm).

Disconnect the high pressure fuel lines (Item 1) [B] from

the injection pump.
NOTE: Hold the delivery valve holder nuts (Item 2)
P–13119
[B] when removing or tightening the high
pressure fuel lines.

Installation: Tighten the high pressure fuel line nuts to

18–25 ft.–lbs. (24–33 Nm).
D
Remove the high pressure tubelines [C].
Remove the fuel return hoses (Item 1) [D] from the banjo 2
2 2
fittings. 1

Remove the three banjo fittings nuts (Item 2) [D] from the
fuel injector nozzles.
Remove the banjo fittings from the fuel injectors. 1

P–13121

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 FUEL INJECTOR NOZZLES (Cont’d)
A
Removal and Installation (Cont’d)
Remove the fuel injector nozzles from the engine [A].
Installation: Tighten the injectors to 22–36 ft.–lbs.
(29–49 Nm) torque.
Checking Fuel Injector Nozzles
The tools listed will be needed to do the following
procedure:
OEM 1064 – Injector Nozzle Tester
OEM 1065 – Accessory Set
P–13120
NOTE: You can adjust the release pressure of the
injector nozzle by adding or removing
spacers (Item 1) [B] from the top of the nozzle
spring (Item 2) [B]. The release pressure must
B
be 1990–2133 PSI (13721–14707 kPa). 2
1

3
Diesel fuel or hydraulic fluid under pressure
can penetrate skin or eyes, causing serious
injury or death. Fluid leaks under pressure may
not be visible. Use a piece of cardboard or wood
to find leaks. Do not use your bare hand. Wear
B–14862
safety goggles. If fluid enters skin or eyes, get
immediate medical attention from a physician
familiar with this injury.
W–2072–0496 C
Connect the injector nozzle to the tester with the nozzle
in the down position [C].
Slowly operate the hand lever of the test pump until the
injector nozzle valve opens. The pressure must be
1990–2133 PSI (13721–14707 kPa).
If the pressure is not correct, disassemble the injector
nozzle and add or remove spacers (Item 1) [B].
NOTE: When assembling the injector nozzle, tighten
the nozzle nut (Item 3) [B] to 36–51 ft.–lbs.
(49–69 Nm) torque. Any higher torque will
A–02513
cause slow action of the valve.
Check for inside leakage. Operate the hand lever until the
pressure is almost enough to open the injector valve.
Make a record of the pressure. Release the hand lever. D Spring
Check the pressure decrease to 10 seconds. The nozzle
has damage if the pressure decrease is more than 740 CORRECT WRONG
Pressure
PSI (5162 kPa) in 10 seconds. Pin
Holder
Check the spray pattern of the nozzle for the following
conditions [D]: Nozzle
Body
Fuel comes out the side of the nozzle.
Has fuel drops coming from the nozzle.
Has a flow (solid stream) coming from the nozzle. Needle
Valve
Any of the above conditions show a defect or a dirty
injector nozzle. Clean the nozzle that does not operate
correctly and check again. A–02621

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 THERMOSTAT
A 1
Removal And Installation
Remove the bolt (Item 1) [A] and nut (Item 2) [A] from the
thermostat housing. 2
Installation: Tighten bolts and nuts to 87–100 in.–lbs.
(9,8–11,3 Nm) torque.

P–10677

Remove thermostat (Item 1) [B] and replace if necessary.

Always replace the thermostat gasket (Item 2) [B].
B 1

P–13267

WATER PUMP
Removal And Installation
C 1

Remove the loader alternator. (See Page 6–1.)

Remove the four mounting bolts (Item 1) [C] from the belt 1
pulley (Item 2) [C] and remove the pulley from the water 1
pump.

NOTE: The bolts may vary in length. Keep the bolts 2

in their original location.
P–13013

Remove the seven mounting bolts (Item 1) [D] from the

water pump. D 1

Installation: Tighten the mounting bolts to 87–100

in.–lbs. (9,8–11,3 Nm) torque. 1
1
Remove the water pump from the engine.
Check the water pump for wear and replace if needed. 1
Thoroughly clean the area between the water pump and
the block flange. 1 1
Install a new water pump gasket and install the water
pump. 1

P–13265

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 TIMING GEAR CASE COVER
Removal And Installation
A
Remove crankshaft pulley bolt (Item 1) [A].
Installation: Tighten crankshaft pulley bolt to 101–116
ft.–lbs. (137–157 Nm) torque. 1

P–13266

Remove the crankshaft pulley (Item 1) [B] from the

crankshaft. B
Installation: When installing the crankshaft pulley on the
crankshaft, align the timing marks (Item 2) [B].
1

2
NOTE: The bolts may vary in length. Keep the bolts
in their original location.
P–13268

Remove the mounting bolts (Item 1) [C] from the timing

case cover, and remove the cover. C 1 1

Installation: Tighten the mounting bolts to 7.2–8.3

in–lbs. (9,8–11,3 Nm) torque. 1
Clean the surface of timing cover. 1
1 1

1 1
1
1
1
P–13270

Remove the timing cover gasket (Item 1) [D]. D

1
P–13271

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 TIMING CASE COVER (Cont’d)
Removal And Installation (Cont’d)
A
Remove the O–rings (Item 1) [A] from the timing case
cover.

1
1 1
P–13272

Remove the crankshaft collar (Item 1) [B] from the

crankshaft.
B
NOTE: The collar may stay in the gearcase cover,
when the cover is removed.
2
Remove the O–ring (Item 2) [B] from the crankshaft and
replace with a new O–ring.

P–13345

Installation: Install the timing case cover, then install the

crankshaft collar with the tapered side (Item 1) [C] toward C 1
the O–ring.

P–13279

NOTE: The idle adjustment spring (Item 1) [D] is

located inside the timing case cover. Be D 1
careful not to damage. If replacement is
necessary see Idle Adjustment Page 7–39.

P–13276

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 OIL PUMP
A
Removal And Installation
Remove timing gear case cover. (See Page 7–32.)
1
Remove the mounting bolts (Item 1) [A] from the back of
the oil pump. 1
Installation: Tighten the mounting bolts to 70–113
in.–lbs. (7,9–12,8 Nm) torque. 2

Remove the rear cover (Item 2) [A]. 1

1
1
P–13272

Remove the oil pump rotor assembly (Item 1) [B] and

check for wear.
B

P–13273

Replace the front crankshaft seal (Item 1) [C]. C

P–13275

Measure the clearance between the lobes of the inner

rotor and the outer rotor with a feeler gauge [D]. D
The clearance between inner rotor and outer rotor is
0.0024–0.0071 inch (0,06–0,18 mm), with an allowable
limit of 0.0118 inch (0,3 mm). If the clearance exceeds the
allowable limit, replace the oil pump rotor assembly.

P–13317

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 OIL PUMP (Cont’d)
Removal And Installation (Cont’d)
A
Measure the clearance between the outer rotor and the
pump body with a feeler gauge [A].
The clearance between outer rotor and the pump body is
0.0039–0.0071 inch (0,100–0,180 mm) with an allowable
limit of 0.0213 inch (0,54 mm). If the clearance exceeds
the allowable limit, replace the oil pump rotor assembly.

P–13316

Put a strip of plastic gauge (Item 1) [B] onto the rotor face.
B 1

P–13273

Install the oil pump cover (Item 1) [C] and tighten the
cover bolts to 70–113 in.–lbs. (7,9–12,8 Nm) torque. C

P–13272

Remove the cover and measure the width of the pressed

plastic gauge (Item 1) [D]. D 1
The end clearance between the inner rotor and the oil
pump cover should be 0.0098–0.0295 inch. (0,025–0,75
mm) with an allowable limit of 0.0089 inch. (0,225 mm).
If the clearance exceeds the allowable limit, replace the
oil pump rotor assembly.

P–13273

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 CRANKSHAFT FRONT SEAL
Removal And Installation
A
Remove the crankshaft pulley bolt (Item 1) [A] and
remove the crankshaft pulley.
Installation: Tighten crankshaft pulley bolt to 101–116 1
ft.–lbs. (137–157 Nm) torque.

P–13266

When installing the crankshaft pulley on the crankshaft,

be sure the timing marks are aligned (Item 1) [B].
B

P–13268

Remove the crankshaft collar (Item 1) [C].

C

1
P–13278

Remove the O–ring (Item 1) [D] from the crankshaft.

D
Remove the front seal (Item 2) [D] from the timing gear
case cover.
Replace the seal.
2
Replace the O–ring. 1

P–13277

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 CRANKSHAFT FRONT SEAL (Cont’d)
A 1
Removal And Installation (Cont’d)
Install the crankshaft collar with the tapered side (Item 1)
[A] toward the O–ring.

P–13279

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 ENGINE SPEED CONTROL PLATE
Removal And Installation
A
Remove the mounting bolts and nuts (Item 1) [A] from the
engine speed control plate. 1
Installation: Tighten mounting bolts and nuts to 87–100
in.–lbs. (9,8–11,3 Nm) torque. 1

P–13280

Remove the speed control plate from the mounting bolts

and unhook the governor spring (Item 1) [B] from the
B
governor compensation lever (Item 2) [B].
1
Check the return spring (Item 3) [B] and internal parts for
wear and replace if needed.

P–13281

Governor Spring Removal

Remove the engine speed control plate. C
Remove the governor spring (Item 1) [C].
Check for wear and replace if needed.

P–13284

Start Spring Removal

D
Remove engine speed control plate.
Remove the governor spring.
Remove start spring (Item 1) [D].
1
Check for wear and replace if needed.

P–13285

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 ENGINE SPEED CONTROL PLATE (Cont’d)
Idle Limit And Fuel Limit Adjustment
A
The idle limit adjustment (Item 1) [A] and the fuel limit
adjustment (Item 2) [A] have sealed caps.
2
1
NOTE: See your authorized Kubota dealer for proper
adjustment before removing the caps.

P–13283

EXHAUST MANIFOLD
B 1
1
1
Removal And Installation
Remove the mounting nuts (Item 1) [B] from the exhaust
manifold.

1 1
1

P–13282

Remove the exhaust manifold from the engine and

remove the exhaust manifold gasket (Item 1) [C] from the
engine.
C 1

Installation: Replace the exhaust manifold gasket.

Tighten the mounting nuts to 12–14 ft.–lbs. (16–19 Nm)
torque.

P–13286

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 VALVE COVER
A 1 1 1
Removal And Installation
Remove the engine from the loader. (See Page 7–12.)
Remove the nuts (Item 1) [A] from the valve cover.
Installation: Tighten valve cover nuts to 5.1–6.5 in.–lbs.
(6,9–8,8 Nm) torque.
Remove the valve cover.

P–13287

Remove the mounting bolts (Item 1) [B] from the breather

oil shield (Item 2) [B].
B
Installation: Tighten the mounting bolts to 24–36 in.–lbs.
(2,7–4,1 Nm) torque.
1 1

P–13295

Remove the breather element plate (Item 1) [C].

C
Remove the breather element (Item 2) [C].
Check element and clean or replace as needed.

2
1

P–13293

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 ROCKER ARM
A 1 1 1
Removal And Installation
Remove the engine from the loader. (See Page 7–12.)
Remove the valve cover. (See Page 7–40.)
Remove the three mounting nuts from the rocker arms
bracket (Item 1) [A], and remove the rocker arms from the
head.

P–13288

Remove the snap ring (Item 1) [B] from the rocker arm
shaft. B

P–13311

Remove the rocker arm shaft washers (Item 1) [C].

Remove the rocker arm assembly (Item 2) [C] from the
C
rocker arm shaft.

P–13312

Measure the outside diameter of the rocker arm shaft [D].

D
The measurement should be 0.4714–0.4718 inch
(11,973–11,984 mm) in diameter.

P–13308

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 ROCKER ARM (Cont’d)
Removal And Installation (Cont’d)
A
Measure the inside diameter of the rocker arm [A].
The measurement should be 0.4724–0.4731 inch
(12,000–12,018 mm) in diameter.
The clearance between the rocker arm shaft and the
rocker arm should be 0.0006–0.0018 inch (0,016–0,045
mm) with an allowable limit 0.0039 (0,10 mm).
If the measurement exceeds the allowable limit replace
the rocker arm or rocker arm shaft.
P–13314

Installation: Tighten the three rocker arm mounting nuts

(Item 1) [B] to 16–20 ft.–lbs. (22–27 Nm) torque.
B 1 1 1

Adjust the valve clearance using a feeler gauge (Item 2)

[B].
Make sure the piston is on top dead center when making
the adjustment and adjust the clearance to 0.005–0.007
inch (0,12–0,18 mm).

P–13289

PUSH ROD
C 1 1 1
Removal And Installation
Remove the six push rods (Item 1) [C].
NOTE: Mark the push rods to prevent interchanging
when installing.

Check for wear and replace if needed.

TAPPET
Removal And Installation
P–13291
Remove the six tappets (Item 1) [D] from the crankcase.
NOTE: Mark the tappets to prevent interchanging
when installing. D 1 1 1 1

Check the tappets for wear. The inside diameter of the

tappet guide is 0.7874–0.7882 inch (20,000–20,021 mm).
The outside diameter of the tappet is 0.7858–0.7866
(19,959–19,980 mm).
1
The clearance between the tappet and the guide is
0.0008–0.0024 inch (0,020–0,062 mm) with an allowable
limit 0.0028 inch (0,07 mm).
If wear exceeds the allowable limit, replace the tappets.
NOTE: If the tappets have to be changed because of
excess wear. Check the camshaft for wear
and replace if needed. (See Page 7–50.) P–13294

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 WATER FLANGE
A
Removal And Installation
Remove the four mounting bolts (Item 1) [A] from the
engine head
Remove water flange from the head.
Installation: Replace the water flange gasket as needed.
Tighten the mounting bolts to 87–100 in–lbs. (9,8–11,3
Nm) torque. 1
1

P–13296

CYLINDER HEAD B 1 1
Removal
1

Remove the fourteen mounting bolts (Item 1) [B] and

remove the head.
1 1
1

1 1

P–13290

Installation C 1
2
Clean the head and the block.
Replace the head gasket (Item 1) [C] and O–ring (Item 2)
[C].

P–13403

Put oil on the cylinder head bolts and tighten to 47–51 D

ft.–lbs. (64–69 Nm) torque. Use the tightening sequence
as shown in [D]. Allow the head to set for at least a 1/2
hour. Then check the torque of the head bolts again using
the sequence shown in [D].

A–02773

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 CYLINDER HEAD (Cont’d)
A
Checking Piston Top Clearance
2 2
Remove the cylinder head. (See Page 7–43.)
Bring the piston (Item 1) [A] to top dead center.
Fasten a 0.06 inch (1,5 mm) diameter by 0.20–0.28 inch 1
(5,1–7,1 mm) piece of solder (Item 2) [A] to four spots on
the piston with grease.
Put the piston to bottom dead center.
2
Install the cylinder head and tighten the cylinder head 2
bolts to specification. (See Page 7–43.)
P–13297
Turn the crankshaft until the piston goes over top dead
center.
B 1 1
Remove the cylinder head and measure the squeezed
solder wire (Item 1) [B] & [C].
The top clearance between the piston and the head
should be 0.0217–0.0276 inch (0,55–0,70 mm).
If the measurement is not within specified valve, check
the oil clearance of the crankpin journal and the piston pin.
(See Page 7–67.) Also check the oil clearance between
the crankshaft journals and the crankshaft bearings. (See
Pages 7–65 & 7–66.)
1
1
P–13300

C
1

P–13299

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 CYLINDER HEAD (Cont’d)
A 1
Disassembly
Using a valve compression tool (Item 1) [A], remove the
valve cap and the valve spring collet [B].
Remove the valve spring.
Remove the seal on the valve and remove the valve from
the cylinder head.
Repeat this procedure for all the valves.

Assembly
P–13302
Install the valves.
Put oil on the valve seal and install the valve seal on the
valve.
B
Install the valve spring and the retainer.
Install the spring collet and the valve cap.
Spring
Collets
Cap

Seal
Valve
Retainer P–13303

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 CYLINDER HEAD (Cont’d)
A
Servicing The Cylinder Head
Clean the surface of the cylinder head.
Put a straight edge on the cylinder head [A].
Put a feeler gauge (Item 1) [A] between the straight edge
and the surface of the cylinder head. 1
The maximum distortion of the cylinder head surface is +
0.0019 inch (+ 0.05 mm).
If the measurement is more than the specification,
remove the combustion chambers see Page 7–48, then P–13298
grind the cylinder head. Grind the same amount of
material from the bottom of the combustion chambers as
was removed from the head.
B
Clean the surface of the valve seat area.

Measure the width of the valve seat [B].

The correct width of the valve seat for both intake and
exhaust, is 0.083 inch (2,1 mm). The seat angle is 45° for
the exhaust valve and 60° for the intake valve.

P–13306

Use the following steps to grind the valve seats [C].

C Valve Contacting
Item A – Use a 45° cutter to grind the surface of the valve C A D Width
seat. 0.083’’ (2,1 mm)
Item B – Use a 15° cutter to grind the front surface of the B
valve seat.
Item C – Use A 65° or 70° cutter to grind the rear surface
of the valve seat to finish the seat of a 0.083 inch (2,1 mm)
width. D
Corrected
Item D – Grind the valve surface to a 45° angle. Surface of Uncorrected
Valve Seat Surface of
A – 45° cutter Valve Seat
B – 15° cutter
C – 65° or 70° cutter
D – 45° valve surface MC–02185
Install the valve in the seat and check the depth [D].
The specification for the depth of the valve is
D
0.0020–0.0060 (–0,05–0,15 mm). Allowable Limit 0.016
inch (0,4 mm).

NOTE: If the measurement is more than the

specifications add the correct thickness
washer under the valve spring to keep the
correct tension on the spring.

P–13305

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 CYLINDER HEAD (Cont’d)
Servicing The Cylinder Head (Cont’d)
A
Clean the valve guide. 1

Install the valve in the cylinder head.

Install a dial indicator gauge (Item 1) [A].
Measure the clearance of the valve guide and the valve.
The measurement must be 0.0014–0.0025 inch
(0,035–0,065 mm). Replace the valve guide and valves
as needed.
P–13310

Measure the valve spring [B]. The length of the spring

must be 1.457–1.476 inch (37,0–37,5 mm). Replace the
valve spring if it does not meet the specification.
B

P–13301

Check the valve spring with a square to make sure it is

straight [C]. Replace the spring if it is not straight.
C

P–13304

Put the valve spring in a tester [D].

Push down on the spring 1.22 inches (31 mm). The D
compression load must be 26.4 lbs. (11,97 kg). Replace
the valve spring if it does not meet these specifications.

A–02759

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 CYLINDER HEAD (Cont’d)
A
Combustion Chamber Removal And Installation
Locate the combustion chamber (Item 1) [A] in the head.

NOTE: Mark the combustion chambers so they do

not get interchanged between cylinders.

P–13305

Locate the notch on the combustion chamber edge (Item

1) [B] (inset). Scribe a line (Item 2) [B] at that point on the B
cylinder head for locating purposes. 3

2
1
4
P–13467

3
B–15124

Remove the combustion chamber by using a blunt punch

through the injector ports (Item 1) [C]. Tap the punch with C
a hammer and remove the combustion chamber.

1 1 1

P–13290

Grind the cylinder head.

D
Grind the same amount of material from the combustion
chamber at points (Item 1 & 2) [D].
Installation: Install two 9 mm dowels in the head bolt
holes (Item 3) [B]. Place a straight edge against the
dowels and scribe a line (Item 4) [B].
Align the notch on the combustion chamber (Item 1) [B]
with the scribe line on the head (Item 4) [B], and install the 1
chamber.

2
P–13467

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 IDLER GEAR
Removal And Installation
A
Remove the timing gear case cover. (See Page 7–32.)
Remove the crankshaft collar (Item 1) [A] and O–ring
(Item 2) [A].
2
NOTE: The crankshaft collar may come off with the
timing case cover, if so remove the O–ring. 1

P–13345

Remove the snap ring (Item 1) [B] from the idler gear
shaft. B
Remove the flat washer.
Remove the idler gear (Item 2) [B].
1

P–13343

Remove the mounting bolts (Item 1) [C] from the idler

shaft. C 1
Remove the shaft.

P–13346

With a micrometer measure the outside diameter of the

idler gear shaft (Item 1) [D]. D
The measurement should be 1.0223–1.0228 inch
(25,967–25,980 mm).
1

P–13368

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 IDLER GEAR (Cont’d)
553ServiceManual(S/N516311001&Above)#6900450–EngineServiceSectionPart2of3

Removal And Installation (Cont’d)

A 1
2
Check the inside diameter of the idler gear bushing (Item
1) [A]. The measurement should be 1.0236–1.0244 inch
(26,000–26,021 mm), with an allowable limit of 0.0039
inch (0,10 mm).
If the clearance exceeds the allowable limit, replace the
busing.
Align the oil hole in bushing (Item 2) [A] with oil hole in
sprocket, when installing the new bushing

P–13365

CAMSHAFT
Removal And Installation
B
1
Remove the tappets from the block. (See Page 7–42.)
Align the holes (Item 1) [B] in the gear on the camshaft
with the mounting plate bolts.
Remove the mounting bolts from the camshaft mounting
plate.
Installation: Tighten the mounting bolts to 89–100
in.–lbs. (9,8–11,3 Nm) torque.
1
Remove the camshaft.
P–13344

Remove the camshaft gear (Item 1) [C] from the

camshaft.
C
Check the key (Item 2) [C] and the key way in the gear and
the camshaft for wear and replace if needed.
1

P–13367

Support the camshaft with V–blocks [D].

D
Measure the height of the intake and exhaust cams at
their highest point with a micrometer.
The measurement should be:
Intake . . . . . . . . . . . . . . . . . . . . . 1.1339 inch (28,80 mm)
Allowable Limit . . . . . . . . . . . . 1.1319 inch (28,75 mm)
Exhaust . . . . . . . . . . . . . . . . . . . 1.1417 inch (29,00 mm)
Allowable Limit . . . . . . . . . . . . 1.1398 inch (28,95 mm)
If the measurement is less than the allowable limit replace
the camshaft.

P–13363

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 CAMSHAFT (Cont’d)
Removal And Installation (Cont’d)
A
Measure the camshaft journal outside diameter (Item 1)
[A] with a micrometer. The measurement should be
1.4147–1.3799 inch (35,934–35,050 mm).

P–13351

Measure the cylinder block bore inside diameter for the

camshaft with an inside micrometer [B] & [C]. B
The measurement should be 1.4173–1.4183 inch
(36,000–36,025 mm).
The oil clearance of the camshaft is 0.0020–0.0036 inch
(0,050–0,091 mm) with an allowable limit of 0.0047 inch
(0,12 mm).
If the clearance exceeds the allowable limit, replace the
camshaft.

P–13347

P–13348

Check the camshaft alignment by supporting the

camshaft in V–blocks. Set a dial indicator with its tip on D
the center journal at a right angle [D].
Rotate the camshaft on the V–blocks and get the
misalignment, which is half of the measurement.
The measurement should be 0.0004 inch (0,01 mm).
If the misalignment exceeds the allowable limit, replace
the camshaft.

P–13364

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Revised Mar. 02 –7–54– Service Manual
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 FUEL CAMSHAFT
A
Removal And Installation 1
Remove the two mounting bolts (Item 1) [A] and remove
the fuel camshaft stop (Item 2) [A].
Installation: Tighten the mounting bolts to 89–100
in.–lbs. (9,8–11,3 Nm) torque. 2
Remove the fuel camshaft from the block.

P–13349

Remove the three mounting bolts (Item 1) [B] from the

injection pump gear (Item 2) [B]. B
Installation: Tighten the mounting bolts to 89–100
in.–lbs. (9,8–11,3 mm) torque.

P–13366

Remove the fuel cam (Item 1) [C] and the cam washer
(Item 2) [C] from the camshaft gear.
C
Installation: When installing the fuel cam and washer to
the cam shaft gear align the timing marks (Item 3) [C] on
the fuel cam with the timing marks (Item 4) [C] on the 4
camshaft gear.

1 3
P–13369

Remove the nut (Item 1) [D] from the fuel camshaft.

Installation: Tighten the nut to 43–51 ft.–lbs. (58,3–69,2 D
Nm) torque.
Remove the injection pump gear (Item 2) [D] from the fuel
camshaft.

2
P–13370

553 Loader
Revised Mar. 02 –7–55– Service Manual
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 FUEL CAMSHAFT (Cont’d)
Removal And Installation (Cont’d)
A
Check the key (Item 1) [A] and the keyways in the gear
and on the shaft for wear and replace if needed.
Check the bearings (Item 2) [A] for wear and replace as
needed. 2

P–13373

553 Loader
Revised Mar. 02 –7–56– Service Manual
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 OIL PAN
Removal And Installation
A
Remove the oil pan mounting bolts (Item 1) [A], and
remove the oil pan.
Installation: Tighten pan mounting bolts to 87–100
in.–lbs. (9,8–11,3 Nm) torque, in a diagonal order from the
center.
1 1
1 1

P–13309

Remove the mounting bolt (Item 1) [B] and remove the oil
pickup tube (Item 2) [B]. B
Installation: Tighten the oil pickup tube mount bolt to
17–20 ft.–lbs. (23,1–27,1 Nm) torque. 1

P–13313

Clean the oil oil pickup tube screen (Item 1) [C].

C 2
Check the O–ring (Item 2) [C] and replace if worn.
Use care not to damage O–ring when installing the oil
pickup tube.

NOTE: Clean the surface of the oil pan and the block
thoroughly. And apply a new liquid gasket to
the oil pan before installing.

1
P–13318

553 Loader
Revised Mar. 02 –7–57– Service Manual
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 GOVERNOR SHAFT
A 1
Removal And Installation
Remove the fuel camshaft plug (Item 1) [A] from the
block.

P–13357

Remove the snap ring (Item 1) [B] from the governor

shaft. B

P–13358

Remove the governor shaft assembly (Item 1) [C] from

the front of the block. C
1

P–13352

NOTE: The set screw (Item 1) [D] must be removed

to remove the rear governor shaft bearing. D
Check the governor gear bushing (Item 2) [C] and replace 1
if needed.

P–13362

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Revised Mar. 02 –7–58– Service Manual
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 GOVERNOR SHAFT (Cont’d)
A
Removal And Installation (Cont’d)
Remove the set screw (Item 1) [A] from the block.

P–13360

Remove the rear bearing (Item 1) [B].

B
NOTE: The bearing must be driven out toward the
front of the block.

P–13359

Check the parts from the governor shaft for wear and
replace if needed [C]. C

P–13379

Remove the governor gear holder and governor gear

(Item 1) [D] from the governor shaft. D
1

P–13371

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Revised Mar. 02 –7–59– Service Manual
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 GOVERNOR SHAFT (Cont’d)
Removal And Installation (Cont’d)
A 2

Remove the governor gear (Item 1) [A] from the gear

holder (Item 2) [A]. 1

P–13378

Remove the governor weight shafts (Item 1) [B] from the

governor weights (Item 2) [B]. B 1 2
Remove the governor weights.
Remove the rollers (Item 3) [B] from the governor
weights.
2
3

3 1
P–13374

Remove the governor weight holder (Item 1) [C] from

governor shaft. C
Remove the governor sleeve (Item 2) [C] and thrust 3
washer (Item 3) [C] from governor shaft. 2
1
Check all parts and replace if needed.

P–13377

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Revised Mar. 02 –7–60– Service Manual
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 GOVERNOR FORK LEVER
Removal And Installation
A
Remove the speed control plate. (See Page 7–38.)
Remove the fuel injection pump. (See Page 7–26.)
Remove the start spring (Item 1) [A] from the fork
compensation lever (Item 2) [A].
1
2

P–13285

Remove the two mounting bolts (Item 1) [B] from fork

lever shaft cover (Item 2) [B]. B

P–13354

Remove the fork lever cover and gasket from the block.
C
Remove the governor fork lever collar (Item 1) [C] from
the block.

P–13356

Remove the governor fork lever shaft (Item 1) [D] and

outer bearing (Item 2) [D], using a metric tap (Item 3) [D] D 2
screwed into the threads of the fork lever shaft for
leverage.
1
Remove the fork compensating lever and fork lever from
the block.

P–13353

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Revised Mar. 02 –7–61– Service Manual
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 GOVERNOR FORK LEVER (Cont’d)
A
Removal And Installation (Cont’d)
Remove the inside governor fork lever bearing (Item 1)
[A].
1

P–13355

Check the parts for wear and replace as needed [B].

B
NOTE: The washer (Item 1) [B] goes between the fork
lever (Item 2) [B] and the fork compensating
lever (Item 3) [B] when being installed.

P–13372

553 Loader
Revised Mar. 02 –7–62– Service Manual
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 PISTON
Removal And Installation
A
1
Remove the engine from the loader. (See Page 7–11.) 1
Remove the cylinder head from the engine. (See Page 2
7–43.) 2
Remove the oil pan and oil pickup tube. (See Page 7–54.)
2 1
NOTE: Mark the connecting rod caps (Item 1) [A].
Replace the cap on the matching connecting
rod as the piston is removed. Replace the
piston back in the same cylinder hole when
installing.
P–13381
Remove the connecting rod bolts (Item 2) [A].
Installation: Tighten bolts to 30–34 ft.–lbs. (41–46 Nm)
torque.
B
2
Remove the piston rings (Item 1) [B] from the piston..
Remove the piston (Item 2)[B] from the connecting rod
(Item 3) [B] by removing the piston pin (Item 4) [B]. 1
4
NOTE: Mark the piston and the connecting rod so
they are assembled correctly.

3
P–13400

Checking The Piston And Connecting Rod

Measure the piston pin hole with an inside micrometer
C
[C].
The specifications are 0.8661–0.8687 inch
(22,000–22,013 mm). The allowable wear limit is 0.8673
inch (22,03 mm).

P–13398

Measure the piston pin (Item 1) [D] with a micrometer and

the connecting rod bushing (Item 2) [D] with an inside
micrometer.
D
The specifications for the outside diameter of the piston
pin are 0.8662–0.8666 inch (22,002–22,011 mm).
The specification for the inside diameter of the connecting 2
rod bushing are 0.8671–0.8677 inch (22,025–22,040
mm). 1

The clearance between the piston pin and the connecting

rod bushing is 0.0006–0.0015 inch (0,014–0,038 mm)
with an allowable limit of 0.0059 (0,15 mm).

P–13401

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Revised Mar. 02 –7–63– Service Manual
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 PISTON (Cont’d)
Connecting Rod Alignment
A
NOTE: Check the I.D. of the connecting rod small
end bushing, because it is used for this
check, make sure it is not worn. (See Page
7–60.)
Install the piston pin into the connecting rod.
Install the connecting rod on the connecting rod alignment
tool [A].
Put a gauge over the piston pin and move it against the
face plate.
If the gauge does not fit squarely against the face plate, B–04067
measure the space between the pin of the gauge and the
face plate.
The allowable wear limit is 0.0020 inch (0,05 mm). B
If measurement exceeds the allowable limit, replace the
connecting rod. 1
Piston Ring Gap
Put the piston ring in the engine cylinder [B]. Use a piston
to push the ring to the lower part of the cylinder liner.
Measure the ring gap with a feeler gauge (Item 1) [B].
The specifications are as listed below:
Top Ring . . . . . . . 0.0098–0.0157 inch (0,25–0,40 mm)
Second Ring . . . . . . . . . . . . . . . . . . . 0.0098–0.0157 inch
(0,25–0,40 mm)
Oil Ring . . . . . . . 0.0098–0.0157 inch (0,25–0,040 mm) P–13402

The allowable wear limit for all the rings is 0.0492 inch
(1,25 mm). C 1
If the ring gap exceeds the allowable limit, replace the 2
ring.
Piston Ring Installation 3
Remove the carbon from the ring grooves in the piston.
B–03614
Install the rings on the piston [C]. Position the top ring so
the gap is not lined up with the piston pin. Position the
other rings so there is a gap every 90°.
NOTE: The top ring (Item 1) [C] (inset) is a 1/2 flat key
stone type ring and must be installed with the
flat side toward the bottom of the piston as
shown.
The second ring (Item 2) [C] (inset) must be P–13393
installed with the notch down as shown.
The oil ring (Item 3) [C] (inset) must be
installed as shown.
Measure the clearance between the ring and
the ring groove in the piston, with a feeler
gauge.
The clearance between compression ring (Item 2) [C] and
the ring groove is 0.0033–0.0044 inch (0,085–0,112 mm)
with an allowable limit of 0.0079 inch (0,20 mm).
The clearance between the oil ring (Item 3) [C] and the
ring groove is 0.0008–0.0021 inch (0,020–0,055 mm)
with an allowable limit of 0.0059 inch (0,15 mm).
If the clearance exceeds the allowable limit, replace the
ring.
If the clearance still exceeds the allowable limit after
replacing the ring, replace the piston.
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Revised Mar. 02 –7–64– Service Manual
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 PISTON (Cont’d)
A
Connecting Rod Installation
Install the connecting rod to the piston.
1
NOTE: The arrow (Item 1) [A] on the piston must
point in the direction of the numbers (Item 1)
[B] on the connecting rod and the connecting
rod cap. The alignment arrow and numbers
must be installed pointing opposite of the
camshaft and in the same cylinder it was
removed from.

P–13393

P–13396

Checking Engine Cylinder Bore

C
Use a micrometer to measure the inside diameter of the
cylinders [C] & [D].
To find the maximum wear, measure the inside diameter
of the cylinder in three different locations. The inside
diameter specification is 2.9921–2.9929 inches
(76,000–76,019 mm). The allowable wear limit is 0.0059
inch (+0,15 mm).
NOTE: When the cylinder has more wear than the
specifications the block can be bored and
honed one time. The oversize cylinder inside
diameter is +0.0197 inch (+0,5 mm). Be sure
to use the correct oversize piston and rings
to match the cylinder. P–13388

P–13382

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Revised Mar. 02 –7–65– Service Manual
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 CRANKSHAFT
Removal And Installation
A
1 1
Remove the engine from the loader. (See Page 7–11.)
Remove engine starter. (See Page 6–1.)
Remove engine flywheel. (See Page 7–17.)
Remove the engine cylinder head. (See Page 7–43.)
Remove the engine oil pan. (See Page 7–54.)
Remove the pistons. (See Page 7–60.)
Remove the two main bearing mounting bolts (Item 1) P–13381
[A].
Installation: Tighten the mounting bolts to 36–40 ft.–lbs.
(49–53,9 Nm) torque.
B 1
1
1
Remove the nine mounting bolts (Item 1) [B] from the
2
crankshaft bearing case cover (Item 2) [B].
1
Installation: Tighten the mounting bolts to 87–100
in.–lbs. (9,8–11 Nm) torque. 1
1

1
1
1
P–13380

Remove the crankshaft from the rear of the engine [C].

Check the gasket (Item 1) [C] and replace. C 1

P–13375

Remove the eight mounting bolts (Item 1) [D] from the

crankshaft bearing case cover and remove the cover.
D 1
1

1
1

1
1
1
1
P–13386

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Revised Mar. 02 –7–66– Service Manual
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 CRANKSHAFT (Cont’d)
A
Removal And Installation (Cont’d)
Replace the crankshaft bearing case cover gasket (Item
1) [A].
Replace the oil seal (Item 2) [A].
1

P–13388

Mark the main bearing caps (Item 1) [B].

Remove the main bearing cap bolts (Item 2) [B].
B
Installation: Tighten the main bearing cap bolts to 22–25 1
ft.–lbs. (24,4–34,3 Nm) torque.
2
NOTE: Since diameters of main bearings vary, install 1
2
the caps back on the bearings as they are
removed. Install them in the order they were 1
marked from the gear case side. When 2
installing the main bearing cap assemblies
face the mark (FLYWHEEL) on the
assemblies, toward the flywheel end of the
crankshaft.
P–13387

Check the thrust bearings (Item 1) [C], located on the rear

main bearing only, and replace if worn. C 1
NOTE: When replacing the thrust bearings be sure
to install the oil groove facing outward.

1
1

1
P–13397

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Revised Mar. 02 –7–67– Service Manual
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 CRANKSHAFT (Cont’d)
Checking Crankshaft Journal And Block Bearing
A
1
Measure the inside diameter of the front crankshaft
bearing (Item 1) [A].

P–13385

The crankshaft bearing inside diameter is 1.8891–1.8917

inch (47,984–48,048 mm). B

P–13383

The outside diameter of the crankshaft number one

journal (Item 1) [C] is 1.8872–1.8878 inch C
(47,934–47,950 mm).
The oil clearance between the crankshaft and the 1
crankshaft bearing is 0.0013–0.0045 inch (0,034–0,114
mm) with an allowable limit of 0.0079 inch (0,2 mm).

P–13391

553 Loader
Revised Mar. 02 –7–68– Service Manual
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 CRANKSHAFT (Cont’d)
Checking The Crankshaft Journal And Main Bearing
A
Clean the crankshaft journal and crankshaft bearing.
Put a strip of plastic gauge (Item 1) [A] on the main 1
bearing.

P–13395

Install the main bearing cap (Item 1) [B] and tighten to

36–40 ft.–lbs. (49,0–53,9 Nm) torque. B 1

P–13392

Remove the bolts and remove the main bearing cap and
measure with the plastic gauge scale [C], to get oil
clearance. C
The oil clearance between crankshaft and crankshaft
number two bearing is 0.0013–0.0037 inch (0,034–0,095
mm) with an allowable limit of 0.0079 inch (0,2 mm).
The oil clearance between the crankshaft and crankshaft
number three bearing is 0.0013–0.0037 (0,034–0,095
mm) with an allowable limit of 0.0079 inch (0,2 mm).
The oil clearance between the crankshaft and crankshaft
number four bearing is 0.0013–0.0039 inch (0,034–0,098
mm) with an allowable limit of 0.0079 inch (0,2 mm).
If the clearance exceeds the allowable limit, replace the P–13394
crankshaft bearing.

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Revised Mar. 02 –7–69– Service Manual
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 CRANKSHAFT (Cont’d)
A
Checking The Crankshaft Journal And Main Bearing
(Cont’d) 3 2 1
The measurement for the outside diameter of crankshaft
number two journal (Item 1) [A] and crankshaft number
three journal (Item 2) [A] is 1.8872–1.8878 inch
(47,934–47,950 mm).
The crankshaft bearing inside diameter for number two
and three journals are 1.8891–1.8909 inch
(47,984–48.029 mm).
The measurement for the outside diameter of the
crankshaft number four journal (Item 3) [A] is
2.0041–2.0449 inch (51,921–51,940 mm). P–13391

The crankshaft bearing inside diameter for number four

journal is 2.0462–2.0480 inches (51,974–52,019 mm). B

Connecting Rod Journal

Measure the connecting rod bearings [B] & [C]. the
measurement should be 1.5750–1.5768 inches
(40,004–40,050 mm).

P–13399

P–13383

Measure the connecting rod journals [D].

D
The measurement should be 1.5732–1.5738 inches
(39,959–39,975 mm).
The oil clearance between the crankpin and the crankpin
bearing is 0.0011–0.0036 (0,029–0,091 mm) with an
allowable limit of 0.0079 inch (0,2 mm).

P–13390

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Revised Mar. 02 –7–70– Service Manual
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 CRANKSHAFT (Cont’d)
Checking The End Play Of The Crankshaft
A
Move the crankshaft toward the crankshaft pulley end.
Set a dial indicator (Item 1) [A] to the crankshaft. 1
Measure the end play by pushing the crankshaft toward
flywheel end.
The end play should be between 0.0059–0.0122 inch
(0,15–0,31 mm) with an allowable limit of 0.0197 inch (0,5
mm).
If the measurement exceeds the allowable limit replace
the thrust bearings. (See Page 7–64.) P–13376

Crankshaft Alignment B
Support the crankshaft with V–blocks and set a dial
indicator on one of the center journals at a right angle [B].
Rotate the crankshaft on the V–blocks and get the
misalignment (half of the measurement).
The measurement should be 0.0008 inch (0,02 mm).
If the misalignment exceeds the allowable limit, replace
the crankshaft.

P–13389

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Revised Mar. 02 –7–71– Service Manual
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 ENGINE TIMING
A
Installation
Install the crankshaft (Item 1) [A]. (See Page 7–63).
Install the camshaft (Item 2) [A]. (See Page 7–50).
2
Install the governor shaft (Item 3) [A]. (See Page 7–55). 3
Install the fuel camshaft (Item 4) [A]. (See Page 7–52).
4

1
P–13346

Install the idler gear (Item 1) [B] on the idler shaft. (See
Page 7–49.) B
Align the timing marks between the idler gear and the
crankshaft (Item 2) [B], the camshaft (Item 3) [B] and the
fuel camshaft (Item 4) [B]. 3

4
2

1
P–13269

TIMING GEAR BACKLASH C

Idler Gear And Crankshaft
Set a dial indicator (lever type) with its tip on a gear tooth
of the idler gear (Item 1) [C].
Hold the crankshaft gear (Item 2) [C] and move the idler 1
gear.
Check the amount of movement on the dial indicator.
2
The measurement should be 0.0013–0.0045 inch
(0,032–0,115 mm) with an allowable limit of 0.0059 inch
(0,15 mm).
P–13271
If the backlash exceeds the allowable limit, check the oil
clearance between idler gear shaft and the idler gear
bushing. (See Page 7–49.)
If the clearance is within the allowable limit, replace the
idler gear.

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Revised Mar. 02 –7–72– Service Manual
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 TIMING GEAR BACKLASH (Cont’d)
553ServiceManual(S/N516311001&Above)#6900450–EngineSystemSectionPart3of3

A
Idler Gear And Camshaft Gear
1
Set a dial indicator (lever type) with its tip on a gear tooth 3
of the camshaft gear (Item 1) [A].
Hold the idler gear (Item 2) [A] and move the camshaft
gear. 2
4
Check the amount of movement on the dial indicator.
The measurement should be 0.0014–0.0045 inch
(0,036–0,114 mm) with an allowable limit of 0.0059 inch
(0,15 mm).
If backlash exceeds allowable limit replace the camshaft P–13271
gear.
If after replacing the camshaft gear the backlash exceeds
the allowable limit check the camshaft bearing. (See
Page 7–50.)

Idler Gear And Fuel Camshaft Gear

Set a dial indicator (lever type) with its tip on a gear tooth
of the fuel camshaft gear (Item 3) [A].
Hold the idler gear (Item 2) [A] and move the fuel
camshaft gear.
Check the amount of movement on the dial indicator.
The measurement should be 0.0013–0.0046 inch
(0,034–0,116 mm) with an allowable limit of 0.0059 inch
(0,15 mm).
If backlash exceeds the allowable limit replace the fuel
camshaft gear.
If after replacing the camshaft gear the backlash exceeds
the allowable limit check the fuel camshaft bearings. (See
Page 7–52.)

Fuel Camshaft Gear And Governor Shaft Gear

Set a dial indicator (lever type) with its tip on a gear tooth
of the governor shaft gear (Item 4) [A].
Hold the fuel camshaft gear (Item 3) [A] and move the
governor gear.
Check the amount of movement on the dial indicator.
The measurement should be 0.0012–0.0046 inch
(0,030–0,117 mm) with an allowable limit of 0.0059 inch
(0,15 mm).
If backlash exceeds the allowable limit replace the
governor shaft gear.
If after replacing the governor shaft gear the backlash
exceeds the allowable limit check the governor shaft
bearings. (See Page 7–55.)

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Revised Mar. 02 –7–73– Service Manual
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 553 Loader
Revised Mar. 02 –7–74– Service Manual
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 SYSTEMS ANALYSIS
Page
Number

BICS™ (With Press To Operate Button)

Additional Inspection For Loaders With Advanced Hand Controls . . . . 8–3
Inspecting Deactivation Of The Auxiliary Hydraulics System
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Inspecting The BICS™ System Controller
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Inspecting The Seat Bar Sensors (Engine Running) . . . . . . . . . . . . . . . 8–3
Inspecting The Traction Lock (Engine Running) . . . . . . . . . . . . . . . . . . . 8–3
Inspecting The Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
BICS™ (Without Press To Operate Button)
Inspecting The Deactivation Of The Auxiliary Hydraulics System
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Inspecting The BICS™ System Controller
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Inspecting The Seat And Seat Bar Sensors (Engine Running) . . . . . . . 8–5
Inspecting The Traction Lock (Engine Running) . . . . . . . . . . . . . . . . . . . 8–5
Inspecting The Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7
BICS™ SYSTEM CONTROLLER
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
SEAT BAR SENSOR
BICS™ Controller Seat Bar Sensor Circuit Test . . . . . . . . . . . . . . . . . . . . 8–13
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–12
Seat Bar Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10
SEAT SENSOR
BICS™ Controller Seat Sensor Circuit Test . . . . . . . . . . . . . . . . . . . . . . . 8–17
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16
Seat Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–15
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14 SYSTEMS
TRACTION LOCK ANALYSIS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–19
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–18

BICS™ – BOBCAT INTERLOCK CONTROL SYSTEM

Continued On Next Page

553 Loader
Revised Apr. 99 –8–1– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 553 Loader
–8–2– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 BICS™ (With Press To Operate Button)
Inspecting The BICS™ Controller
A 1
(Engine STOPPED – Key ON)
1. Sit in the operator’s seat. Turn key ON, lower the 2
seat bar and disengage the parking brake pedal.
Press the green PRESS TO OPERATE Button. All 3
five BICS controller lights should be ON (Items 1, 4
2, 3, 4 & 5) [A].
2. Engage the parking brake pedal and raise the seat 5
bar fully. System Activated (Item 1), Seat Bar (Item
2), Valve (Item 3) and Traction lights (Item 4) [A]
should be OFF.
NOTE: Record what lights are blinking (if any) and
number of blinks. Refer to Page 8–4
3. Exit the loader and press Traction Lock Override P–10157
button. Traction light (Item 4) [A] should be ON.
Press override button again and Traction light
(Item 4) [A] should be OFF.
Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED – Key ON)
4. Sit in the operator’s seat. Lower the Seat Bar.
Press the green PRESS TO OPERATE Button.
Press the auxiliary hydraulics switch. The auxiliary
switch light will come ON. Raise the Seat Bar. The AVOID INJURY OR DEATH
light should be OFF.
Inspecting The Seat Bar Sensor The Bobcat Interlock Control System (BICS)
(Engine RUNNING) must deactivate the lift, tilt and traction drive
functions. If it does not, contact your dealer for
5. Sit in the operator’s seat. Lower the seat bar. service. DO NOT modify the system.
Engage the parking brake pedal. Fasten the seat
belt. W–2151–0394
6. Start the engine and operate at low idle. Press the
green PRESS TO OPERATE Button. While
raising the lift arms, raise the Seat Bar fully. The lift
arms should stop. Repeat using the tilt function.
Inspecting The Traction Lock
(Engine RUNNING)
7. Fasten the seat belt, disengage the parking brake
pedal, press the green PRESS TO OPERATE
Button and raise the Seat Bar fully. Move the
steering levers slowly forward and backward. The
Traction lock should be engaged. Lower the Seat
Bar. Press the green PRESS TO OPERATE
Button.
8. Engage the parking brake pedal and move the
steering levers slowly forward and backward. The
Traction lock should be engaged.
Inspecting The Lift Arm By–Pass Control
9. Raise the lift arms 6 feet (2 meters) off the ground.
Stop the engine.
Turn the lift arm by–pass control knob clockwise
1/4 turn. Then pull up and hold the lift arm by–pass
control knob until the lift arms slowly lower.
Additional Inspection For Loaders With Advanced
Hand Controls
10. Sit in the operator’s seat and fasten the Seat Belt.
Lower the Seat Bar, start the engine and press the
green PRESS TO OPERATE Button.
11. Raise the lift arms about 6 feet (2 meters) off the
ground.
12. Turn the key OFF and wait for the engine to come
to a complete stop.
13. Turn the key ON. Press the green PRESS TO
OPERATE Button, move the left hand control
toward the operator. The lift arms should not lower.
14. Move the right hand control away from the
operator. The bucket (or attachment) should not tilt
forward.

553 Loader
Revised Apr. 99 –8–3– Service Manual
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 BICS™ (With Press To Operate Button) (Cont’d)

Troubleshooting Chart
The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller
lights are off or flashing. Have the service procedure performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.

Flashing Indicator Means System Problem

Effect on Operation (See Your Bobcat Dealer for Service)
of Loader
Indicator When Light Is Number of
Light Light ON Light OFF OFF Flashes Cause
System PRESS TO OPERATE PRESS TO OPERATE Lift, tilt and traction 2 System Activated circuit shorted to
Activated button is activated button not activated functions will not battery voltage.*
operate. 3 System Activated circuit shorted to
ground.
Seat Bar Seat Bar Down. Seat Bar Up. Lift, tilt and traction 2 Seat bar sensor circuit shorted to
functions will not battery voltage*.
operate. 3 Seat bar sensor circuit shorted to
ground.
Valve Control Valve Control Valve Lift and tilt functions 2 Valve output circuit shorted to battery
Can Be Used. Cannot Be Used. will not operate. voltage*.
3 Valve output circuit shorted to ground.
3 Valve output circuit is not grounded.
Traction Loader can be Loader cannot be Loader cannot be 1 Traction lock hold coil circuit is open.
moved forward moved forward and moved forward and 2 Traction lock hold coil circuit shorted
& backward. backward. backward. to battery voltage*.
3 Traction lock hold coil circuit shorted
to ground.
4 Traction lock pull coil circuit is open.
5 Traction lock pull coil circuit is shorted
to battery voltage*.
6 Traction lock pull coil circuit is shorted
to ground.
Power BICS Controller BICS Controller is Lift, tilt and traction
is operating not operating functions will not N/A N/A
correctly. correctly. operate.

* Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted
to system voltage.

NOTES:
(1) If the System Activated and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If
one of the lights stay OFF, check the circuit for continuity.
(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.
(3) Flashing patterns will repeat every 3.25 seconds.

553 Loader
Revised Apr. 99 –8–4– Service Manual
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 BICS™ (Without Press To Operate Button)
Inspecting The BICS Controller (Engine STOPPED –
A
Key ON) 1
1. Sit in the operator’s seat. Turn key ON, lower the 2
seat bar and disengage the parking brake. All five
BICS Controller lights should be ON (Items 1, 2, 3, 3
4 & 5) [A]. 4
2. Engage the parking brake, raise the seat bar fully.
Seat bar light (Item 2) [A], valve light (Item 3) [A] 5
and traction light (Item 4) [A] should be OFF.
3. Raise up slightly off the seat. Seat light (Item 1) [A]
should be OFF.
P–03760
NOTE: Record what lights are blinking (if any) and
number of blinks. Refer to BICS
Troubleshooting Chart, Page 8–7.
4. Exit the loader and press traction lock override
button. Traction light (Item 4) [A] should be ON.
Press override button again and traction light (Item
4) [A] should be OFF.

Later Model Loaders Only

Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED–Key ON)
5. Sit in the operator’s seat. Lower the seat bar.
Press the auxiliary hydraulics mode switch. The
auxiliary switch light will come ON. Raise the seat
bar. The light should be OFF.
Inspecting The Seat And Seat Bar Sensors (Engine
RUNNING)
6. Sit in the operator’s seat, lower the seat bar and
engage the parking brake. Fasten the seat belt.
7. Start the engine and operate at low idle. While
raising the lift arms, raise the seat bar fully. The lift
arms should stop. Repeat using the tilt function.

NOTE: The auxiliary hydraulic functions are not

affected by the Bobcat Interlock Control
System (BICS).
Inspecting The Traction Lock (Engine RUNNING)
8. Fasten the seat belt, disengage the parking brake,
and raise the seat bar fully. Move the steering
levers slowly forward and backward. The traction
lock should be engaged. Lower the seat bar.
9. Engage the parking brake pedal and move the
steering levers slowly forward and backward. The
traction lock should be engaged.

Inspecting The Lift Arm By–Pass Control

Early Models:
Raise the lift arms six feet (2 m) off the ground. Stop the
engine, pull and hold the by–pass control knob. Push the
toe of the left foot pedal or move the left hand control in
toward the operator (mechanical hand controls) and the
lift arms should lower slowly.
Later Models:
Raise the lift arms six feet (2 m) off the ground. Stop the
engine. Turn the Lift Arm By–Pass Control Knob
clockwise 1/4 turn. Then pull up and hold the Lift Arm
By–Pass Control Knob until the lift arms slowly lower.
553 Loader
Revised Apr. 99 –8–5– Service Manual
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 BICS™ (Without Press To Operate Button) (Cont’d) Clean area behind
A and under seat.
Maintenance
Clean any debris, dirt or objects from under or behind the
operator seat [A] & [B]. The rear of the seat must move
up and down.

P–03763
Inspect both Seat Rail Covers [B] for wear or damage.
Replace if necessary.
Operator
Clearance is necessary under the seat spring (Item 1) [B]
B Seat
and the seat, to allow the seat to move up and down freely.
With adequate clearance, the seat sensor will be allowed
to function properly.
Seat Seat
1 Spring
Inspect seat bar pivot area for tightness of linkage bolts.
Sensor
Replace parts that are damaged. Use only genuine
Melroe replacement parts. Seat Rail
Cover

MC–02043

AVOID INJURY OR DEATH

The Bobcat Interlock Control System (BICS)
must deactivate the lift, tilt and traction drive
functions. If it does not, contact your dealer for
service. DO NOT modify the system.
W–2151–0394

553 Loader
Revised Apr. 99 –8–6– Service Manual
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 BICS™ (Without Press To Operate Button)
Troubleshooting Chart
The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller
lights are off or flashing. Have the service procedure performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.

Flashing Indicator Means System Problem

Effect on Operation (See Your Bobcat Dealer for Service)
of Loader
Indicator When Light Is Number of
Light Light ON Light OFF OFF Flashes Cause
Seat Operator in Seat No Operator in Seat Lift and tilt functions 2 Seat sensor circuit shorted to battery
will not operate. voltage*.
3 Seat sensor circuit shorted to ground
Seat Bar Seat Bar Down Seat Bar Up Lift, tilt and traction 2 Seat bar sensor circuit shorted to
functions will not battery voltage*.
operate. 3 Seat bar sensor circuit shorted to
ground.
Valve Control Valve Can Control Valve Lift and tilt functions 1 Valve output circuit is open.
Be Used Cannot Be Used will not operate. 2 Valve output circuit shorted to battery
voltage*.
3 Valve output circuit shorted to ground.
3 Valve output circuit is not grounded.
Traction Loader can be Loader cannot be Loader cannot be 1 Traction lock hold coil circuit is open.
moved forward & moved forward and moved forward and 2 Traction lock hold coil circuit shorted
backward. backward. backward. to battery voltage*.
3 Traction lock hold coil circuit shorted
to ground.
4 Traction lock pull coil circuit is open.
5 Traction lock pull coil circuit is shorted
to battery voltage*.
6 Traction lock pull coil circuit is shorted
to ground.
Power BICS Controller BICS Controller is Lift, tilt and traction
is operating not operating functions will not
correctly. correctly. operate.

NOTES:
(1) If the seat and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If one of the lights
stay OFF, check the circuit for continuity. See Inspection & Maintenance Instructions in Preventive
Maintenance section.
(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.
(3) Flashing patterns will repeat every 3.25 seconds.
(4) If seat indicator light does not go ON, check for debris, dirt or objects under or behind the seat.
NOTE: On some early models with BICS controller S/N 200,000 and Above only, if the Seat Bar is lowered before
the seat sensor is activated, a 10 second delay will occur before the valve and traction lights come on.
* Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted
to system voltage.

553 Loader
Revised Apr. 99 –8–7– Service Manual
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 BICS™ SYSTEM CONTROLLER
Troubleshooting Guide
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only. Check for correct function after adjustments,
repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

PROBLEM SOLUTION #

Power indicator light does not come ON. 1, 2, 3, 6

All indicator lights flashing. 4
One of the indicator lights flashing. 5

Intermittent indicator lights. 6, 7, 8, 9

Key ON, Seat bar down, push the Press to Operate Button. The System
Activated, Valve And Traction indicator lights do not come ON. 10

SOLUTION SUGGESTIONS

1. Check that ignition switch ON.

2. Check BICS 10 amp. fuse.

3. Check wiring and connections. Make sure the connector is securely connected
to the controller. Remove controller and pull on connector to check.

4. Look at indicator light windows, if they are milky white in appearance it is most
likely caused by moisture in the controller. Allow to dry or replace the controller.

5. Refer to BICS controller troubleshooting chart. (See Page 8–4 or 8–7.)

6. Check wire connections to make sure connectors are locked into place.
7. Check pins in connectors for pins pushed back or bent.

8. Move the system wiring back & forth to try to find area that may be causing the
intermittent connection.
9. Use sensor tester MEL1428 to isolate problem between sensor and controller
and wiring.

10. Check the wiring and connections. Remove the left instrument panel and check the Push
to Operate Button with an Ohmmeter at the two–pin connector.

553 Loader
Revised Apr. 99 –8–8– Service Manual
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 BICS™ SYSTEM CONTROLLER (Cont’d)
A
Removal And Installation
NOTE: Photo’s may be different but the procedure is 2
the same for all models.

Raise the loader operator cab. (See Page 1–1.) 1

The controller mounting bolts are located on the back of
the operator cab [A].
Remove the top mounting bolt (Item 1) [A] from the
controller.
Loosen the two lower mounting bolts (Item 2) [A].
P–05865
Lower the operator cab.
NOTE: The operator seat is removed in photo [B] for
clarity purpose only. The seat does not need
B
to be removed to remove the controller.
1
Slide the controller (Item 1) [B] up and remove it from the
back of the operator cab.
Disconnect the electrical harness from the controller and
remove the controller from the loader.

P–05917

NOTE: Install the harness connector (Item 1) [C] into

the controller (Item 2) [C] before installing the
controller.
C

Be sure the connector to the BICS system

controller are correctly engaged in the
controller when installing the controller. An 1
audible snap can be heard when the
connector is correctly installed. Try to pull the
connector out of the controller, if it cannot be P–04707
removed it has been correctly installed [C].
I–2087–1095

Installation: Tighten the controller mounting bolts to

80–90 in.–lbs. (9–10 Nm) torque.
Reverse the removal procedure to install the controller.

553 Loader
Revised Apr. 99 –8–9– Service Manual
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 SEAT BAR SENSOR
Troubleshooting Guide
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only. Check for correct function after adjustments,
repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

PROBLEM SOLUTION #

Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5, 6

SOLUTION SUGGESTIONS

1. Check controller power indicator light . It must be ON.

2. Check sensor wire connection.

3. Use the BICS sensor tester MEL1428 to check sensor and controller.

4. Check for loose hardware.

5. Check keyed bushing to make sure magnet collar rotates with seat bar.

6. Check magnet collar magnets for contamination such as metal particles.

553 Loader
Revised Apr. 99 –8–10– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SEAT BAR SENSOR (Cont’d)
Seat Bar Sensor Test
A
Use Sensor Tester (MEL1428) for the following
procedure: 1
Disconnect the short adapter test leads if connected.
Disconnect the seat bar sensor connector (Item 1) [A].

P–04702

Connect Sensor Tester (Item 1) [B] inline as shown to the

seat bar sensor connectors. See inset [B]. B
Turn the key to the ON position. DO NOT START THE
ENGINE.
The toggle switch (Item 2) [C] can be in either the Absent 1
or Present position.

P–04701

P–04700

The power light (Item 1) [C] will illuminate, if the light is not
on, check the tester or wiring harness. C

P–04698

Lower the seat bar. The Sensor Test light (Item 1) [D]
should illuminate. D
Raise the seat bar. The Sensor Test light (Item 1) [D]
should go off.
1
If the above tests fail, there is a problem with the seat bar
sensor.
Disconnect the Sensor Tester.
Replace the Seat Bar Sensor. (See Page 8–12.)
If the above tests pass, run BICS controller seat bar
circuit test. (See Page 8–13.)
P–04699

553 Loader
Revised Apr. 99 –8–11– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SEAT BAR SENSOR (Cont’d)
Removal And Installation
A
Disconnect the seat bar sensor connector (Item 1) [A].
1

P–04702

Remove the mounting bolt (Item 1) [B] from the pivot

bushing. B
Installation: Tighten the mounting bolt to 25–28 ft.–lbs.
(34–38 Nm) torque.
Remove the sensor mounting bolt (Item 2) [B] and nut. 1

2
Be careful to not overtighten the sensor
mounting bolt and nut to prevent breakage of P–03246
the sensor.
I–2088–1095

Installation: Be sure the tabs on the pivot bushing are

C
positioned in the slotted hole (Item 1) [C] of the operator
cab as shown.
Pull the seat bar back and remove the assembly as
follows:
NOTE: The sensor assembly [D] is shown removed 1
from the operator cab for clarity purpose
only. The sensor assembly can be removed
without removing the seat bar from the
operator cab.
Remove the pivot bushing mounting bolt (Item 1) [D] and
washer (Item 2) [D] from the pivot bushing (Item 3) [D]. P–03247

Installation: Tighten the pivot bushing mounting bolt to

180–200 in.–lbs. (21–23 Nm) torque.
D
Remove the pivot bushing (Item 3) [D], sensor (Item 4)
[D], magnet (Item 5) [D] and plastic bushing (Item 6) [D] 3 6 2
from the seat bar. 1

Inspect all parts for damage and wear and replace if

necessary.
Reverse the removal procedure to install the seat bar
sensor.
Left Side
4 5 of Seat Bar

P–03284

553 Loader
Revised Apr. 99 –8–12– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SEAT BAR SENSOR (Cont’d)
A
BICS™ Controller Seat Bar Sensor Circuit Test
Use Sensor Tester (MEL1428) for the following
procedure:
1
Disconnect the short adapter test leads if connected.

Disconnect the seat bar sensor connector (Item 1) [A].

P–04701
Connect Sensor Tester (Item 1) [B] inline as shown to the
seat bar sensor connectors. See inset [A].
Turn the key to the ON position. DO NOT START THE
ENGINE. P–04702

No power light on the sensor tester check the tester or

wiring harness.
B
Power light illuminated, move the toggle switch (Item 2)
[B] on the sensor tester (Item 1) [B] to the Present 3
position.

NOTE: The sensor test light (Item 3) [B] is activated 2

by the seat bar. It will be off with the seat bar
up or on with the seat bar down.
1

P–04703

The seat bar light (Item 1) [C] on the BICS controller

should illuminate. C

P–04704

Move the toggle switch (Item 1) [D] on the sensor tester

to the Absent position. D
The Seat Bar light (Item 1) [C] should go off.
If the tests above fail, there is a problem with the BICS™
system controller or the wiring harness.

P–04699

553 Loader
Revised Apr. 99 –8–13– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SEAT SENSOR
Troubleshooting Guide
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems It is recommended that these procedures be Check for correct function after adjustments,
done by authorized Bobcat Service Personnel only. repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

PROBLEM SOLUTION #

Seat indicator light does not come ON with operator in seat.. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11
Seat indicator light stays ON when operator out of seat. 2, 3, 6, 10, 11, 12, 13, 14

Intermittent indicator light during operation. 11, 15, 16, 17, 18

SOLUTION SUGGESTIONS

1. Check to make sure power indicator light is ON.

2. Check for debris under and around seat.
3. Look for any obstruction around seat.
4. Check to make sure seat rail lowers when weight is in seat.
5. Raise cab and check for magnet collar movement when weight is added to seat.
(Magnet collar should extend approximately 3/8 inch beyond the sensor assembly
with weight in the seat).
6. Use sensor tester to check operation of sensor and controller. Follow instructions
on tester.
7. Check to make sure the magnet guide pin is in place.
8. Check for contamination on magnets such as metal particles or for shipping plate
over magnets.
9. Check to make sure both magnets are in collar.
10. Check for binding of magnet collar or bushing with hex head on other side for
binding.
11. Check for correct mounting. One spring for standard seat. Two springs for
suspension seats. Thick washers should be under front seat mounting rails on
both sides.
12. Check for loose hardware mounting magnet collar. Check to make sure the
magnet collar bushing is threaded on all the way so it is contacting seat rail.
13. Check to make sure seat rail raises when weight is removed from the seat.
14. Raise cab and check for magnet collar movement when weight is removed from
seat. (Magnet collar should extend approximately 1/8 inch beyond the sensor
assembly without weight in seat.)
15. With smaller operators that operate with the seat forward some mounting
alterations may be required. (See solution suggestions 16, 17 and 18.)
16. Adjust suspension seat to lightest weight setting.
17. Check to make sure the seat rails move up and down freely when weight is added.
18. Add washer between the bushing the magnet collar assembly slides on and the
seat rail. This will reduce the amount of seat travel required to activate the system.
Must check, with seat moved all the way back, that indicator light does not stay
on with operator out of seat. If light does not go out with operator out of the seat,
the washer must be removed.

553 Loader
Revised Apr. 99 –8–14– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SEAT SENSOR (Cont’d)
A
Seat Sensor Test
Use (MEL1428) Sensor Tester for the following 2
procedure:
Disconnect the short adapter test leads if connected.

NOTE: Clean any debris, dirt or objects from under

or behind the operator seat before starting
the test. The rear of the seat must move up
and down.

Raise the operator cab. (See Page 1–1.)

Disconnect the seat sensor connector (Item 1 – Inset)
[A].
Connect Sensor Tester (Item 2) [A] inline as shown to the
seat sensor.
Lower the operator cab. (See Page 1–1.)

N–00960 P–04705

Move the toggle switch (Item 1) [B] on the sensor tester

to the Absent position. B
Turn the key to the ON position. DO NOT START THE
ENGINE.
The power light (Item 2) [B] will illuminate, if the light is not
on, check the tester or wiring harness.
1
Sit on the operator seat.

P–04698

The Sensor Test light (item 1) [C] should illuminate.

C
Get off the operator seat. The Sensor Test light (Item 1)
[C] should go off.
If the above tests fail, there is a problem with the seat 1
sensor.
Disconnect the Sensor Tester.
Replace the Seat Sensor. (See Page 8–16.)
If the above tests pass, run BICS™ controller seat sensor
circuit test. (See Page 8–17.)

P–04699

553 Loader
Revised Apr. 99 –8–15– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SEAT SENSOR (Cont’d)
A
Removal And Installation
Raise the loader operator cab. (See Page 1–1.)
Locate the seat sensor (Item 1) [A] beneath the operator
cab.

Remove the sensor connector (Item 1) [B] from the

holder and disconnect from the harness. 1
Remove the magnet collar mounting bolt (Item 2) [B] and
washer (Item 1) [C].
Installation: Tighten the bolt to 180–200 in.–lbs. (21–23 P–03987
Nm) torque.

B
2

3
DO NOT overtighten the magnet mounting 1
bolt to prevent damage to the magnet.
I–2089–1095

4
Remove the magnet (Item 2) [C] from the sensor (Item 3)
[B].
Installation: If the magnet collar (Item 2) [C] is tapered, N–00960
install the tapered end to the seat. If the magnet collar
(Item 2) [C] is not tapered, install as shown [C].
Remove the sensor mounting bolt (Item 4) [B] and nut.
C
5
Installation: Tighten the nut and bolt (Item 4) [B] until
light pressure is applied to the sensor (Item 3) [B].
3
2
1
4

Be careful to not overtighten the sensor

mounting bolt and nut to prevent breakage of
the sensor. P–04041
I–2088–1095

Remove the sensor (Item 3) [C].

D
NOTE: Be sure not to lose the magnet collar
alignment pin (Item 4) [C] which is located in
the sensor (Item 3) [C] when removing the
sensor. 1

Remove the threaded bushing (Item 5) [C] from the seat

track mounting bolt (Item 1) [D].
Inspect all parts for damage and wear and replace if
necessary.
Reverse the removal procedure to install the seat sensor.
P–04044

553 Loader
Revised Apr. 99 –8–16– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SEAT SENSOR (Cont’d)
BICS™ Controller Seat Sensor Circuit Test
A
Use Sensor Tester (MEL1428) for the following 2
procedure:
Disconnect the short adapter test leads if connected.
NOTE: Clean any debris, dirt or objects from under
or behind the operator seat before starting
the test. The rear of the seat must move up
and down.

Raise the operator cab. (See Page 1–1.)

Disconnect the seat sensor connector (Item 1 – Inset)
[A].
Connect MEL1428 Sensor Tester (Item 2) [A] inline as
shown to the seat sensor.
Lower the operator cab. (See Page 1–1.)

N–00960 P–04705

Turn the key to the ON position. DO NOT START THE

ENGINE. B
The power light (Item 1) [B] will illuminate, if the light is not
on, check the tester or wiring harness.
3
Move the toggle switch (Item 2) [B] on the sensor tester
to the Present position.
2
NOTE: The sensor test light (Item 3) [B] is activated
by the seat sensor switch. 1

P–04703

The Seat light (Item 1) [C] on the controller will illuminate. C

Move the toggle switch to Absent position, the seat light
on the controller will go off.
If the tests above fail, there is a problem with the BICS
system controller or the wiring harness.
1

P–04706

553 Loader
Added Apr. 99 –8–17– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 TRACTION LOCK
Troubleshooting Guide
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be
done by authorized Bobcat Service Personnel only. Check for correct function after adjustments,
repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285

PROBLEM SOLUTION #

Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7, 8

Intermittent activation of traction lock. 9, 10, 11

SOLUTION SUGGESTIONS

1. Check that controller power indicator light is ON.

2. Make sure brake pedal is not engaged.

3. Maneuver loader to allow brake discs to move and remove pressure on the brake
wedge so it can retract.

4. If all lights indicate the brake should be released, but it doesn’t, check the brake
25 amp. fuse.

5. When checking fuse, also check other fuses. Check the fuse block for correct
orientation and location of fuses. (See Electrical System, Page 6–1.)
6. To test the solenoid, the pull coil should be .4 to .5 ohms and the hold coil 10.5 to
11.0 ohms.

7. Check brake solenoid and cover mounting hardware for the correct torque.
8. Remove brake cover and check wedges for binding in the wedge guides.

9. Check wire connections for loose connector body.

10. Check for loose or bent pins in connectors.

11. Check for loose spade connectors in fuse holder.

553 Loader
Added Apr. 99 –8–18– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 TRACTION LOCK (Cont’d)
Removal and Installation
A 2
1

P–4712
AVOID INJURY OR DEATH
Do not modify the electrical wiring connected
to the traction lock solenoid or any part of the
traction lock system. The traction lock 2
provides the locking function of the parking
brake. Service work on the traction lock system P–13238
should only be performed by a qualified P–13233
technician. Use only genuine Melroe parts if
repair is necessary.
W–2165–0195
B
Install jackstands under the rear of the loader. (See Page 3
1–1.)
1
Raise the loader operator cab. (See Page 1–1.)
NOTE: The loader control panel is removed for
clarity purpose only. The traction lock can be
removed without removing the control panel.
Remove the Do Not Modify sta–strap (P/N 6665527) from 2
the electric solenoid connector (Item 1) [A], and
disconnect the solenoid from the loader wiring harness.
Installation: Install a new Do Not Modify sta–strap (P/N
6665527) on the electric solenoid connector. P–13240

Remove the two mounting bolts (Item 2) [A] from the

electric solenoid mounting bracket.
C
Installation: Tighten the mounting bolts to 25–28 ft.–lbs.
(34–38 Nm) torque. Be sure the solenoid mounting
bracket is installed in the same position. The solenoid
mounting surface has a slight angle which tips the top of
the solenoid toward the rear of the loader when installed
correctly. (See inset photo [A].)
Remove the electric solenoid/mounting bracket
assembly (Item 1) [B] from the chaincase cover. 1
Remove and inspect the compression spring (Item 2) [B] 3
for wear or damage. Replace if necessary. The spring
may also stay with the shaft when the electric solenoid 2 4
and bracket are removed from the chaincase. P–13237
Installation: Install the compression spring on the collar
(Item 1) [C] (cupped side toward spring).
Remove the traction lock assembly (Item 3) [B] from the
chaincase.
Remove the shaft mounting bolt (Item 2) [C], washer and
spring from the assembly shaft (Item 3) [C]. Remove the
wedge (Item 4) [C] and inspect all parts for damage or Failure to use LOCTITE may allow the traction
wear. Replace if necessary. lock assembly to loosen up which can cause
damage to the traction lock system.
Installation: Thoroughly clean and dry the shaft I–2090–1095
mounting bolt, the shaft and wedge. Use LOCTITE 242
when assembling these parts to the traction lock
assembly.
Refer to Page 8–3 for the traction lock inspection
procedure.
553 Loader
Added Apr. 99 –8–19– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 553ServiceManual(S/N516311001&Above)#6900450–BICSSystemSection

553 Loader
Added Apr. 99 –8–20– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SPECIFICATIONS
Page
Number
DECIMAL & MILLIMETER EQUIVALENTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–13
ENGINE SPECIFICATIONS
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Engine Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Grinding Specifications For The Crankshaft . . . . . . . . . . . . . . . . . . . . . . . 9–7
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Fuel Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . 9–14
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
LOADER SPECIFICATIONS
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
METRIC TORQUE SPECIFICATIONS FOR BOLTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12
SPECIFICATIONS
TORQUE SPECIFICATIONS FOR LOADER
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
U.S. TO METRIC CONVERSION
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–13

553 Loader
Revised Apr. 99 –9–1– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 553 Loader
–9–2– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 LOADER SPECIFICATIONS SDimensions are given for loader equipped with standard tires and dirt bucket and may
vary with other bucket types. All dimensions are shown in inches. Respective metric
dimensions are given in millimeters enclosed by parentheses.
Loader Dimensions SWhere applicable, specification conform to SAE or ISO standards and are subject to
change without notice.

95°
C

61.9
(1572) 42° 128.6
(3266)
12.3
(312)
103.7
(2634)
82.0
72.5 (2083)
(1842)
9.0
(229)

24° 26°

6.8 31.1

Bob–tach
Face of
B (173) (790)
87.9
(2233)
107.3
A (2725)

‘‘A” 8.5–15 TIRES – 47.0” (1194 mm) ‘‘B” 8.5–15 TIRES – 38.2” (970 mm) ‘‘C” 48 in. BUCKET WIDTH – 49.4” (1255 mm)

Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.
553

Performance
Rated Operating Capacity (SAE) . . . . . . 950 lbs. (431 kg)
Tipping Load (SAE Rating) . . . . . . . . . . . 1953 lbs. (886 kg)
Operating Weight . . . . . . . . . . . . . . . . . . . 3664 lbs. (1662 kg)
SAE Breakout Force – Lift . . . . . . . . . . . . 1900 lbf. (8451 N)
– Tilt 1800 lbf. (8006 N)
Axle Torque . . . . . . . . . . . . . . . . . . . . . . . . 2650 ft.–lbs. (3593 Nm)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . 0–6.0 MPH (9,7 km/hr.)
Controls
Vehicle Steering . . . . . . . . . . . . . . . . . . . . Direction and Speed controlled by two hand levers.
Loader Hydraulics
Lift and Tilt . . . . . . . . . . . . . . . . . . . . . . . . Controlled by separate foot pedals.
Front Auxiliary (optional) . . . . . . . . . . . . Controlled by lateral movement of RH steering lever.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand lever throttle; Key–Type starter switch & shutdown.
Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . Glow Plug–Push button activated.
Service Brake . . . . . . . . . . . . . . . . . . . . . Two independent hydrostatic systems controlled by two hand
operated steering levers.
Secondary Brake . . . . . . . . . . . . . . . . . . One of the hydrostatic transmissions
Parking Brake . . . . . . . . . . . . . . . . . . . . . . Mechanical Disc, foot operated pedal
Engine
Make/Model . . . . . . . . . . . . . . . . . . . . . . . . Kubota/D1005–B
Fuel/Cooling . . . . . . . . . . . . . . . . . . . . . . . . Diesel/Liquid
Horsepower (SAE) . . . . . . . . . . . . . . . . . . Gross: 25.0 HP (18,6 kW) Net: 22.5 HP(16,8 kW)
Maximum Governed RPM . . . . . . . . . . . . Low Idle 1125–1175
..................................... High Idle 3100–3200
Torque @ 2400 RPM (SAE) . . . . . . . . . . Gross: Net: 43.6 ft.–lbs.(59,1 Nm)
Number of Cylinders . . . . . . . . . . . . . . . . . Three
Displacement . . . . . . . . . . . . . . . . . . . . . . . 61.1 cu.–in (1002 cm3)
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . 2.99/2.90 (76/73,6)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Pressure System W/Filter
Crankcase Ventilation . . . . . . . . . . . . . . . . External
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Dry replaceable paper cartridge w/safety element
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression Diesel
553 Loader
Revised Mar. 02 –9–3– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 LOADER SPECIFICATIONS (Cont’d)
553
Hydraulic System
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Driven, Gear Type
Pump Capacity . . . . . . . . . . . . . . . . . . . . . 8.5 GPM (32,2 L/min.) @ 3150 RPM
System Relief @ Quick Couplers . . . . . . 2000 PSI (138 Bar)
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full flow replaceable, 3 micron synthetic media element
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . Double–acting
Bore Diameter:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . 2.0 (50,8)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . 3.0 (76,2)
Rod Diameter:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . 1.25 (31,8)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . 1.50 (38,1)
Stroke:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . 25.7 (652,0)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . 13.3 (336,6)
Control Valve . . . . . . . . . . . . . . . . . . . . . . . 3–spool, series type, open center w/float detent on lift
and detent on auxiliary
Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . SAE standard tubes, hoses & fittings
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . Bobcat Fluid (P/N 6563328) if fluid is not available, use
10W–30/10W40 Class SE motor oil for temperature above 0°F (–18°C)
5W–30 Motor Oil for temperatures below 0°F (–18° C).
Hydraulic Function Time:
Raise Lift Arms . . . . . . . . . . . . . . . . . . . . 4.7 Seconds
Lower Lift Arms . . . . . . . . . . . . . . . . . . . . 3.5 Seconds
Bucket Dump . . . . . . . . . . . . . . . . . . . . . . 3.0 Seconds
Bucket Rollback . . . . . . . . . . . . . . . . . . . 2.4 Seconds
Electrical
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 40 amp open
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt, 530 cold cranking amps @ 0° F (–18 ° C)
120 minute reserve capacity
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt Gear Reduction Type; 1.88 HP (1,4 kW)
Instrumentation . . . . . . . . . . . . . . . . . . . . . Gauges: Hourmeter, Fuel, Voltmeter, Engine Temperature.
Warning lights: Engine Temperature, Engine Oil Pressure,
Hydraulic Oil Temperature & Pressure, Air Filter (Plugged)
Drive System
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic 4 wheel drive
Transmission . . . . . . . . . . . . . . . . . . . . . . . Infinitely variable tandem hydrostatic piston pumps, driving 2 fully
reversing hydrostatic motors
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . #60 HS endless roller chain & sprockets in sealed chaincase with
oil lubrication
Axle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.75 (44,5)
Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . (6) 9/16”
Capacities
Cooling System . . . . . . . . . . . . . . . . . . . . . 9 qts. (8,5 L)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 gals. (38 L)
Engine Oil W/Filter . . . . . . . . . . . . . . . . . . 5.4 qts. (5.1 L)
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . 2.3 gals. (8,7 L)
Hydraulic/Hydrostatic System . . . . . . . . . 4.8 gals. (18,2 L)
Chaincase Reservoir . . . . . . . . . . . . . . . . 4 gals. (15 L)
Tires
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 x 8.50–15, 4 or 6 ply rating
Recommended Pressure . . . . . . . . . . . Inflate tires to MAXIMUM pressure shown on the side wall
of the tire. DO NOT mix brands of tires used on the same loader.

553 Loader
–9–4– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Engine Compression @ 200 to 300 RPM (Operating Temperature) . . . . . . . . . . . . . . . 412–469 PSI (2841–3234 kPa)

Fuel Injection Nozzles

Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990–2133 PSI (13721–14707 kPa)

Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Nozzle at 1848 PSI (12742 kPa)

Fuel Injection Pump

Fuel Tightness Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2133 PSI (14707 kPa)
Fuel Tightness of Delivery Valve . . . . . . . . . . . . . . 10 sec: initial pressure drop from 2133–1990 PSI (14707–13721 kPa)
Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . 5 sec: initial pressure drop from 2133–1990 PSI (14707–13721 kPa)
Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.0–20.0 degrees B.T.D.C.

Cylinder Head

Cylinder Distortion Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0019’’ (0,05 mm) in 4’’ (100 mm)

of the length of the cylinder head surface.
Thickness of Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0413–0.0453’’ (1,05–1,15 mm)
Thickness of Gasket Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079’’ (0,2 mm)
Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0217–0.0276’’ (0,55–0,70 mm)
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412–469 PSI (2840–3234 kPa)
Head Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48–51 ft.–lbs. (65–69 Nm)

Valves

Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0835’’ (2,12 mm)

Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
O.D. of the Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2740–0.2746’’ (6,960–6,975 mm)
I.D. of the Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2759–0.2765’’ (7,010–7,025 mm)
Clearance Between Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0014–0.0025’’ (0,035–0,065 mm)
Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004’’ (0,1 mm)
Depth of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035–0.043’’ (0,9–1,1 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.51’’ (1,3 mm)
Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0057–0.0073’’ (0,145–0,185 mm)
Valve Springs

Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.457–1.496’’ (37,0–37,5 mm)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.437’’ (36,5 mm)
Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22’’ (31,0 mm)
Load to Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.4 lbs. (11,98 kg)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 lbs. (10,2 kg)
Limit Permitted for Spring being Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.039’’ (1,0 mm)

Rocker Arms

O.D. of Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4714–0.4718’’ (11,973–11,984 mm)

I.D. of Rocker Arm Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4724–0.4731’’ (12,000–12,018 mm)
Clearance Between Rocker Arm Shaft & Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006–0.0018’’ (0,016–0,045 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039’’ (0,10 mm)

Camshaft
O.D. of Camshaft Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4147–1.3799’’ (35,934–35,050 mm)
I.D. of Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4173–1.4183’’ (36,000–36,025 mm)
Clearance Between Camshaft Bearing & Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0020–0.0036’’ (0,050–0,091 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0047’’ (0,12 mm)
Alignment of the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0004’’ (0,01 mm)
Cam Lobe Height . . Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1339’’ (28,80 mm)
. . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1417’’ (29,00 mm)
Limit Permitted . . . Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1319’’ (28,75 mm)
. . . . . . . . . . . . . . . . . . Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1398’’ (28,95 mm)
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0013–0.0045’’ (0,032–0,115 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059’’ (0,15mm)
553 Loader
Revised Mar. 02 –9–5– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE SPECIFICATIONS (Cont’d)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Cylinders

I.D. of Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9921–2.9929’’ (76,00–76,019 mm)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.0059’’ (+0,15 mm)
I.D. of Oversized Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0118–3.0126’’ (76,500–76,519 mm)

Piston Rings

Ring Gap, Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0098–0.0157’’ (0,25–0,40 mm)

Ring Gap, 2nd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0098–0.0157’’ (0,25–0,40 mm)
Ring Gap, Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0098–0.0157’’ (0,25–0,40 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0492’’ (1,25 mm)
Side Clearance of Ring in Groove
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Can not measure accurately
2nd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0033–0.0044’’ (0,085–0,112 mm)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008–0.0021’’ (0,020–0,055 mm)

Pistons

I.D. of Piston Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.784–0.7879’’ (20,00–20,013 mm)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7885’’ (20,03 mm)
O.D. of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8662–0.8666’’ (22,002–22,011 mm)
I.D. of Connecting Rod Bushing (Small End, Fitted) . . . . . . . . . . . . . . . . . . . . . . . . . 0.8671–0.8677’’ (22,025–22,040 mm)
Clearance Between Piston Pin & Bushing (New Engine) . . . . . . . . . . . . . . . . . . . . . . . 0.0006–0.0015’’ (0,014–0,038 mm)
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006–0.0026’’ (0,015–0,066 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059’’ (0,15 mm)
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008’’ (0,02 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0020’’ (0,05 mm)
Oversize Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020’’ (0,5 mm)

Crankshaft

Crankshaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008’’ (0,02 mm)

O.D. of Crankshaft Journals No. 1, NO. 2 & No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8872–1.8878’’ (47,934–47,950 mm)
O.D. of Crankshaft Journal No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0441–2.0449” (51,921–51,940 mm)
I.D. of Crankshaft Bearing No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8891–1.8917’’ (47,984–48,048 mm)
I.D. of Crankshaft Bearing No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7317–1.7339’’ (43,984–44,041 mm)
Clearance Between Crankshaft Journals & Bearing No. 1 . . . . . . . . . . . . . . . . . . . . . . 0.0013–0.0045’’ (0,034–0,114 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079’’ (0,20 mm)
Clearance Between Crankshaft Journals & Bearing No. 2 & No. 3 . . . . . . . . . . . . . . . 0.0013–0.0037’’ (0,034–0,095 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079’’ (0,20 mm)
Clearance Between Crankshaft Journal & Bearing No. 4 . . . . . . . . . . . . . . . . . . . . . . . 0.0013–0.0039” (0,034–0,098 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079” (0,20 mm)
O.D. of Connecting Rod Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5732–1.5738’’ (39,959–39,975 mm)
I.D. of Connecting Rod Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5750–1.5768’’ (40,004–40,050 mm)
Clearance Between Connecting Rod Journals & Bearing . . . . . . . . . . . . . . . . . . . . . . . 0.0011–0.0036’’ (0,029–0,091 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079’’ (0,20 mm)
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059–0.0122’’ (0,15–0,31 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0197’’ (0,5 mm)

Oil Pump

Oil Pressure @ Rated RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28–64 PSI (196–441 kPa)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 PSI (147.1 kPa)
Oil Pressure @ Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PSI (49 kPa)
Clearance Between Inner and Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0024–0.0071’’ (0,06–0,18 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118’’ (0,3 mm)
Clearance Between Outer Rotor & Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039–0.0071’’ (0,10–0,18 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0213’’ (0,54 mm)
End Clearance Between Rotor & Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0098–0.0295’’ (0,025–0,75 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.089’’ (0,225 mm)

Thermostat

Opening Temperature (Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157.1°–162.5°F (69.5°–72.5°C)

(Full Open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185°F (85°C)
553 Loader
Revised Mar. 02 –9–6– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE SPECIFICATIONS (Cont’d)
Grinding Specifications for the Crankshaft
If the standard–size bearing cannot be used due to excessive wear of the crankpin and crank journals, use undersize or
oversize bearings.

C
3 3
1 2
2
B

A A

2 4 5

Undersize and Oversize Bearings

If the standard size bearing cannot be employed due to excessive wear of the crankpin and crank journal, employ
undersize or oversize bearings.
For under size or oversize bearing use, the following precautions noted below.

1. Grind the crankpin corner ( 1 ) and journal corner ( 2 ) with a wheel which has specified round corner and width without
shoulder.
Item 1 .1102 – .1260 inch ( 2.8–3.2 mm)
Item 2 .0906 – .1063 inch ( 2.3–2.7 mm)
2. Be sure to chamfer the oil hole ( 3 ) circumference to .04–.06 inch ( 1,5 mm) radius with an oil stone.

3. The crankpin ( 4 ) must be fine–finished to higher than ∇∇∇∇ (.8–S).

4. The crank journal ( 5 ) must be fine–finished to higher than ∇∇∇∇ (.8–S).

5. The crank journal side surface ( C ) must be fine–finished to higher than ∇∇∇∇ (.8–S).

553 Loader
–9–7– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 ENGINE SPECIFICATIONS (Cont’d)
Grinding Specifications for the Crankshaft (Cont’d)
If the standard–size bearing cannot be used due to excessive wear of the crankpin and crank journals, use undersize or
oversize bearings.

REF. SIZE CODE NUMBER DESCRIPTION DIMENSION MARK

–0.008 in . 16241–2391–1 Crankshaft Bearing #1 1.8793–1.8799 in. 020US

–0,2 mm (0.2 minus) 47,734–47,750 mm
–0.016 in. 16241–2392–1 Crankshaft Bearing #1 1.8714–1.8720 in. 040US
–0,4 mm (0.4 minus) 47,534–47,550 mm
–0,008 in. 16241–2393–1 Crankshaft Bearing #2 1.8793–1.8799 in. 020US
–0,2 mm (0.2 minus) 47,734–47,750 mm
A
–0.016 in. 16241–2394–1 Crankshaft Bearing #2 1.8714–1.8720 in. 040US
–0,4 mm (0.4 minus) 47,534–47,550 mm
–0.008 in. 16241–2396–1 Crankshaft Bearing #3 2.0363–2.0370 in. 020US
–0,2 mm (0.2 minus) 51,721–51,740 mm
–0.008 in. 16241–2397–1 Crankshaft Bearing #3 2.0284–2.0291 in. 040US
–0,4 mm (0.4 minus) 51,521–51,540mm
–0.008 in. 16241–2297–1 Crank pin Bearing 1.5653–1.5659 in. 020US
–0,2 mm (0.2 minus) 39,759–39,775 mm
B
–0.016 in. 16241–2298–1 Crank pin Bearing 1.5574–1.5581 in. 040US
–0,4 mm (0.4 minus) 39,559–39,575 mm
+0.008 in. 19202–2397–1 Thrust Bearing 2 (0.2 +) 1.1102–1.1122 in. 0.20 OS
+0,2 mm 15521–2395–1 Thrust Bearing 1 (0.2 +) 28,20–28,25 mm
C
+0.016 in. 19202–2398–1 Thrust Bearing 2 (0.4 +) 1.1181 –1.1201 in. 0.40 OS
+0,4 mm 15521–2396–1 Thrust Bearing 1 (0.4 +) 28,40–28,45 mm

553 Loader
–9–8– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 TORQUE SPECIFICATIONS FOR LOADER
Specifications
Item Ft.–Lbs. Nm
Air Cleaner Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Alternator Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 68
Axle Hub Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575–625 780–848
Axle Sprocket Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220–245 298–332
Bob–Tach Pivot Pin Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300–330 407–447
Bob–Tach Lever Pivot Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Camshaft Retainer Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–20 23–27
Centering Spring Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Chaincase to Main Frame Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90–100 122–136
Connecting Rod Bolts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–22 27–30
Control Pedal Linkage Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–22 27–30
Hydraulic Control Valve Mounting Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 23
Crankshaft Pulley Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101–116 137–157
Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–51 64–69
Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–43 54–59
Front Panel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–20 22–27
Fuel Camshaft Retainer Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6 6,8–8,1
Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8–10.8 7.8–14.7
Hydraulic Reservoir Strap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–20 22–27
Hydraulic Filter Housing Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 34
Hydrostatic Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65–70 88–95
Hydrostatic Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65–70 88–95
Idler Gear Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 9–11
Injection Pump Mounting Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–20 23–27
Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36–51 46–69
Injector Nozzle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43–58 59–79
Lift Cylinder Pivot Pin Retainer Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–20 24–27
Main Bearing Case Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36–40 49–54
Main Bearing Case Half Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.7–25.3 29.4–34.3
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–40 47–54
Operator Cab Fastening Nuts (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50 54–68
Operator Cab Pivot Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–35 34–47
Pedal Interlock Linkage Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 34
Pedal Linkage Locking Tab Mounting Bolt & Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 34
Pintle Arm Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50 54–68
Pintle Arm Lobe Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Pintle Bar Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 38
Pivot Pins Lock Bolt & Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–20 24–27
Rear Bearing Case Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–15 18–20
Seat Belt Fastening Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–45 54–61
Seat Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11 12,2–15
Seat Bar Pivot Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Steering Linkage Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 31
Steering Linkage Lock Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 31
Timing Gearcase Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2–8.3 9.8–11.3
Tilt Cylinder Pivot Pin Retainer Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–20 24–27
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105–115 142–156

553 Loader
Revised Mar. 02 –9–9– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
Use Melroe hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not
available, use 10W–30 or 10W–40 SAE Motor Oil (5W–30 for 0°F [–18°C] and
Below).

DO NOT use automatic transmission fluids in the loader or permanent damage to the
transmission will result.

Diesel fuel or hydraulic fluid under pressure can

penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be
visible. Use a piece of cardboard or wood to find
leaks. Do not use your bare hand. Wear safety
goggles. If fluid enters skin or eyes, get immediate
medical attention from a physician familiar with
this injury.
W–2072–0496

When temperatures below zero degree F (–18°C) are common, the loader must be
kept in a warm building. Extra warm–up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will not flow easily and it makes
action of the hydraulic function slower. Loss of fluid flow to the hydrostatic
transmission pump (indicated by TRANS light ON) can cause transmission damage
in less than 60 seconds.

During cold weather 32°F (0°C) and

below, do not operate machine until
the engine has run for at least five (5)
minutes at less than half throttle.
This warm–up period is necessary
for foot pedal operation and safe
stopping. Do not operate controls
during warm–up period. When
temperatures are below –20°F
(30°C), the hydrostatic oil must be
heated or kept warm. The
hydrostatic system will not get
enough oil at low temperatures. Park
the machine in an area where the
temperature will be above 0°F
(–18°C), if possible.
W–2027–1285

553 Loader
Revised Mar. 02 –9–10– Service Manual
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 METRIC TORQUE SPECIFICATIONS FOR BOLTS

Material
Thread Size
(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M 5 x 0.8 3–4 ft.–lbs.
(4–5 Nm)
M 6 x 1.0 6–7 ft.–lbs. 6–9 ft.–lbs.
(8–9 Nm) (8–12 Nm)
M 8 x 1.25 6–9 ft.–lbs. 11–16 ft.–lbs. 18–25 ft.–lbs.
(8–12 Nm) (15–22 Nm) (24–34 Nm)
M 10 x 1.25 13–18 ft.–lbs. 22–30 ft.–lbs. 36–50 ft.–lbs.
(18–24 Nm) (30–41 Nm) (49–68 Nm)
M 12 x 1.25 22–30 ft.–lbs. 40–54 ft.–lbs. 69–87 ft.–lbs.
(30–41 Nm) (54–73 Nm) (94–118 Nm)
M 14 x 1.25 36–50 ft.–lbs. 58–80 ft.–lbs. 116–137 ft.–lbs.
(49–68 Nm) (79–108 Nm) (157–186 Nm)

553 Loader
–9–11– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 STANDARD TORQUE SPECIFICATIONS FOR BOLTS
The following table shows standard torque specifications for bolts with zinc
phosphate coating. Bolts purchased from Melroe that have zinc phosphate coating
are specified by the letter H following the part number.

THREAD
SIZE SAE GRADE 5 SAE GRADE 8

INCH. .250 80–90 110–120

LBS. (9,0–10,2) (12,4–13,6)
(Nm)
.3125 180–200 215–240
(20,3–22,6) 24,2–27,1)
.375 25–28 35–40
(34–38) (47–54)
.4375 40–45 60–65
(54–61) (81–88)
.500 65–70 90–100
(88–95) (122–136)
.5625 90–100 125–140
(122–136) (170–190)
.625 125–140 175–190
(170–190) (240–260)
FOOT .750 220–245 300–330
LBS. (300–330) (410–450)
(Nm)
.875 330–360 475–525
(450–490) (645–710)
1.000 475–525 725–800
(645–710) (985–1085)
1.125 650–720 1050–1175
(880–975) (1425–1600)
1.250 900–1000 1475–1625
(1200–1360) (2000–2200)
1.375 1200–1350 2000–2200
(1630–1830) (2720–2980)
1.500 1500–1650 2600–2850
(2040–2240) (3530–3870)
1.625 2000–2800 3450–3800
(2720–2980) (4680–5150)
1.750 2500–2750 4300–4800
(3390–3730) (5830–6500)
1.875 3150–3500 5500–6100
(4270–4750) (7450–8300)
2.000 3800–4200 6500–7200
(5150–5700) (8800–9800)

553 Loader
–9–12– Service Manual
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 DECIMAL AND MILLIMETER EQUIVALENTS

FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 0.015625 — 0.397 33/64 0.515625 — 13.097
1/32 0.03125 — 0.794 17/32 0.53125 — 13.494
3/64 0.046875 — 1.191 35/64 0.546875 — 13.891
1/16 0.0625 — 1.588 9/16 0.5625 — 14.288
5/64 0.078125 — 1.984 37/64 0.578125 — 14.684
3/32 0.09375 — 2.381 19/32 0.59375 — 15.081
7/64 0.109375 — 2.778 39/64 0.609375 — 15.478
1/8 0.1250 — 3.175 5/8 0.6250 — 15.875
9/64 0.140625 — 3.572 41/64 0.640625 — 16.272
5/32 0.15625 — 3.969 21/32 0.65625 — 16.669
11/64 0.171875 — 4.366 43/64 0.671875 — 17.066
3/16 0.1876 — 4.762 11/16 0.6875 — 17.462
13/64 0.203125 — 5.159 45/64 0.703125 — 17.859
7/32 0.21875 — 5.556 23/32 0.71875 — 18.256
15/64 0.234375 — 5.953 47/64 0.734375 — 18.653
1/4 0.2500 — 6.350 3/4 0.7500 — 19.050
17/64 0.265625 — 6.747 49/64 0.765625 — 19.447
9/32 0.28125 — 7.144 25/32 0.78125 — 19.844
19/64 0.296875 — 7.541 51/64 0.796875 — 20.241
5/16 0.3125 — 7.938 13/16 0.8125 — 20.638
21/64 0.328125 — 8.334 53/64 0.828125 — 21.034
11/32 0.34375 — 8.731 27/32 0.84375 — 21.431
23/64 0.359375 — 9.128 55/64 0.859375 — 21.828
3/8 0.3750 — 9.525 7/8 0.8750 — 22.225
25/64 0.390625 — 9.922 57/64 0.890625 — 22.622
13/32 0.40625 — 10.319 29/32 0.90625 — 23.019
27/64 0.421875 — 10.716 59/64 0.921875 — 23.416
7/16 0.4375 — 11.112 15/16 0.9375 — 23.812
29/64 0.453125 — 11.509 61/64 0.953125 — 24.209
15/32 0.46875 — 11.906 31/32 0.96875 — 24.606
31/64 0.484375 — 12.303 63/64 0.984375 — 25.003
1/2 0.5000 — 12.700 1 1.000 — 25.400

1 mm = 0.03937’’ 0.001’’ = 0.0254 mm

U.S. TO METRIC CONVERSION

TO CONVERT INTO MULTIPLY BY
LINEAR Miles Kilometers 1.609
MEASUREMENT Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Millimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0.7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
WEIGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Pounds/Sq. In. Kilopascal 6.895
WORK Foot–Pounds Newton–Metre 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPERATURE Fahrenheit Celsius 1.Subtract 32°
2. Multiply by 5/9
553 Loader
–9–13– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC CONNECTION SPECIFICATIONS
A

When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
B–07575

O–ring Face Seal Connection

When the fitting is tightened, you can feel when the fitting B
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O–ring in position until the fittings are assembled [A]. Nut
Nut
Straight Thread O–ring Fitting
Washer Washer
Lubricate the O–ring before installing the fitting. Loosen
the jam nut and install the fitting. Tighten the jam nut until O–ring
the washer is tight against the surface [B]. O–ring
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will
restrict flow, which will slow hydraulic action and cause
heat. A–01852

Replace hoses which show signs of wear, damage or

weather cracked rubber. C
Always use two wrenches when loosening and tightening
hose or tubeline fittings. 1
Flare Fitting
Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat. Make 2
a mark across the flats of both the male and female parts
of the connection (Item 1) [C].
Use the chart below to find the correct tightness needed
(Item 2) [C]. If the fitting leaks after tightening, disconnect
it and inspect the seat area for damage. TS–01619

Flare Fitting Tightening Torque

Tubeline TORQUE NEW RE–ASSEMBLY
Outside Ft.–lbs. Rotate No. Rotate No.
Wrench Size Diameter Thread Size (Nm) of Hex Flats of Hex Flats
5/8’’ 5/16’’ 1/2’’ – 20 17 (23) 2–1/2 1
11/16’’ 3/8’’ 9/16’’ – 18 22 (30) 2 1
7/8’’ 1/2’’ 3/4’’ – 16 40 (54) 2 1
1’’ 5/8’’ 7/8’’ – 14 60 (81) 1–1/2 1
1–1/4’’ 3/4’’ 1–1/16’’ – 12 84 (114) 1 3/4
1–3/8’’ 1’’ 1–5/16’’ – 12 118 (160) 3/4 3/4

553 Loader
Revised Apr. 99 –9–14– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 HYDRAULIC CONNECTION SPECIFICATIONS
(Cont’d) A O–ring Flare
Primary
O–ring Flare Fitting Seal
The flare is the primary seal, the O–ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [A].
If necessary, the O–ring–flare fitting can be used without
an O–ring.
Use the following procedure to tighten the O–ring flare
fitting. Secondary
Seal
Tighten the nut until it contacts with the seat. Make a mark
P–13009
across the flats of both the male and female parts of the
connection (Item 1) [B].
Use the chart below to find the correct tightness needed
(Item 2) [B]. If the fitting leaks after tightening, disconnect
B Hex Flat Tightening Method

it and inspect the seat area for damage.

1

TS–01619

O–ring Flare Fitting Tightening Torque

* ** ***
Tubeline TORQUE NEW RE–ASSEMBLY
Outside Ft.–lbs. Rotate No. Rotate No.
Wrench Size Diameter Thread Size (Nm) of Hex Flats of Hex Flats
5/8’’ 5/16’’ 1/2’’ – 20 17 (23) 2–1/2 1
11/16’’ 3/8’’ 9/16’’ – 18 22 (30) 2 1
7/8’’ 1/2’’ 3/4’’ – 16 40 (54) 2 1
1’’ 5/8’’ 7/8’’ – 14 60 (81) 1–1/2 1
1–1/4’’ 3/4’’ 1–1/16’’ – 12 84 (114) 1 3/4
1–3/8’’ 1’’ 1–5/16’’ – 12 118 (160) 3/4 3/4

* If a torque wrench is used to tighten a new fitting to a ** If using the hex flat tightening method to tighten a new
used hose/tubeline. fitting to a new hose/tubeline.
* If a torque wrench is used to tighten a used fitting to a ** If using the hex flat tightening method to tighten a new
new hose/tubeline. fitting to a used hose/tubeline.
* If a torque wrench is used to tighten a new fitting to a *** If using the hex flat tightening method to tighten a used
new hose/tubeline. fitting to a new hose/tubeline.

553 Loader
Added Apr. 99 –9–15– Service Manual
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 HYDRAULIC CONNECTION SPECIFICATIONS
(Cont’d) A Copper Bonnet Orifice

O–ring Flare Fitting (Cont’d)

NOTE: O–ring flare fittings are not recommended in

all applications. Use the standard flare
fittings in these applications.
1

Do not use a O–ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from P–13572
sealing.
Use a standard flare fitting (Item 1) [A] as shown. B
When a O–ring flare fitting is used as a straight thread port
adapter the O–ring flare face is not used to seal. The 2
O–ring may come off the fitting and enter the system.
Always remove the O–ring (Item 1) [B] from the flare
face as shown.
An O–ring (Item 2) [B] is added to the flat boss of the
fitting to seal the connection in this application.

1
P–13573

553 Loader
Added Apr. 99 –9–16– Service Manual
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 HYDRAULIC CONNECTION SPECIFICATIONS A
(Cont’d)
Port Seal Fitting
The nut is the primary seal, the O–ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [A].
The hex portion of the nut does not contact the surface of
the component when the nut is tight.

Use the following procedure to tighten the port seal fitting:

Port seal and nut, washer and O–ring (O–ring Boss)
fittings use the same tightening torque valve chart. Nut Seals
to Fitting
If a torque wrench cannot be used, use the following
method.
Nut Seals
Tighten the nut until it just makes metal to metal contact, to Port
you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
Secondary O–ring Seal

NOTE: If a torque wrench cannot be used, use the P–13008

hex flat tightening method as an approximate
guideline.
Port Seal and O–ring Boss
NOTE: Port seal fittings are not recommended in all
applications. Use O–ring boss fittings in Tightening Torque
these applications.
Fitting TORQUE
Nut Ft.–lbs.
Wrench Size Thread Size (Nm)
11/16’’ 9/16’’ – 18 22 (30)
15/16’’ 3/4’’ – 16 40 (54)
1–1/8’’ 7/8’’ – 14 60 (81)
1–1/4’’ 1–1/16’’ – 12 84 (114)
1–1/2’’ 1–5/16’’ – 12 118 (160)

553 Loader
Added Apr. 99 –9–17– Service Manual
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 553ServiceManual(S/N516311001&Above)#6900450–SpecificationsSection

553 Loader
Added Apr. 99 –9–18– Service Manual
Downloaded from www.Manualslib.com manuals search engine
 553–1
® Revision Number

9 March 1998
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 553 (S/N 516311001 & Above) SALES MANAGER
Manual No. 6900450 (1–98)

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the 553 (516311001& Above) Service Manual P/N 6900450 (1–98).
Take out and put in the revised pages as listed below:
TAKE OUT PUT IN
4–3 thru 4–6 4–3, 4–4 (Revised Mar. 98),
4–5 (Revised Mar. 98), 4–6
7–1, 7–2 7–1 (Revised Mar. 98), 7–2 (Revised Mar. 98)
7–3, 7–4 7–3 (Revised Mar. 98), 7–4
7–31 thru 7–70 (Added Mar. 98)
8–15, 8–16 8–15, 8–16 (Revised Mar. 98)

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Downloaded from www.Manualslib.com manuals search engine
 553–2
® Revision Number

6 April 1999
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 553 (S/N 516311001 & Above) SALES MANAGER
Manual No. 6900450 (1–98)

NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.

The following pages are a revision to the above Service Manual. This update incorporates the Press To Operate Button
and Lift Arm Support Device Decal.
Take out and put in the revised pages as listed below:

TAKE OUT PUT IN

Cover Cover
Maintenance Safety Page Maintenance Safety Page
Alphabetical Index Alphabetical Index
i–x i–viii
Section 1 Section 1
2–1 thru 2–4 2–1 thru 2–4
DO NOT REMOVE the Hydraulic Schematics
in Section 2
2–17 thru 2–18 2–17 thru 2–18
2–33 thru 2–48 2–33 thru 2–48
3–5 thru 3–14 3–5 thru 3–14
3–25 thru 3–26 3–25 thru 3–26
Section 4 Section 4
7–5 thru 7–30 7–5 thru 7–30
Section 8 Section 8
9–1 thru 9–2 9–1 thru 9–2
9–13 thru 9–14 9–13 thru 9–18

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Downloaded from www.Manualslib.com manuals search engine
 553–3
Revision Number

8 March 2002
SERVICE MANUAL Date

REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER
SERVICE MANAGER X
Model 553 (S/N 516311001 & Above) SALES MANAGER
Manual No. 6900450 (1–98)

NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.

The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below:

TAKE OUT PUT IN REVISION DESCRIPTION

Cover Cover
Alphabetical Index Alphabetical Index
1–3, 1–4 1–3, 1–4 Added information
Glossary (1–3) Glossary (1–3)
2–13, 2–14 2–13, 2–14 Torque change
2–19 thru 2–22 2–19 thru 2–22 Torque change, text change
3–19 thru 3–22 3–19 thru 3–22 Text change
3–27, 3–28 3–27, 3–28 Text and photo change
5–1, 5–2 5–1, 5–2 Text change
5–13 thru 5–24 5–13 thru 5–26 Text change
6–3, 6–4 6–3, 6–4 Warning date change
7–1 thru 7–4 7–1 thru 7–4 Text change
7–15 thru 7–70 7–15 thru 7–74 Added information, page change
9–3 thru 9–6 9–3 thru 9–6 Text change
9–9, 9–10 9–9, 9–10 Text change

Printed in U.S.A.
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