453 6900363 SM 5-97 PDF

Service
Manual
Dealer Copy -- Not for Resale

S/N 515011001 & Above
S/N 515111001 & Above
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICSTM)
6900363 (5–97) Printed in U.S.A. © Bobcat Company 1997
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in 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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ALPHABETICAL INDEX
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . 1–1 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . 1–1 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1
AXLE, BEARINGS AND SPROCKET . . . . . . . . . . . . 4–1 OPERATOR CAB GAS CYLINDER . . . . . . . . . . . . . . . 5–1
AXLE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
AXLE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 PARKING BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . 4–1
BICS™ (With Press To Operate Button) . . . . . . . . . . 8–1 PARKING BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . 4–1
BICS™ (Without Press To Operate Button) . . . . . . . 8–1 PEDAL INTERLOCK LINKAGE . . . . . . . . . . . . . . . . . . 2–1
BICS™ BLOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 PISTONS AND CONNECTING ROD . . . . . . . . . . . . . 7–1
BICS™ SYSTEM CONTROLLER . . . . . . . . . . . . . . . . 8–1 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
CHAINCASE COVERS . . . . . . . . . . . . . . . . . . . . . . . . 4–1 RADIATOR MOUNTING BRACKET . . . . . . . . . . . . . . 7–1
CHAINCASE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 REAR LIGHTS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . 6–1
CONTROL SHIELD AND REAR WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
STEERING LEVER PANELS . . . . . . . . . . . . . . . . . . 3–1 REMOTE START SWITCH . . . . . . . . . . . . . . . . . . . . . . 1–1
CRANKSHAFT AND BEARINGS . . . . . . . . . . . . . . . . 7–1 ROCKER ARM AND SHAFT . . . . . . . . . . . . . . . . . . . . . 7–1
CRANKSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . 1–1
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
DECIMAL & MILLIMETER EQUIVALENTS . . . . . . . 9–1 SEAT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . 1–1

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . 6–1 STANDARD TORQUE SPECIFICATIONS
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
ENGINE COMPRESSTION TEST . . . . . . . . . . . . . . . 7–1 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . 1–1 STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . 1–1 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
ENGINE MOUNTING BRACKET . . . . . . . . . . . . . . . . 7–1
ENGINE OIL COOLER AND SHROUDING . . . . . . . 7–1 TENSION PULLEY AND SPRING . . . . . . . . . . . . . . . . 3–1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 9–1 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . 7–1 TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
TIMING GEARCASE COVER . . . . . . . . . . . . . . . . . . . . 7–1
FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . 1–1 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . 1–1
FRONT LIGHTS (OPTIONAL) . . . . . . . . . . . . . . . . . . 6–1 TORQUE SPECIFICATION FOR BOLTS . . . . . . . . . . 9–1
FUEL CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . 7–1 TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . . 1–1
FUEL INJECTOR NOZZLES . . . . . . . . . . . . . . . . . . . . 7–1 TROUBLESHOOTING . . . . . . . . . . . . 2–1, 3–1, 6–1, 7–1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 7–1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . . 9–1
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
VALVE & VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . 7–1
HYDRAULIC CONNECTION SPECIFICATION . . . . 9–1 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . 2–1 VALE GUIDE, VALVE & VALVE SEAT . . . . . . . . . . . . . 7–1
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC FILTER BLOCK . . . . . . . . . . . . . . . . . . . 2–1 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
HYDRAULIC/HYDROSTATIC
FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 9–1
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . 1–1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . 2–1
HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . 3–1
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . 3–1
IDLER GEAR AND CAMSHAFT . . . . . . . . . . . . . . . . . 7–1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . 1–1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
LIFT CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
LIFTING AND BLOCKING THE LOADER . . . . . . . . 1–1
LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . 1–1
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 9–1
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . 1–1
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CONTENTS
PREVENTIVE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii MAINTENANCE
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
SYSTEMS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
DRIVE
CALIFORNIA SYSTEM
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm. MAIN
FRAME

ELECTRICAL
SYSTEM
ENGINE
SERVICE
SYSTEMS
ANALYSIS
SPECIFICATIONS
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FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. 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.
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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.
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Revised Mar. 99
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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–2003–0199
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.
SIO5–0299
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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
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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 on the right fender and in front of the seat
[A].
P–04399
Explanation of loader Serial Number:
XXXX XXXXX
Module 2. – Production
B
Sequence (Series)
Module 1. – Model/Engine
Combination
ENGINE SERIAL NUMBER

The engine serial number is located on the engine fuel
injection pump. [B].
P–09791
DELIVERY REPORT
C
The Delivery Report must be filled out by the dealer and
signed by the owner or operator when the Bobcat loader
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [C].
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BOBCAT SKID STEER LOADER IDENTIFICATION
453ServiceManual#6900363(S/N515011001&Above)–ContentsSection
◊ OPERATING LIGHTS
SEAT BAR
GRAB OPERATOR
HANDLES HANDBOOK
STEERING OPERATOR
LEVER SEAT
SAFETY TREAD

TILT CYLINDER
BUCKET
OPERATOR CAB
◊ OPERATING LIGHT (ROPS & FOPS)
UPRIGHTS
LIFT ARM SUPPORT
DEVICE
LIFT ARMS
REAR DOOR LIFT

CYLINDER
B–14268
TIRES* B–14269
◊ FACTORY OPTION OR FIELD ACCESSORY (Not Standard Equipment)

* TIRES – Flotation tires (Optional) are shown. Bobcats are base–equipped with standard tires.
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. The Bobcat loader is base–
equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise
level).
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PREVENTIVE MAINTENANCE
PREVENTIVE
Page MAINTENANCE
Number
AIR CLEANER SERVICE
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13
ALTERNATOR BELT
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19
AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24

BOB–TACH
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27
ENGINE COOLING SYSTEM

Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18
Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18
ENGINE LUBRICATION SYSTEM

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17

FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24
FUEL SYSTEM
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20
Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 1–21
Replacing The Hydraulic/Hydrostatic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 1–21
LIFT ARM SUPPORT DEVICE
Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Disengaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . 1–8
LIFTING AND BLOCKING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
LUBRICATING THE LOADER

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–25
OPERATOR CAB
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Continued On Next Page
453 Bobcat Loader

15 of 294Jan. 01
Revised –1–1– Service Manual
PREVENTIVE MAINTENANCE (Cont’d)
Page
Number
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27
REMOTE START SWITCH
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28
SEAT BAR RESTRAINT SYSTEM

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
SERVICE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
SPARK ARRESTOR MUFFLER
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22
TIRE MAINTENANCE
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23

TOWING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
TRANSPORTING THE LOADER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
453 Bobcat Loader

16 of 294Jan. 01
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 50 100 250 500 1000

Engine Air Cleaner Empty the dust cup & replace the filter element as needed.
Engine Oil Check the oil level & add oil as needed.
Engine Cooling System Clean debris from oil cooler and radiator. Check coolant level
in recovery tank and add as needed.
Tires Check the air pressure & for damaged tires.
Indicators, Gauges Check for correct operation of all indicators, gauges &

& Lights (Opt.) lights (Opt.).
Seat Belt and Seat Bar Check the condition of seat belt. Check the seat bar & pedal
interlocks for correct operation. Clean dirt and debris from
moving parts.
Safety Signs (Decals) and Check for damaged signs and safety treads. Replace any
Safety Tread signs or safety treads that are damaged or worn.
Lift Arm and Bob–Tach Lubricate with multi–purpose lithium based grease.
Pivot Pin and Wedges
Engine Fuel Filter Remove the water from the filter.
Hyd. Fluid, Hoses & Check fluid level & add as needed. Check for damage &
Tubelines leaks. Repair & replace as needed.
Bobcat Interlock Control Check BICS™ System Controller functions. Clean dirt,
System (BICS™) debris or objects from under or behind seat as required.
Battery Check cables, connections & electrolyte level. Add distilled
water as needed
Control Pedals & Steering Check for correct operation repair or adjust as needed.
Bob–Tach Check locking levers & wedges for condition & operation.
Wheel Nuts Check for loose wheel nuts & tighten to 40–45 ft.–lbs.
(54–61 Nm) torque.
Parking Brake Check operation.
Alternator Belt Check tension & adjust as needed.
Engine Oil & Filter Replace oil & filter. See engine Oil Chart.
Hydraulic Filter Element Replace filter element.
Spark Arrestor Muffler Clean the spark chamber.
Drive Belt Check drive belt for condition and tension.
Steering Lever Pivots Lubricate grease fittings and oil hole in the steering shaft.
Engine Fuel Filter Replace filter element.
Hydraulic Reservoir Breather Replace the breather cap.
Final Drive Trans (Chaincase) Replace the fluid.
Hydraulic/Hydrostatic
Reservoir 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.
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17 of 294Mar. 99
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 [A].
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
Put a floor jack under the rear of the loader [B].
Lift the rear of the loader and install jackstands [B].
P–07288
Put the floor jack under the front of the loader [C].
C
Lift the front of the loader and put jackstands under the
loader frame.
NOTE: Make sure the jackstands do not touch the

tires.
P–07289
453 Bobcat Loader

18 of
Revised Mar. 99294 –1–4– Service Manual
TRANSPORTING THE LOADER
Procedure
A
Be sure the transport and towing vehicles are of adequate
size and capacity.
Adequately designed ramps of sufficient

strength are needed to support the weight of
the machine when loading onto a transport SUPPORT B–06198
vehicle. Wood ramps can break and cause
personal injury.
W–2058–0494
B
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
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
during sudden stops or when going up or down slopes [B].
Fully lower any bucket or attachment. Stop the engine.
Engage the parking brake.
P–09921
Fasten chains at the front using the slots in the axle
gussets [B]. Couterweight is removed (Inset) to show
clarity. DO NOT operate with counterweight removed.
P–09926
P–09927
B–6200
Fasten the rear of the loader as shown with a loop of chain

trhough the tie down provided [C]. C
P–09925 P–09924
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TOWING THE LOADER
Procedure
A
To prevent damage to the loaders hydrostatic system, the
loader must be towed only a short distance at slow speed.
(Example: Moving the loader onto a transport vehicle).
Relief valve release tool set MEL1220 is available from
your dealer. Tool must be installed before towing.
Raise the operator cab. (See Page 1–9 for the correct
procedure.)
Clean the area around the hydrostatic pumps.
E–01457
Remove the high pressure relief valve from one side of B–06924
each hydrostatic pump [A] and install the relief valve
tubes. Install the plugs and tighten.
The towing chain (or cable) must be rated at 1–1/2 times
the weight of the loader. (See SPECIFICATIONS Page
9–1.)
Turn the key switch to ON and press the traction
lock override button.
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
Bobcat loader dealer. (Part of the brake system must be
disassembled to move the loader.)
Do not push or pull the machine at more than

2 MPH (3,2 km/h) or for a distance of more than
25 feet (7,6 meters) with the towing tool in
place.
I–2017–0389
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20 of
LIFT ARM SUPPORT DEVICE
1. A
P–09773 P–07139
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 1
lift arms or attachment to fall and cause injury
or death. W–2059–0598
Engaging The Lift Arm Support Device

Put jackstands under the rear corners of the loader (Inset)
[A].
Disconnect the spring from the lift arm support device
retaining pin (Item 1) [A], hold the support device and P–09810
remove the retaining pin.
Lower the lift arm support device on top of the lift cylinder.
Fasten the free end of the spring (Item 1) [B] to the lift arm C
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. Loader without seat
sensors press the green PRESS TO OPERATE Button.
Raise the lift arms until the lift arm support device drops
onto the lift cylinder rod [C].
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move pedals until both pedals P–09800
lock.
Install the retaining pin (Item 1) [D] into the rear of the lift D
arm support device below the cylinder rod.
Service lift arm support device if damaged or if

parts are missing. Using a damaged lift arm
support or with missing parts can cause lift 1
arms to drop causing injury or death.
W–2271–1197
P–09808
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LIFT ARM SUPPORT DEVICE (Cont’d)
Disengaging The Lift Arm Support Device
A
Remove the retaining pin (Item 1) [A] from the lift arm
support device.
P–09808
Connect the spring from the lift arm support device to the
tubeline bracket (Item 1) [B] on the lift arms.
B
bar lowered, start the engine. Loaders without seat
sensor press the green PRESS TO OPERATE Button.
Raise the lift arms a small amount and the spring will lift 1
the support device off the lift cylinder rod. Lower the lift

arms. Stop the engine.
Raise the seat bar and move pedals until both pedals
lock.
Disconnect the spring from the bracket.
P–09807
Raise the support device into storage position and insert C

pin through lift arm support device and bracket (Item 1)
[C].
Connect spring to pin [C].
1
P–07139
453 Bobcat Loader

Revised Mar. 99294
22 of –1–8– Service Manual
OPERATOR CAB
Description
A
1
The Bobcat loader has an operator cab (ROPS and
FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer
if the operator cab has been damaged. The seat belt must
be worn for roll over protection.
ROPS/FOPS Roll Over Protective Structure per SAE
J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449, Level l.
Level l – Protection from falling bricks, small concrete
blocks and hand tools encountered in operations such as
highway maintenance, landscaping, and other P–09771
construction site services.
Check with your dealer if the operator cab has been
changed.
B
The operator cab fastening nuts (Item 1) [A] must be
tightened to 40–50 ft.–lbs. (54–68 Nm) torque.

Before the cab or the lift arms are raised for
service, jackstands must be put under the rear
corners of the frame. Failure to use jackstands P–09773
can allow the machine to tip backward causing
injury or death.
W–2014–0895
Raising The Operator Cab

Stop the loader on a level surface. Put the lift arms all the
way down.
Install jackstands under the rear of the loader frame [B].
Never modify operator cab by welding,
Open the rear door. (See REAR DOOR Page .) grinding, drilling holes or adding attachments
unless instructed to do so by Melroe
If the lift arms must be up while raising the cab, install the Company. Changes to the cab can cause loss
lift arm support device. (See Engaging The Lift Arm of operator protection from rollover and falling
Support Device Page 1–7.) objects, and result in injury or death.
W–2069–1285
Remove the two fasteners (Item 1) [A] at the front (both
sides) of the operator cab.
Stand on the ground. Lift slowly until operator cab is all the
way up [B].
The operator cab will lock in the raised position.
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OPERATOR CAB (Cont’d)
Lowering The Operator Cab
A
1
Hold the operator cab. Release the locking mechanism by
pushing the lever (Item 1) [A] inward from the locked
position (Item 2) [A] and turning the lever until it stays in 2
the unlocked position [B].
The cab must be held to prevent falling while P–09823

hand is in access hole.
W–2205–0695
B
REMOVE YOUR HAND FROM THE HOLE BEFORE
LOWERING THE OPERATOR CAB
Stand on the ground and pull down on the operator cab.
Avoid slippery surfaces when lowering the cab.

NOTE: Guide the operator cab over the fastening
bolts to prevent thread damage.
P–09825
Install the cab washers and nuts. Tighten the nuts (Item
1) [C] (both sides) to 40–50 ft.–lbs. (54–68 Nm) torque. C
1
P–09771
453 Bobcat Loader

24 98
Revised Oct. of 294 –1–10– Service Manual
Emergency Exit
A
The front opening on the operator cab and rear window
provide exits.
Pull on the tag at 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–09829
Exit through the rear of the operator cab [B]. B

P–09774
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25 of 294
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. 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.
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
Inspectng The Seat Bar

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
PRESS TO OPERATE Button. Operate each foot pedal
to check both the lift and tilt functions. Raise the lift arms
P–09790
until the bucket is about 2 feet (600 mm) off the ground.
Raise the seat bar, try to move each pedal. The pedals
must be firmly locked in neutral position. There must be
no motion of the tilt (bucket) or the lift arms when the
B
pedals are pushed.
Pull the seat bar down, Loaders without seat sensors
press the green PRESS TO OPERATE Button and lower
the lift arms. Operate the lift pedal. While the lift arms are
going up, raise the seat bar and the lift arms should stop.
Lower the seat bar, Loaders without seat sensors press
the green PRESS TO OPERATE Button, lower the lift
arms and put the bucket flat on the ground. Stop the
engine. Raise the seat bar and operate the foot pedals to
be sure that the pedals are firmly locked in the neutral
position. Unbuckle the seat belt.
P–04400
Maintaining The Seat Bar

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.
453 Bobcat Loader

Revised Mar. 99294
AIR CLEANER SERVICE
Replacing Filter Element
A
See the SERVICE SCHEDULE Page 1–3 for the interval
to service the air cleaner system.
Check the air intake hose for damage. Check the air
cleaner housing for damage. Check to make sure all
connections are tight.
Service the air cleaner as follows:
Loosen the wing nut (Item 1) [A].
1
P–09767
Remove the cover (Item 1) [B], remove the dust cup (Item
2) [B]. Empty the debris from the dust cover. B

2 1
P–09768
Remove the wing nut (Item 1) [C] from the air filter.
C
P–09766
Remove the air filter (Item 1) [D].

D
NOTE: Make sure all sealing surfaces are free of dirt
and debris.
1
Install a new air filter using the wing nut.
Install the dust cup and cover.
P–09765
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27 of 294
FUEL SYSTEM
A
Fuel Specifications
Use only clean, high quality diesel fuel, Grade No. 2 or 2
Grade No. 1.
The following is one suggested blending guideline which
should prevent fuel gelling problems:
1
Temp. F°/C° No. 2 No. 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–09831
local recommendations.
The fuel gauge (Item 1) [A] and the fuel shut off valve
(Item 2) [A] are located on the right side of the loader. B

Stop and cool the engine before adding fuel. 1
NO SMOKING! Failure to obey warnings can
cause an explosion or fire.
W–2063–0887
Filling The Fuel Tank P–09830
Remove the fuel fill cap (Item 1) [B].

Use a clean, approved safety container to add fuel of the
C WRONG
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 (Item 1) [B].
B–06108
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
453 Bobcat Loader

28 of
Revised Jan. 01294 –1–14– Service Manual
FUEL SYSTEM (Cont’d)
A OFF
1
ON
W–2103–1285
P–09831
Fuel Filter
Drain Water: B
See the SERVICE SCHEDULE Page 1–3 for the service
interval when to remove the water from the fuel filter.
Turn the fuel shut–off valve (Item 1) [A] clockwise to shut
off the fuel supply.

Loosen the drain (Item 1) [B] at the bottom of the filter
element to drain the water from the filter. Close the drain.
Open the shut–off valve (Item 1) [A] to turn on the fuel
supply. 1
Replace Fuel Filter: P–09880

interval when to replace the fuel filter.
Clean the area around the fuel filter.
Close the shut–off valve (Item 1) [A].
Remove the fuel filter [B].
NOTE: Be sure the filter gasket is removed with the

old fuel filter.
Install the new filter element hand tight.

Open the shut–off valve (Item 1) [A].
453 Bobcat Loader

29 of 294
FUEL SYSTEM (Cont’d)
Removing Air From The Fuel System
A
After replacing the fuel filter element or when the fuel tank 1
has run out of fuel, the air must be removed from the fuel
system before starting the engine.
Open the rear door. The engine must be cool.
2
Open the vent plug (Item 1) [A].
Operate the hand pump (priming bulb) (Item 2) [A] until
fuel flows from the vent plug with no air bubbles.
Close the vent plug.
P–09880
bar lowered, and parking brake engaged, start the
engine. B
NOTE: If engine fails to start, remove air from the
fuel injection pump as follows:
Put jackstands under the rear of the frame. (See Page
1–4.)
Raise the operator cab. (See Page 1–9.)
1

Open the valve (Item 1) [B] on the injector pump and
squeeze the hand pump several times until fuel flows from
the valve.
Close the valve (Item 1) [B]. P–09912
Lower the operator cab. (See Page 1–10.)
Start the engine.

W–2103–1285
453 Bobcat Loader

30 of
ENGINE LUBRICATION SYSTEM
A
Checking Engine Oil
Check the oil level every day.
2 1
Stop the engine 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.)
Oil Chart
RECOMMENDED SAE VISCOSITY NUMBER
C° (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE) P–09892
–40 –34 –29 –23 –18 –13 –7 –1 +4 +10 +15 +21 +27 +32 +38 +43 +49
SAE 40W or 20W–50

B
SAE 10W–30
SAE 15W–40
SAE 30W
* SAE 5W–30

SAE 20W–20
SAE 10W
SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

P–09882
–40 –30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120
F°
TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API C
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 1
interval for replacing the engine oil and filter.
Run the engine until it is at operating temperature. Stop
the engine.
Open the rear door and remove the cap from the end of
the hose. Drain the oil into a container [B].
P–09874
Remove the filter (Item 2) [A].
Clean the filter housing surface. Put clean oil on the
gasket of the new filter. Install the filter and hand tighten.
Install and tighten the cap on the drain hose.
Turn the oil fill cap (Item 1) [C] counterclockwise to
remove the cap.
Fill to capacity. (See SPECIFICATION Section Page
9–1.)
Start the engine and let it run for about 5 minutes. Check
for leaks at the filter. Check the oil level. Add oil until the
level is at the FULL mark on the dipstick. Install the oil fill
cap (Item 1) [C].
NOTE: DO NOT overfill the crankcase.
453 Bobcat Loader
31 of 294
ENGINE COOLING SYSTEM
Check the cooling system every day to prevent
A
overheating, loss of performance or engine damage.
Checking The Coolant Level

Open the rear door. 1
The coolant recovery tank (Item 1) [A] is located between
the radiator and the right upright.
The coolant level in the recovery tank must be between
the maximum and minimum mark when engine is cool.
NOTE: The loader is factory filled with propylene P–09816

glycol coolant. DO NOT mix propylene glycol
with ethylene glycol.
Add premixed coolant; 47% water and 53% propylene B

glycol to the recovery tank if the coolant level is low.
One gallon and one pint of propylene glycol mixed with
one gallon of water is the correct mixture of coolant to
provide a –34°F (–37°C) freeze protection.
1
Use a refractometer to check the condition of propylene
glycol in your cooling system.

NOTE: Coolant testing strips are available for
checking the coolant condition. (See your
Bobcat loader dealer.)
P–09881
Cleaning The Cooling System
Open the rear door.
C
Use safety goggles when using air or water

under pressure. Do not use cold water to clean
a hot engine. Failure to obey warnings can
cause serious injury.
W–2064–1285
Use air pressure or water pressure to remove the debris P–09818

in the area of the radiator and oil cooler.
If debris is a problem, check with your dealer about the
special debris screens.
D
Replacing the Coolant
Open the rear door.
Place the drain hose (Item 1) [B] into a clean container. 1

Remove the radiator cap [C].
Open the drain valve (Item 1) [D]. Located on the front
engine by the fuel lift pump. Turn the valve
counterclockwise to open. P–09806
453 Bobcat Loader

Revised Jan. 01294
ALTERNATOR BELT
A 1
Adjusting The Alternator Belt
Stop the engine.
Loosen the mounting bolts (Item 1) [A] to move the
alternator.
1
P–09895
Set the belt tension to 1/4 inch (6 mm) movement

B
between pulleys with 15 pounds (67 N) of force [B].
Tighten the adjustment bolts.

P–09770
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33 of 294
HYDRAULIC/HYDROSTATIC SYSTEM
A
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
1
Checking And Adding Fluid
Use only recommended fluid in the hydraulic system.
(See SPECIFICATIONS Page 9–1 for the correct fluid.)
Stop the loader on a level surface. Lower the lift arms and
tilt the Bob–Tach fully back.

Stop the engine.
Open the rear door. Remove the dipstick (Item 1) [A].
The fluid level is correct if the fluid level is between the
marks on the dipstick.
P–09865
NOTE: The dipstick may indicate an incorrect level

of fluid when first removed because of
expansion or contraction of oil in the fill tube.
Always (1) remove the dipstick, (2) wipe the
dipstick, (3) insert the dipstick again and (4)
re–check the fluid level.
If fluid is needed , remove the dipstick (Item 1) [A] and add

fluid to the reservoir until the level is correct.
453 Bobcat Loader

Revised Jan. 01294
HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)
A
Hydraulic/Hydrostatic Filter Replacement
See the SERVICE SCHEDULE Page 1–3 for the correct
service interval.
Stop the engine. Open the rear door. Raise the operator 1
cab. (See Page 1–9 for the correct procedure.) Clean the
area around the filter housing. Remove the plug (Item 1)
[A] from the filter housing (located on the outside of the
loader at the right side).
After the fluid is drained from the filter, install the plug
(Item 1) [A] and tighten.
P–07302
Remove the filter element (Item 1) [B]. B

Clean the surface of the filter housing where the filter
element seal contacts the filter housing.
Put grease on the seal of the filter element, install the
element and hand tighten only. 1
Lower the operator cab.

Start the engine and operate the loader through the
hydraulic and hydrostatic functions. Stop the engine.
Check the fluid level and add fluid to the reservoir as
needed.
P–07527
Replacing The Hydraulic/Hydrostatic Fluid
interval to replace the fluid. The fluid must also be
C
replaced if it becomes contaminated and after any major
repairs.
Stop the engine. Open the rear door.
Remove the fill cap/dipstick.
Loosen the nut (Item 1) [C] which fastens the fill tube to
the loader frame.
1
Loosen the clamp at the fill tube, turn the fill tube down to
drain the fluid from the reservoir [C].
After the fluid is removed, put the fill tube in the correct P–09863
position, tighten the hose clamp and tighten the bolt.
Replace the hydraulic filter element.
Add hydraulic/hydrostatic fluid to the reservoir. (See
SPECIFICATIONS, Page 9–1 for the correct fluid.)
Do Not over fill the reservoir.
453 Bobcat Loader

35 of 294
SPARK ARRESTOR MUFFLER
A
See the SERVICE SCHEDULE Page 1–3 for correct
service interval. Do not operate the loader with a defective
exhaust system.
Cleaning Procedure
1
Stop engine and allow the muffler to cool
before cleaning the spark chamber. Wear P–09764
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
This loader is factory equipped with a U.S.D.A.

Forestry Service approved spark arrestor
muffler. It is necessary to do maintenance on
Stop the engine. Open the rear door. this spark arrestor muffler to keep it in working
condition. The spark arrestor muffler must be
Remove the plug (Item 1) [A] from the bottom of the serviced by dumping the spark chamber every
muffler. 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
Never use machine in atmosphere with spark arrestor requirements.
explosive dust or gases or where exhaust can I–2022–0595
contact flammable material. Failure to obey
warnings can cause injury or death.
W–2068–1285
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
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.
453 Bobcat Loader

36 of
TIRE MAINTENANCE
Wheel Nuts
A
interval to check the wheel nuts. The correct torque is
40–45 ft.–lbs. (54–61 Nm) torque.
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 B–09976
to the front [C].
It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
turning at a different rate and cause 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 Inflate tires to the MAXIMUM pressure shown
capability. Check for the correct pressure before on the sidewall of the tire. DO NOT mix brands
operating the loader. of tires used on the same loader.

I–2057–0794
Tire Inflation
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.
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 excessive
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.
Do not inflate tires above specified pressure.

Failure to use correct tire mounting procedure
can cause an explosion which can result in
injury or death. W–2078–1285
453 Bobcat Loader

37 of 294
FINAL DRIVE TRANSMISSION (CHAINCASE)
The chaincase contains the final drive sprockets and the
A
chains and is filled with the same type of fluid as is used
in the hydraulic system. (See SPECIFICATIONS, Page 1
9–1.)
Checking And Adding Oil
Put the loader on a level surface.Remove the plug (Item
1) [A] from the front of the chaincase. If the fluid can be
reached with the tip of your finger through the hole, the
level is correct.
Add fluid through the check plug hole until the fluid flows
from the hole. Install and tighten the plug.
P–07561
AUXILIARY CONTROL LOCKBOLT

The Auxiliary control has a lockbolt (Item 1) [B] that must
B
be removed to use the optional auxiliary hydraulics.
Remove the nut and bolt (Item 1) [B] from the right hand 1
steering lever.

P–09787
453 Bobcat Loader

38 of
LUBRICATING THE LOADER
453ServiceManual#6900363(S/N515011001&Above)–PreventiveMaintenanceSectionPart1of2
Procedure
A
Lubricate the loader as specified in the SERVICE
SCHEDULE Page 1–3 for the best performance of the
loader.
Record the operating hours each time you lubricate the 1
Bobcat loader.
Always use a good quality lithium based multi–purpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader:
P–07548
Base End Lift Cylinder (Item 1–Both sides) [A].
B
Rod End Lift Cylinder (Item 1–Both sides) [B].

1
P–07549
Lift Arm Pivot Pin (Item 1–Both sides) [C].

C
P–07553
Rod End Tilt Cylinder (Item 1) [D].

D
P–07560
453 Bobcat Loader

39 of 294
LUBRICATING THE LOADER (Cont’d)
Procedure (Cont’d)
A
1
Base End Tilt Cylinder (Item 1) [A].
P–07552
Bob–Tach pivot pins (Item 1) [B] (Both sides). B

P–07150
Steering shaft pivot bearings (Item 1) [C] (Both sides).

C
NOTE: If the steering levers do not move freely, see
page 3–1 to disassemble and lubricate the
plastic bushings. 1
P–07554
453 Bobcat Loader

40 of
PIVOT PINS
All pivot pins, lift arms and cylinders have a large pin held
A
in position with lockbolts and retainer (Item 1) [A] & [B].
Check that the lockbolts are tightened to 8–10 ft.–lbs.
Do not over–tighten.
1
P–07161

1
P–07173
BOB–TACH
Inspection And Maintenance C 1
Move the Bob–Tach lever to engage the wedges [C]. The
levers and wedges must move freely.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [D].
P–09887
Bob–Tach wedges must extend through the
holes in attachment. Lever(s) must be fully
down and locked. Failure to secure wedges can
allow attachment to come off and cause injury D
or death.
W–2102–0497
Inspect the mounting frame on the attachment and the

Bpb–Tach, linkages and wedges for excessive wear or
damage. Replace anyu parts that are damaged, bent, or
missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for 1
repair or replacement parts.
Lubricate the wedges (See SERVICE SCHEDULE,Page
1–3 and LUBRICATION OF THE BOBCAT LOADER,
Page 1–25.) P–09889
453 Bobcat Loader

Revised Jan. 01
41 of 294 –1–27– Service Manual
REMOTE START SWITCH
A
Procedure
The tool listed will be needed to do the following
procedure:
MEL1429–B – Remote Start Switch Kit
Kit Includes:
1
MEL1429–1 Adapter
MEL1429–2 Start Switch
MEL1429–3 Adapter
The Remote Start Switch is required when the operator
cab is in the raised position for service and the service
technician needs to start the engine. The operator cab
wire harness connectors must be separated from the
engine wiring harness connector under the cab.
The remote start switch is required when the service
technician is adjusting the steering linkage and checking
the hydraulic/hydrostatic system.

the machine to fall or move and cause injury or P–07523
death.
W–2017–0286
Lift and block the loader. (See Page 1–4.)
Never work on a machine with the lift arms up

approved lift arm support device can allow the
or death. W–2059–0598
Raise the lift arms and install the lift arm support device.
(See Page 1–7.)
Connect the remote start switch to the connectors (Item
1) [A].
453 Bobcat Loader

42 of
REMOTE START SWITCH (Cont’d)
Procedure (Cont’d)
A
NOTE: On late model loaders, the connector on the
BICS™ harness is a round 7–pin connector,
NOT a rectangular 8–pin connector. Use the
adapter (Item 1) [A] if your loader has a round
7–pin BICS harness connector.
1
P–07101
Put the traction lock override switch (Item 1) [B] in the ON

position so the traction function is locked. The wheels are B
not able to turn. 1
Turn the key to the right and start the engine.

P–04713
Move the traction lock override switch (Item 1) [C] to the

OFF position so the traction function is unlocked. The C
wheels are now able to turn. 1
P–04714
453 Bobcat Loader

43 of 294
453ServiceManual#6900363(S/N515011001&Above)–PreventiveMaintenanceSectionPart2of2
453 Bobcat Loader

44 of01
HYDRAULIC SYSTEM
Page
Number
BICS™ BLOCK VALVE
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16 HYDRAULIC
SYSTEM
CONTROL PEDALS
Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42
HYDRAULIC CONTROL VALVE
Anti–Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
Auxiliary Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24
Lift Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25
Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26
Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32
Tilt Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31

HYDRAULIC CYLINDERS
Lift Cylinder Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
Tilt Cylinder Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13
HYDRAULIC FILTER BLOCK

HYDRAULIC PUMP
Checking The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . 2–33
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–36
HYDRAULIC RESERVOIR
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic/Hydrostatic Symbols For Loaders . . . . . . . . . . . 2–3
LIFT CYLINDER(S)
Checking The Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
453 Bobcat Loader

45 of 294Mar. 99
HYDRAULIC SYSTEM (Cont’d)
Page
Number
MIAN RELIEF VALVE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Checking The Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20
Checking The Main Relief Valve With Auxiliaries . . . . . . . . . . . . . . . . . . 2–21
PEDAL INTERLOCK LINKAGE

TILT CYLINDER
Checking The Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
453 Bobcat Loader

46 of 294Mar. 99
HYDRAULIC SYSTEM INFORMATION
453 Bobcat Loader

47 of 294Mar. 99
HYDRAULIC SYSTEM INFORMATION (Cont’d)
453 Bobcat Loader

Revised Mar.
48 of99
294 –2–4– Service Manual
HYDRAULIC SYSTEM INFORMATION (Cont’d)
453 Bobcat Loader

49 of 294Mar. 99
453 Bobcat Loader

50 of99
HYDRAULIC/HYDROSTATIC SCHEMATIC
453 (S/N 515011001-13712)
(S/N 515111001-13619)
(PRINTED JANUARY 2001)
V-0059legend
LEGEND
1 RESERVOIR: 17 ANTICAVITATION VALVE
Capacity . . . . . . . . . 5.3 Qts. (5,0 L)
18 FILTER - BICS CONTROL VALVE
2 FILTER - HYDRAULIC/HYDROSTATIC
(CANISTER)
19 CHECK VALVE - BICS CONTROL VALVE
3 CHARGE PRESSURE SWITCH:
17-21 PSI (118-144 kPa) 20 SOLENOID ACTIVATED DIRECTIONAL
4 TEMPERATURE SWITCH CONTROL VALVE - BICS CONTROL
225-232 degrees F. 21 PULL BUTTON ACTIVATED
(108-111 degrees C.) DIRECTIONAL CONTROL VALVE - LIFT
5 RELIEF VALVE - CHARGE: ARM BY PASS
85 PSI (586 kPa)
6 BY PASS VALVE - COOLER:
275 PSI (1896 kPa) 23 PILOTED ACTIVATED DIRECTIONAL

7 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - LIFT CONTROL
BIDIRECTIONAL HYDRAULIC/
HYDROSTATIC MOTOR 24 PILOTED ACTIVATED DIRECTIONAL
8 CONTROL VALVE - TILT CONTROL
VARIABLE CAPACITY DISPLACEMENT
HYDROSTATIC PUMP 25 CHECK VALVE - BUCKET POSITION
VALVE
9 HYDRAULIC PUMP:
Gear Type . . . 6.8 GPM (25,7 L/min.) 26 FLOW DIVIDER ADJUSTMENT VALVE
at 3000 RPM
10 RELIEF/REPLENISHING VALVE - HIGH 27 RESTRICTION - HYDRAULIC FILTER
PRESSURE: 3400 PSI (23440 kPa)
11 REPLENISHING VALVE
12 RELIEF VALVE - MAIN:

1400-1450 PSI (9652-9996 kPa)
at Front Quick Couplers
13 LOAD CHECK VALVE
14 PILOTED ACTIVATED DIRECTIONAL

CONTROL VALVE - FLOW CONTROL
SPOOL
15 CHECK VALVE - BUCKET POSITION

VALVE NOTE: Unless otherwise specified
springs have NO significant
pressure value.
CONTROL VALVE - UNLOADING
SPOOL
Printed in U.S.A. V-0059legend (1-10-01)
51 of 294
52 of 294
453 (S/N 515011001-13712) BUCKET POSITION VALVE (OPTIONAL)
(S/N 515111001-13619)
(PRINTED JANUARY 2001) D
V-0059 15
2 MALE
HYDRAULIC
FILTER
(FRONT AUXILIARY
QUICK COUPLERS)
DRIVE MOTOR 26
3
FEMALE
27
A
7
4
OIL COOLER
C
14
5 25
HYDROSTATIC PUMPS 16
8 B
HYDRAULIC CONTROL VAVLE
11
10 TILT CYLINDER
AUXILIARY
SPOOL
INLET 13
11
10
BICS CONTROL VALVE
8 Dealer Copy -- Not for Resale

17
P2 B1
24
9 TILT
INLET OUTLET CYLINDER
SPOOL
13
23 LIFT CYLINDERS
DRIVE MOTOR
P1 L1
7
22
LIFT
CYLINDER
SPOOL
13
21
12
PP
20
18 19
PT
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
1 V-0059 (1-10-01)
53 of 294
54 of 294
453 (S/N 515013713 AND ABOVE)
(S/N 515113620 AND ABOVE)
V-0058legend
LEGEND
1 RESERVOIR: 17 ANTICAVITATION VALVE
Capacity . . . . . . . . . 5.3 Qts. (5,0 L)
18 FILTER - BICS CONTROL VALVE
2 FILTER - HYDRAULIC/HYDROSTATIC
(CANISTER)
3 CHARGE PRESSURE SWITCH:
17-21 PSI (118-144 kPa) 20 SOLENOID ACTIVATED DIRECTIONAL
4 TEMPERATURE SWITCH CONTROL VALVE - BICS CONTROL
225-232 degrees F. 21 PULL BUTTON ACTIVATED
(108-111 degrees C.) DIRECTIONAL CONTROL VALVE - LIFT
5 RELIEF VALVE - CHARGE: ARM BY PASS
85 PSI (586 kPa)
6 BY PASS VALVE - COOLER:
275 PSI (1896 kPa) 23 PILOTED ACTIVATED DIRECTIONAL

7 FIXED CAPACITY DISPLACEMENT CONTROL VALVE - LIFT CONTROL
HYDROSTATIC MOTOR 24 PILOTED ACTIVATED DIRECTIONAL
8 CONTROL VALVE - TILT CONTROL
VARIABLE CAPACITY DISPLACEMENT
HYDROSTATIC PUMP 25 CHECK VALVE - BUCKET POSITION
VALVE
9 HYDRAULIC PUMP:
Gear Type . . . 6.8 GPM (25,7 L/min.) 26 FLOW DIVIDER ADJUSTMENT VALVE
at 3000 RPM
10 RELIEF/REPLENISHING VALVE - HIGH 27 RESTRICTION - HYDRAULIC FILTER
PRESSURE: 3400 PSI (23440 kPa)
11 REPLENISHING VALVE
12 RELIEF VALVE - MAIN:

1400-1450 PSI (9652-9996 kPa)
at Front Quick Couplers
13 LOAD CHECK VALVE

CONTROL VALVE - FLOW CONTROL
SPOOL
15 CHECK VALVE - BUCKET POSITION

VALVE NOTE: Unless otherwise specified
springs have NO significant
pressure value.
CONTROL VALVE - UNLOADING
SPOOL
Printed in U.S.A. V-0058legend (1-10-01)
55 of 294
56 of 294
453 (S/N 515013713 AND ABOVE) BUCKET POSITION VALVE (OPTIONAL)
(S/N 515113620 AND ABOVE)
(PRINTED JANUARY 2001) D
V-0058
15
DRIVE MOTOR
2 MALE
HYDRAULIC
FILTER
(FRONT AUXILIARY
QUICK COUPLERS)
26
7
3
FEMALE
27
A
4
OIL COOLER
C
5
14
25
HYDROSTATIC PUMPS 6 16
8 B
HYDRAULIC CONTROL VAVLE
11
10 TILT CYLINDER
AUXILIARY
SPOOL
INLET 13
11
10
BICS CONTROL VALVE
8 Dealer Copy -- Not for Resale

17
P2 B1
24
9 TILT
INLET OUTLET CYLINDER
SPOOL
13
23 LIFT CYLINDERS
P1 L1
DRIVE MOTOR
7
22
LIFT
CYLINDER
SPOOL
13
21
12
PP
20
18 19
PT
WORKING CIRCUITS
PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS
1 V-0058 (1-10-01)
57 of 294
58 of 294
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are
most common. Many of the recommended procedures Check for correct function after adjustments,
must be done by authorized Bobcat Service Personnel repairs or service. Failure to make correct
only. 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.
453 Bobcat Loader

59 of 294Mar. 99
LIFT CYLINDER(S)
Checking The Lift Cylinders
A
Open the rear door.
Remove the nut (Item 1) [A] from the base end pin
retainer (left side shown). 1
P–07174
Use a slide hammer to remove the pivot pin (left side

shown) [B]. B

P–07177
Pull the cylinder forward. Mark the hoses for correct

reassembly. C
1
Check only one cylinder at a time.
Disconnect the hose (Item 1) [C] from the lift cylinder
base end port. 2
Install a plug in the hose and tighten the plug.
Lower the seat bar, engage the parking brake and start
the engine. Loarders without seat sensors press the
green PRESS TO OPERATE button.
Push the top (toe) of the lift pedal until system relief
pressure is reached. P–07175
There should be no leaks at the base end port.

If there is leakage from the open base end port of the lift
cylinder, remove the lift cylinder for repair.
Install the cylinder(s) in the reverse order.
453 Bobcat Loader

60 of
LIFT CYLINDER(S) (Cont’d)
Removal And Installation
A
Fully lower the lift arms.
Stop the engine. Pull up on the lift arm by–pass control
and move the lift pedal to release the hydraulic pressure.
Raise the seat bar. Engage the parking brake. Raise the
operator cab. (See Page 1–1.)
Install a lifting strap around the center of the lift arms
crossmember, fasten the strap to a chain hoist and raise
the lift arms slightly as shown [A].
1
Remove the rod end retainer bolt (Item 1) [A] from the left
cylinder. P–07161
Remove the retainer and rod end pin [A].

B
Lower the left cylinder onto the fender [B].

P–07166
Remove the bolt (Item 1) [C] to remove the cover and

pivot pin from the right lift cylinder. C
Remove the cover and pivot pin [C].
P–07164
Lower the right lift cylinder onto the fender [D].

D
P–07169
453 Bobcat Loader

Revised Mar. 99
LIFT CYLINDER(S) (Cont’d)
Removal And Installation (Cont’d)
A
Open the rear door.
Remove the nut (Item 1) [A] from the base end pin
retainer (left side shown). 1
P–07174
Use a slide hammer to remove the pivot pin (left side

shown) [B]. B

P–07177
Pull the cylinder forward to remove the hose (Item 1) [C]

from the base end and the hose (Item 2) [C] from the rod C
end. Mark the hoses for correct reassembly.
1
Install the cylinder(s) in the reverse order.
P–07175
453 Bobcat Loader

62 of
TILT CYLINDER
Checking The Tilt Cylinder
A
NOTE: The tilt cylinder is removed from the

Bob–Tach for clarity purposes only.
Stop the engine and raise the seat bar.

1
P–07163
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 1) [A] from the base end of the
tilt cylinder.

Install a plug in the hose and tighten the plug.
Lower the seat bar, engage the parking brake and start
the engine.
Push the bottom (heel) of the tilt pedal until system relief
pressure is reached.
There should be no leaks from the base end port.
If there is leakage from the open port of the tilt cylinder,
remove the cylinder for repairs.
453 Bobcat Loader

63 of 294
TILT CYLINDER (Cont’d)
A
Tilt the Bob–Tach fully forward until it rests on the floor.
1
Stop the engine and raise the seat bar.
Engage the parking brake. 2
Remove the bolt (Item 1) [A] from the retainer (Item 2)
[A].
Remove the pivot pin from the Bob–Tach.
P–07144
Remove the hoses (Item 1) [B] from the tilt cylinder

fittings.
B

1
P–07163
Fasten a lifting strap to the center of the lift arms

crossmember [C]. C
Install the lifting strap to a chain hoist and raise the lift
arms up for clearance to remove the base end pivot pin
from the tilt cylinder.
Remove the bolt (Item 1) [C] from the pivot pin retainer.
1
P–07162
Remove the pivot pin (Item 1) [D].

D 1
Remove the tilt cylinder from the loader.
Install the tilt cylinder in the reverse order.
P–07165
453 Bobcat Loader

64 of
HYDRAULIC CYLINDERS
Lift Cylinder Parts Identification
1. Tube 8. O–ring
2. Case 9. Washer
3. Nut 10. Head
4. Piston 11. Seal
5. Ring 12. Seal 5 7
6. O–ring 13. Rod 4
7. Spacer
3 6
13
12
1
11
2
10
9
8

B–06942
Tilt Cylinder Parts Identification
1. Tubeline 9. Nut
2. Case 10. O–ring 11
3. Nut 11. Seal 7
4. Piston 12. Head 11
5. Seal 13. Rod
6. O–ring 14. Seal 1
7. Bolt
8. Clamp
2 10 13
8
3 11
4 9 12 14
C–01808
453 Bobcat Loader

65 of 294Mar. 99
HYDRAULIC CYLINDERS (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 105 ft.–lbs. (142 Nm)
torque.
Tilt: Tighten the nut to 300 ft.–lbs. (407 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
453 Bobcat Loader

66 of
HYDRAULIC CYLINDERS (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.
Assemble the cylinder(s) in the reverse order.
P–07425
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67 of 294
BICS™ BLOCK VALVE
A
Put jackstands under the rear corners of the loader.
1
P–07294
B
1

or death. W–2059–0598
(See Page 1–1).
P–07296
C
1
Before the cab or the lift arms are raised for

service, jackstands must be put under the rear
corners of the frame. Failure to use jackstands
can allow the machine to tip backward causing
injury or death. 2
W–2014–0895
Raise the operator cab. (See Page 1–1).

Remove the control shield and the steering lever panels. P–07221
(See Page 3–1.)
Install caps and plugs on hoses, tubelines and fittings.
Remove the tubelines and hose from the top of the
BICS™ block valve [A].
Remove the return hose (Item 1) [A].
Disconnect the electric solenoid (Item 2) [A] from the When repairing hydrostatic and hydraulic
loader harness. systems, clean the work area before
disassembly and keep all parts clean. Always
Remove the tubelines (Item 1) [B] from the rear of the use caps and plugs on hoses, tubelines and
block. ports to keep dirt out. Dirt can quickly damage
the system.
Remove the bolt (Item 1) [C] from the mounting bracket. I–2003–0888
Remove the block (Item 2) [C].

453 Bobcat Loader
Revised Mar. 99294
BICS™ BLOCK VALVE (Cont’d)
A
Remove the nut (Item 1) [A], the solenoid (Item 2) [A] and
the O–rings (Item 3) [A] from the electric solenoid spool. 3
2
3
1
P–07451
Remove the spool [B].

Replace the spool if damaged.
B

P–07453
Reseal if seals are damaged. C

If damaged, seal identification: 1
1. O–ring 2
2. O–rings 3
3. Back–up washers
P–07456
Remove the by–pass valve (Item 1) [D] from the block.

Reseal if seals are damaged.
D
Replace the by–pass valve if damaged. 1
P–07454
453 Bobcat Loader

Revised Mar. 99
A
Remove the damaged O–rings (Item 1) [A] and back–up
washers (Item 2) [A] from the by–pass valve. 2
2
2
1
1
1
P–07457
Remove the check valves (Item 1) [B] from the block.

Replace check valves if damaged.
B
1

P–07455
Remove the damaged O–rings (Item 1) [C] and back–up
washers (Item 2) [C] from the check valve.
C
2 2
2
2
1 1
1 1
P–07458
453 Bobcat Loader

Revised Mar. 99294
A
Remove the plugs (Item 1) [A] & [B] from the block.
Remove the damaged O–ring (Item 2) [A] & [B] from the
plugs.
Remove the check valves (Item 3) [A] & [B] from the
block.
3
2 1 N–18047

1
2
N–18048
Remove the damaged O–ring (Item 1) [C] and back–up

washer (Item 2) [C] from the check valve. C
2
1
N–18049
453 Bobcat Loader

Revised Mar. 99
MAIN RELIEF VALVE
Checking The Main Relief Valve
A
1
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
pump is not working correctly, refer to
checking the output of the hydraulic pump.
(See Page 2–30.)
The tools listed will be needed to do the following

procedure:
MEL10003 – Hydraulic Tester P–07145
MEL10006 – Hydraulic Test Kit
Disconnect the rod end hydraulic hose (Item 1) [A] from
the tilt cylinder.
Connect the IN port of the hydraulic tester to the rod end
hydraulic hose (Item 1) [A].
To release cab lock when the lift arms are up,
Connect the OUT port of the hydraulic tester to the rod reach under the lift cylinder and pull the ring on
end of the tilt cylinder port. (Where the hydraulic hose was the cable. Failure to release lock correctly can

disconnected.) cause serious injury.
W–2008–1285
The hydraulic tester must be in the fully open

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

Check the hose routing, from the tester, for clearance corners of the frame before running the engine
while doing this procedure. for service. Failure to use jackstands can allow
Sit in the operator seat, lower the seat bar and fasten the death.
seat belt. W–2017–0286
Start the engine and run at low RPM. Push the bottom
(heel) of the right foot pedal to retract the tilt cylinder.
Check for hydraulic leaks. Be sure the tester is showing
flow.
Increase the engine speed to full RPM.
Push the bottom (heel) of the right foot pedal until the
system relief pressure is reached.
The correct pressure for the main relief valve is
1400–1450 PSI (9652–9996 kPa).
If the relief valve pressure is not correct, stop the engine.
Adjust or replace the main relief valve. (See Page 2–19.)
When the test is complete return the foot pedal to neutral
position, reduce the engine RPM to idle.
Stop the engine.
453 Bobcat Loader

Revised Mar. 99294
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.

procedure:
MEL10003 – Hydraulic Tester 1
P–05933
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.)
Start the engine and run at low idle RPM. Push the right
steering lever all the way to the right to engage the front
auxiliary hydraulics detent [B]. Put jackstands under the front axles and rear
Increase the engine speed to full RPM. Watch the flow for service. Failure to use jackstands can allow
meter on the hydraulic tester to make sure the flow is the machine to fall or move and cause injury or
correct. death.
W–2017–0286
There should be 6.3 GPM (23,8 L/min.) free flow
The correct pressure for the main relief valve is
1400–1450 PSI (9652–9996 kPa).
If the relief valve pressure is not correct, stop the engine.
Adjust or replace the main relief valve. (See Page 2–19.)
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
453 Bobcat Loader

Revised Mar. 99
MAIN RELIEF VALVE (Cont’d)
A
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
ft.–lbs. (47–54 Nm) torque. 1
P–07551
When repairing hydrostatic and hydraulic

systems, clean the work area before
B
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage O–ring
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. 1
Main Relief Valve Adjustment

Backup
Connect the hydraulic tester. (See Page 2–17.)
B–06764
An adjusting screw is located on the end of the main relief
valve (Item 1) [A].
Remove the end cap (Item 1) [B] from the main relief
valve.
Turn the adjusting screw in (increase pressure) or out
(decrease pressure) until the correct main relief pressure
1400–1450 PSI (9652–9996 kPa) is obtained.
If the correct pressure can not be obtained, remove the
main relief valve from the the main control valve. (See
procedure above.)
Remove the O–rings and back–up washers from the main
relief valve [B].
Clean the main relief valve in clean solvent. Use air
pressure to dry the valve.
Install new O–rings and back–up washers. Install the
main relief valve (Item 1) [A] 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. Always check
the pressure of a new relief valve.
453 Bobcat Loader

Revised Mar. 99294
HYDRAULIC CONTROL VALVE
A
3
Raise the lift arms and install the lift arm support device. 2
(See Page 5–1.) P–07312


or death. W–2059–0598
Stop the engine. Pull out on the lift arm by–pass knob and 1
move the lift pedal to release the hydraulic pressure. P–07307
Raise the seat bar.
Install jackstands under the rear corners of the loader.
(See Page 1–1.) C
Remove the center control shield and the steering lever
3
covers. (See Page 3–1.)
Remove the steering levers. (See Page 3–1.)
Remove the BICS™ block valve. (See Page 2–13.)
Thoroughly clean the control valve area. 1 2
Remove the hair pin (Item 1) [A], the fastener link (Item
2) [A] and the foot pedal linkage from the control valve P–07311
spool (lift and tilt).
Remove the hair pin fastener (Item 3) [A] from the
auxiliary spool. D
Remove the retaining pins from the spool and pivot [A].
2
Remove the two screws (Item 1) [B] to remove the
auxiliary bracket from the control valve.
Remove the tubelines (Items 1, 2 & 3) [C] from the control
valve and filter block.
Remove the lift and tilt tubelines (Item 1) [D] and the
auxiliary tubelines (Item 2) [D] from the control valve. 1
P–07309
453 Bobcat Loader

75 of 294
HYDRAULIC CONTROL VALVE (Cont’d)
A
Remove the hoses from the control valve [A].
Remove the mounting bolts (Item 1) [A] and remove the
control valve.
1
1
P–07314
Identification Chart
B D1 D3
Item 450 Series MR
A1 Lift Cylinder Base End D2
A2 Tilt Cylinder Base End F1
A3 Auxiliary Hydraulics

B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
B1 B2 B3
B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function
C1 C2 C3
C2 Load Check Valve/Tilt Function
INLET
C3 Load Check Valve/Auxiliary Function A1 A2 A3
D1 Lift Spool Detent OUTLET
D2 Centering Spring Tilt Spool

D3 Auxiliary Spool Detent
E2 Anti–Cav. Valve
E2
F1 Plug
G1 G2 G3
G1 Lift Spool LIFT TILT AUX. B–06283
G2 Tilt Spool
G3 Auxiliary Spool
MR Main Relief Valve
453 Bobcat Loader

76 of
A
Refer to the control valve identification chart on page
2–21 for the control valve parts assembly.

P–07355
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
B
Mark each valve section and spool so that the parts will 3
be returned to their original bore during assembly.
1 2
Use bolts to fasten the control valve to a work bench for
easier disassembly and assembly.

Load Check Valve
Loosen the load check plug (Item 1) [A].
P–07367
Assembly: Always use new O–rings. Tighten the plug to
35–40 ft.–lbs. (47–54 Nm) torque.
C
Remove the load check plug (Item 1) [B], spring (Item 2)
[B], and load check valve (Item 3) [B].
Main Relief Valve

Remove the main relief valve (Item 1) [C] from the control
valve.
Assembly: Always use new O–rings and back–up
washers. Tighten to 35–40 ft.–lbs. (47–54 Nm) torque.
1
P–07358
Remove the O–rings (Item 1) [D] and back–up washers

(Item 2) [D] from the main relief valve. D 1
2
P–07359
453 Bobcat Loader

Revised Mar. 99
A
Anti–Cavitation Valve
Loosen the Anti Cavitation valve (Item 1) [A].

Assembly: Always use new O–rings and back–up
washers. Tighten to 35–40 ft.–lbs. (47–54 Nm) torque.
P–07368
Remove the Anti–Cavitation valve (Item 1) [B] from the

control valve. B
Remove the O–rings (Item 2) [B] and back–up washers
(Item 3) [B].

1
3
P–07366
Rubber Boot
Remove the two screws (Item 1) [C] from the rubber boot
C
retainer.
Assembly: Tighten the screws to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.
P–07264
Remove the rubber boot (Item 1) [D] and boot retainer
(Item 2) [D].
Remove the O–ring retainer plate (Item 3) [D] and O–ring D
(Item 4) [D].
Assembly: Use a new O–ring (Item 4) [D] for assembly.
2
P–07273
453 Bobcat Loader

78 of
Lift Spool Detent
A
procedure:
MEL1278 – Detent Tool
The lift spool detent (Item 1) [A] is located next to the main
relief valve (Item 2) [A].
1 2
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

1
4
The detent assembly has small springs and
balls. Do not lose these parts during
disassembly and assembly.
3
I–2012–0284 P–07361
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 for the lift spool (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–07362
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 2–23 for the correct procedure.)
2 2
3
1
P–07357
453 Bobcat Loader

Revised Mar. 99
Lift Spool Detent (Cont’d)
A
Remove the spool assembly (Item 1) [A], back–up
washer (Item 2) [A], and spool seal (Item 3) [A] from the
control valve.
3
1
P–07360
Put the linkage end of the spool assembly (Item 1) [B] in

a vise.
B
Install MEL1285 Spring Compressor Tool (Item 2) [B] on
the spring assembly.
Loosen the detent adapter [B]. 2

The detent assembly has small springs and 1
balls. Do not lose these parts during P–07306
I–2012–0284
C
Wrap a clean rag around the assembled detent adapter 2
(Item 1) [C] and adapter retainer (Item 2) [C].
1
Remove the detent adapter (Item 1) [C] from the adapter
retainer (Item 2) [C].
6
Remove the detent spring (Item 3) [C] and detent balls 5
(Item 4) [C].
3
Remove the centering spring (Item 5) [C] and end cap
(Item 6) [C] from the spool. 4
P–07280
Lift Spool Only: Remove the stud from the end of the
spool [D]. D
P–07278
453 Bobcat Loader

80 of
A
Removal of the plastic plug. 1
• Make a center point in the plug using a 3/16 inch drill. 1
• Drill a hole all the way through the plug using a 7/64 2
inch tap drill.
2
• Turn a 6–62 tap into the plug. Pull the tap and plug out
of the spool. BE CAREFUL, do not break the tap.
• Clean all the debris from the inside of the spool bore.
P–07448 P–07443
Assembly: Install the new plastic plug (Item 1) [A] and
O–ring (Item 2) [A].
Install the stud and leave 0.600 inch (15,2 mm) past the
B
end of the spool [B].
NOTE: DO NOT USE LOCTITE ON THE STUD

THREADS. DO NOT EXCEED 70 in.–lbs. (8
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. 0.600’’
(15,2 mm)
B–09973
Install the detent balls and spring into the detent adapter
(Item 1) [C]. Hold the detent balls in position with the tool
and install the detent adapter into the end cap (Item 2)
C
[C]. 1
NOTE: The detent cap (Item 3) [C] shown, is used for
support during assembly.
Install the spool seal and back–up washer on the spool.
(See Page 2–29 for correct installation procedure for the 2
spool seal.)
Use MEL1285 Compression Spring Tool and install the
centering spring retainer, centering spring, and detent 3
adapter/end cap assembly on the spool. (See Page 2–25
for correct installation sequence of these parts.)
P–07282
Tighten the detent adapter (Item 1) [D] to 90–100 in.–lbs.

(10,2–11,3 Nm) torque. D
P–07306
453 Bobcat Loader

81 of 294
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
Install the detent cap (Item 1) [D].

Install the washer and snap ring [D]. D
Install the mounting bolts [D].
Tighten the mounting bolts to 90–100 in.–lbs. (10,2–11,3
Nm) torque.
1
P–07355
453 Bobcat Loader

82 of
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 2–24 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 for the auxiliary spool (Item
5) [B] is shorter than the detent sleeve on the
lift spool. DO NOT switch the sleeves from
one spool to the other.
453 Bobcat Loader

83 of 294
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.

1
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
453 Bobcat Loader

84 of
HYDRAULIC PUMP
Checking the Output of the Hydraulic Pump
A
procedure:
MEL1429 – Remote Start Switch
MEL10003 – Hydraulic Tester
NOTE: The relief pressure must be per specification
before the output test is performed. 1
2
P–07517

B EXAMPLE: TESTER
CONNECTION
corners of the frame before running the engine Reservoir
death.
W–2017–0286

Raise the lift arms and install an approved lift arm support
device. (See Page 1–1.)
Raise the operator cab. (See Page 1–1.) Hydraulic Pump
Connect the remote start switch. (See Page 1–1.) Out In

Hydraulic Control
Disconnect the OUTLET hose (Item 1) [A] from the Valve
hydraulic pump. Connect the OUTLET hose from the
tester to the hose (Item 1) [A].
1
Connect the INLET hose (Item 2) [A] from the tester to the
OUTLET fitting on the hydraulic pump. BH–00196
A sample tester connection is shown in picture [B].
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 (Item 1) [B] on the tester to about 1000 The hydraulic tester must be in the fully open
PSI (6895 kPa). DO NOT exceed system relief pressure. position before you start the engine.
Open the restrictor control and record the free flow (GPM) I–2024–0284
at full RPM.
Remove the auxiliary hydraulics lock bolt and push the
right steering lever all the way to the right (detent) [B] 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 is not to
specifications, first adjust the main relief valve. (See Page
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).
453 Bobcat Loader

85 of 294
HYDRAULIC PUMP (Cont’d)
A
1 2

the system. P–09875
I–2003–0888
Never work on a machine with the lift arms up 2


or death. W–2059–0598 1 1
P–09911
(See Page 1–1.)
Stop the engine and raise the seat bar. C 1
Lift and block the loader. (See Page 1–1.) Raise the
operator cab. (See Page 1–1.)
NOTE: The engine and hydrostatic pump assembly

must be moved to the right to remove the
hydraulic pump.
Remove the hydraulic reservoir. (See Page 2–36.)

Loosen the left engine mounting bolt (Item 1) [A], and
remove the right engine mounting bolt (Item 2) [A].
P–09914
Remove the bolts (Item 1) [B] from the steering lever

linkage. Remove the linkage from the hydrostatic pumps.
Disconnect the hair pin fastener (Item 2) [B] from the
speed control linkage. Remove the linkage.
Remove the two bolts (Item 1) [C] from the fan housing
stabilizer.
453 Bobcat Loader

86 of
A
Remove the nut (Item 1) [A] from the left side hydrostatic
pump mounting bolt. Remove the mounting bolt.
P–07324
Remove the bolt (Item 1) [B] and washer from the

hydrostatic pump pulley. B
Remove the nut (Item 2) [B] from the right side
hydrostatic pump mounting bolt.
1
Remove the rubber mount and install the bolt. Tighten the
bolt to pull the hydrostatic pump assembly to the right to
allow clearance for hydraulic pump removal.

2
P–07313
Remove the outlet hose (Item 1) [C] from the top of the
hydraulic pump and the inlet hose from the bottom of the
C
pump.
NOTE: Remove the battery Page 1–1 for access to 2
the inlet hose removal.
1
Remove the two hydraulic pump mounting bolts (Item 2)
[C] (top and bottom).
P–07327
Remove the hydraulic pump and the coupler (Item 1) [D].

D
1
P–07320
453 Bobcat Loader

87 of 294
Parts Identification
6
3
7
4
8

9
12
10
11
C–02733
MODEL: 453
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
453 Bobcat Loader

88 of99
A

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
453 Bobcat Loader

Revised Mar. 99
A
Disassembly and Assembly (Cont’d)
Remove the pump gears [A].
B–05946
Remove the wear plate (Item 1) [B].

Remove the gasket and diaphragm seal from the pump
B 1
housing [B].
Remove the spring and steel ball from the pump housing
[C].

NOTE: Make sure to mark the port where the spring
and ball are removed.
Clean and dry all the parts.
2
Inspect the drive gears [D].
B–05947
Inspect both drive gear and idler gear shafts at the
bearing points and seal area for rough surface and wear.
Check the face of the gears for wear.
C
Check for wear on the face of the wear plate. If the wear
is more than 0.0015 inch (0,038 mm) from one side to the
other, the wear plate must be replaced.
Check the housing in the gear area for wear.
The detent assembly has small springs and B–05950

balls. Do not lose these parts during
I–2012–0284 D
Put the spring and steel ball in the port that was marked
during disassembly [C].
Install Install the wear plate and diaphragm seal in the
housing (Item 1 & 2) [B].
Put oil in the port of the pump, use a grip pliers to rotate
the pump shaft. The pump will have some resistance but
will turn freely.
B–04426
453 Bobcat Loader

90 of
HYDRAULIC RESERVOIR
A
Install jackstands under the rear corners of the loader.
(See Page 1–1.)
1
Remove the hydraulic fluid from the reservoir. (See Page
1–1.)
Remove the center shield and the steering lever panels.
(See Page 3–1.)
P–07310
Remove the BICS™ block valve. (See Page 2–13.)
Remove the control valve. (See Page 2–19.) B
Remove the filter return hose (Item 1) [A] and the
hydraulic pump inlet hose from the tee fitting below the
reservoir.
Remove the return hoses (Item 1) [B] from the reservoir. 1

2

Remove the nuts (Item 2) [B] and bolts from the reservoir
holding strap.
1
Remove the reservoir.
P–07318
453 Bobcat Loader

91 of 294
HYDRAULIC FILTER BLOCK
A
2
Put jackstands under the front axles and rear 2

death.
W–2017–0286 P–07300
Put jackstands under the front and rear of the loader. (See
Page 1–1.) B
Raise the operator cab. (See Page 1–1.) 1

unless the lift arms are secured by a lift arm
support device. Failure to use an approved lift
arm support device can allow the lift arms or
attachment to fall and cause injury or death. P–07302
W–2059–0991
(See Page 1–1.)
Remove the center shield and steering lever panels. (See
Page 3–1.)
Remove the tubelines (Item 1) [A] and hoses (Item 2) [A]
from the filter block.
Disconnect the electrical connectors from the charge
pressure switch and the temperature sender.
Remove the two mounting bolts (Item 1) [B] from the

outside of the fender.
453 Bobcat Loader

92 of
HYDRAULIC FILTER (Cont’d)
A
Block Disassembly And Assembly
Remove the plug (Item 1) [A], the charge pressure spring
(Item 2) [A], and the poppet (Item 3) [A]. 3
Clean and inspect the parts. Replace as needed.
2
Install a new O–ring on the plug. 1
P–19886
Remove the fitting (Item 1) [B], the by–pass spring (Item

2) [B], and poppet (Item 3) [B].
B
Clean and inspect the parts. Replace as needed.
3
Install a new O–ring on the plug.
2

1
P–19887
Remove the temperature sender (Item 1) [C] from the filter

block.
C
1
P–19888
Remove the charge pressure switch (Item 1) [D] from the

filter block fitting. D
P–19889
453 Bobcat Loader

93 of 294
PEDAL INTERLOCK LINKAGE
453ServiceManual#6900363(S/N515011001&Above)–HydraulicSystemSectionPart2of2
A
Remove the nut (Item 1) [A] from the top bolt on the
interlock. 3
1
Remove the spring (Item 2) [A] from the bolt and
interlock.
Installation: Tighten the interlock nut to 80–90 in.–lbs. 2
(9–10 Nm) torque.
Remove the nut (Item 3) [A] and plastic washer from the
interlock bolt.
Remove the bolt from the outside of the fender. P–07207
NOTE: Note the location of the interlock parts during

removal for assembly purposes. There is a
B
plastic washer which must be installed on 2
each side of the interlock bar during
assembly.
1
Remove the nut (Item 1) [B] from the bottom bolt on the
interlock and pedal.
Installation: The bottom slot (Item 2) [B] & [C] on both

interlock bars must be toward the rear of the pedal.
Always check for free movement of the interlock after
assembly.
P–07198
Remove the interlock assembly [C].

C
P–07211
CONTROL PEDALS
D
Removal and Installation
Remove the bottom nut, washers and bolt from the
interlock and pedal [B].
Remove the bolt (Item 1) [D] from the pedal linkage pivot.
Remove the pedal from the linkage.
Pedal Adjustment 1
When installing the pedal and interlock, align them by

moving the interlock forward or backward in the slot in the
fender.
P–07202
453 Bobcat Loader

Added Mar.9499of 294 –2–42– Service Manual
HYDROSTATIC SYSTEM
Page
Number
CONTROL SHIELD AND STEERING LEVER PANELS
DRIVE BELT
HYDROSTATIC MOTOR
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17 HYDROSTATIC
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12 SYSTEM
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
HYDROSTATIC PUMP
Checking Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29

HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
STEERING LEVERS
STEERING LINKAGE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
Pintle Arm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
TENSION PULLEY AND SPRING

TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
453 Bobcat Loader

453 Bobcat Loader

TROUBLESHOOTING
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
Chart
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

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 hydrostatic 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 defect.
17. There is low charge pressure.
18. The charge relief has a defect.
19. Steering lever is obstructed.
453 Bobcat Loader

97 of 294Mar. 99
HYDROSTATIC SYSTEM INFORMATION
A CHARGE OIL

ports to keep dirt out. Dirt can quickly damage Valve Moves for Charge
the system. FUNCTION 1 Oil Replacement
I–2003–0888
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
453 Bobcat Loader

A

for service. Failure to use jackstands can allow 3
the machine to fall or move and cause injury or 3
death.
W–2017–0286 1
P–09824

or death. W–2059–0598
Open the rear door.

Raise the lift arms. (See Page 1–1.)
Raise the operators cab. (See Page 1–1.)
Hold the lock nut and remove the lift arm by–pass knob
(Item 1) [A].
Remove the lock nut and rubber washer (Item 2) [A] from
the BICS™ valve block.
Remove the four mounting bolts (Item 3) [A] from the
control shield.
Remove the control shield.
453 Bobcat Loader

Revised Mar. 99
(Cont’d) A
Removal And Installation (Cont’d) 1
Remove the two bolts (Item 1) [A] from the steering lever
panels. Remove the panels.
STEERING LEVERS
P–07216
B
the machine to fall or move and cause injury or 1 1
death.
W–2017–0286

P–07213

C 1
or death. W–2059–0598
Raise the lift arms and install an approved lift arm support 1
Remove the control shield and steering panels. (See
Page 3–5.) 2
Remove the nuts and bolts (Item 1) [B] from the steering P–07221
linkage.
Remove the bolts (Item 1) [C] and the support bracket

from the BICS™ block valve.
Remove the two bolts (Item 2) [C] from the parking brake
solenoid.
453 Bobcat Loader

10099
Revised Mar. of 294 –3–6– Service Manual
STEERING LEVERS (Cont’d)
A 1
Remove the parking brake solenoid and spring.
Disconnect the electrical connector from the by–pass
solenoid (Item 1) [A].
P–07222
Remove the nut (Item 1) [B] from the auxiliary hydraulics

cable bolt (if equipped). Remove the cable. B

1
P–07218
Remove the nuts (Item 1) [C] from the pivot bearings

(both sides). Hold the bolts from outside the fender.
C 1
Remove the steering lever assembly from the loader.
P–07220

D
Remove the bearings (Item 1) [D] from the shaft. 3
2 2
Slide the steering levers (Item 2) [D] from the shaft. 4 3
Check the plastic bushings (Item 3) [D] and the wave
washers (Item 4) [D] for damage or wear and replace as 1
necessary.
Assembly: Lightly lubricate the steering shaft during
assembly. 1
P–07229
453 Bobcat Loader

STEERING LINKAGE
A 3
Adjustment 1

death.
W–2017–0286
P–07325

Install the Remote Start Switch. (See Page 1–1.) Start
the engine and run at a slow RPM.
Loosen the nuts and bolts on the pintle arms (Item 1) [A].

Hold the nuts (Item 2) [A] and turn the bolts so the
centering springs just touch the pin (Item 3) [A] and the
adjustment bolts heads.
If the wheels are turning (creeping), move the steering
lever to stop the creeping. Locate the correct side of the
centering spring where the adjustment is to be made.
Turn the bolt out a small amount until the wheels stop
turning.
Move the steering lever forward and backward and let
the transmission return to neutral position. If the
transmission does not return to the neutral position,
repeat the adjustment.
Repeat the steps for the other side.
Installation: Tighten the nuts (Item 1) [A] on the
steering linkage to 11–13 ft.–lbs. (15–18 Nm) torque.
Remove the jackstands from the loader frame.
453 Bobcat Loader

10298
STEERING LINKAGE (Cont’d)
Pintle Arm Removal And Installation
A
Put jackstands under the rear of the frame. (See Page
1–1.)
2 2

lift arm support device. Failure to use an 1
approved lift arm support device can allow the P–07476
or death. W–2059–0598
B
(See Page 1–1.) 2
Remove the steering linkage from the pintle arm.
1
Remove the adjustment nuts and bolts (Item 1) [A] from

the centering spring.
Remove the spring retainer brackets (Item 2) [A].
Use a pliers to remove one of the spring ends from the P–07475
bracket (Item 1) [B]. Remove the spring.
Loosen the pintle arm clamping bolt (Item 2) [B].
C
Use a small gear puller and remove the assembly from
the shaft of the hydrostatic pump.
NOTE: Do not use a screwdriver to pry the pintle arm

off, it will cause damage to the seal retainer.
Pintle Arm Disassembly And Assembly 1

Put the pintle arm on a vise and use a hammer to drive the
bushing (Item 1) [C] from the pintle arm.
Replace the bushing if damaged.
P–07479
Put the pintle arm on a vise and use a hammer to drive the
bushing (Item 1) [D] into position. D
Install the pintle arm on the hydrostatic pump in the
reverse order.
Adjust the steering linkage. (See Page 3–8.)
P–07481
453 Bobcat Loader

103 of Mar.
Revised 294 99 –3–9– Service Manual
HYDROSTATIC MOTOR
A
1 1

death.
W–2017–0286
P–09903


the system.
I–2003–0888

or death. W–2059–0598

(See Page 1–1.)
Remove the wheels from the side of the loader where the
motor is to be removed.
Remove the control shield and steering lever panels.
(See Page 3–5.)
Remove the motor cover bolts (Item 1) [A] from the
outside of the loader.
Pull the cover outward and free from the slots under the
frame.
453 Bobcat Loader

10499
HYDROSTATIC MOTOR (Cont’d)
A 1
NOTE: Mark the hoses for installation purposes.
Remove the parking brake cover from the chaincase. 3

(See Page 4–1.)
NOTE: Always use caps and plugs on hoses and

fittings during disassembly and assembly.
2
Remove the high pressure hoses (Item 1) [A], and the
drain hose (Item 2) [A] from the motor. Cap and plug the
hoses and fittings.
P–07493
Remove the four motor mounting bolts (Item 3) [A].
Installation: Lift the drive sprocket to align it with the
motor splines. Be sure the O–ring is installed on the motor
flange during installation. Tighten the bolts to 90–100
ft.–lbs. (123–135 Nm) torque.
Remove the motor from the chaincase.

9
7 10
4 6
2
1 8
11
19
5 1
3 18
1. O–RING
2. PLATE, valve 19 17
3. VALVE
4. PLATE, balancing 16 1
5. SEAL, inner 19
6. SEAL, outer 12 15
7. PLUG
8. PIN 14
9. SPRING
10. HOUSING
11. BOLT 12 1
12. SEAL
13. HOUSING
14. SHAFT & BEARING ASSY. 12 13
15. PLATE, wear
16. SHAFT, long
17. GEROLER
18. SHAFT, short
19. BALL D–01635
453 Bobcat Loader

Disassembly
A
3 1
2 4
systems, clean the work area before B–07382
the system. B–06464
I–2003–0888
NOTE: Clean the outside of the motor before

disassembly. Keep all the parts of the motor
B
clean.
Put the motor in a vise, holding it by the mounting flange
with the shaft down [A]. Put a mark across the motor
housing for correct assembly.
Remove the four bolts from the motor [A].

Installation: Tighten the bolts to 37 ft.–lbs. (50 Nm)
torque in the sequence shown [A].
Lift the valve housing straight up [B]. If done carefully the

balance ring assembly and valve will stay on the valve B–06472
plate.
C
Remove the 3 inches (76 mm) diameter O–ring from the
valve housing [C].
B–06402
Remove the pins and springs from the valve housing [D].
D
B–06401
453 Bobcat Loader

A
Disassembly (Cont’d)
Remove the case drain fitting from the valve housing [A].
Case Drain
Fitting
B–09971
Remove the balance ring assembly [B].

B

B–06400
Remove the inner face seal from the balance plate [C].
Installation: Put grease on the inner seal during
C
assembly.
Balance Plate
Outer Outer
Seal Seal
B–08733
Pin Inner Seal Pin B–03046
Remove the outer face seal [D].

D
Installation: Put grease on the outer seal during
assembly.
Balance Plate
Outer Outer
Seal Seal
B–08732
Pin Inner Seal Pin B–03046
453 Bobcat Loader

A
Remove the valve [A].
B–09927
Remove the valve drive [B]. B

B–09925
Remove the valve plate [C].

C
Remove the 3 inch diameter O–ring from the valve plate
[C].
B–09928
Remove the geroler [D]. Make sure the rollers are kept in
place. D
B–09926
453 Bobcat Loader

A
Remove the drive shaft [A].
Remove the 3 inch diameter O–ring (Item 1) [A] from the
wear plate. 1
B–09924
Remove the wear plate [B].

Wear
Remove the shaft face seal (Item 1) [B] from the wear
B Plate
plate.
Remove the 3 inch diameter O–ring from the bearing
housing.

1
B–06374 B–06396
Remove the shaft and bearing assembly from the housing

[C]. C
B–06373
Remove the dust seal from the housing [D]. D Dust

Seal
Remove the shaft seal from inside the housing [D].
NOTE: The shaft and bearing assembly are not sold
as individual parts. Replace as a unit.
Shaft
Seal
B–06372 B–06395
453 Bobcat Loader

Inspection
A
Before the motor is assembled, check the following items:
Check the geroler for wear or scratches [A].
B–06394
Check the geroler rollers [B]. B

Check the rotor.
NOTE: Put all the rollers back in their original
position.

B–06392
Check the valve plate for wear or scratches [C].

C
B–06391
Check the valve [D]. D
B–06390
453 Bobcat Loader

A
Inspection (Cont’d)
Check the balance plate [A].
Check the valve drive shaft and main drive shaft for wear.
B–06389
Check the end plate for scratches [B].

Check all the contact surfaces. Replace any parts that
B
have scratches or are worn.
Clean all the parts in solvent and use air pressure to dry
the parts. DO NOT use cloth or paper because some
material may get into the hydrostatic system and cause
damage. DO NOT use sandpaper or a file to remove
scratches on any of the parts.

Assembly
B–06388
C
Use grease such as Dow Corning #44 or
Vaseline petroleum jelly to hold seals, O–rings
and bearings in position during assembly.
I–2010–0284
NOTE: Always use a NEW seal kit when assembling

the hydrostatic motor.
B–06387
Install the back–up washer and use a press to install the

shaft seal (Item 9) [D] in the bearing housing [C]. D 1 1. Shaft
2 2. Shaft Seal
3. Wear Plate
4. Seal
3 5. Shaft & Bearing
6. Shaft Seal
7. Bearing Housing
5 8. Dust Seal
9. Back–Up Washer
4
7
9
8 6
B–09931
453 Bobcat Loader

Assembly (Cont’d)
A
Install the dust seal [A] as shown in (Item 8) [D] Page
3–17.
B–06386
Use a press to install the bearing and shaft assembly in

the housing [B]. B
Lubricate and install the 3 inch diameter O–ring on the
bearing housing.
NOTE: You can use alignment studs for easier

assembly of the motor.

B–06385
Install the shaft face seal (Item 2) [D] page 3–17 in the
wear plate [C]. C
B–06396
Install the wear plate [D].

D
B–06374
453 Bobcat Loader

Revised Mar.
11299
of 294 –3–18– Service Manual
Assembly (Cont’d)
A
Lubricate the 3 inch diameter O–ring (Item 1) [A].
Install the drive in the housing [A]. 1
B–09924
Align the notch on the outside of the geroler with the notch
on the wear plate. Install the geroler against the wear
plate. Hold the rollers in the geroler while installing it [B].
B

The timing of the motor controls the direction of the B–09926
rotation of the drive shaft of the motor. The timing parts
are as follows [C]:
Geroler Ring (Item 1). C Rotate Valve Clockwise
1/2 Tooth to Engage Spline
Valve Drive (Item 2)
Valve Plate (Item 3)
Any One of 6 Ports
Valve (Item 4) Open to Outside of Valve
Find the largest opening between the geroler star and the
geroler ring and mark the outside of the geroler ring at the Largest Opening
location [C].
Install the valve drive in the geroler (Item 2) [C].
Lubricate the 3 inch diameter O–ring and install it on the
valve plate.
4
Align the notch on the outside of the valve plate with the
notch on the geroler ring [C]. Install the valve plate 3 Valve
(O–ring side toward the geroler) on the geroler.
2
Valve Plate
Align the slot opening in the valve plate with the largest
opening of the geroler. 1
NOTE: If you can see a roller (in the geroler) in all the
holes of the valve plate the motor is timed Geroler
wrong. Pressure
Relef Hole (3) Star
Align the valve on the valve drive so that any one of the
side openings is in alignment with the open slot of the
valve plate and the largest opening of the geroler. Turn the Geroler Ring
valve CLOCKWISE 1/2 tooth to engage the drive.
B–09972
453 Bobcat Loader

Assembly (Cont’d)
A Balance
Ring
Outer
Outer Seal
Lubricate the inner and outer seals and install the seals Seal
on the balance ring [A].
Inner Seal
Install the seals in the position as shown [A] or
the motor will not operate correctly. Do not
force or bend the seals. Any damage to these B–09930
seals will have a direct effect on the motor
operation.
I–2098–1295
B
Install the seals and the case drain fitting on the valve
housing [B].

Case Drain
Fitting
Seal
B–09971
Install the pins and springs in the valve housing [C].

C
Lubricate the 3 inch diameter O–ring and install on the
valve housing.
Align the pin grooves in the balance ring with the pins in
the valve housing. Install the balance ring assembly in the
housing.
B–06401
Put your finger through the port in the valve housing to

hold the balance ring in position [D] D
NOTE: You must feel a spring action of the balance
ring after the valve housing is installed.
B–06370
453 Bobcat Loader

DRIVE BELT
A
Put jackstands under the rear of the loader. (See Page 1
1–1.)
Use a pry bar to lift the tension pulley.
Remove the belt (Item 1) [A] from the pulley. Lower the
pulley slowly onto a wooden block.
P–07319
453 Bobcat Loader

CHARGE PRESSURE
A
Checking
The tools listed are needed to complete the following
procedure:
3
MEL1173 – Test Kit
1
Put jackstands under the front axles and rear P–19129
death.
B
W–2017–0286

Raise the operator cab. (See Page 10–01).

Disconnect the electrical connector (Item 1) [A] from the
charge pressure switch. 1
Remove the charge pressure switch from the filter port
block.
Connect the pressure gauge into the sender port of the filter P–19232
port block (Item 1) [B].
Start the engine and run at full RPM. The pressure must be
75–85 PSI (241–586 kPa) minimum with no hydraulic
C
action.
Stop the engine.
1
If the pressure is not correct, check the charge pressure
poppet (Item 1) [C], the spring (Item 2) [C], by removing the 2
plug (Item 3) [C] & [A].
3
Disconnect the pressure gauge.
Install and tighten the charge pressure switch.
Reconnect the electrical connector to the charge pressure
switch. P–19886

Remove the jackstands from under the loader frame.
453 Bobcat Loader

11601
Revised Jan. of 294 –3–22– Service Manual
HYDROSTATIC PUMP (Cont’d)
Hydraulic Pump End Drive End
37
37 17
9 10 15
17 16
15 11
9 10 12 36
16 13
11 14
12
13
34 35
20
7 54 21
20 21 6
5
54 34 8 13 9
56 1
2 18
34 8 13 9 23 12
2 18 19
1 23 12 25
25 19 26 27
26 22
27 24

22 28
24
28
31 32
33
32 23
31 33 29 30 22
23
2930 22
E–01406 E–01408
Ref. Description Ref. Description

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

A
Put jackstands under rear of the frame. (See Page 1–1.)
1 2
P–09875


or death. W–2059–0598
1 1
Raise lift arms and install lift arm support device. (See
Page 1–1.)
P–09911
NOTE: The engine and hydrostatic pump assembly

C
must be moved to the right to remove the 1
hydrostatic pumps.
Use the following procedure to remove the hydrostatic

pumps:
Loosen the left engine mounting bolt (Item 1) [A], and
remove the right engine mounting bolt (Item 2) [A].
Remove the nuts (Item 1) [B] from the steering lever P–09914
linkages. Remove the linkages from the hydrostatic
pumps.
Disconnect the clip (Item 2) [B] from the speed control
linkage. Remove the linkage.
Remove the two bolts (Item 1) [C] from the fan housing
stabilizer bracket.
Remove the hydraulic reservoir. (See Page 2–1.)
Remove the control valve. (See Page 2–1.)
453 Bobcat Loader

Revised Mar.
11899
453ServiceManual#6900363(S/N515011001&Above)–HydrostaticSystemSectionPart1of2
A
Remove the high pressure hoses from the drive motors.
(See Page 3–10.)
Remove the nut (Item 1) [A] from the left side hydrostatic
pump mounting bolt. Remove the mounting bolt.
Remove the charge pressure hose (Item 2) [A] from the 2
fitting on the rear hydrostatic pump.
1
P–07324
Remove the drain hose (Item 1) [B] from the front

hydrostatic pump housing.
B
Remove the belt (Item 2) [B] from the pulley. 2
Remove the bolt (Item 3) [B] and washer from the
hydrostatic pump pulley. 3
Remove the pulley. (See Page 3–21.)

Remove the nut (Item 4) [B] and bolt from the right side 4
hydrostatic pump mounting bolt. 1
Remove the rubber mount and install the bolt. Tighten the
bolt to pull the hydrostatic pump assembly to the right to
allow clearance for hydrostatic pump removal. P–07313 P–19029
Remove the two bolts (Item 1) [C] from the hydrostatic

pump mounting bracket.
C
Installation: Tighten the bolts to 27–31 ft.–lbs. (37–42
Nm) torque. 1
P–07327
Remove the two bolts (Item 1) [D] from the hydrostatic

pump mounting bracket. D
Nm) torque.
1
Remove the hydrostatic pump.
P–07317
453 Bobcat Loader

119 of Jan.
A
procedure:
MEL1219–4 – Torx Socket
2
2
1
When repairing hydrostatic and hydraulic B–06422
B
the system.
I–2003–0888
NOTE: Before you begin the disassembly

procedure, remove the hydraulic pump from
the loader.

Remove the charge tubeline (Item 1) [A].
Remove the four replenishing valves from the pump [B].
NOTE: Install relief/replenishing valves in the B–06419

forward drive circuit (Item 2) [A] during
assembly of hydrostatic pump. (See Service
Letter dated 4 December 1996 for loader
serial numbers affected.)
C
Remove the bolts and center bracket from the pumps [C].
Nm) torque.
Separate the pump housing from the center section.
Remove the coupler from the center section.
Remove the pintle levers from the pump.
B–06424
NOTE: The hydrostatic pump front and rear pump

internal parts are the same. Keep all the parts D
for one pump separated from the parts for the
other pump.
Remove the four bolts from the center section [D].

Nm) torque.
B–06062
453 Bobcat Loader

A
Remove the center section [A].
B–06063
Remove the rotating group [B]. B

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

B–06064
Remove the snap ring from the rear housing [C].

Hit the shaft on a block of wood to remove the bearing and C
shaft.
B–06072
B–06071
Remove the seal and back–up washer from the shaft [D].
D
B–06073
453 Bobcat Loader

A
Remove the bolts from the cover of the long pintle shaft
[A].
Remove the pintle cover.
B–06065
Remove the seal and washer [B]. B

B–06067
Remove the pintle shaft bearing [C].

C
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
[D]. D
B–06068
453 Bobcat Loader

A
Remove the washer and O–ring from the shaft [A].
B–06069
Remove the bearing and bearing race from the shaft [B]. B
Assembly: When installing the race, make sure that the
chamfer side of the race is toward the cam plate.

B–06070
Remove the cam plate from the housing [C].

C
B–06074
Inspection
D
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 [D].
B–08859
453 Bobcat Loader

A
Inspect the input drive shafts, bearings and races for wear
and damage to the shaft splines [A].
The bearings in the center section and housing, only need
to be removed if they are loose and show wear. Use a
press to remove and replace the bearings.
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
B
the finished surfaced with a fingernail, replace the part
[B].

B–06076
Inspect the camplate for wear. The finish must be smooth

and free of grooves. If the grooves can be felt with a C
fingernail, replace the camplate [C].
B–06079
Inspect the rotating group as follows:

D
Check each piston in its bore. The piston must move
freely.
Check the pins for wear or damage [D].
All the pins must be the same length and must not be bent.
Check the spherical washer for sharp edges, wear or
scratches.
B–08860
453 Bobcat Loader

A
Check the piston shoe for scratches [A].
B–06077
B This Dimension Must be Maintained on All

Nine Shoes Within 0.001’’ (0,0254 mm)
Check the end play of each piston assembly [B]. Measure
the thickness of each shoe. All shoes must be within
0.001 inch (0,025 mm) of each other [B].
Piston
Shoe

Shoe Must Swivel
Smoothly on Ball
End Play Must Not
Exceed .003’’ (0,076 mm)
A–01850
Check the flat surface of the piston block for being smooth
and free of scratches [C].
C
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
453 Bobcat Loader

TENSION PULLEY AND SPRING
A
NOTE: Remove the engine and pump assembly from
the loader. (See Page 7–1.)
Use a wrench to lift the tension pulley (Item 1) [A].

Remove the drive belt.
P–09794
Use the wrench to turn the tension pulley clockwise to

install a wooden block (Item 1) [B] between the flywheel
and the tension pulley arm. Rest the pulley against the B 1
3
wooden block.
Remove bolt (Item 2) [B] and washer.
Install two 5/16 inch x 2.5 inch bolts in the holes (Item 3)
[B]. Attach flanged 5/16 inch nuts to the bolts on the 2
backside of the pulley.

P–09795
Install a small wheel puller (Item 1) [C] and remove pulley

from shaft. C
P–09799
Hold the tension pulley arm and remove the wood block.
Rotate the arm (Item 1) [D] counterclockwise to release D
the spring tension.
P–7391
453 Bobcat Loader

Revised Mar. 99
TENSION PULLEY AND SPRING (Cont’d)
A
Pull the shaft (Item 1) [A] from the spring and mounting
brackets.
Installation: Align the spring with the slot in the shaft
(Item 2) [A].
1
P–07389
Remove the spring and tube from the mounting bracket

[B].
B
Installation: Install the spring hook in the mounting
bracket.

P–07390
Remove the bearing mounting bolts (Item 1) [C].

C
Check the parts for damage and replace as needed.
P–07393
453 Bobcat Loader

453ServiceManual#6900363(S/N515011001&Above)–HydrostaticSystemSectionPart2of2
453 Bobcat Loader

DRIVE SYSTEM
Page
Number
AXLE, BEARINGS AND SPROCKET
Installing The Bearing Races . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11
Installing The Inner Bearing And Axle Sprocket . . . . . . . . . . . . . . . . . . . 4–11
Removing And Installing The Axle Bearing . . . . . . . . . . . . . . . . . . . . . . . 4–9
Removing The Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
Removing The Bearing Race . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10
AXLE HUB
AXLE SEAL
CHAINCASE COVERS DRIVE
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4 SYSTEM
CHAINCASE FLUID
Removing Oil From The Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4

DRIVE CHAIN
PARKING BRAKE DISC

PARKING BRAKE PEDAL

453 Bobcat Loader

129 of 294
Revised Oct. 98 –4–1– Service Manual
453 Bobcat Loader

PARKING BRAKE PEDAL
A
Raise the loader lift arms and install the lift arm support
Put jackstands under the rear of the loader. (See Page
1–1.)
Remove the control shield. (See Page 3–1.) 1 2
Remove the two bolts (Item 1) [A] from the parking brake
mounting bracket.
P–07209
Installation: Tighten the mounting bolts to 25–28 ft.–lbs.
Remove the bolt (Item 2) [A] from the wiring tube clamp.
B
Disconnect the electrical connector (Item 1) [B].

1
Remove the parking brake assembly from the loader.
Reverse the removal procedure to install the parking

brake assembly in the loader.
P–07210
Disassembly And Assembly C 5

Loosen and remove the mounting bolt (Item 1) [C] and nut
from the spring mounting bracket (Item 2) [C]. 6
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].
Remove the two mounting bolts, washers, and nuts (Item 1
5) [C] from the brake pedal sensor. 4
Remove the harness mounting clamp (Item 1) [D] from
the pedal mounting bracket (Item 4) [C].
2
Remove the sensor harness from the pedal mounting
3
P–04189
bracket.
Remove the pedal mounting bolt (Item 6) [C], plastic
spacers, and bushing nut from the brake pedal. D
1
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
453 Bobcat Loader

131 of Mar.
CHAINCASE FLUID
A
Removing Oil From The Chaincase
Remove the plug located in front of the chaincase (Item 1
1) [A].
Use a transfer pump [A] to remove the oil from the
chaincase into a clean container.
Installation: Add oil to the chaincase through the check
plug hole. (See SPECIFICATIONS section Page 9–1.)
NOTE: Oil can also be removed or added through

the chaincase cover.
P–07490
CHAINCASE COVER B 2
1

lift arms or attachment to fall and cause injury P–07221
or death. W–2059–0598
Raise the loader lift arms and install the lift arm support
C
Put jackstands under the rear of the loader. (See Page
1–1.)
1 1
(See Page 3–1.)
Disconnect the electrical harness (Item 1) [B] for the
parking brake.
Remove the mounting bracket bolts (Item 2) [B] from the P–07223
BICS™ block valve.
Remove the traction lock assembly. (See Page 8–1.) D
Remove the mounting bolts (Item 1) [C] from the
chaincase cover.
1 1
Remove the chaincase cover.
Remove the four bolts (Item 1) [D] from the brake disc
guide block.
Assembly: Put liquid adhesive (LOCTITE #242) on the
bolt threads for the disc guide block. Tighten the bolts to
65–70 ft.–lbs. (88–95 Nm) torque. P–07227
453 Bobcat Loader

13299
CHAINCASE COVER (Cont’d)
A 1
Remove the four mounting bolts (Item 1) [A] from the disc
guides.
2
P–07228
Assembly: The guide blocks (Item 1) [B] have angled

slots (Item 2) [B] which must be parallel with each other B REAR OF LOADER
when installed in the disc guide (Item 3) [B]. When
installed in the chain case cover correctly the top of both
slots must be toward the rear of the loader. Put liquid
adhesive (LOCTITE #242) on the bolt threads for the disc
guide. Tighten the bolts to 25–28 ft.–lbs. (34–38 Nm) 1
torque.
Installation: Install a new gasket (Item 2) [A] under the

cover during assembly.
2
3
MC–02327
PARKING BRAKE DISC 1

Remove the chaincase cover. (See Page 4–4.)
Use a snap ring pliers with a 90° tips to remove the
parking brake disc.
Remove the snap ring (Item 1) [C] from the cluster
sprocket.
P–07224
Remove the brake disc (Item 1) [D]. D 1

Reverse the procedure to install the parking brake disc.
P–07226
453 Bobcat Loader

AXLE HUB
A 1
Removal And Installation 2
Axle Hub Puller Tool
Slide Hammer
MEL1525 – Seal Driver Tool
NOTE: The procedure is the same for the front and

rear axles. The front axle will be used for the
procedure.
To loosen the axle hub mounting bolt, use the following

procedure:
P–07519
Before lifting and blocking the loader, loosen the hub
mounting bolt.
NOTE: If the axle and bearings are being replaced,

B
loosen the sprocket mounting bolt inside the
chaincase before lifting and blocking the
loader.
1
Installation: Install thread adhesive LOCTITE # 242 to
the bolt threads and tighten the axle hub mounting bolt to
175–190 ft.–lbs. (240–255 Nm) torque.

Remove the front wheel from the loader.
Installation: Tighten the wheel mounting nuts to 40–45
P–07508
Loosen the axle bolt 2–4 turns.
Install a nut on one of the wheel studs and use a hammer
to remove the wheel stud (Item 1) [A].
Installation: Support the flange of the axle hub and install
the stud with a hammer. Use a hydraulic press if available
for this procedure.
Install the puller tool (Item 2) [A] on the axle hub bolt.
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
Turn the threaded rod of the puller to remove the axle hub
from the axle.
Remove the key (Item 1) [B] from the axle.
453 Bobcat Loader

AXLE SEAL
A
Remove the axle hub.(See Page 4–6.)
Drill a small hole in the axle seal [A].
Install a slide hammer (Item 1) [A] 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 for removal.
Remove the axle seal. 1
Installation: Use MEL1525 – seal driver to install the seal P–07507

in the axle housing.
Clean the seal area and inspect the shaft for wear.
B
NOTE: If the shaft is damaged or worn, an axle repair
sleeve kit is available from Melroe Parts Sales
in Chicago or remove the axle. (See Page 1
4–8.)
Lubricate the seal lips before installation.
Put the new axle seal over the axle and into the axle tube.

Install MEL1525 seal driver tool (Item 1) [B] over the end
of the axle and against the seal.
Hit the seal driver tool with a hammer [B].
P–07513
Drive the seal (Item 1) [C] into the axle tube until the seal
tool is against the axle tube. C
If installed correctly, the axle seal will be slightly recessed
1
in the axle tube after installation.
Reverse the removal procedure to install the axle hub and
wheel on the loader.
P–07515
453 Bobcat Loader

AXLE, BEARINGS, AND SPROCKET
A
Removing The Axle
The tools listed are needed for the following procedure:
MEL1202A – Axle Bearing Service Tool
Slide Hammer
1
NOTE: The procedure is the same procedure for the
front and rear axle. The front axle will be used
for the procedure.
P–07522
Never work on a machine with the lift arms up B

or death. W–2059–0598
1

(See Page 1–1.)
P–07518
(See Page 3–1.)
Remove the oil from the chaincase. (See Page 4–4.)
NOTE: Grind the correct size box end wrench to fit
between the two axle bolts [A]. Loosen the
bolt (Item 1) [A].
Remove the axle hub. (See Page 4–6.)
Remove the hydrostatic motor. (See Page 3–1.)
Install the axle puller (Item 1) [B], loosen the sprocket bolt
as much as possible and pull the axle out until the
sprocket bolt stops the travel.
Repeat the procedure until the sprocket bolt is free from
the axle. Remove the sprocket and bearing from the axle.
Installation: Apply grease to the axle bearing before
installation.
Installation: Apply a small amount of liquid adhesive
(LOCTITE #242) to the bolt threads and tighten the bolt
to 175–190 ft.–lbs. (238–257 Nm) torque.
Remove the axle from the tube.
453 Bobcat Loader

13699
AXLE, BEARINGS, AND SPROCKET (Cont’d)
Removing And Installing The Axle Bearing
A
1
Install a bearing puller (Item 1) [A] between the bearing
and the tapered flange for the hub. Be sure the bearing
puller makes good contact with the inner race of the
bearing.
Put the axle and the bearing puller in the hydraulic press
[A].
Press the bearing off the mounting surface of the axle.
Be sure to hold onto the axle during removal. The bearing
will slide freely along the axle shaft when the bearing is
free of the mounting surfaces. P–07494
Press the bearing from the splined end of the axle [B]. B

P–07496
Installation: Apply grease to the bearing before

installation. C
3 4
Installation: Use a piece of round tube (Item 1) [C] to
install the bearing on the axle shaft. The inside diameter
of the tube should be slightly larger than the inside
diameter of the bearing race (for axle diameter clearance) 1
and must make contact with only the inner race
during installation.
Use the same bearing puller (Item 2) [C] to install the
bearing on the axle.
2
Put the tube (Item 1) [C] on the bearing puller (Item 2) [C].
Put the bearing (Item 3) [C] on the tube as shown. P–07495
Put the splined end of the axle shaft (Item 4) [C] in the
bearing and press the bearing onto the axle.
D
Be sure to hold the axle during installation. It will slide
freely along the axle shaft after the splined end has
passed through the bearing until it reaches the bearing
mounting surface on the hub end of the axle.
Press the bearing until it is fully seated on the mounting

surface at the hub end of the axle [D].
P–07498
453 Bobcat Loader

AXLE, BEARINGS, AND SPROCKET (Cont’d)
A
Removing The Bearing Races
Use the tools provided in the MEL1202A 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 inner
bearing cup from the axle tube [A].
P–07510
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.
2

1
P–07509
Use the slide hammer to remove the bearing cup from the
axle tube [C]. C
P–07511
453 Bobcat Loader

AXLE, BEARING, AND SPROCKET (Cont’d)
A
Installing The Bearing Races
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]. 3
Put the installation tool (Item 1) [A] in the axle tube. 2
1
Install the long threaded rod (Item 2) [B] into the axle tube
and through the installation tool (Item 1) [A].
Secure the tool to the threaded rod with a nut (Item 3) [A].
P–07497
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.
2

1
P–07492
To install the outer bearing cup, install the installation tool

(Item 1) [C] and tighten the nut until the bearing is seated. C
Installing The Inner Bearing And Axle Sprocket
Apply grease to the axle bearing before installation.
Install and hold the bearing in the inner race while sliding
the axle in the tube and through the bearing.
1
Apply a small amount of liquid adhesive (LOCTITE #242)
to the bolt threads.
Install the washer and bolt in the sprocket, align the
sprocket splines with the axle splines. Continue to install
the axle in the sprocket while threading the bolt in the axle. P–07516
Tighten the bolt to 175–190 ft.–lbs. (238–257 Nm) torque.
453 Bobcat Loader

DRIVE CHAIN
453ServiceManual#6900363(S/N515011001&Above)–DriveSystemSection
A
1
or death. W–2059–0598 P–07514
Lift and block the loader. (See Page 1–1.) B

(See Page 1–1.)
(See Page 3–1.)

Remove the oil from the chaincase. (See Page 4–4.)
Remove the brake disc. (See Page 4–5.)
P–07512
Remove the axle hub. (See Page 4–6.)
Remove the hydrostatic motor. (See Page 3–1.)
Remove the axle. (See Page 4–8.)
Remove the cluster sprocket (Item 1) [A] from the drive
chains.
Remove the drive chain and axle sprocket from the
chaincase [B].
NOTE: Installing an old or new chain will be easier

after using the above procedure.
NOTE: Due to the small area in the chaincase,
assemble a new chain on a bench before
installation, using a chain compression tool.
453 Bobcat Loader

Revised Mar.
14099
MAIN FRAME
Page
Number
BOB–TACH
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
Lever And Wedge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16
Lever And Wedge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12
Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
FUEL TANK
LIFT ARMS
OPERATOR CAB
OPERATOR CAB GAS SPRING

MAIN
OPERATOR SEAT FRAME

REAR DOOR
Exhaust Pipe Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5–23
REAR WINDOW
SEAT BAR
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
Seat Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE

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

453 Bobcat Loader

SEAT BAR
A
Lower the seat bar (Item 1) [A] so the compression
springs (Item 2) [A] will be in a down position.
1
2 2
P–09543
Loosen the adjustment lock nut (Item 1) [B] (both sides). B

2

1
1/16inch
(1.58mm)
P–09542
Turn the bolt (Item 1) [C] into the clevis five turns (both
sides).
C
Installation: Adjust the clearance between the bolt head
(Item 2) [B] and the seat bar tab (Item 3) [B] to 1/16 inch
(1,58 mm).
1
P–09544
Remove the retaining pin (Item 1) [D] and clevis pin (both
sides). D
P–09541
453 Bobcat Loader

SEAT BAR (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
Remove the mounting bolt and nut (Item 1) [C] and

remove the mounting bracket (Item 2) [C] (both sides). C
2
Installation: Tighten the mounting bolt and nut (Item 1)
[C] to 180 – 200 in.–lbs. (21 – 23 Nm) torque.
P–09554
NOTE: Hook a 3/16 inch diameter rod, 22 inches (558

mm) long, on each end as shown [D]. Pulling D
the seat bar together and holding it at the
pivot holes with the 3/16 inch rod, will make
removal and installation easier. 22’’
(558 mm)
P–07587
453 Bobcat Loader

SEAT BAR (Cont’d)
A 2
Seat Bar Removal And Installation (Cont’d)
Use a clamp (Item 1) [A] to hold one side of the seat bar
against the side screen.
Install the rod (Item 2) [A] in the pivot hole.
P–09930
Use a wooden 2 x 4, installed with one end against the

side screen to pry the seat bar together [B]. B
Install the rod (Item 1) [B] in the seat bar pivot hole.
Remove the wooden 2 x 4.

P–09931
To prevent damage, use cardboard (Item 1) [C] and duct

tape (Item 2) [C] to protect the cab during removal and
C
installation.
P–09932
Position the seat bar in the recess of the left side of the
cab (Item 1) [D]. Position the left side pivot end of the seat D
bar between the cab and the grab handle (Item 2) [D].
Lift straight up on the right side of the seat bar (Item 3) [D].
2
Continue to lift on the right side of the seat bar and allow
the left side to rotate between the cab and the grab 3
handle. Lift the right side of the seat bar until it clears the 1
right side screen of the cab.
Reverse the above procedure to install the seat bar into
the operator cab.
P–09933
453 Bobcat Loader

SEAT BAR (Cont’d)
A
Assembly
Assemble the parts as shown for the left side of the seat 7 6 3 2 1
bar pivot assembly [A].
Mounting Bolt – (Item 1).
Washer – (Item 2).
Keyed Plastic Bushing – (Item 3).
Magnetic Bushing Assembly – (Item 4).
Sensor Bracket – (Item 5).
Pivot Bushing – (Item 6). Left Side
Mounting Bolt – (Item 7). 8 5 4 of Seat Bar
Sensor Mounting Bolt – (Item 8). 9
Sensor Mounting Nut – (Item 9).
P–03284
Assemble the parts as shown for the right side of the seat
bar pivot assembly [B]. B
Mounting Bolt (Item 1).
Pivot Bushing (Item 2).
Keyed Plastic Bushing (Item 3).
Washer (Item 4).
Mounting Bolt (Item 5).
Tighten the mounting bolt to 180–200 in.–lbs. (21–23 Nm)
5 3 2 1

torque. 4
Right Side
of Seat Bar
P–07332
453 Bobcat Loader

OPERATOR CAB
A
Put jackstands under the rear corners of the loader. (See
Page 1–1.)
Install a lift strap through the grab handles and connect
the lift strap to a chain hoist to support the operator cab
[A].
Release the lock pin.

P–07180
Disconnect the electrical harness (Item 1) [B] from the

operator cab.
B
Remove the gas cylinder from the operator cab. (See
Page 5–9.) 1
P–07183
453 Bobcat Loader

147 of Mar.
A
Disconnect the ground wire (Item 1) [A] from the operator
cab.
Remove the U–bolt nuts (Item 2) [A] (both sides) from the
rear mounting bolts.
1
2
P–07176
Install a lift strap through the fuel fill access hole (Item 1)
[B] in the operator cab. B
Use a chain connected to the two lift straps (Items 1 & 2)
[B] and remove the operator cab.
Reverse the procedure to install the operator cab.

2
1
P–07179
453 Bobcat Loader

OPERATOR CAB GAS CYLINDER
A
The cab must be held to prevent falling while

hand is in access hole.
W–2205–0695
P–07301

approved lift arm support device can allow the 1

or death. W–2059–0598
Raise the lift arm and install the lift arm support device.
(See Page 1–1.)
P–07303
Pull the clip (Item 1) [A] enough to clear the base end ball
of the cylinder.
C
1
Turn the clip (Item 1) [B] to remove it from the hole in the
base end of the cylinder.
Rotate the cylinder to remove it from the ball (Item 1) [C].
P–07304
Hold the nut under the fender and remove the bolt (Item
1) [D] from the rod end of the cylinder. D
Remove the cylinder.
Reverse the procedure to install the gas cylinder.
1
P–07299
453 Bobcat Loader

149 of 294
OPERATOR SEAT
A
1
Remove the two rear seat mounting bolts (Item 1) [A]
from the seat mount.
If equipped with seat sensor:
Disconnect the electrical socket (Item 2) [A] from the seat
sensor.
2
P–07186
Remove the magnet collar (Item 1) [B] from the seat

sensor. B

P–07187
Remove the mounting bolt (Item 1) [C] from the sensor.

Remove the sensor.
C
1
P–07192
Lower the operator cab and remove the two mounting

bolts (Item 1) [D] from the front of the seat.
D
Remove the operator seat.
1
P–07190
453 Bobcat Loader

OPERATOR SEAT (Cont’d)
A
Remove the seat spring (Item 1) [A] from under the right
side of the seat.
P–07193
The seat sensor bushing (Item 1) [B] is located in the right

rear corner of the seat.
B

1
P–07196
Operator
Check for excessive dirt build up under the seat rail
covers (Item 1) [C], if your loader is so equipped. C Seat
The area must be clean to allow for proper seat sensor
operation. (See BICS™ inspection procedure Page 8–1.)
Seat
Seat Spring
Sensor
Seat Rail
Cover
1
MC–02043
453 Bobcat Loader

BOB–TACH
A
Removal
Tilt the Bob–Tach forward so it is parallel to the floor. Put
blocks under the Bob–Tach and lower the Bob–Tach onto
the blocks [A].
P–07145
Remove the retainer bolt (Item 1) [B] from the rod end
pivot pin retainer (Item 2) [B].
B
Installation: Tighten the retainer bolt to 18–20 ft.–lbs.
1

P–07144
Remove the pivot pin (Item 1) [C] from the tilt cylinder and
the Bob–Tach.
C
1
P–07142
Lift the Bob–Tach and support it to remove the Bob–Tach

pivot pin. D
Remove the grease fitting (Item 1) [D] and slightly loosen
the bolt (Item 2) [D].
Cover the grease fitting hole with a rag and strike the pivot
pin bolt with a hammer to loosen the tapered pin.
Repeat the procedure for the other side.
Remove the Bob–Tach. 1
2
P–07150
453 Bobcat Loader

BOB–TACH (Cont’d)
A
Installation
Push the pivot pin (Item 1) [A] in fully and install the 2
grease fitting (Item 2) [A].
P–07157
Align the Bob–Tach pivot pin with the lift arm hole (both
sides).
B
Add grease to the fitting (Item 1) [B] to force the pivot pin
into the lift arm hole.
Install the bolt (Item 2) [B] in the pivot pin. Tighten the bolt

1
2
P–07150
Align the tilt cylinder rod end with the bushings in the
Bob–Tach and install the pin (Item 1) [C].
C
1
P–07147
Install the pin retainer (Item 1) [D] and the retainer bolt
(Item 2) [D]. D
Tighten the bolt (Item 2) [D] to 18–20 ft.–lbs. (24–27 Nm)
torque.
1
P–07144
453 Bobcat Loader

A
Seal Removal And Installation
Remove the Bob–Tach. (See Page 5–12.)
1
Remove the grease fitting from the pivot pin grease 2
chamber (Item 1) [A].
Install the Bob–Tach mounting bolt (Item 2) [A] in the pivot
pin and remove the pivot pin.
P–07159
Remove the seal (Item 1) [B] from the Bob–Tach. B

NOTE: Install the seal with the lip facing outward.

1
P–07160
Lever And Wedge Removal

C
Remove the bolts (Items 1 & 2) [C] to remove the 3
Bob–Tach lever.
Remove the access cover bolt (Item 3) [C]
Remove the access cover. 2
P–07149
Use a punch to remove the plugs (Item 1) [D] from the

front of the Bob–Tach. D
Remove the plugs through the access hole.
P–07151
453 Bobcat Loader

A
Lever And Wedge Removal (Cont’d)
Remove the bolts (Item 1) [A] from the wedge linkage
pivots.
NOTE: The linkage pivots have spacers that must be 2

installed during assembly.
P–07152
Remove the bolt (Item 1) [B] from the Bob–Tach lever

linkage. B
NOTE: Install the linkage spacer during assembly.
Remove the nut (Item 2) [B] from the wedge pivot plate
by holding the bolt (Item 2) [A] on the front of the 1
Bob–Tach. 2

P–07153
Remove the wedge assembly from the access hole in the

Bob–Tach [C]. C
P–07156
Check the wedge assembly for damage or wear and

replace as needed [D].
D
P–07154
453 Bobcat Loader

A
Lever And Wedge Removal (Cont’d)
Remove the plastic wedge guides as follows:
Tap the plastic guide plugs (Item 1) [A] from the holes to
remove the plastic guides (Item 2) [A].
Replace worn or broken guides. 1
P–07157
Lever And Wedge Installation

Assemble the wedge and linkage parts. Install a 1/2 inch
B
long bolt (Item 1) [B] to temporarily hold the spring and
link together during installation.
NOTE: The bolt (Item 1) [B] will be removed at the
end of the assembly procedure.
Install the right wedge assembly into the access hole first,

then install the left assembly.
The wedges must go between the plastic guides. 1
P–07155
Install the pivot plate in the access hole [C]. Install the bolt
(Item 1) [D] from the front of the Bob–Tach and install the C
nut (Item 1) [C] on the bolt.
Install the lever linkage bolt (Item 2) [C] in the pivot plate.
2
1
P–07153
Align the wedge assembly mounting holes with the holes

in the pivot plate and install the bolts (Item 2) [D] and D
bushings through the holes in the front of the Bob–Tach.
Nm) torque.
1
P–07152
453 Bobcat Loader

A
Lever And Wedge Installation (Cont’d)
Move the Bob–Tach lever to align the temporary bolts
(Item 1) [A] with the holes in the front of the Bob–Tach.
Remove the bolts.
Install the plugs in the holes.
1
Install the access cover and bolt.
P–07158
453 Bobcat Loader

LIFT ARMS
A
Put jackstands under the front and rear corners of the
loader. (See Page 1–1.)
1
Remove the Bob–Tach. (See Page 5–12.)
Install a sling (Item 1) [A] around the lift arm
crossmember and use a chain hoist to raise the lift arms. 2
Remove the tilt cylinder. (See Page 2–1.)

Remove the bolt (Item 2) [A] from the rod end pivot pin
retainer on the left lift cylinder. Remove the pivot pin.
P–07161
Lower the cylinder to the fender.
Remove the auxiliary tubeline clamps (Item 1) [B] (if
equipped).
B
1

P–07171
Remove the auxiliary couplers and tubelines (Item 1) [C]

from the left lift arm.
C
P–07167
Remove the rod end pivot pin bolt (Item 1) [D] from the
right lift cylinder. Remove the pivot pin. D
Lower the cylinder to the fender.
Remove the bolt (Item 2) [D] from the tilt cylinder tubeline
cover. 1
Remove the tubeline clamps from the right lift arm.
2
P–07164
453 Bobcat Loader

15899
LIFT ARMS (Cont’d)
A
Put the loop of a second lift strap up into the lift arm as
shown [A] (both sides).
Install the lift cylinder pivot pin (Item 1) [A] and secure the
pin with the retainer and bolt.
Wrap the lifting strap around the lift arm (both sides) and
attach it to the chain hoist.
1
P–07170
Remove the nut (Item 1) [B] from the upright pivot pin
retainer (both sides).
B

1
P–07173
Use a slide hammer to remove the pivot pin from the

upright (both sides) [C].
C
P–07168
453 Bobcat Loader

LIFT ARMS (Cont’d)
A
Use the chain hoist to remove the lift arms from the loader.
Use the reverse procedure to install the lift arms on the
loader.

P–07172
453 Bobcat Loader

FUEL TANK
A
Remove the hose clamps (Items 1 & 2) [A] to remove the
fuel supply and return lines.
1
2
P–09937
Remove the two bolts (Item 1) [B] from the fuel tank
mounting strap. B
Remove the fuel tank from the loader.

1 1
P–09938
453 Bobcat Loader

REAR WINDOW Viewed From the
A Outside of the Window
Removal And Installation Operator Cab Outside
of
Put the molding in the opening in the rear of the cab [A]. Operator
The groove for the rubber must be toward the inside of the Cab
cab.
Put the window in molding.
Round Notch
Goes to the
Inside Operator
Cab
B–03864 B–04360
Insert the eye of the tool into the groove of molding [B]. B
Insert cord from front of the tool eye [B].
Slide the tool forward, following groove in the molding,
while inserting the cord into the tool eye [B].
Do not stretch the cord.

When completed, cut excess cord, leaving a small
overlap. Push overlap into the groove to form a tight joint.
B–08281
453 Bobcat Loader

REAR DOOR
A
Exhaust Pipe Removal And Installation
Open the rear door.
Remove the mounting bolts (Item 1) [A] to remove the
exhaust pipe.
NOTE: The larger exhaust pipe shown is optional [A]

& [B].

P–07194

Install a lifting strap (Item 1) [B] through the slots in the
B
rear door.
Remove the hinge pins (Item 2) [B] from the door hinges.
Remove the door from the loader.
1
P–07189
453 Bobcat Loader

453ServiceManual#6900363(S/N515011001&Above)–MainFrameSection
453 Bobcat Loader

ELECTRICAL SYSTEM
Page
Number
ALTERNATOR
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
Alternator Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
Alternator Regulator Test With Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Full Field Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
BATTERY
Servicing The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
ELECTRICAL SYSTEM INFORMATION

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
Relay Switches Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4

FRONT LIGHTS (OPTIONAL)
INSTRUMENT PANEL ELECTRICAL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–31 SYSTEM
REAR LIGHTS (OPTIONAL)

STARTER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24
Checking The Starter In the Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–20
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–23
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
453 Bobcat Loader

453 Bobcat Loader

453 WIRING SCHEMATIC RED = RED
WIRES CONNECT BY LETTER BATTERY FEED 1000-1999 RED, RED/WHT, RNG
ACROSS CONNECTORS GROUND 2000-2999 BLK RNG = ORANGE
MONITORING 3000-3999 LBL
BLK = BLACK
A B
LBL = LIGHT BLUE
B A HYDRAULIC 4000-4999 LGN
DBL = DARK BLUE
S/N 515011001 AND ABOVE ATTACHMENT CONTROLS 5000-5999 YEL LGN = LIGHT GREEN
LIGHTS 6000-6999 PNK DGN = DARK GREEN
S/N 515111001 AND ABOVE SOME CONNECTOR
ACCESSORIES 7000-7999 WHT
YEL = YELLOW
PNK = PINK
(PRINTED JANUARY 2001) BODIES NOT SHOWN
FOR DRAWING CLARITY
ENGINE 8000-8999 TAN
WHT = WHITE
COMMUNICATION 9000-9999 PUR BRN = BROWN
V-0060 TAN = TAN
PUR = PURPLE
GRY = GRAY
TO OPTIONS ENGINE HARNESS - 6714018 BLK HORN

STARTER CAB HARNESS - 6707498
C109
B RNG/DBL X X RNG/DBL (If Equipped)
A RNG
BUCKET LEVEL SWITCH
BLK WHT WHT M M WHT (If Equipped) GLOW PLUG
86 85
BUCKET POSITION VALVE OFF
WHT/LGN RED
87 30 (If Equipped) 1 2 RUN
START
87A BLK RNG V V RNG
3
DIODE
4 5
GLOW PLUG 6
SO
GLOW PLUG SWITCH
BLK LBL/BLK J J LBL/BLK WHT

86 85 1 2 B ST
RED/WHT
HR LBL/RNG RED
87 30 3 RED/WHT
GLOW PLUG
87A 4 5
WHT/BLK
6 RNG
I
RED/WHT G G RED/WHT IGNITION SWITCH
RNG L L RNG
ENGINE WARNING LIGHT
RNG C C RNG RNG

LGN/WHT
RNG
HYDROSTATIC OIL ENGINE OIL
C201
TEMPERATURE PRESSURE SWITCH YEL/DGN F F YEL/DGN YEL/DGN
C114
SWITCH A YEL/DBL YEL/DBL
C C YEL YEL/DBL A
C110
DIODE CHARGE OIL RNG
PRESSURE B B BLK
YEL/BRN RNG
SWITCH A A YEL/BRN YEL/BRN K K
TRANSMISSION WARNING LIGHT
LGN/WHT
t
LGN
ENGINE COOLANT
SENDER PUR/WHT P P PUR/WHT
3 2 1
C162 COOLANT
3 2 1
ACCESSORY FUSE
BLK - AUXILIARY
TEMPERATURE
HOURMETER
POWER
RED RED/WHT B B RED/WHT GAUGE H RNG
+
25A SOCKET S VOLTMETER
LIGHT FUSE I RNG I
C206
C207
RED RED/WHT E E RED/WHT T G BLK G
25A V
LIGHT BRN LIGHT
RNG
BAT
GRY BLK
ALTERNATOR DBL BLK

GAUGE
FUSE RIGHT FRONT
25A HEADLIGHT
C208 (Domestic) or
C216 (European)
RED
A
D BRN/YEL Dealer Copy -- Not for Resale
PNK
BRN/YEL
R
T
R
T
PNK
BRN/YEL
C101
BRN/ BRN/
E BRN/GRN U U REAR
DGN DGN
TAIL DBL BLK
RED
C
LAMP
F BLK D D BLK LIGHT SWITCH LEFT FRONT
B BLK BRN H H BRN (IF EQUIPPED) HEADLIGHT
TO OPTIONS RED/WHT 1
TO OPTIONS 2
BLK
C105
A RNG L X BLK
(European)
3
SWITCHED B
C216
BLK
POWER FLASHER BRN/DGN 5
4
B
(Domestic)
(If Equipped) PNK
C208
C108
87A TO OPTIONS C BRN/YEL
ENGINE FUSE 6
PNK
B BRN/DGN
C164
RED ACCESSORY FUSE
30 87 BLK DBL/WHT
S 15A RED RED RED RNG A
TIMER
FUEL SOLENOID FUSE 25A REAR WORK LAMP
4 3 85 86 TO OPTIONS
RED WHT/BLK RNG RNG BLK HAZARD SWITCH
STARTER 25A (If Equipped)
BL
WHT/BLK
K
DIODE
1 2 2 1 BRN/
BRN BRN
DGN
FUEL SOLENOID 3
BRN/YEL
4 BEACON SWITCH
BRN
RED
5 (If Equipped)
6 BLK
BICS
BLK
FUSE 6 5
4
10A
RED
3
RED/WHT
1 2
RIGHT TURN SIGNAL
BATTERY LIGHT INDICATOR
RED/WHT
- + BLK BRN/DGN
* SEAT SENSOR found ONLY on Machines -
BLK
LEFT TURN SIGNAL
LIGHT INDICATOR S/N 515011700-12399
B A
BRN BLK
C209 S/N 515111873-12399
B A
BLK
RE
D
TO OPTIONS
BICS CONTROLLER HARNESS -
B BRN/DGN
A BRN/YEL 6710422 or 6717581
C215
DOME LIGHT
C DBL WITH SWITCH
E BRN/RED
(If Equipped)
D
F
PNK
BLK * SEAT
SENSOR
RED A A YEL/RED
C304
14
BLK B B YEL/BLK 9
DGN C C YEL/DGN 19
BRAKE SOLENOID
BICS BRAKE 2
MAINFRAME CONTROLLER HARNESS - 6710423
ENGINE
15A
10A 87A SEAT BAR 7

21
BICS CONTROLLER
SENSOR
BRAKE FUSE
GAUGE
30 87
RED A A LBL/RED 15
C305
10A
RED RED/WHT WHT

25A
25A BLK B B LBL/BLK 10
FUEL SOL 85 86
PNK/WHT BLK DGN C C LBL/DGN 20
17
WHT
RED
BLK
LIGHT 6
BRAKE
TRACTION
25A
25A 4
LOCK
ACCESSORY
B C A OVERRIDE 18
C308 SWITCH 11
25A
C307
25A MANUAL
B C A A A DBL/WHT 12
ACCESSORY HYDRAULIC BRAKE
SWITCH B B GRY 22
LOCK SOLENOID
DBL F F DBL 13
BLK
WHT G G WHT 23
C301
FUSE BLOCK BLK DGN C C DGN 1
WHT C C WHT BLK B B BLK 16
C115
BLK B B BLK RED D D RED 3

PNK/WHT D D PNK/WHT PNK/WHT E E PNK/WHT 5
RNG A A RNG RNG A A RNG 8
H H
Printed in U.S.A. V-0060 (1-17-01)

167 of 294
168 of 294
453 WIRING SCHEMATIC
OPTIONS
S/N 515011001 AND ABOVE
S/N 515111001 AND ABOVE
V-0061
EUROPEAN ONLY
HORN RIGHT LEFT

(Optional) TO ENGINE REAR REAR
TAILLIGHT TAILLIGHT
C109
RNG/DBL B LICENSE
RNG A E A C B D F PLATE E F C B D A
LIGHT
HORN HARNESS - C702 C701
6708506 or 6709526 E A C B D F E F C B D A
LBL/WHT
PNK
PNK
BLK
BLK
TO ENGINE
TO ATTACHMENT HORN
SKI CONTROL TO ENGINE
C441
B DBL RNG/WHT A C109

RNG/ BRN/YEL D
A WHT DBL
B
BLK B
C101
PNK A
REAR AUX. TURN SIGNAL F
C YEL/LGN DGN B
C
C457
C108
B YEL/RED BRN A BRN/DGN E

A RNG YEL C
TO ATTACHMENT TO ENGINE TAILGATE HARNESS - 6707509
LEFT HANDLE
(If Equipped)
TO CAB
B
A
C215

C
BACKUP ALARM D
SWITCHES BEACON
C609
A A BRN/RED E
BLK OR
TO ENGINE STROBE B B BLK F
-
C105
BLK BLK BLK B

RNG A
+ RNG
BEACON/STROBE HARNESS - 6708318
BACKUP ADDITIONAL POWER
ALARM CONNECTOR
C717
BLK B
BLK A
BACKUP ALARM HARNESS - 6708739 EUROPEAN ONLY
LEFT RIGHT BEACON

CLEARANCE CLEARANCE OR
BLK
(WORK LIGHT) (WORK LIGHT) BLK STROBE

LEFT LAMP LAMP
TURN RIGHT
BEACON LAMP TURN
OR LAMP
B A STROBE B A
PNK
BLK
BLK
C607 C608
LEFT B A B A
TURN RIGHT TO CAB TO CAB
LAMP TURN
BLK
LAMP
BRN/RED E BRN/RED E
BLK F BLK F
C215
C215
C C
DGN B DGN B
D PNK D
YEL A YEL A
JV FLASHER LIGHT HARNESS - 6710905 4-WAY FLASHER HARNESS - 6709530
EUROPEAN ONLY
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
LEFT RIGHT BEACON
A B CLEARANCE CLEARANCE OR
BLK
BLK
BLK
BLK
B A (WORK LIGHT) (WORK LIGHT) STROBE

LAMP LAMP
LEFT
TURN RIGHT LEFT
RIGHT
LAMP TURN HEADLIGH
SOME CONNECTOR HEADLIGHT
LAMP T
BODIES NOT SHOWN B A
DBL
PNK
FOR DRAWING CLARITY

RED = RED C716
RNG = ORANGE B A
BLK = BLACK
TO CAB
BATTERY FEED 1000-1999 RED, RED/WHT, RNG LBL = LIGHT BLUE
GROUND 2000-2999 BLK
DBL = DARK BLUE BRN/RED E
LGN = LIGHT GREEN BLK F
MONITORING 3000-3999 LBL
C215
DGN = DARK GREEN

DBL C
HYDRAULIC 4000-4999 LGN YEL = YELLOW
ATTACHMENT CONTROLS 5000-5999 YEL PNK = PINK DGN B
LIGHTS 6000-6999 PNK
WHT = WHITE PNK D
BRN = BROWN YEL A
ACCESSORIES 7000-7999 WHT
TAN = TAN
ENGINE 8000-8999 TAN PUR = PURPLE
GRY = GRAY
HEADLIGHT HARNESS - 6707672
COMMUNICATION 9000-9999 PUR
Printed in U.S.A. V-0061 (1-17-01)
169 of 294
170 of 294
TROUBLESHOOTING
Chart
death.
W–2004–1285
PROBLEM CAUSE
Battery loses 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

1. Alternator belt is loose or damaged.

2. Battery connections are dirty or loose.
3. Battery is defective.
4. The ground is not correct in the electrical system.

5. The alternator has a defect.
6. Engine seizure.
7. Starter has a defect.

8. Wiring or solenoid has a defect.
9. Fuse has a defect.
453 Bobcat Loader

ELECTRICAL SYSTEM INFORMATION
A
Description
The loader has a 12 volt, negative ground alternator
charging system [A].
Do Not use silicone base sprays and/or

sealants on harness connectors or
components. I–2123–0397 P–09895
Fuse Location B
The electrical system is protected by 6 fuses located in
the engine compartment [B].
2
Remove the clips (Item 1) [B] and remove the fuse covers
to access the fuses [C]. 1
The decal (Item 2) [B] located by the fuse holders

specifies the fuse sizes used in the various electrical
circuits.
P–09815
P–07417
Relay Switches Location

D
The loader engine harness relay switches (Item 1) [D] are
located on the lower right side of the engine compartment.
There are five relay switches for the circuitry on the
loader.
The relay switches are for the starter, switch power, glow
plugs, brake, and fuel shut down solenoid. 1
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.
P–09769
453 Bobcat Loader

BATTERY
A
1
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–09864
water. In case of eye contact get prompt medical
attention and wash eye with clean, cool water
for at least 15 minutes.
If electrolyte is taken internally drink large
B
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention.
W–2065–1296
1
Open the rear door.

1

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

clamp.
Loosen the nut (Item 2) [B] which fastens the hydraulic fill
tube to the frame, and move out of the way.
Keep arcs, sparks, flames and lighted tobacco

away from batteries. When jumping from
booster battery make final connection
(negative) at engine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F. (16°C.) before
connecting to a charger. Unplug charger before P–09865
connecting or disconnecting cables to battery.
Never lean over battery while boosting, testing
or charging. B
Battery gas can explode and cause serious
injury.
W–2066–1296
Remove battery from loader and set on floor.

Remove positive (+) cable from battery.
Use the reverse procedure to install the battery.
P–09871
453 Bobcat Loader

BATTERY (Cont’d)
A
Always clean the terminals and cable ends when
installing a new battery [A] and [B].
When installing the battery in the loader, do not touch any
metal parts with the battery terminal posts.
Connect and tighten the battery cables. Connect the
negative (–) cable last to prevent sparks.
P–09589

B
body.
In case of acid contact, wash immediately with

If electrolyte is taken internally drink large
quantities of water or milk. DO NOT induce
W–2065–1296
P–09590
Servicing The Electrical System

The battery cables must be clean and the connections
C
tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
water solution [C].
Clean the terminals and cable ends as shown in Fig. [A]
and [B].
Check the electrolyte level in the battery. Add distilled
water as needed.
Put Battery Saver (P/N 6664458) or grease on the battery
terminals and cable ends to prevent corrosion.
P–09588
453 Bobcat Loader

BATTERY (Cont’d)
Using A Booster Battery (Jump Starting)
A 1
1 3
2
2
body.
In case of acid contact, wash immediately with P–07294
P–09872
B 1
If electrolyte is taken internally drink large 1 2
quantities of water or milk! DO NOT induce
W–2065–1296
Keep arcs, sparks, flames and lighted tobacco

away from batteries. When jumping from
booster battery make final connection

(negative) at engine frame.
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F. (16°C.) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery.
Never lean over battery while boosting, testing P–07296
P–09873
or charging.
Battery gas can explode and cause serious
injury. W–2066–1296
If it is necessary to use a booster 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.
The ignition must be in the OFF position. The booster
battery to be used must be 12 volt.
Connect the end of the first cable (Item 1) [A] to the
positive (+) terminal of the booster battery. Connect the
other end of the same cable (Item 1) [B] to the positive (+)
terminal on the starter.
Connect the end of the second cable (Item 2) [A] to the
negative (–) terminal of the booster battery. Connect the
other end of the second cable (Item 2) [B] to the engine
frame mount.
Keep the cables away from moving parts. Start the
engine. (See Cold Temperture Starting Condition,
Operation & Maintenance Manual.)
After the engine has started, remove the ground (–) cable
(Item 2) [B] first.
Remove the cable from the starter.
453 Bobcat Loader

ALTERNATOR
A
Damage to the alternator can occur if: 2

• Engine is operated with battery cables
disconnected. 1
• Battery cables are connected when using a
fast charger or when welding on the loader P–09817
(Remove both cables from the battery).
• Extra battery cables (booster cables) are
connected wrong.
I–2023–1285 B
Open the rear door. Disconnect the negative (–) battery
cable. 1
Remove battery from loader. (See Page 6–5.)
Disconnect the wiring harness connector (Item 1) [A]

from the alternator.
Move the protective cover (Item 2) [A] from red alternator
wires.
P–09792
Disconnect the red wires (Item 1) [B] from the alternator.
Loosen the alternator adjustment bolts (Item 1) [C]. C

Remove the mounting bolts and remove the alternator. 1
Reverse the removal procedure to install the alternator.
1
P–09895
Adjusting The Alternator Belt

D
Stop the engine and open the rear door.
Loosen the adjustment bolts (Item 1) [C] and move the
alternator so there is 1/4 inch (6 mm) movement between
the pulleys with 15 pounds (67 N) of force [D].
Tighten the adjustment bolts.
P–09770
453 Bobcat Loader

ALTERNATOR (Cont’d)
A
Alternator Belt Removal And Installation 1
Open the rear door. Disconnect the negative (–) battery
cable.
Remove the battery from the loader. (See Page 6–5.)
Put jackstands under rear corner of the loader.
Raise the Operator Cab. (See Page 1–1.)
Loosen the alternator adjustment bolts (Item 1) [A]. 1
Move the alternator ahead to loosen and remove the P–09895
alternator belt from the pulley.
Remove the bolt (Item 1) [B] from the belt shield. B

P–09817
Remove the bolt (Item 1) [C] from the rear fuel filter
mount. C
P–09814
453 Bobcat Loader

Alternator Belt Removal And Installation (Cont’d)
A
Move the alternator belt shield and fan housing cover [A].

P–09812
Through the end of the fan housing [B] loosen and

remove the four bolts (Item 1) [B] holding the fan to the
water pump. B
Installation: Apply liquid adhesive (LOCTITE #242) to
the mounting bolts and tighten to 85–92 in.–lbs. (9.5–10.5
Nm) torque.
1
P–09797
Remove the aluminum bushing (Item 1) [A].
Remove the alternator belt.
Reverse the removal procedure to install the alternator
belt.
P–09802
453 Bobcat Loader

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
Check battery and battery connections. (See Page 6–5.)
P–09792
Disconnect the negative (–) cable from the battery.
Disconnect the red wire (Item 1) [B] from the alternator.

C 1
Connect that wire to the negative (–) side of the ammeter
(Item 1) [C].
Connect the positive (+) side of the ammeter to the output 2
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.
If the ammeter reading is less than 35 amps do the full P–10017
field test.
When an engine is running in an enclosed

Exhaust fumes contain odorless, invisible
W–2050–1285
453 Bobcat Loader

Full Field Test
A
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 1


Exhaust fumes contain odorless, invisible 2
W–2050–1285
Alternator Regulator Test

Disconnect the fuel stop solenoid connector.
Turn the lights on (if equipped) and crank the engine for
30 seconds to discharge the battery.
Connect the fuel stop solenoid connector.
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.
Reconnect the alternator wires.
P–10019
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].
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.
453 Bobcat Loader
STARTER
A
Stop the engine and open the rear door.
Installation: Make note of the wiring connections on the 1
starter to ensure correct installation.
Remove the rubber covers from the solenoid terminal 2
(Item 1) [A] and positive (+) starter terminal (Item 2) [A].
P–09896
Remove the positive (+) wires (Item 1) [B] from the

starter. B 2
Remove the solenoid wire (Item 2) [B]. 4
Remove the starter mounting bolt (Item 3) [B] and
negative (–) cables.
Remove the starter mounting bolt (Item 4) [B].

Remove the starter.
3
Installation: Tighten the starter mounting bolts to 25–28 1
P–09878
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
453 Bobcat Loader

STARTER
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
453 Bobcat Loader

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
453 Bobcat Loader

STARTER (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
453 Bobcat Loader

STARTER (Cont’d)
A
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
453 Bobcat Loader

STARTER (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.

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
453 Bobcat Loader

STARTER (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
453 Bobcat Loader

STARTER (Cont’d)
A
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
453 Bobcat Loader

STARTER (Cont’d)
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
453 Bobcat Loader

STARTER (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
453 Bobcat Loader

STARTER (Cont’d)
A 50
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
453 Bobcat Loader

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
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
453 Bobcat Loader

STARTER (Cont’d)
453ServiceManual#6900363(S/N515011001&Above)–ElectricalSystemSectionPart1of2
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
453 Bobcat Loader

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
453 Bobcat Loader

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.

1
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
453 Bobcat Loader

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
453 Bobcat Loader

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
453 Bobcat Loader

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
453 Bobcat Loader

INSTRUMENT PANEL
A
Pry the rubber light mount (optional) loose from the
operator cab (both sides) [A].
P–03995
Lower the light (optional) from the operator cab and locate
the three instrument panel mounting bolts (Item 1) [B]
(both sides).
B
1
Remove the three mounting bolts (Item 1) [B].
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels.
1

P–03955
Pull the right instrument panel down and disconnect the

wire harness connectors from the panel. Remove the
C
panel [C].
P–07184
Repeat steps [A] and [B]. Pull the left 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–07182
453 Bobcat Loader

FRONT LIGHTS (OPTIONAL)
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 three 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.
P–03955
Disconnect the electrical connector (Item 1) [D] to

remove the light from the rubber light mount. D
P–07416
453 Bobcat Loader

FRONT LIGHT (OPTIONAL)
A
Turn the bulb (Item 1) [A] and remove it from the cover 1
(Item 2) [A].
P–07414
REAR LIGHT (OPTIONAL)

B
Remove the light from the rubber mount.
2
Push the work bulb (Item 1) [B] in and turn it 4
counterclockwise to remove it from the socket.
3
Disconnect the electrical connector (Item 2) [B] from the

cab harness.
Remove the screw (Item 3) [B] to remove the work light
socket from the rear light. 1
Remove the screws (Items 3 & 4) [B] to remove the rear
light P–07447
453 Bobcat Loader

453ServiceManual#6900363(S/N515011001&Above)–ElectricalSystemSectionPart2of2
453 Bobcat Loader

ENGINE SERVICE
Page
Number
CRANKSHAFT AND BEARINGS
Inspection Of Crankshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41
CRANKSHAFT GEAR
CYLINDER BORE
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–44
CYLINDER HEAD
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23
Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23
ENGINE
ENGINE COMPRESSION TEST
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–15

ENGINE SPEED CONTROL
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
ENGINE MOUNTING BRACKET
FAN
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7 ENGINE
SERVICE
FLYWHEEL
FUEL CAMSHAFT
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33
FUEL INJECTION PUMP

Checking The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12
FUEL INJECTOR NOZZLES

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14
GLOW PLUGS
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–15
HYDRAULIC OIL COOLER AND SHROUDING

453 Bobcat Loader
203 of 294
ENGINE SERVICE (Cont’d)
Page
Number
IDLER GEAR AND CAMSHAFT
Servicing the Idler Gear And Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32
OIL PUMP
Checking Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35
PISTON AND CONNECTING ROD

Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39
Servicing the Piston And Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . 7–37
RADIATOR
RADIATOR MOUNTING BRACKET

ROCKER ARM AND SHAFT
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–24
THERMOSTAT
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–46
TIMING GEARCASE COVER

TIMING GEARS
Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
VALVE AND VALVE SPRINGS

Checking Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–25
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–25
VALVE GUIDE, VALVE AND VALVE SEAT
Checking The Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–26
Reconditioning The Valve And Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . 7–27
VALVE CLEARANCE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
WATER PUMP
453 Bobcat Loader

204 of 294
TROUBLESHOOTING
Chart
death.
W–2004–1285
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 from the 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, 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, 32, 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
453 Bobcat Loader

TROUBLESHOOTING (Cont’d)
Chart (Cont’d)
DESCRIPTION OF THE CAUSE
1. Battery capacity low. 30. Worn cylinder bores.

2. Bad electrical connection. 31. Worn valves and seats.
3. Faulty starter motor. 32. Broken, worn or sticking piston rings.
4. Incorrect grade of oil. 33. Worn valve stems and 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 oil pan.
8. Plugged fuel line. 37. Gauge is not correct.
9. Faulty 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. 42. 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 the 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 valve tappet adjustment. 56. Plugged oil pump pipe strainer.
28. Sticking valves. 57. Broken valve spring.
29. Incorrect high pressure tubelines.
453 Bobcat Loader

ENGINE SPEED CONTROL
Adjustment
A
Install jackstands under the rear of the loader. (See Page
1–1.)
1
2
Never work on a machine with the lift arms up 3

P–07212
or death. W–2059–0598
B
(See Page 1–1.)
Remove the center shield and left steering lever panel.
(See Page 3–1.)

1
Mark the position of the two adjustment bolts and nuts
(Item 1) [A] for installation purposes.
Move the bolts as needed to adjust the engine speed.
P–09911
Remove the mounting bolt and nut (Item 2) [A], and the
tension spring from the speed control mounting bracket.
Remove the lever and fiber washer between the lever and
the fender.
Installation: Tighten the mounting bolt until the speed
control lever moves back and forth at a comfortable
tension.
Remove the speed control rod (Item 3) [A] from the lever.
Remove the clip (Item 1) [B] from the speed control lever.
Remove the speed control rod from the lever.
453 Bobcat Loader

207 of Mar.
RADIATOR
A
Open the rear door.
Drain the coolant from the engine. (See Page 1–1.)
Remove the oil cooler and shroud. (See Page 7–12.)
Remove the two hose clamps (Item 1) [A] and hoses from 1
the radiator. 1 2 2
Remove the two mounting bolts (Item 2) [A] and remove

the radiator.
Reverse the procedure to install the radiator. P–09820
RADIATOR MOUNTING BRACKET

B
Remove the radiator. (See Page 7–13.)
Remove the two mounting bolts (Item 1) [B].

1 1
P–09820
Remove the mounting bolt and bracket (Item 1) [C] from

the engine coolant tank.
C
Loosen the right side mounting bolt (Item 2) [C].
P–09816
Loosen the left side mounting bolt (Item 1) [D].

D
Remove the radiator and the radiator mounting bracket.
Reverse the procedure to install the radiator and
mounting bracket.
P–09818
453 Bobcat Loader

FAN
A

or death. W–2059–0598
P–09797
(See Page 1–1.)
B
Install jackstands under the rear of the loader. (See Page
1–1.)
Remove the engine and hydrostatic pump assembly from 1

Loosen the alternator adjustment bolts. (See Page 1–1.)
Remove the mounting bolts (Item 1) [A] from the fan. 2
Remove the fan and water pump pulley.
Installation: Apply liquid adhesive (LOCTITE #242) to P–09802
the mounting bolts and tighten to 85–92 in–lbs. (9.5–10.5
Nm) torque.
Remove the radiator hose mounting bolts (Item 1) [B]. C
Remove the nut (Item 2) [B] and remove the radiator hose
guide clamp and the hose.
Remove the mounting bolts (Item 1) [C] and remove the 1

fan shroud.
P–09791
Remove the bolts (Item 1) [D] to remove the water pump

shield. D
Reverse the removal procedure to install the fan.
1
P–09907
453 Bobcat Loader

Revised
209 of Mar.
294 99 –7–7– Service Manual
FLYWHEEL
A
1

approved lift arm support device can allow the P–09805
or death. W–2059–0598
B
(See Page 1–1.)
Remove the engine and hydrostatic pump assembly from

Remove the hydrostatic pump drive belt (Item 1) [A]. (See
Page 3–1.) 1
Remove the hydrostatic pump pulley and the idler pulley

from the hydrostatic pump shaft. (See Page 3–1.)
P–09796
Remove the five mounting bolts (Item 1) [B] from the
flywheel.
C 4
Installation: Apply liquid adhesive (LOCTITE #242) to
the mounting bolts and tighten to 40–45 ft.–lbs. (54–61
Nm) torque.
ENGINE MOUNTING BRACKET

1
2
1
Remove the flywheel.
Remove the bolts (Item 1) [C] from the end plate. 3
1 1
Installation: Tighten the bolts to 29–33 ft.–lbs. (39–45 P–09801
Nm) torque.
Remove the bolts (Item 2) [C] from the hydrostatic pump.

(See Page 3–1.)
Remove the tension spring (Item 3) [C]. (See Page 3–1.)
Remove the muffler mount bolts (Item 4) [C].
Remove the end plate.
Reverse the removal procedure to install the end plate.
453 Bobcat Loader

21099
VALVE CLEARANCE
A
Ajustment
2
Adjust the valve clearance as follows:
1
Loosen the lock nut (Item 1) [A].
Turn the adjusment screw (Item 2) [A] until the correct
clearance is obtained.
NOTE: The clearance is measured between the
rocker arm and valve stem tip (Item 3) [A]. 3
With No. 1 piston at TDC (compression) both the intake B–05893

and exhaust valves are up. Set valves 1, 2, 4 & 5 [C].
Rotate the flywheel 360°, No. 1 piston on exhaust stoke 0.0057–0.0073 in.
(overlap position) intake valve open, exhaust valve
closed. Set valves 3 & 6 [C].
B (0,145–0,185 mm)
Make sure the piston is at TDC when adjusting the

clearance at the valves. The correct clearance is
0.0057–0.0073 inch (0,145–0,185 mm) cold clearance
[B].

A–02730
B–15284
453 Bobcat Loader

211 of 294
FUEL INJECTION PUMP
Checking The Injection Pump
A
procedure:
MEL1237 – Adapter Fuel Line
MEL1173–1 – Pressure Gauge
To check the initial discharge pressure, remove a high 1
pressure tubeline (Item 1) [A] from the fuel injection
pump.
Loosen the other end of the tubeline at the injector, so that
the tubeline can be turned away from the fitting.
P–09912
Connect a pressure gauge (Item 1) [B] to the long leg of

the test tubeline (Item 2) [B] and tighten.
B
Connect the short leg of the tubeline to the fitting at the
fuel injection pump (Item 3) [B].
3
With the starter, rotate the engine to increase the
pressure to 2133 PSI (14707 kPa). Align the plunger with
TDC. 2

The pressure should hold at 2133 PSI (14707 kPa), for 5
seconds or more. 1
If the time is less than the allowable limit, replace the
injection pump.
B–08235
453 Bobcat Loader

21299
FUEL INJECTION PUMP (Cont’d)
Removal
A
Do not attempt to maintain or adjust unless 1

you are trained and have the correct
equipment.
I–2028–0289
P–09791
Clean the injection pump and area around it with a
cleaning solvent or steam cleaning.
B
Never steam clean or put cold water on an

injection pump while the engine is running or

while it is hot. If you do it will cause serious 1
damage to the injection pump.
I–2135–0997
Use these tools for the following procedure:

P–09918
MEL1270 – Fuel Line Removal Tool
MEL1271 – Delivery Valve Removal Tool
Remove the injector nozzle tubelines (Item 1) [A] from the
C
injection pump.
Remove the injector tubelines (Item 1) [B] from the

injectors.
2
Remove the injector lines.
Disconnect the fuel inlet hose (Item 1) [C].

1
Disconnect the fuel return hose (Item 2) [C].
P–09912
453 Bobcat Loader

213 of Mar.
FUEL INJECTION PUMP (Cont’d)
Removal (Cont’d)
A
1
Remove the four bolts (Item 1) [A] from the injection
pump.
1
Put the pin in the control rack in alignment with the slot in
the engine block (Item 1) [B].
NOTE: Make note of the number of shims installed

under the injection pump. The shims are for
the engine timing.
1 1
Installation
P–09912
When the injection pump is installed, make sure the pin
on the control rack is correctly installed in the fork lever
number 1 slot (Item 1) [B]. If the pin is not correctly
installed, the engine will run over maximum speed and
serious damage can result.
B
To install the injection pump, use the following procedure:
Install the injection pump with the shims between the
pump housing and the engine block [B].
Tighten the four nuts to 17–20 ft.–lbs. (23–27 Nm) torque.

Install the fuel inlet hose and the return hose. (See Page
7–11.)
Install the engine lift hook.
1
Connect the wires to the glow plug.
B–05966
Install the high pressure tubelines at the injection pump
and injector nozzles. Tighten to 11–19 ft.–lbs. (15–26 Nm)
torque. C
Remove the air from the fuel system. (See Page 1–1.)
If the injection pump was replaced, check the timing of the
injection pump. (See below.)
Timing Procedure
Timing the fuel injection pump is done by changing the 1
number of shims between the injection pump and engine
block (Item 1) [C]. Each shim will change the timing 1.5
degrees. The timing of the pump will be later when a shim
is added, and earlier when a shim is removed.
To time the injection pump, use the following procedure: B–10007
Remove the number 1 cylinder high pressure tubeline

from the injection pump. D
Install a short pipe to the number 1 outlet of the pump.
Point the pipe up (vertical).
2
With supply to the injection pump rotate the engine in a
clockwise direction. Fuel must flow from the pipe as the
timing mark (Item 1) [D] on the flywheel pulley and the
timing point (Item 2) [D] are in alignment.
The correct timing for the engine is 20 to 22 degrees
B.T.D.C. 1
Add or subtract shims as needed to adjust the delivery
time of the fuel injection pump. Each shim will change the
timing 1.5 degrees.
P–10030
453 Bobcat Loader

21499
FUEL INJECTOR NOZZLES
Checking
A
procedure:
OEM1064 – Injector Nozzle Tester
OEM1065 – Accessory Set
NOTE: You can adjust the release pressure of the

injector nozzle by adding or removing 3
spacers (Item 1) [A] from the top of the nozzle 2
spring (Item 2) [A]. Each spacer will change
the release pressure about 142 PSI (980 kPa). 1
The release pressure must be 1990–2133 PSI
B–04103
(13721–14707 kPa).
Connect the injector nozzle to the tester with the nozzle

in the down position [B]. B
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) [A].

NOTE: When assembling the injector nozzle, tighten
the retainer nut (Item 3) [A] to 43–58 ft.–lbs.
(59–79 Nm) torque. Any higher torque will
cause slow action of the valve.
A–02513
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.
Check the pressure decrease to 10 seconds. The nozzle C Spring
has damage if the pressure decrease is more than 740
PSI (5162 kPa) in 10 seconds. CORRECT WRONG
Pressure
Pin
Check the spray pattern of the nozzle for the following Holder
conditions [C]:
Nozzle
Does not come out the side of the nozzle. Body
Does not have drops coming from the nozzle.
Does not have 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

injury or death. Fluid leaks under pressure may
W–2072–0496
453 Bobcat Loader

215 of Mar.
FUEL INJECTOR NOZZLES (Cont’d)
A

injury or death. Fluid leaks under pressure may 1
W–2072–0496 P–09791
Removal
B
The tool listed will be needed to do the following 1 1
procedure:
MEL1485 – Socket
To remove the injector nozzles, use the following
procedure:
2

Remove the injector tubelines (Item 1) [A] from the
injector pump.
3
Remove the injector tubelines (Item 1) [B] from the
injectors.
P–09918
Remove the fuel return hoses (Item 2) [B] from the banjo
fittings.
Remove the banjo fittings (Item 3) [B] from the fuel C
injector nozzles.
Loosen the fuel injector with a special socket [C].
Remove the fuel injector nozzle from the engine [D].
Do not disassemble or test the fuel injector

nozzles unless you have the correct service B–05970
and testing tools.
I–2027–0284
D
Installation
Install the injector nozzle in the cylinder head and tighten
Install the banjo fitting on the injector nozzle and tighten.
Connect the return fuel line to the banjo fittings.
Install the high pressure tubelines at the injectors and
tighten.
Remove the air from the fuel system. (See Page 1–1 for
the correct procedure.)
B–05971
453 Bobcat Loader

21699
GLOW PLUGS
Checking
A
Disconnect the three nuts (Item 1) [A] that hold the glow
plug electrical bar to the glow plugs. 2 2
Remove the electrical bar (Item 2) [A] from the glow
plugs.
Test the glow plugs by touching one probe to the end of
the glow plug and the other probe to the body of the glow
plug.
Threading must be approximately 1.5. If the resistance is
zero ohms the glow plug has a short circuit. 1
P–09918
If the resistance is infinite the coil of the glow plug is
broken.
Replace the glow plug as needed [B].
B
ENGINE COMPRESSION TEST
Procedure

procedure:
MEL10630 – Engine Compression Test Kit
MEL 1546 – Engine Compression Test Adapter
Warm the engine.
P–03420
Remove the fuel injector nozzles from the engine. (See
Page 7–14.)
Install the compression adapter in the cylinder head. C
Connect the compression gauge to the adapter [C].
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 337–448 PSI
(2324–3089 kPa) with no more than 10% difference
between the cylinders.
P–07537
453 Bobcat Loader

Revised
217 of Mar.
ENGINE
A
NOTE: The engine and hydrostatic pumps are
removed from the loader as an assembly.
2
4 3 3
4
Never work on a machine with the lift arms up P–09877
lift arms or attachment to fall and cause injury B
or death. W–2059–0598
(See Page 1–1.) 1
Open rear door.

Drain the hydraulic/hydrostatic fluid. (See Page 1–1.)
Remove the battery. (See Page 6–1.)
P–09914
Disconnect the speed control linkage (Item 1) [A] from the
injector pump. (See Page 7–15.)
Disconnect the outlet hose (Item 2) [A] from the hydraulic
C 3
pump. (Cap the lines.)
Remove the nuts (Item 3) [A] from the steering lever
linkage. Remove the linkage from the hydrostatic pumps.
Remove the high pressure hoses (Item 4) [A] from the
hydrostatic pumps. (Cap the lines.)
2
Disconnect the charge pressure hose (Item 1) [B] from 1
the hydrostatic pump. (Cap the lines.) 4
Disconnect the hydraulic oil temperature wire (Item 1)
[C]. P–09915
Disconnect the hydraulic oil pressure wires (Item 2) [C].

Disconnect the optional horn wire (Item 3) [C], if loader is
D
so equipped.
Disconnect the optional flasher wire (Item 4) [C], if loader

is so equipped. 2
Disconnect the brake solenoid wiring harness (Item 1)

[D]. 1
Disconnect the brake switch wiring harness (Item 2) [D].
Installation: Install a new Do Not Modify sta–strap (P/N
6665527) on the brake switch and solenoid harness
connectors.
P–09916
453 Bobcat Loader

Revised Mar.
21899
ENGINE (Cont’d)
A
Disconnect the lift lock valve wiring harness (Item 1) [A].
1
P–09900
Remove the hydrostatic motor cover (Item 1) [B]. (Both

sides.) B 1

P–09903
Remove the high pressure hose (Item 1) [C] from the right
hydrostatic drive motor. (Cap the lines.)
C
P–09902
Remove the high pressure hose (Item 1) [D] from the left
hydrostatic drive motor. (Cap the lines.) D
P–09904
453 Bobcat Loader

219 of Mar.
ENGINE (Cont’d)
A
Open the coolant valve (Item 1) [A] to drain the coolant.
(See Page 1–1.)
P–09806
Open the radiator cap [B]. B

Remove the hydraulic cooler and shroud. (See Page
7–45.)
Remove the radiator and radiator mounting bracket and
engine coolant tank. (See Page 7–13.)

P–07531
Close the fuel shutoff valve. (See Page 1–1.)

C 1
Drain the fuel system. (See Page 1–1.)
Remove and plug the fuel lines (Item 1) [C].
Remove the fuel filter assembly by removing the two
mounting bolts (Item 2) [C].
2 1
P–09814
Remove the engine mounting bolts (Item 1) [D].

D
1
P–09875
453 Bobcat Loader

22099
ENGINE (Cont’d)
A
Remove the mounting bolts (Item 1) [A] from the relay
switch bracket.
1
P–10029
Remove the nut (Item 1) [B] from the starter mounting

bolt and remove the battery and engine negative (–)
cables.
B
Remove the starter solenoid wire (Item 2) [B].
Remove the positive (+) wires (Item 3) [B] from the
2
starter.

3 1
P–09896
Remove the wire (Item 1) [C] from the oil pressure

sender.
C
P–09891
Remove the positive (+) wires (Item 1) [D] from the

alternator. D
Disconnect the electrical connector (Item 2) [D] from the
alternator.
2
P–09817
453 Bobcat Loader

221 of Mar.
ENGINE (Cont’d)
A
Remove the wire (Item 1) [A] from the water temperature
sender.
P–09894
Remove the wire (Item 1) [B] from the glow plug. B

Disconnect the electrical harness (Item 2) [B] from the
fuel shutoff solenoid.

1
P–09918
Remove the engine air intake hose (Item 1) [C].

Disconnect the hydraulic hose (Item 2) [C] from the oil
C
cooler tubeline.
P–09876
Remove the muffler exhaust extension (Item 1) [D].

D 1
P–09764
453 Bobcat Loader

22299
ENGINE (Cont’d)
A 2
Install a chain with a hook on each end, to each lift eye

(Item 1) [A] on the engine.
Use a chain lift device (Item 2) [A] and chain hoist to
remove the engine and hydrostatic pump. 1
Raise the chain hoist slowly until the hoist supports the 1
engine.
P–09920
Remove the nuts, bolts, and spacers (Item 1) [B] & [C]
from the hydrostatic pump mounts. B
Lift the engine with the chain hoist until the engine mounts
clear the rear lip of the loader frame.
1

P–09914
P–09899
Remove the hydraulic inlet line (Item 1) [D] from the

hydrostatic pump. Cap the lines. D
Continue to remove the engine and hydrostatic pump
assembly from the loader.
Replace the engine mounts if they are damaged.
Reverse the removal procedure to install the engine and 1
hydrostatic pump in the loader.
P–09884
453 Bobcat Loader

223 of Mar.
CYLINDER HEAD
A 1
Remove the bolts (Item 1) [A] from the valve cover and
remove the valve cover and gasket.
B–14415
Remove the fuel injector nozzles. (See Page 7–14.) B

Remove the glow plugs. (See Page 7–15.)
1
Remove the alternator. (See Page 6–1.)
Remove the rocker arm and shaft assembly (Item 1) [B].
Installation: Tighten the nuts to 7–8 in.–lbs. (9,8–11,3

mm) torque.
Remove the intake and exhaust manifolds.
B–14416
Remove the water return hose [C].

C
B–14417
Remove the cylinder head bolts in order of #14 to #1 [D].

D
Installation: Put oil on the bolt threads. Tighten the bolts
in the correct sequence to 29–33 ft.–lbs. (39–44 Nm)
torque.
NOTE: Re–tighten the cylinder head bolts in the

correct sequence after the engine has been
run for 30 minutes.
B–14490
453 Bobcat Loader

22499
CYLINDER HEAD (Cont’d)
A
Remove the cylinder head from the engine block.
Installation: Always use a new head gasket and new
O–ring. Make sure the O–ring (Item 1) [A] is seated over
the dowel.
1
B–14334
Inspection
Clean the surface of the cylinder head.
B
1
Put a straight edge (Item 1) [B] on the cylinder head.
NOTE: Do not put the straight edge across
combustion chambers.
Put a feeler gauge (Item 2) [B] between the straight edge 2

and the surface of the cylinder head.
A–02735
Put the straight edge on the cylinder head’s four sides and
two diagonal as shown in figure [C]. C
The maximum distortion of the head surface ± 0.002 in.
(± 0,05 mm). If the measurement exceeds the
specification, replace the cylinder head. A
E F
C D
Top Clearance
Install the cylinder head gasket. Put the piston (Item 1) [D] B
being checked at T.D.C.
Put 3 pieces of 0.06 in. (1,5 mm) diameter solder (Item 2)
[C] on the top piston. Use grease to hold them in position. PI–09988
NOTE: Put the solder in position so they do not

touch the valves. D
2
Turn the piston to bottom dead center.
Install the cylinder head and tighten to the correct torque
in the correct sequence. (See Page 7–22.)
Turn the crankshaft until the piston exceeds T.D.C.
Remove the cylinder head.
Remove the solder wire (Item 3) [C] and measure it.
If the measurement exceeds the specifications, check the 1 3
oil clearance of the crank pin journal or the piston pin.
Top clearance .........0.0197–0.0256 in. (0,50–0,65 mm) PI–09989
453 Bobcat Loader

225 of Mar.
ROCKER ARM AND SHAFT
A
Checking
Measure the rocker arm I.D. (Item 1) [A] with an inside
micrometer. 2
1
Measure the rocker shaft O.D. (Item 2) [A] with an outside
micrometer.
If the clearance exceeds the allowable limit, replace the
bushing.
If the clearance still exceeds the allowable limit after the
bushing is replaced, replace the rocker arm shaft.
Oil Clearance Between B–03697
Rocker Arm & Shaft . . . . . . . . . . 0.0006–0.0018 inch
(0,016–0,045 mm)
Allowable Limit . . . . . . . . . . . . . . 0.0059 inch (0,15 mm)
Rocker Arm
Shaft O.D. . . 0.4123–0.4128 inch (10,47–10,48 mm)
Rocker Arm I.D. 0.4134–0.4141 inch (10,5–10,52 mm)
453 Bobcat Loader

22699
VALVE AND VALVE SPRINGS
453ServiceManual#6900363(S/N515011001&Above)–EngineServiceSectionPart1of2
A
Valve Removal
Use a valve spring compressor to compress the valve
spring (Item 1) [a].
1
2
5
4
B–14418
B 2
Remove the valve cap (Item 1) [b] and valve spring collet
(Item 2) [A] & [B].
Remove the valve spring retainer (Item 3) [A] & [B] and
the spring (Item 4) [A] & [B].
Remove the valve (Item 5) [A] & [B].

1 2 3
Remove the seal (Item 6) [B]. 5
4 6
B–04122
Checking Valve Spring

Measure the length of the valve spring. If the
C
measurement is less than the allowable limit, replace the
spring [C].
Free Length . . . . . . . . . . . . . . . . . . 1.244 inch (31,6 mm)
Allowable Limit . . . . . . . . . . . . . . . . 1.118 inch (28,4 mm)
Put the spring on a flat surface, place a square on the side
of the spring [C].
Rotate the spring and measure the maximum tilt. If the
measurement is in excess of the allowable limit, replace
the spring.
Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.047 inch (1,2 mm) B–03680
Put the spring on a tester and compress to specified

length [D]. D
Read the compressed load on the gauge. If the
measurement exceeds allowable limit, replace the spring.
Setting Length . . . . . . . . . . . . . . . . . 1.063 inch (27 mm)
Setting Load . . . . . . . . . . . . . . . . . . . . . 14.6 lbs. (64.1 N)
Allowable Limit (setting load) . . . . . . . 12.3 lbs. (54.9 N)
A–02759
453 Bobcat Loader

Revised
227 of Mar.
VALVE GUIDE, VALVE AND VALVE SEAT
Checking The Valve Guide
A
Remove the valve and spring from the cylinder head.
(See Page 7–25.)
Clean the valve seat and combustion chamber.
Install the valve into the guide. Measure the valve
recessing with a depth gauge [A].
B–03634
If the measurement exceeds the allowable limit, replace

the valve or cylinder head [B].
B 2
Recessing . . . . . . . . . . . . . . . . . . . . 0.004 inch (0,10 mm)

Allowable Limit (Recessing) . . . . . . 0.012 inch (0,3 mm)

1. Cylinder Head
Surface
2. Recessing
PI–09990
Remove the carbon from the valve guide.

Measure the valve stem O.D. [C].
C
Measure the valve guide I.D. [C].
Calculate the clearance. If the clearance exceeds the
allowable limit, replace the valve and/or valve guide.
Valve Guide I.D . . . . . . . . . . . . . . . . 0.2366–0.2372 inch

(6,01–6,025 mm)
Valve Stem O.D . . . . . . . . . . . . . . . . 0.2350–0.2354 inch
(5,9168–5,980 mm)
Clearance Between Valve Stem
and guide . . . 0.0016–0.0018 inch (0,04–0,07 mm)
B–14335
To remove and replace the valve guide, make the driver 7.87’’ (200 mm)
tools as shown in figure [D]. D 3.15” (80 mm)
1.57’’
(40 mm)
0.79” 0.3921–0.3929”
(20 mm) (9,96–9,98 mm)
0.2165–0.2244”
(5,5–5,7 mm)
0.2’’ 0.276” 0.71’’

(5,0 mm) (7 mm) (18,0 mm)
0.236–0.240” 0.59” 0.417–0.421”

(6,0–6,1 mm) (15,0 mm) (10,6–10,7 mm) MC–01364
453 Bobcat Loader

VALVE GUIDE, VALVE AND VALVE SEAT (Cont’d)
Checking The Valve Guide (Cont’d)
A
Press the used valve guide out of the cylinder head using
the special driver tool [A]. (See previous page for tool
dimensions.)
1
Put oil on the outside diameter of the new valve guide.
Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Item 1 & 2) [A], 2
press the new guide until the tools contact the cylinder
head.
Ream the valve guide to the correct specifications.
PI–09992
Reconditioning The Valve And Valve Seat
Grind the valve face to the correct angle using a valve
refacer [B].
B

PI–09993
Grind the valve surface in the cylinder head to the correct

angle [C]. C
15° 45° (30°)
PI–09994
Check the seat surface and valve face (Item 1) [D]. 1 2

D
If the seat surface is too wide, use a 15 degree cutter 15°
(Item 2) [D] to get the correct width (Item 3) [D].
Valve Seat Width
Intake . . . . . . . . . . . . . . . . . . 0.0835 inch (2,12 mm)
Exhaust . . . . . . . . . . . . . . . . 0.0835 inch (2,12 mm)
Valve Seat & Face Angle 3
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
0.0835” (2,12 mm) PI–09995
453 Bobcat Loader

TIMING GEARCASE COVER
A 1
Remove the fuel injection pump. (See Page 7–11.)

Remove the cylinder head, rocker arms and push rods.
(See page 7–22.) 2
Remove the screws (Item 1) [A] from the speed control
plate (Item 2) [A].
B–14868
Separate the speed control plate from the engine and

remove the spring (Item 1) [B].
B
Remove the speed control plate.
1

B–14869
Remove the bolt (Item 1) [C] and disconnect the shaft

spring (Item 2) [C]. C
B–14870
Remove the crankshaft pulley bolt. D

Installation: Tighten the bolt 72–80 ft.–lbs. (98–108 Nm)
torque.
Use a puller and remove the cranksahft pulley [D].
B–14871
453 Bobcat Loader

Revised Mar. 99
TIMING GEARCASE COVER (Cont’d)
A
When installing the crank shaft pulley, make sure to align
the marks [A].
B–14872
Remove the timing gear case cover bolts. B

Installation: Tighten the bolts to 7–8 ft.–lbs. (10–11 Nm)
torque.
Remove the timing gear case [B].

B–14873
Installation: Install three new O–rings and the oil seal

into the timing gear case cover. C
Oil Seal O–rings
B–03617
453 Bobcat Loader

231 of 294
IDLER GEAR AND CAMSHAFT
A
Remove the snap ring (Item 1) [A] and collar (Item 2) [A]
from the idler gear shaft (Item 3) [A].
1
3
2
B–14341
Remove the idler gear (Item 1) [B]. B

1

B–03699
Installation: Make sure the timing marks are aligned

when installing the timing gears [C]. C
Align the holes on the camshaft gear with the camshaft
retainer plate bolts.
Remove the bolts.
Installation: Tighten the camshaft retainer bolts to
14–15 ft.–lbs. (18–21 Nm) torque.
B–14874
Remove the camshaft from the engine block [D].

D
B–03655
453 Bobcat Loader

23299
IDLER GEAR AND CAMSHAFT (Cont’d)
A
Measure the camshaft bearing in the engine block [A].
B–03620
Measure the camshaft journal [B]. B

Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the camshaft.
Bearing I.D. . . . . . 1.299–1.300 inch (33,0–33,03 mm)
Journal O.D. . . . 1.2966–1.2973 inch(32,93–32,95 mm)
Clearance of Camshaft
Journal . . . . . . . . 0.002–0.004 inch(0,05–0,09 mm)

A–02761
Measure the cam lobes at their highest point [C].

C
If the measurement is less than the allowable limit,
replace the camshaft.
Cam Lob Height . . . . . . . . . . . . . 1.058 inch (26.88 mm)
B–05001
Put the camshaft in V–blocks. Install a dial indicator [D].

D
Turn the camshaft at a slow rate. If the misalignment
exceeds the allowable limit, replace the camshaft.
Camshaft Alignment
Allowable Limit . . . . . . . . . . 0.0004 inch (0,01 mm)
A–02760
453 Bobcat Loader

233 of Mar.
IDLER GEAR AND CAMSHAFT (Cont’d)
Servicing The Idler Gear And Shaft
A
Measure the O.D. of the idler gear shaft [A].
Measure the I.D. of the idler gear bushing [A].
bushing.
Idler Gear Shaft O.D..786–.787 inch (19.97–19.98 mm)
Idler Gear Shaft I.D. . . . . . . . . . . . . . . 0.787–0.789 inch
(20,00–29,05 mm)
Oil Clearance between idler shaft & PI–10003
Gear Bushing . . . . . . . . . . . . . . 0.0008–0.0033 inch
(0,020–0,089 mm)
Allowable Limit . . . . . . . . . . . . . . . . . 0.004 inch (0,1 mm) B 0.79” (20 mm)
To replace the idler gear bushing, make a driver tool as
shown in figure [B].
5.91” (150 mm)
0.98” 1.18”
(25 mm) (30 mm)

0.862–0.864”
(21,9–21,95 mm) 0.784–0.785”
(19,9–19,95 mm)
Use a press and special driver tool, to remove the old MC–01366
bushing and install the new bushing [C].
TIMING GEARS C
Checking Backlash
When the gears are installed, check the backlash as
follows:
Install a dial indicator [D].
Hold one gear while turning the other gear [D].
If the backlash exceeds the allowable limit, check the oil
clearance of the shaft and gear. If the oil clearance is
correct, replace the gear.
PI–10004
Crank Gear & Idler Gear . . . . . . . . . . 0.002–0.005 inch
(0,043–0,124 mm)
Allowable Limit . . . . . . . . . . . . . . . . 0.006 inch (0,15 mm) D
Cam Gear & Idler Gear . . . . . . . . . . . 0.002–0.005 inch
(0,047–0,12 mm)
Injection Pump Gear &
Idler Gear . . 0.002–0.005 inch (0,046–0,124 mm)
Oil Pump Gear &
Crankshaft Cover . . . . . . . . . . . . . 0.002–0.005 inch
(0,041–0,123 mm)
Allowable Limit . . . . . . . . . . . . . . . . 0.006 inch (),15 mm) PI–10005
453 Bobcat Loader

23499
FUEL CAMSHAFT
A 2
Remove the timing gearcase cover. (See Page 7–28.)

Remove the idler gear. (See Page 7–30.)
Remove the bolt (Item 1) [A] from the retainer plate (Item
2) [A].
Installation: Tighten the bolt to 6–72 in.–lbs. (6,8–8,1
Nm) torque.
1
Remove the fuel camshaft retainer plate (Item 2) [A].
Remove the fuel camshaft and fork lever assembly at the B–14342
same time.
Governor
B
2
The governor serves to keep the engine speed constant 4
by automatically adjusting the amount of fuel supplied to 1
the engine according to changes in the load.
Disassemble and assemble the governor and fuel 5
camshaft as shown in figure [B].

Check all the parts for wear or damage and replace as
needed.
3
11
10
6 9
8
7
1. Start Spring
2. Governor Spring
3. Fork Lever
4. Fork Lever
5. Fork Lever Shaft
6. Governor Sleeve
7. Retainer Plate
8. Bearing
9. Fuel Camshaft
10. Bearing
11. Snap Ring
B–14875
453 Bobcat Loader

Revised Mar. 99
CRANKSHAFT GEAR
A
Remove the timing gearcase cover. (See page 7–28.)
Remove the idler gear. (See Page 7–30.)
Remove the crankshaft gear with a puller [A].
Remove the crankshaft key.
OIL PUMP
B–03686
Remove the timing gearcase cover. (See Page 7–28.) B
Remove the crankshaft gear.
1
Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [B].
Remove the oil pump mounting bolts. Remove the oil
pump (Item 2) [B].

Installation: Tighten the oil pump mounting bolts to
60–72 in.–lbs. (6,9–8,1 Nm) torque.
2
B–03658
Oil Pump Service

C
Measure the clearance between the lobes of the inner
rotor and outer rotor [C].
B–03616
Measure the clearance between the outer rotor and pump

body [D]. D
If the clearance exceeds the factory limit, replace the oil
pump.
Clearance Between Inner &
Outer Rotor . . . . 0.002–0.006 inch (0,03–0,14 mm)
Clearance Between Outer rotor
& Body . . . . . . . . 0.003–0.006 inch (0,07–0,15 mm)
A–02732
453 Bobcat Loader

23699
OIL PUMP (Cont’d)
Oil Pump Service (Cont’d)
A
Put a piece of press gauge on the rotor face [A].
Install the cover and tighten the bolts.
Remove the cover carefully. Measure the width of the
press gauge [A].
If the clearance exceeds the factory limit replace the oil
pump.
End Clearance . . . . . 0.003–0.005 inch (0,75–0,14 mm)
PI–10009
Checking Engine Oil Pressure
Remove the oil pressure sensor. B
Install a pressure gauge [B].
Start the engine and run until it is at operating
temperature.
If the oil pressure is less than the allowable limit, check the
following item:

• Engine Oil Level Low
• Oil Pump Defective
• Oil Galley Plugged
• Oil Strainer Plugged
• Excessive Clearance at the Rod & Main Bearings
• Relief Valve Stuck B–14876
At Idle Speed Allowable Limit . . . . . . . 14 PSI (98 kPa)

At Rated Speed . . . . . . . . . . . 28–64 PSI (196–441 kPa) C
Allowable Limit . . . . . . . . . . . . . . . . . . . . 14 PSI (98 kPa) 1 3
2
Relief Valve
The relief valve prevents damage of the lubricating
system due to high pressure. This relief valve is a ball
type.
Remove the valve seat (Item 1) [C], ball (Item 2) [C] and
spring (Item 3) [C].
Check the parts for wear or damage and replace as
needed. PI–10011
453 Bobcat Loader

237 of Mar.
PISTON AND CONNECTING ROD
A
Remove the cylinder head. (See Page 7–22.)
Remove the top edge from the cylinder bore with a ridge
reamer.
Remove the oil pan. 1
Remove the oil pump strainer (Item 1) [A].
Turn the flywheel and put a pair of connecting rods at
bottom dead center.
Remove the connecting rod bolts. B–14344
Installation: Tighten the connecting rod bolts to 20–23

ft.–lbs. (27–30 Nm) torque. B
Remove the rod cap and bearing [B].
Use a hammer handle and push the piston connecting rod
assembly out of the cylinder bore [B].
NOTE: Make sure the pistons are marked so they will

be returned to the same cylinder bore.
PI–10013
Installation: Make sure the marks (Item 1) [C] on the

connecting rod and bearing are aligned when installing C
the bearing cap [C].
Repeat the procedure to remove the other
piston/connecting rod assemblies from the engine block.
828
1
828
A–02903
Remove the first compression ring (Item 1) [D].

Remove the second compression ring (Item 2) [D]. D 6
1
Remove the oil ring (Item 3) [D].
4
Remove the snap ring (Item 4) [D] and piston pin (Item 5)
[D]. 5 2
Separate the piston (Item 6) [D] from the connecting rod
(Item 7) [D]. 4
3
NOTE: Make sure the piston and rod assembly is
marked so as not to change the piston rod 7
assembly with another piston or connecting
rod.
B–03621
453 Bobcat Loader

Revised Mar.
23899
PISTON AND CONNECTING ROD (Cont’d)
A
2
Installation: When installing new rings, assemble the
ring so the mark (Item 1) [A] near the gap faces the top
of the piston. When installing the oil ring, place the
expander joint gap (Item 2) [A] 180° from the oil ring gap
(Item 3) [A].
3
PI–10015
Installation: When reassembling, align the marks (Item

1) [B] on the connecting rod and piston (Item 2) [B]. Heat
B 3
4
the piston in oil to 176° F (80° C) for 10 to 15 minutes and
tap the piston pin into position. Place the piston ring gaps
every 120° (Item 3, 4 & 5) [B] with no gap facing the piston
pin in the cylinder.
1
2

5
PI–10014
Servicing The Piston And Connecting Rod

C
Measure the I.D. of the piston pin bore in both horizontal
and vertical direction [C].
the piston.
Piston Pin Bore I.D. . . . . . . . . . . . . 0.7874–0.7879 inch
(20,0–20,013 mm)
A–02733
Measure the O.D. of the piston pin (Item 1) [D].

Measure the I.D. of the connecting rod small end (Item 2) D
[D].
Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the bushing. If it still exceeds the 2
specifications, replace the piston pin.
Piston Pin O.D. . . . . . . . . . . . . . . . . 0.7875–0.7878 inch
(20,002–20,011 mm)
Bushing I.D. . . . . . . . . . . . . . . . . . . 0.7884–0.7890 inch
(20,025–20,04 mm)
Oil Clearance between Piston Pin
& Bushing . . . . . . . . . . . . . . . . . 0.0006–0.0015 inch
(0,014–0,0398 mm)
Allowable Limit . . . . . . . . . . . . . . . . 0.004 inch (0,10 mm) 1
B–03633
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239 of Mar.
Servicing The Piston And Connecting Rod (Cont’d)
A 0.79” (20 mm)
To replace the connecting rod small end bushing, make 5.7” (145 mm)
a driver tool as shown in figure [A].
0.98”
(25 mm) 0.98”
(25 mm)
0.8622–0.8642”
(21,9–21,96 mm) 0.7835–0.7854”
(19,9–19,95 mm)
MC–01366
Use a press and special driver tool to remove the small

end bushing [B].
B
Installation: Clean the small end bushing and bore. Put
oil on the bushing and press into the connecting rod until
it is flush [B].

Removal Installation
PI–10016
Install a new piston ring into the lower part of the cylinder
bore. Measure the ring gap with a feeler gauge [C]. C
If the gap exceeds the allowable limit, replace the ring.
Top Compression Ring & Oil Ring . . 0.006–0.012 inch
(0,15–0,30 mm)
Second Compression Ring . . . . . . . . 0.012–0.018 inch
(0,30–0,45 mm)
Allowable Limit . . . . . . . . . . . . . . . . . 0.047 inch (1,2 mm)
B–03622
Remove the carbon from the ring grooves. Measure the

clearance between the ring and groove with a feeler D
gauge [D].
piston.
Second ring 0.0035–0.0043 inch (0,09–0,12 mm)
Oil ring 0.0016–0.0031 inch (0,04–0,08 mm)
Allowable limit second ring 0.0059 inch (0,2 mm)
Allowable limit oil ring 0.0059 inch (0,2 mm)
B–14475
453 Bobcat Loader

24099
Connecting Rod Alignment
A
NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
doing this check.
Install the piston pin into the connecting rod.

Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate.
If the gauge does not fit squarely against the face place, B–04067
measure the space between the gauge and face plate
[A].
the connecting rod.
Rod Alignment Allowable Limit . . 0.002 inch (0,05 mm)
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CRANKSHAFT AND BEARINGS
A
Remove the piston and connecting rod assemblies. (See
Page 7–36.)
Remove the engine flywheel. (See Page 7–8.)
Remove the bolts which fasten the bearing case cover to
the block.
Installation: Tighten the bearing case cover bolts to 7–8
Install two bolts into the bearing case cover and pull the
cover out [A]. B–03648
Installation: When installing the cover (Item 1) [B], make

sure the casting mark (Item 2) [B] is in the up position.
B 2

B–14877
Before removing the crankshaft/main bearings, check the

end play. Install a dial indicator. Measure the end play by C
moving the crankshaft back and forth [C].
the thrust washers.
End Play . . . . . . . . . 0.006–0.012 inch (0,15–0,31 mm)
B–09565
Remove the main bearing case bolt (Item 1) [D].

D
Installation: Align the bearing case hole (Item 2) [D] with 2
the hole in the block. Put oil on the bolt threads and tighten
B–14346
453 Bobcat Loader

24299
CRANKSHAFT AND BEARINGS (cont’d)
A
Remove the crankshaft/main bearing assembly from the
engine block [A].
Mark the bearing case halves for correct installation.
B–14878
Remove the two bearing case bolts [B].

Remove the bearing case and bearing.
B
Installation: Tighten the bearing case bolts to 9–12

B–04092
Installation: When installing the main bearing case

assemblies, face the mark FLYWHEEL to the flywheel
C
side of the engine block [C]. Be sure the thrust washer
with its oil grooves face outward.
PI–10021
Inspection Of Crankshaft And Bearings

D
Put the crankshaft on V–blocks. Install a dial indicator on
the center journal [B].
Turn the crankshaft at a slow rate.
If the misalignment exceeds the allowable limit, replace
the crankshaft.
Alignment . . . . . . . . . . . . . . . . . . 0.0031 inch (0,02 mm)
A–02763
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243 of Mar.
CRANKSHAFT AND BEARINGS (Cont’d)
A
Inspection Of Crankshaft And Bearings (Cont’d)
Tighten the connecting rod cap bolts 20–22 ft.–lbs.
Measure the crankpin bearing I.D. [A].
120°
A–02727
Measure the crankpin O.D. [B]. B

Calculate the oil clearance.
Crankpin Bearing I.D. . . . . . . . . . . . . . 1.338–1.340 inch
(33,99 –34,04 mm)
Crankpin O.D. . . . . . . . . . . . . . . . . . . . 1.337–1.338 inch
(33,96–33,98 mm)
Oil Clearance . . . . . . . . . . . . . . . . . . 0.0008–0.0032 inch

(0,019–0,081 mm)
Allowable limit . . . . . . . . . . . . . . 0.0059 inch (0,15 mm)
A–02716
453 Bobcat Loader

24499
CRANKSHAFT AND BEARINGS (Cont’d)
Inspection Of Crankshaft And Bearings (Cont’d)
A
Remove the bearing (Item 1) [A] from the front of the
engine block with the removal tool shown in [B].
Installation: Clean the new bearing and bore and apply
oil to them. Install the new bearing with the installation
driver tool [A].
1
PI–10024
B 5.12”
(130 mm)
0.79” 1.5709–1.5728”
(20 mm) (39,90–39,95 mm)

1.7283–1.7303” 0.87”
(43.90–43.95 mm) (22 mm)
0.39”
(10 mm) B–14879
Clean the crankshaft journal and bearing. Put a strip of

press gauge on the center journal.
C
Install the main bearing case halves and tighten the bolts.
Remove the bearing case halves.
Measure the flattened press gauge [C].
crankshaft bearing.
Crankshaft Journal O.D.
(Flywheel side) . . . . . . . . . . . . 1.7297–1.7303 inch
(43,93–43,95 mm)
Bearing I.D. . . 1.7317–1.7333 inch (43,90–44,03 mm)
Crankshaft Journal O.D.
(Middle) . . . . . . . . . . . . . . . . . . 1.5722–1.5728 inch PI–10025
(39,93–39,95 mm)
Bearing I.D. . . 1.5742–1.5758 inch (39,98–40,04 mm)
Crankshaft jounal O.D.
(Front) . . . 1.5722–1.5728 inch (33,98–30,03 mm)
Bearing I.D. . . . .5742–1.5764 inch (33,98–40,04 mm)
Oil Clearance . . . . . . . 0.001–0.004 inch (0,4–0,10 mm)
453 Bobcat Loader

245 of Mar.
CYLINDER BORE
A
Inspection
Check the inside diameter of the cylinder line [A].
B–10073
To find the maximum wear check the inside diameter in

six different locations [B].
B
When the cylinder bore is not within specifications, bore
the cylinder for an oversize piston.
Cylinder Bore I.D. . . . . . . . . . . . . . . . . 2.638–2.639 inch
(67,0–67,02 mm)

NOTE: Make sure you use the correct oversize
pistons and rings.
A–02717
453 Bobcat Loader

Revised Mar.
24699
HYDRAULIC OIL COOLER AND SHROUDING
A
Open the rear door.
Remove the fuse holder (Item 1) [A].
1
P–09815
Remove the oil cooler hose (Item 1) [B] and drain the
hydraulic oil into a clear container. B

P–09905
Remove the hydraulic tubeline (Item 1) [C]. C

1
P–09813
Remove the two bolts (Item 1) [D] from the oil cooler
shrouding. D
Slide the oil cooler and shrouding to the rear and remove.
The oil cooler will lift out of the shroud.
Reverse the procedure to install the oil cooler and shroud.
1 1
P–09819
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247 of Mar.
THERMOSTAT
A
Drain the engine coolant until it is below the thermostat
level.
Remove the bolts (Item 1) [A] and thermostat housing.
Installation: Make sure all gasket surfaces are clean.
Replace the gasket before installing the thermostat
housing.
P–09918
Remove the housing and thermostat (Item 1) [B].

Remove the four mounting bolts at the coolant housing
B 1
(Item 2) [B].
Remove coolant housing from the engine block.
Testing
Hang the thermostats in a suitable container filled with

coolant.
Heat the coolant gradually. Use a thermometer to check
the temperature when it starts to open and when it’s fully
open. 2
If the thermostats do not operate correctly they must be B–03643
replaced.
NOTE: Identify thermostat temperature by the

stamping on the by–pass valve.
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24899
WATER PUMP
A
Drain the cooling system. 4
Remove the radiator. (See Page 7–6.)

3
Remove the alternator belt.
Remove the fan. 5
Remove the water pump bolts (Item 1) [A].
Remove the water pump. 2
1
Installation: Always use a new gasket (Item 2) [A] when B–14859
installing the water pump.

Put the water pump in a vise.
Remove the pulley.
Press the shaft (Item 3) [A] out of the pulley side of the
water pump.

Remove the seal (Item 4) [A] and impeller (Item 5) [A].
Install a new seal when assembling the water pump.
453 Bobcat Loader

Revised Mar. 99
453ServiceManual#6900363(S/N515011001&Above)–EngineServiceSectionPart2of2
453 Bobcat Loader

250 of
SYSTEMS ANALYSIS
Page
Number
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
BICS™ (With Press To Operate Button)

Inspecting the BICS™ System Controller (Engine STOPPED–Key ON) 8–3
Inspecting the Seat Bar Sensor (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 BICS™ System Controller (Engine STOPPED–Key ON) 8–5
Inspecting the Seat And Seat Bar Sensor (Engine RUNNING) . . . . . . 8–5
Inspecting the Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . 8–5
Inspecting the Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
BICS™ SYSTEM CONTROLLER

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7

SEAT BAR SENSOR
BICS™ Controller Seat Bar Sensor Circuit Test . . . . . . . . . . . . . . . . . . . . 8–12
Seat Bar Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10
SEAT SENSOR
BICS™ Controller Seat Bar Sensor Circuit Test . . . . . . . . . . . . . . . . . . . . 8–16
Seat Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14
TRACTION LOCK
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–17 SYSTEMS
ANALYSIS
453 Bobcat Loader

251 of Mar.
453 Bobcat Loader

25299
BICS™ (With Press To Operate Button)
Inspecting The BICS™ Controller
A
(Engine STOPPED – Key ON)
1
1. Sit in the operator’s seat. Turn key ON, lower the
seat bar and disengage the parking brake pedal. 2
Press the green PRESS TO OPERATE Button. All
five BICS controller lights should be ON (Items 1, 2, 3
3, 4 & 5) [A]. 4
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. P–04242
3. 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.
Inspecting The Seat Bar Sensor

(Engine RUNNING)
4. Sit in the operator’s seat. Lower the seat bar. AVOID INJURY OR DEATH
Engage the parking brake pedal. Fasten the seat The Bobcat Interlock Control System (BICS™)
belt.

must deactivate the lift, tilt and traction drive
5. Start the engine and operate at low idle. Press the functions. If it does not, contact your dealer
green PRESS TO OPERATE Button. While raising for service. DO NOT modify the system.
the lift arms, raise the Seat Bar fully. The lift arms W–2151–0394
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)
6. 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.
7. 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
8. Raise the lift arms 6 feet (2 meters) off the ground.
Stop the engine.
Pull and hold the by–pass control knob. Push the toe
of the left foot pedal until the lift arms slowly lower.
453 Bobcat Loader

253 of Mar.
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*.
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. 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.
453 Bobcat Loader

25499
BICS™ (Without Press To Operate Button)
A
Inspecting The BICSTM Controller
(Engine STOPPED – Key ON) 1
Sit in the operator’s seat. Turn key ON, lower the seat bar 2
and disengage the parking brake. All five BICSTM System 3
Controller lights should be ON (Items 1, 2, 3, 4 & 5) [A].
4
Engage the parking brake, raise the seat bar fully. Seat
bar light (Item 2) [A], valve light (Item 3) [A] and traction 5
light (Item 4) should be OFF.
Raise up slightly off the seat. Seat light (Item 1) [A] should
be OFF.
P–04242
NOTE: Record what lights are blinking (if any) and
number of blinks. Refer to Page 8–6.
Clean area behind
Exit the loader and press traction lock override button. B and under seat.
Traction light (Item 4) [A] should be ON. Press override
button again and traction light (Item 4) [A] should be OFF.
Inspecting The Seat And Seat Bar Sensors (Engine

RUNNING)
Sit in the operator’s seat, lower the seat bar and engage
the parking brake. Fasten the seat belt.

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 P–04399
System (BICSTM).
Inspecting The Traction Lock (Engine Running)
Sit in the operator’s seat.
C
Operator
Seat
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.
Seat
1 Spring
Engage the parking brake pedal and move the steering
levers slowly forward and backward. The traction lock Seat
should be engaged. Sensor
Inspecting The Lift Arm By–Pass Control
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 and the lift arms should lower MC–02218
slowly.
Maintenance
Clean any debris, dirt or objects from under or behind the
operators seat [B] & [C]. The right side of the seat must
move up and down.
Clearance is necessary between the seat mount (Item 1) AVOID INJURY OR DEATH
[C] and the seat pan, to allow the seat to move up and
down freely. With adequate clearance, the seat sensor The Bobcat Interlock Control System (BICS)
will be allowed to function properly. must deactivate the lift, tilt and traction drive
functions. If it does not, contact your dealer for
Inspect seat bar pivot area for tight linkage bolts. service. DO NOT modify the system.
W–2151–0394
Replace parts that are damaged. Use only genuine
Melroe replacement parts.
453 Bobcat Loader

255 of Mar.
BICS™ (Without Press To Operate Button) (Cont’d)
Troubleshoot 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.
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.
operate. 3 Seat bar sensor circuit shorted to
ground.
Valve Control Valve Can Control Valve Lift and tilt functions 1 Valve output is open.
Be Used Cannot Be Used will not operate. 2 Valve output circuit shorted to battery.
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.

3 Traction lock hold coil circuit shorted
to ground.
4 Traction lock pull coil circuit is open.
to battery.
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: 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.
453 Bobcat Loader

25699
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,
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.
453 Bobcat Loader

257 of Mar.
BICS™ SYSTEM CONTROLLER (Cont’d)
A 2
NOTE: Photo’s may be different but the procedure is
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–07186
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.
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.

1
NOTE: Install the harness connector (Item 1) [C] into

the controller (Item 2) [C] before installing the
controller.
Be sure the connector to the BICS system

controller are correctly engaged in the
controller when installing the controller. An
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–07191
removed it has been correctly installed [C].
I–2087–1095
Installation: Tighten the controller mounting bolts to

C
80–90 in.–lbs. (9–10 Nm) torque.
Reverse the removal procedure to install the controller.
2
P–04707
453 Bobcat Loader

25899
SEAT BAR SENSOR
death.
W–2004–1285
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5, 6

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.
453 Bobcat Loader

259 of Mar.
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
453 Bobcat Loader

26099
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.
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
453 Bobcat Loader

261 of Mar.
A
BICS™ Controller Seat Bar Sensor Circuit Test
Use Sensor Tester (MEL1428) for the following
procedure:
1

P–04701
Connect Sensor Tester (Item 1) [B] inline as shown to the
seat bar sensor connectors. See inset [A].
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
453 Bobcat Loader

26299
SEAT SENSOR
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
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

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.
453 Bobcat Loader

263 of Mar.
SEAT SENSOR (Cont’d)
A
Seat Sensor Test
Use (MEL1428) Sensor Tester for the following 2
procedure:
Disconnect the short adatper 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.

Disconnect the seat sensor connector (Item 1 – Inset)
[A].
Connect Sensor Tester (Item 2) [A] inline as shown to the
seat sensor.

1
N–00960 P–04705
Move the toggle switch (Item 1) [B] on the sensor tester

to the Absent position. B
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
453 Bobcat Loader

26499
A
Raise the loader operator cab. (See Page 1–1.)
2
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.
Remove the magnet collar mounting bolt (Item 2) [B] and
washer (Item 1) [C].
1
Installation: Tighten the bolt to 180–200 in.–lbs. (21–23 P–07186
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
453 Bobcat Loader

265 of Mar.
BICS™ Controller Seat Sensor Circuit Test
A
Use Sensor Tester (MEL1428) for the following 2
procedure:
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.

Disconnect the seat sensor connector (Item 1 – Inset)
[A].
Connect MEL1428 Sensor Tester (Item 2) [A] inline as
shown to the seat sensor.

1
N–00960 P–04705

ENGINE. B
The power light (Item 1) [B] will illuminate, if the light is not
on, check the tester or wiring harenss.
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
453 Bobcat Loader

26699
TRACTION LOCK
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

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.
453 Bobcat Loader

267 of Mar.
TRACTION LOCK
A
P–04712
AVOID INJURY OR DEATH 1

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–07210
should only be performed by a qualified
technician. Use only genuine Melroe parts if
repair is necessary.
W–2165–0195 B
1
Put jackstands under the rear of the loader.
Raise the loader operator cab. (See Page 1–1.)
Remove the center shield. (See Page 3–1.)
2
Remove the Do Not Modify sta–strap (P/N 6665527) from

the electric solenoid connector (Item 1) [A].
Installation: Install a new Do Not Modify sta–strap (P/N 3
6665527) on the electric solenoid connector.
4
Remove the two mounting bolts (Item 2) [A] from the
P–07225
electric solenoid mounting bracket.
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
C
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 2
assembly (Item 1) [B] from the chaincase cover.
Remove and inspect the compression spring (Item 2) [B]
for wear or damage. Replace if necessary. The spring
may also stay with the shaft when the electric solenoid 3
and bracket are removed from the chaincase.
1
Installation: Install the compression spring (Item 2) [B]
on the collar located on the electric solenoid. P–07025
Remove the traction lock assembly (Item 3) [B] from the

chaincase.
Check the gasket (Item 4) [B] condition and replace as
needed.
Remove the shaft mounting bolt (Item 1) [C], washer and
spring from the assembly shaft (Item 2) [C]. Remove the
wedge (Item 3) [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 (Item 1) [C], the shaft (Item 2) [C] and
wedge (Item 3) [C]. Use LOCTITE #242 when
assembling these parts to the traction lock assembly.
Refer to Page 8–3 for the traction lock inspection
procedure.
453 Bobcat Loader
26899
SPECIFICATIONS
Page
Number
DECIMAL AND MILLIMETER EQUIVALENTS

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
ENGINE SPECIFICATIONS
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Engine Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
Fuel Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Re–Grinding The Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5

Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
HYDRAULIC CONNECTION SPECIFICATIONS

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12
O–ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12
O–ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–13
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–15
Straight Thread O–ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–16
LOADER SPECIFICATIONS
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Floor Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4 SPECIFICATIONS
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
TORQUE SPECIFICATIONS FOR BOLTS

Torque for Geneal Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11
Torque for Geneal SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
U.S. TO METRIC CONVERSION

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
453 Bobcat Loader

269 of 294Mar. 99
453 Bobcat Loader

SKID STEER LOADER S Dimensions are given for loader equipped with standard tires and dirt bucket and may
SPECIFICATIONS vary with other bucket types. All dimensions are shown in inches. Respective metric
dimensions are given in millimeters enclosed by parentheses.
S Where applicable, specification conform to SAE or ISO standards and are subject to
change without notice.
56.4 99°
(1433) ‘‘C”
33.9 38°
(862)
120.0
(3048)
15.0
(381) 92.4
(2347)
71.5 71.2
(1816) (1808)
26° 25°
28.4
45.6 5.9 (721) 7.0
(1155) ‘‘B” (150) 72.8 (180)
(1849)
‘‘A” 97.2 6708828

(2468)
‘‘A” STD. TIRES – 35.4 (900) ‘‘B” STD. TIRES – 29.4 (747) ‘‘C” 36 in. BUCKET WIDTH – 35.48 in. (901 mm)
FLOTATON – 43.3 (1100) FLOTATION – 34.8 (884) 44 in. BUCKET WIDTH – 44.5 in. (1130 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.
SPECIFICATIONS 453
PERFORMANCE
Rated Operating Capacity (SAE) . . . . . . 600 lbs. (272 kg)
Tipping Load (SAE Rating) . . . . . . . . . . . 1431 lbs. (649,1 kg)
Operating Weight . . . . . . . . . . . . . . . . . . . 2501 lbs. (1134,5 kg)
SAE Breakout Force – Lift . . . . . . . . . . . . 1200 lbs. (544 kg)
– Tilt . . . . . . . . . . . . 1150 lbs. (522 kg)
Axle Torque . . . . . . . . . . . . . . . . . . . . . . . . 1775 ft.–lbs. (2407 Nm)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . 0–5.2 MPH (8,4 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 and shutdown.
Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . Key activated glow plugs.
Service Brake . . . . . . . . . . . . . . . . . . . . . Two independent hydrostatic systems controlled by tow hand
operated steering levers.
Secondary Brake . . . . . . . . . . . . . . . . . . One of the hydrostatic transmissions
Parking Brake . . . . . . . . . . . . . . . . . . . . . . Mechanical Disc, foot operated pedal.
ENGINE
Make/Model . . . . . . . . . . . . . . . . . . . . . . . . Kubota/D722
Fuel/Cooling . . . . . . . . . . . . . . . . . . . . . . . . Diesel/Liquid
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . 15.7 HP (11,7 kW)
Maximum Governed RPM . . . . . . . . . . . . 3000 RPM
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ft.–lbs.(42 Nm)@ 2200 RPM
Number of Cylinders . . . . . . . . . . . . . . . . . Three
Displacement . . . . . . . . . . . . . . . . . . . . . . . 44.01 cu.–in (719 cm3)
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . 2.64/2.68 (67,0/68,0)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Pressure System W/Filter
Crankcase Ventilation . . . . . . . . . . . . . . . . External
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Dry replaceable paper cartridge
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression Diesel
453 Bobcat Loader

SPECIFICATIONS (Cont’d)
453
HYDRAULIC SYSTEM
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven, Gear type
Pump Capacity . . . . . . . . . . . . . . . . . . . . . 6.3 GPM (23,8 L/min.) @ 3000 RPM
System Relief at Quick Couplers . . . . . . 1195–1245 PSI (8239–8584 kPa)
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 micron replaceable cartridge in the hydrostatic pump charge line.
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . Double–acting
Bore Diameter:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . 2.00 (50,8)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . 3.00 (76,2)
Rod Diameter:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . 1.00 (25,4)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . 1.25 (31,8)
Stroke:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . 21.88 (555,8)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . 10.94 (277,9)
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 . . . . . . . . . . . . . . . . . . . 5.0 Seconds
Lower Lift Arms . . . . . . . . . . . . . . . . . . . . 4.0 Seconds
Bucket Dump . . . . . . . . . . . . . . . . . . . . . . 3.0 Seconds
Bucket Rollback . . . . . . . . . . . . . . . . . . . 2.5 Seconds
ELECTRICAL

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 40 amp open
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt, 530 cold cranking amps
@ 0° F (–18° C), 120 minute
reserve capacity
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt Straight Drive
Instrumentation . . . . . . . . . . . . . . . . . . . . . Gauges: Hourmeter, Voltmeter Eng. Temp. & Fuel (on tank)
Warning Lights: Engine Oil Pressure & Temperature,
Hyd. Oil Temp. & Pressure.
DRIVE SYSTEM
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic 4 wheel drive
Transmission . . . . . . . . . . . . . . . . . . . . . . . Infinitely variable tandem hydrostatic piston pumps, driving two fully
reversing hydrostatic motors
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . #60 endless roller chain & sprockets in sealed chaincase with
oil lubrication
Total Engine to Wheel
Reduction . . . . . . . . . . . . . . . . . . . . . . . . . 38.49:1
Axle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 (38,1)
Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . (5) 7/16”
CAPACITIES
Cooling System . . . . . . . . . . . . . . . . . . . . . 7 qts. (6,6 L)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 gals. (24,6 L)
Engine Oil W/Filter . . . . . . . . . . . . . . . . . . 3.4 qts. (3,2 L)
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . 5.3 qts. (5,0 L)
Hydraulic/Hydrostatic System . . . . . . . . . 4.0 gals. (15,1 L)
Chaincase Reservoir . . . . . . . . . . . . . . . . 3.0 gals. (11,4 L)
TIRES
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.70–12, 4 ply rating
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 x 8.5–12, 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.
FLOOR PRESSURE Front Rear Front Rear
Std. Tires–Rated Load . . . . . . . . . . . . . . . . . . . 68 PSI (469 kPa) 61 PSI (420 kPa) 68 PSI (469 kPa) 64 PSI (441kPa)
Unloaded . . . . . . . . . . . . . . . . . . . . . . 49 PSI (338 kPa) 67 PSI (462 kPa) 49 PSI (338 kPa) 69 PSI (476 kPa)
Flot. Tires–Rated load . . . . . . . . . . . . . . . . . . . . . 25 PSI (172 kPa) 21 PSI ( 145 kPa) 25 PSI (172 kPa) 23 PSI (159 kPa)
Unloaded . . . . . . . . . . . . . . . . . . . . . . . 14 PSI (97 kPa) 25 PSI (172 kPa) 14 PSI (97 kPa) 27 PSI (186 kPa)
453 Bobcat Loader

272 of 97
Revised Sept. 294 –9–4– Service Manual
ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Engine
Compression (At Operating Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412–469 PSI (2839–3231 kPa)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 PSI (2253 kPa)
Fuel Injector Nozzles
Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1991–2133 PSI (13726–14705 kPa)

Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1849 PSI (12,747 kPa)
Fuel Injection Pump
Fuel Tightness of Plunger Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sec. Initital Pressure Drop From
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2133 PSI (14696 kPa)
Fuel Tightness of Delivery Valve Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sec. Initital Pressure Drop From
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2133–1990 PSI (14708–13721 kPa)
Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–22 degrees B.T.D.C.
Cylinder Head
Cylinder Distortion Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) in 3.9 (100) of the length

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . of the cylinder head

Thickness of Gasket Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0415–0.0512 (1,15–1,30 )
Thickness of Gasket Tightened . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0413–0.0453 (1,05–1,15 )
Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020–0.030 (0,51–0,8 )
Valves
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees

Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 (2,1)
O.D. of Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.235–0.2354
I.D. of Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2366–0.2372 (6,01–6,025)
Clearance between Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0012–0.0022 (0,03–0,057)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,1)
Depth of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . –0.004–0.004 (–0,10–0,10)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 (0,30)
Valve Clearance (Cold) (Intake & Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006–0.007 (0,145–0,185)
Valve Springs
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.244 (31,6)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.118 (28,4)
Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.063 (27)
Load to Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6 lbs (6,6 Kg)
Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3 lbs (5,6 Kg)
Limited Permitted for Spring Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.047 (1,2)
Rocker Arms
O.D. of Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4123–0.4128 (10,47–10,48)

I.D. of Rocker Arm Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4134–0.4141 (10,5–10,52)
Clearance between Rocker Arm Shaft & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006–0.0018 (0,016–0,045)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
453 Bobcat Loader

ENGINE SPECIFICATIONS (Cont’d)
Camshaft
O.D. of Camshaft Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2966–1.2972 (32,93–32,95)

I.D. of Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2992–1.3002 (32,99–33,025)
Clearance between Camshaft Bearing & Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002–0.004 (0,05–0,91)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Alignment of the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0004 (0,01)
Cam Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0583 (26,88)
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002–0.005 (0,047–0,123)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Cylinders
I.D. of Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6378–2.6385 (67,0–67,019)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6444 (67,169)
Rebore Size for Oversize Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6476–2.6483 (67,249–67,267)
Piston Rings
Ring Gap, Top & Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059–0.0118 (0,15–0,30)

Ring Gap, 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00118–0.0177 (0,30–0,45)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0472 (1,2)
Side Clearance of Ring in Groove;

Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Beacuse of top ring design, measurement does not apply
2nd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0035–0.0045 (0,09–0,12)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016–0.0031 (0,04–0,08)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Oversize of Piston & Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0098 (0,25)
Pistons
I.D. of Piston Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.787–0.788 (19,98–20,02)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.789 (20,04)
O.D. of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.787–0.788 (19,98–20,04)
I.D. of Connecting Rod Bushing (Small End, Fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.788–0.790 (20,02–20,07)
Clearance between Piston Pin & Bushing Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,10)
Connecting Rod Alignment Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05)
Crankshaft
Crankshaft Alignment Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,02)

O.D. of Crankshaft Journal No. 1 & No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5722–1.5728 (39,93–39,95)
O.D. of Crankshaft Journal No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7297–1.7303 (43,93–43,95)
I.D. of Crankshaft Bearing No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5742–1.5763 (39,98–40,04)
Clearance between No. 1 Crankshaft Journal and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0013–0.0042 (0,03–0,11)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,20)
Clearance between No. 2 Crankshaft Journal Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0013–0.0036 (0,03–0,09)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,20)
Clearance between No. 3 Crankshaft Journal and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0013–0.0036 (0,03–0,09)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,20)
O.D. of Connecting Rod Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3370–1.3376 (33,96–33,98)
I.D. of Connecting Rod Bearings‘ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3386–1.3402 (33,99–34,04)
Clearance between Coinnecting Rod Journals and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008–0.0032 (0,02–0,08)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006–0.012 (0,15–0,30)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,50)
453 Bobcat Loader

Oil Pump
Oil Pressure @ Rated RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28–64 PSI (193–441 kPa)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PSI (98 kPa)
Oil Pressure @ Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PSI (98 kPa)
Rotor Lobe Clearance Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Clearance between Outer Rotor & Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003–0.006 (0,08–0,15)
End Clearance between Inner Rotor & Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003–0.005 (0,08–0,13)
Clearance between Inner Rotor and Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012–0.006 (0,03–0,14)
Thermostat
Opening Temperature
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157–163°F (70–73°C)
Full Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185°F (85°C)
453 Bobcat Loader

1.
ENGINE BOLT TORQUE
ft. lbs. Nm
*Cylinder Head Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29–33 39–44

*Main Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–22 27–30
*Main Bearing Case Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–12 13–16
*Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–43 54–59
*Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–22 27–30
*Rocker Arm Bracket Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 10–11
*Idler Gear Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 9–11
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11 8–15
Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36–50 49–69
Oil Pressure Sending Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–15 15–20
Fuel Injection Tubeline Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–25 25–34
Crankshaft Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72–80 91–108
Injection Pump Mounting Bolt and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 10–11
*Lightly Oiled Threads
PUNCHED NUMBER BOLT MATERIAL GRADE

None Standard Bolts SS41, S20C
7 Special Bolts S43C, 248C (Refined)

9 Special Bolts SCM3, SCR3 (Refined)
BOLT TORQUES
MATERIAL GRADE STANDARD BOLT SPECIAL BOLT SPECIAL BOLT
NOMINAL DIAMETER SS42, S20C S43C, S48C (Refined) SCR3, SCM3 (Refined)
M6 6 to 7 ft. lbs. 7 to 8 ft. lbs. 9 to 11 ft. lbs.
(8 to 9 Nm) (9 to 11 Nm) (12 to 15 Nm)
(18 to 20 Nm) (23 to 27 Nm) (30–34 Nm)
(39 to 45 Nm) (47 to 56 Nm) (61 to 71 Nm)
(62 to 73 Nm) (77 to 91 Nm) (103 to 118 Nm)
(108 to 126 Nm) (123 to 148 Nm) (167 to 197 Nm)
(167 to 191 Nm) (197 to 225 Nm) (260 to 304 Nm)
M18 181 to 210 ft.–lbs 203 to 235 ft. lbs. 253 to 297 ft. lbs.
(245 to 285 Nm) (275 to 319 Nm) (343 to 403 Nm)
M20 246 to 289 ft.–lbs 271 to 318 ft. lbs. 362 to 420 ft. lbs.
(334 to 392 Nm) (367 to 431 Nm) (491 to 578 Nm)
453 Bobcat Loader

Re–Grinding The Crankshaft
6 B
If the standard size bearing cannot be used due to 1
excessive wear of the crank pin and crank journal use 3
undersize or oversize bearings. 1
For undersize or oversize bearing use, follow the
precautions noted below. A
Grind the crankpin and journal with a wheel which has
specified round corner and width without shoulder [A].
1. 0.071–0.087 (1,8–2,2 mm) C
2. 0.091–0.106 (2,3–2,7 mm) 1
3. Be sure to chamfer the oil hole circumference to 2 D
0.04–0.06” (1,0–1,5 mm) radius with an oil stone. 5
4. The crankpin must be fine finished to higher than 4
(0,4–S).
5. The crank journal must be fine–finished to higher
than (0,4–S).
6. The crank journal side surface must be fine–finished B–05928
to higher than (1,6–S).
SIZE CODE NO. NAME OF BEARING BEARING MARK CRANKSHAFT PROCESSING DIM.
–.008” Crankshaft Bearing 1
(–0,2 mm) 15861–23911 0.008” minus (0,2 minus) 020 US
1.5643–1.5650”
–0.008” Crankshaft Bearing 2 (39,734–39,750 mm)

(–0,2 mm) 15694–23931 0.008” minus (0,2 minus) 020 US
–0.008” Crankshaft Bearing 3 1.7218–1.7224 in.
(–0,2 mm) 15861–23861 0.008 minus (0,2 minus) 020 US (43,734–43,750 mm)
–0.016” Crankshaft Bearing 1 A

(–0,4 mm) 15861–23921 0.016” minus (0,4 minus) 040 US
1.5565–1.5571””
–0.016” Crankshaft Bearing 2 (39,534–39,550 mm)
(–0,4 mm) 15699–23941 0.016” minus (0,4 minus) 040 US
–0.0016” Crankshaft Bearing 3 1.7139–1.7146”

(–0,4 mm) 15861–23871 0.016 minus (0,4 minus) 040 US (43,534–43,550 mm)
–0.008” Crank Pin Bearing 1.3291–1.3297”

(–0,2 mm) 15861–22971 0.008” minus (0,2 minus) 020 US (33,759–33,775mm)
–0.016 Crank Pin Bearing B 1.3212–1.3219”

(–0,4 mm) 15861–22981 0.016” minus (0,4 minus) 040 US (33,559–33,575 mm)
+0.008” Thrust Bearing 1

(+0,2 mm) 15261–23951 0.008” plus (0,2 plus) 020 OS
1.815–1.823”
Thrust Bearing 2 (46,1–46,3 mm)
15261–23971 0.008” plus (0,2 plus)
Thrust Bearing 1 C
+0.016” 15261–23961 0.016” plus (0,4 plus) 040 OS 1.823–1.831”
(+0,4 mm) (46,3–46,5 mm)
Thrust Bearing 2
15261–23981 0.016” plus (0,4 plus)
0.008” Crankshaft over size 1.815–1.823”
(0,2 mm) Dimension D (46,1–46,3 mm)
0.016” 1.823–1.831”
(0,4 mm) (46,3–46,5 mm)
453 Bobcat Loader

TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE 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. (9–10) (13–14)
(Nm)
.3125 180–200 215–240
(21–23) (24–27)
.375 25–28 35–40
(34–38) (48–54)
.4375 40–45 60–65
(54–61) (82–88)
.500 65–70 90–100
(88–95) (125–135)
.5625 90–100 125–140
(125–135) (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)
453 Bobcat Loader

Revised Oct. 98
TORQUE SPECIFICATIONS FOR BOLTS (Cont’d)
Torque For General Metric 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)
(18–24 Nm) (30–41 Nm) (49–68 Nm)
(30–41 Nm) (54–73 Nm) (94–118 Nm)
(49–68 Nm) (79–108 Nm) (157–186 Nm)
453 Bobcat Loader

279 of 294
A

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
Revised Oct. 453 Bobcat Loader

280 of 294 98 –9–12– Service Manual
(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

2
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.
453 Bobcat Loader

281 of 294
(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
sealing. P–13572
Use a standard flare fitting (Item 1) [A] as shown.
When a O–ring flare fitting is used as a straight thread port B
adapter the O–ring flare face is not used to seal. The
O–ring may come off the fitting and enter the system.
2
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
453 Bobcat Loader

28298
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.
NOTE: Port seal fittings are not recommended in all

Port Seal and O–ring Boss
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)
453 Bobcat Loader

283 of 294
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 or 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
453 Bobcat Loader

28498
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–Meter 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
453 Bobcat Loader
Added Oct. 98
453ServiceManual#6900363(S/N515011001&Above)–SpecificationsSection
453 Bobcat Loader

453–1
® Revision Number
12 September 1997
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER
SERVICE MANAGER X
Model 453 SALES MANAGER
Manual No. 6900363 (5–97)
NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.
The following pages are a revision to the 453 Service Manual P/N 6900363 (5–97).
Take out the pages shown and put in the revised pages as follows:

TAKE OUT PUT IN
v, vi v (Revised Sept. 97), vi
1–3, 1–4 1–3 (Revised Sept. 97), 1–4 (Revised Sept. 97)
3–21, 3–22 3–21, 3–22 (Revised Sept. 97)
7–7, 7–8 7–7, 7–8 (Revised Sept. 97)
9–3, 9–4 9–3, 9–4 (Revised Sept. 97)
287 of 294 Printed in U.S.A.

288 of 294
453–2
® Revision Number
9 October 1998
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6900363 (5–97)
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
Maintenance Safety Page Maintenance Safety Page
ALPHABETICAL INDEX ALPHABETICAL INDEX
v thru vi v thru vi
1–1 thru 1–2 1–1 thru 1–2
1–5 thru 1–10 1–5 thru 1–10
1–15 thru 1–26 1–15 thru 1–26
DO NOT REMOVE the Hydraulic Schematics
in Section 2
2–1 thru 2–4 2–1 thru 2–4
2–11 thru 2–12 2–11 thru 2–12
2–15 thru 2–22 2–15 thru 2–22
2–35 thru 2–36 2–35 thru 2–36
3–7 thru 3–10 3–7 thru 3–10

4–1 thru 4–2 4–1 thru 4–2
7–1 thru 7–2 7–1 thru 7–2
7–9 thru 7–10 7–9 thru 7–10
8–17 thru 8–18 8–17 thru 8–18
9–1 thru 9–2 9–1 thru 9–2
9–9 thru 9–16 9–9 thru 9–20
289 of 294
290 of 294
453–3
® Revision Number
24 March 1999
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER X
Manual No. 6900363 (5–97)


TAKE OUT PUT IN
Cover Cover
Maintenance Safety Page Maintenance Safety Page
ALPHABETICAL INDEX ALPHABETICAL INDEX
i thru x i thru viiii
Section 1 Section 1
Section 2 Section 2
HYDRAULIC SCHEMATICS HYDRAULIC SCHEMATICS
3–3 thru 3–10 3–3 thru 3–10
3–17 thru 24 3–17 thru 24
3–31 thru 3–32 3–31 thru 3–32
Section 4 Section 4
5–7 thru 5–10 5–7 thru 5–10
5–17 thru 5–18 5–17 thru 5–18
Section 7 Section 7
Section 8 Section 8
9–1 thru 9–2 9–1 thru 9–2
9–17 thru 9–20 9–17 thru 9–18
291 of 294
292 of 294
453–4
Revision Number
15 January 2001
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
453 (S/N 515011001 & Above) & SERVICE MANAGER X
Model (S/N 515111001 & Above) SALES MANAGER
Manual No. 6900363 (5–97)


TAKE OUT PUT IN REVISION DESCRIPTION
Cover Cover Updated to New logos
Cartoon Cartoon Updated
v, vi v, vi Updated
1–1, 1–2 1–1, 1–2 Text change
1–13 thru 1–32 1–13 thru 1–30 Air cleaner
Information removed
HYD./HYDRO. SCHEMATIC HYD./HYDRO. SCHEMATIC Shuttle valves removed from
453 (S/N 515011001 and Above) 453 (S/N 515011001 – 515013712) drive motors
(S/N 515111001 and Above) (S/N 515111001 – 515113619)
(Printed April 1999) (Printed January 2001)
V–0059
HYD./HYDRO. SCHEMATIC Drain line added between
453 (S/N 515013713 and Above) Filter block and
(S/N 515113620 and Above) Hydrostatic pump
(Printed January 2001)
V–0058
2–41, 2–42 2–41, 2–42 Filter block changes
3–21, 3–22 3–21, 3–22 Filter block changes
3–25, 3–26 3–25, 3–26 Hydro. pump, text,
and photo changes
453 BICSt 453 WIRING SCHEMATIC Electric charts combined
CAB WIRING DIAGRAM (S/N 515011001 and Above)
INDEX (S/N 515111001 and Above)
(Printed January 2001)
V–0060
CAB WIRING DIAGRAM – SHEET 1 453 WIRING SCHEMATIC

(Harness 6707498 Rev. D) OPTIONS
453 BICSt (515011001 and Above) (S/N 515011001 and Above)
(515111001 and Above) (S/N 515111001 and Above)
(Printed May 1999) (Printed January 2001)
V–0061
Printed in U.S.A.
293 of 294
TAKE OUT PUT IN REVISION DESCRIPTION
453 BICSt
ENGINE WIRING DIAGRAM
INDEX
ENGINE WIRING DIAGRAM – SHEET 1
(Harness 6714018 Rev. A)
453 BICSt (515011001 and Above)
(515111001 and Above)
(Printed May 1997)
453 BICSt
OPERATOR CONTROLS
WIRING DIAGRAM
INDEX
OPERATOR CONTROLS (Optional)
WIRING DIAGRAM – SHEET 1
(515111001 and Above)
(Printed May 1997)
453 BICSt
BICSt WIRING DIAGRAM
INDEX
BICSt WIRING DIAGRAM – SHEET 1
(BICSt Controller Harness 6710422)

(515111001 and Above)
(Printed May 1997)
294 of 294

453 6900363 SM 5-97 PDF

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What safety precautions are mentioned for working on the machine?

What safety precautions are mentioned for working on the machine?

What maintenance tasks can an operator perform without training?

What maintenance tasks can an operator perform without training?

Service

Dealer Copy -- Not for Resale

6900363 (5–97) Printed in U.S.A. © Bobcat Company 1997

CORRECT CORRECT CORRECT

B-10731a B-12365 B-7469

Dealer Copy -- Not for Resale

B-6590 B-6580 B-6589

Dealer Copy -- Not for Resale

Dealer Copy -- Not for Resale

453 Bobcat Loader

1. Check that the ROPS/FOPS 9. The parking brake must

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

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

Dealer Copy -- Not for Resale

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

453 Bobcat Loader

18. Inspect the air cleaner for

19. Check the electrical charging

20. Check tires for wear and

Dealer Copy -- Not for Resale

22. Operate the loader and check

23. Check for any field

24. Check for correct function of

Recommend to the owner that all

453 Bobcat Loader

453 Bobcat Loader

Dealer Copy -- Not for Resale

Warnings on the machine and in the This notice identifies procedures

453 Bobcat Loader

Dealer Copy -- Not for Resale

453 Bobcat Loader

LOADER SERIAL NUMBER

The loader serial number plate is located on the inside of

ENGINE SERIAL NUMBER

Dealer Copy -- Not for Resale

453 Bobcat Loader

Dealer Copy -- Not for Resale

REAR DOOR LIFT

◊ FACTORY OPTION OR FIELD ACCESSORY (Not Standard Equipment)

453 Bobcat Loader

AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24

ENGINE COOLING SYSTEM

ENGINE LUBRICATION SYSTEM

Dealer Copy -- Not for Resale

LUBRICATING THE LOADER

Continued On Next Page

453 Bobcat Loader

SEAT BAR RESTRAINT SYSTEM

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453 Bobcat Loader

Instructions are necessary before operating or servicing machine.

ITEM SERVICE REQUIRED 8–10 50 100 250 500 1000

Dealer Copy -- Not for Resale

453 Bobcat Loader

Instructions are necessary before operating or