PDF Service Manual Bobcat S550 Skid Steer Loader - 4 MB
Get the official service manual for the popular Bobcat S550 Skid Steer Loader.
This comprehensive document contains all the information a technician needs for maintenance, diagnostics, and complex repairs.
It covers everything from the hydraulic system to the engine and electrical components.
Trust this manual to help you keep your S550 working hard and reliably.
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--- Page 1 ---
Service Manual
Skid-Steer Loader
S550 S/N B4ZD11001 & Above
7417391enUS (11-20) (0) Printed in Belgium ©2020 Bobcat Company. All rights reserved.
EU S5
--- Page 3 ---
SAFETY INSTRUCTIONS The following publications provide information on the safe
use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
AVOID INJURY OR DEATH
Instructions are necessary before operating or • Machine signs (decals) instruct on the safe operation
servicing machine. Read and understand the and care of your Bobcat machine or attachment. The
Operation & Maintenance Manual, Operator’s signs and their locations are shown in the Operation
Handbook and signs (decals) on machine. Follow & Maintenance Manual. Replacement signs are
warnings and instructions in the manuals when available from your Bobcat dealer.
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or • An Operator’s Handbook fastened to the operator
service. Untrained operators and failure to follow cab. It’s brief instructions are convenient to the
instructions can cause injury or death. operator. The handbook is available from your dealer
W-2003-0807
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT • The AEM Safety Manual delivered with the machine
gives general safety information.
This notice identifies procedures which must be • The Service Manual and Parts Manual are available
followed to avoid damage to the machine. from your dealer for use by mechanics to do shop-
I-2019-0284 type service and repair work.
• The Skid-Steer Loader Operator Training Course is
available through your local dealer or at Bobcat.com/
training or Bobcat.com. This course is intended to
DANGER provide rules and practices of correct operation of the
skid-steer loader. The course is available in English
and Spanish versions.
The signal word DANGER on the machine and in the
manuals indicates a hazardous situation which, if not • Service Safety Training Courses are available from
avoided, will result in death or serious injury. your Bobcat dealer or at Bobcat.com/training or
D-1002-1107 Bobcat.com. They provide information for safe and
correct service procedures.
• The Skid-Steer Loader Safety Video is available from
WARNING your Bobcat dealer or at Bobcat.com/training or
Bobcat.com.
The signal word WARNING on the machine and in the
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI SSL-1016 SM
1-9 S550 Service Manual
--- Page 4 ---
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-2
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
10-03 S550 Service Manual
--- Page 5 ---
OPERATOR CAB (CONT’D) the latch stop. Use both hands to lower the operator cab
all the way down.
Lowering
Always stop the engine before raising or lowering the
operator cab. WARNING
NOTE: Always use the grab handles to lower the
operator cab. PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
Figure 10-30-6 when the cab is past the latch stop.
W-2469-0803
Figure 10-30-7
Hardware Removed Hardware Installed
P100953 P-85461A
Pull down on the bottom of the operator cab until stopped
by the latching mechanism [Figure 10-30-6]. P100236A P100235A
NOTE: The weight of the operator cab increases Install the washers and nuts (both sides) [Figure 10-30-
when equipped with options and accessories 7].
such as: cab door, heater, air conditioning. In
these cases, the operator cab may need to be Tighten the nuts to 54 - 61 N•m (40 - 45 ft-lb) torque.
raised slightly from the latch to be able to
release the latch. Remove the jackstands.
WARNING
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
NOTE: On some machines, the operator cab frame
can contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.
Support the operator cab and release the latching
mechanism (Inset) [Figure 10-30-6]. Remove your hand
from the latch mechanism when the operator cab is past
10-30-3 S550 Service Manual
--- Page 6 ---
REMOTE START TOOL - MEL1563 (CONT'D) Remote Start Procedure
Service Tool Harness Communicator - MEL1566 The tool listed will be needed to do the following
procedure:
Figure 10-60-6
MEL1563: Remote Start Tool Kit
2
Figure 10-60-7
1
1
P16119
The Service Tool Harness Communicator (Item 1) is P16115
required to connect Remote Start Tool to the Service PC
(Item 2) [Figure 10-60-6].
The Remote Start Tool (Item 1) [Figure 10-60-7] is
required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.
Lift and block the loader.
Raise the lift arms (if required by the procedure) and
install an approved lift arm support.
Raise the operator cab (if required by the procedure).
Open the rear door of the loader.
10-60-3 S550 Service Manual
--- Page 7 ---
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-14
7217666 (CONT'D)
Remote Start Procedure (Cont'd)
Figure 10-61-13
1 2
P106657
Push the couplers on the front auxiliary block toward the
block and hold for five seconds to release the front
P-76441 auxiliary pressure [Figure 10-61-14].
The gear icon with the left facing arrows (Item 1) [Figure
10-61-13] will illuminate and blink when the RUN key is
pressed and the loader is communicating with the service
tool.
The computer icon with the right facing arrows (Item 2)
[Figure 10-61-13] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
and from the computer.
NOTE: To relieve the pressure at the rear or
secondary front auxiliary, (if equipped) press
the RUN button on the Remote Start Tool.
Then press the auxiliary (AUX) hydraulics
button on the Remote Start Tool and move the
AUXILIARY Hydraulic Switch to the right and
left several times.
10-61-7 S550 Service Manual
--- Page 8 ---
ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-10
Removing And Replacing Coolant
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Stop the engine, open the rear door, and remove the rear
grille. (See REAR GRILLE on Page 50-60-1.) 1
WARNING
AVOID INJURY
Do not remove engine coolant cap when the engine P138587
is hot. You can be seriously burned.
W-2607-0804 Remove the drain plug (Item 1) [Figure 10-90-10] from
the engine oil cooler.
NOTE: This procedure requires the use of a spare
0.75 in coolant hose approximately 600 mm Quickly install the spare 0.75 in. coolant hose over the
(24 in) long. drain opening.
Figure 10-90-9 Drain the coolant into a container.
1 Remove the coolant fill cap [Figure 10-90-9] to drain the
coolant faster.
Remove the spare 0.75 in. coolant hose from the drain
opening after the coolant has drained.
Install the drain plug [Figure 10-90-10].
Recycle or dispose of used coolant in an environmentally
safe manner.
Mix new coolant in a separate container. (See Capacities
on Page -222.)
P109634C
The correct mixture of coolant to provide a -37°C (-34°F)
freeze protection is 5 L propylene glycol mixed with 4,4 L
Remove the coolant fill cap (Item 1) [Figure 10-90-9] to of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
relieve pressure. of water.
Install the coolant fill cap [Figure 10-90-9].
10-90-5 S550 Service Manual
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ENGINE LUBRICATION SYSTEM (CONT’D) Remove the dipstick (Item 1) [Figure 10-110-6] and
check the oil level.
Removing and Replacing Oil And Filter (Cont’d)
Add oil as needed if oil level is not at the top mark on the
Figure 10-110-6 dipstick. Install the dipstick and close the rear door.
WARNING
1
AVOID INJURY OR DEATH
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.
2
W-2103-0508
3
P138754
Remove the oil filter (Item 3) [Figure 10-110-6] and clean
the filter base.
Put clean oil on the new filter gasket, install the new filter,
and hand tighten. Use genuine Bobcat filter only.
Remove the oil fill cap (Item 2) [Figure 10-110-6].
Put oil into the engine and replace the oil fill cap. (See
Capacities on Page SPEC-10-5.) Do not overfill.
Start the engine and allow to operate for several minutes.
WARNING
AVOID INJURY OR DEATH
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-2072-0807
Stop the engine and check for leaks at the filter.
10-110-3 S550 Service Manual
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BOB-TACH (HAND LEVER) Figure 10-140-2
Inspection And Maintenance
1
Figure 10-140-1
2
Both wedges must
contact lower edge of
holes in the attachment
mounting frame.
P-31233A NA3098
The wedges (Item 1) [Figure 10-140-2] must extend
P-85513A
through the holes in the attachment mounting frame.
The spring loaded wedges (Item 1) must contact the
Move the Bob-Tach levers down to engage the wedges lower edge of the holes in the attachment mounting
[Figure 10-140-1]. frame (Item 2) [Figure 10-140-2].
The levers and wedges must move freely. If the wedges do not contact the lower edge of the holes
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
WARNING Figure 10-140-3
AVOID INJURY OR DEATH
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
NA13065S
Inspect the mounting frame on the attachment and Bob-
Tach, linkages, and wedges for excessive wear or
damage [Figure 10-140-3]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Inspect for cracked welds.
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-150-1.)
10-140-1 S550 Service Manual
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PIVOT PINS
Inspection And Maintenance
Figure 10-170-1
1
P109020A
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and locknut (Item 1) [Figure
10-170-1].
Check that the locknuts are tightened to 48 - 54 N•m (35 -
40 ft-lb) torque.
10-170-1 S550 Service Manual
--- Page 12 ---
SEAT BELT Figure 10-210-1
Inspection And Maintenance
1
WARNING 3
Failure to properly inspect and maintain the seat belt
can cause lack of operator restraint resulting in
serious injury or death.
W-2466-0703
Check the seat belt daily for correct function. 2 4
Inspect the seat belt system thoroughly at least once
each year, or more often if the machine is exposed to
severe environmental conditions or applications.
Any seat belt system that shows cuts, fraying, extreme or
unusual wear, significant discolorations due to ultraviolet
UV exposure, dusty / dirty conditions, abrasion to the
seat belt webbing, or damage to the buckle, latch plate,
retractor (if equipped), hardware, or any other obvious
problem should be replaced immediately. 5
The items below are referenced in [Figure 10-210-1].
NA3113
1. Check the webbing. If the system is equipped with a
retractor, pull the webbing completely out and inspect
the full length of the webbing. Look for cuts, wear,
fraying, dirt, and stiffness.
2. Check the buckle and latch for correct operation.
Make sure latch plate is not excessively worn or
deformed and buckle is not damaged or casing
broken.
3. Check the retractor web storage device (if equipped)
by extending webbing to determine if it looks correct,
and that it spools out and retracts webbing correctly.
4. Check webbing in areas exposed to ultraviolet (UV)
rays from the sun, or extreme dust or dirt. If the
original color of the webbing in these areas is
extremely faded and / or the webbing is packed with
dirt, the webbing strength may have deteriorated.
5. Check the hardware on both sides of the seat.
Hardware should be tight. Hardware must not be
missing, rusted, corroded, or damaged.
10-210-1 S550 Service Manual
--- Page 13 ---
Printable Version Click Here
HYDRAULIC/HYDROSTATIC SCHEMATIC
SJC WITH NO OPTIONS
S550 (S/N B4ZD11001 AND ABOVE)
(PRINTED SEPTEMEBER 2020)
V-1712 legend
LEGEND
1 RESERVOIR: 17 CHECK VALVE - With 100 kPa (1,0 bar) 35 NOT USED FOR THIS MODEL
Capacity at sight gauge . . 7,6 L (2.0 U.S. gal) (14.5 psi) Spring
System Capacity . . . . . . . 32,2 L (8.5 U.S. gal) CHARGE PUMP -
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 36
2 SIGHT GUAGE 49,1 L/min (13.0 U.S. gpm) at High Engine Idle
19 PULL BUTTON ACTIVATED HYDRAULIC PUMP . . . . . . . Gear Type
3 DIFFERENTIAL PRESSURE SWITCH: 37
DIRECTIONAL CONTROL VALVE - LIFT 64,7 L/min (17.1 U.S. gpm) at High Engine Idle
107 kPa (1,07 bar) (15 psi)
ARM BY-PASS 38 VARIABLE CAPACITY DISPLACEMENT
Normally Closed
20 LIFT CYLINDER SPOOL - MADE TO BIDIRECTIONAL HYDROSTATIC PUMP
4 FILTER - HYDRAULIC (CANISTER)
RESTRICT FLOW DURING BOOM
39 RELIEF/REPLENISHING VALVE - HIGH
5 SPRING LOADED FILTER BY-PASS DOWN BUT NOT DURING BOOM UP
PRESSURE: 35000 kPa (350 bar) (5076 psi)
VALVE: 172 kPa (1,7 bar) (25 psi) 21 ANTICAVITATION VALVE
6 RELIEF VALVE - CHARGE INLET:
DIAGNOSTIC COUPLER 40
22 PROPORTIONAL RELIEF VALVE – 2825-3515 kPa (28-35 bar) (410-510 psi) at
6A DIAGNOSTIC COUPLER – FILL (Fan Speed Regulator): 16547 kPa High Engine Idle With 60 ° C (140 ° F) Fluid
PORT – Factory Hydraulic Oil (165 bar) (2400 psi)
41 CHECK VALVE – COLD WEATHER BY-PASS
23 SPRING LOADED FILTER BY-PASS VALVE:
RELIEF VALVE - MAIN: With 345 kPa (3,45 bar) (50 psi) Spring
7 300 – 390 kPa (3 - 3,9 bar) (43 - 57 psi)
24100 kPa (241 bar) (3500 psi) at SOLENOID ACTIVATED DIRECTIONAL
Front Quick Couplers 24 FIXED CAPACITY DISPLACEMENT 42
CONTROL VALVE – FORWARD/REVERSE
8 HYDRAULIC MOTOR
RELIEF/ANTICAVITATION VALVE - 43 FILTER
25 FILTER - HYDRAULIC (CANISTER)
PORT: 27579 kPa (276 bar) (4000 psi)
26 SENSOR – CHARGE PRESSURE 44 SERVO PISTON – Swash Plate
9 RELIEF/ANTICAVITATION VALVE -
PORT (OPTIONAL):
27 FRONT AUXILIARY MANUAL PRESSURE
27579 kPa (276 bar) (4000 psi)
BLEED-OFF VALVE
10 SOLENOID ACTIVATED DIRECTIONAL
28 SENSOR – HYD. TEMPERATURE
CONTROL VALVE - AUXILIARY
11 LOAD CHECK VALVE 29 FLUSHING RELIEF VALVE:
450 kPa (4,5 bar) (65 psi)
12 ANTICAVITATION VALVE
30 DRIVE MOTOR SHUTTLE VALVE -
13 PILOTED ACTIVATED DIRECTIONAL Cracking: 634 kPa (6,3 bar) (92 psi)
CONTROL VALVE - TILT CONTROL Full: 814 kPa (8,1 bar) (118 psi)
14 PILOTED ACTIVATED DIRECTIONAL 31 NOT USED FOR THIS MODEL
CONTROL VALVE - LIFT CONTROL
32 FIXED CAPACITY DISPLACEMENT
SOLENOID ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC MOTOR
15
CONTROL VALVE - BICS CONTROL
33 NOT USED FOR THIS MODEL
16 FILTER - BICS CONTROL VALVE
NOTE: Unless otherwise specified
(SCREEN) 34 ANGLE SENSOR springs have NO significant
pressure value.
Printed in BELGIUM V-1712 legend (9-1-20)
--- Page 14 ---
CYLINDER (LIFT) Figure 20-20-2
Testing
1
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury 2
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
P106658
Lower the lift arms. Stop the engine. Raise the seat bar.
Install a plug (Item 1) [Figure 20-20-2] in the hose and
Figure 20-20-1 tighten.
Engage the parking brake. Lower the seat bar. Start the
engine and press the PTOL button.
Operate the controls that lower the lift arms.
If there is any leakage from the fitting on the cylinder
(Item 2) [Figure 20-20-2] remove the cylinder for repair.
Repeat the procedure to test the other cylinder.
1
P106656
Test only one cylinder at a time. Disconnect the hose
(Item 1) [Figure 20-20-1] from the base end of the
cylinder.