Bobcat 753, 753H Skid-Steer Loader Repair Service Manual - 6900090

(S/N: 508630001 & Above - S/N: 511476001 & Above - S/N: 512716001 & Above - S/N: 513911001–513911148 - S/N: 515811001–515829999 - S/N: 516211001–516219999) 
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This workshop repair service manual PDF download for the 753, 753H Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Loader 753, 753H BICS
INCLUDES HIGH FLOW OPTION
S/N: 508630001 & Above
S/N: 511476001 & Above
S/N: 512716001 & Above
S/N: 513911001–513911148
S/N: 515811001–515829999
S/N: 516211001–516219999


TABLE OF CONTENTS :

FOREWORD 
SAFETY INSTRUCTIONS 
SERIAL NUMBER LOCATIONS 
DELIVERY REPORT 
BOBCAT LOADER IDENTIFICATION 
PREVENTIVE MAINTENANCE 
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
MAIN FRAME 
ELECTRICAL SYSTEM 
ENGINE SERVICE 
SYSTEMS ANALYSIS 
SPECIFICATIONS 
ADVANCE HAND CONTROL SYSTEM 
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6900090 (6–97)
Total Pages : 568


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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
    SERIAL NUMBER LOCATIONS
    LOADER SERIAL NUMBER
    ENGINE SERIAL NUMBER
    DELIVERY REPORT
    BOBCAT LOADER IDENTIFICATION
    
PREVENTIVE MAINTENANCE
    SERVICE SCHEDULE
    LIFTING AND BLOCKING THE LOADER
        Procedure
    TRANSPORTING THE LOADER
        Procedure
    TOWING THE LOADER
        Procedure
    STOPPING THE BOBCAT LOADER
    LIFTING THE LOADER
        Four Point Lift
        Single Point Lift
    LIFT ARM SUPPORT DEVICE
        Engaging The Lift Arm Support Device
        Disengaging The Lift Arm Support Device
    OPERATOR CAB
        Description
        Raising The Operator Cab
        Lowering The Operator Cab
        Emergency Exit
    SEAT BAR RESTRAINT SYSTEM (Foot Pedals)
        Description
        Seat Bar Inspection
        Seat Bar Maintenance
    SEAT BAR RESTRAINT SYSTEM (Mechanical Hand Controls)
        Description
        Seat Bar Inspection
        Seat Bar Maintenance
    SEAT BAR RESTRAINT SYSTEM (Advanced Hand Controls)
        Description
        Seat Bar Inspection
        Seat Bar Maintenance
    AIR CLEANER SERVICE
        Replacing Filter Element
    FUEL SYSTEM
        Fuel Specifications
        Filling The Fuel Tank
        Fuel Filter
        Removing Air From The Fuel System
    ENGINE LUBRICATION SYSTEM
        Checking Engine Oil
        Oil Chart
        Replacing Oil And Filter
    ENGINE COOLING SYSTEM
        Cleaning The Cooling System
        Checking The Coolant Level
        Replacing The Coolant
    ALTERNATOR BELT
        Adjusting
    FAN GEARBOX
        Checking And Maintaining
    HYDRAULIC/HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Replacing Hydraulic/Hydrostatic Filter
        Replacing Hydraulic Fluid
        Breather Cap
    SPARK ARRESTOR MUFFLER
        Cleaning Procedure
    TIRE MAINTENANCE
        Wheel Nuts
        Tire Rotation
        Tire Mounting
    FINAL DRIVE TRANSMISSION (CHAINCASE)
        Checking and Adding Oil
        Removing Oil From The Chaincase
    DRIVE BELT
        Adjusting The Drive Belt Equipped With The Fixed Drive Idler
        Adjusting the Drive Belt Equipped With The Spring Loaded Drive Idler
        Replacing The Drive Belt
    LUBRICATION OF THE BOBCAT LOADER
        Procedure
    PIVOT PINS
    BOB–TACH
        Inspection and Maintenance
    REMOTE START SWITCH
        Procedure
        
HYDRAULIC SYSTEM
    HYDRAULIC/ HYDROSTATIC SCHEMATICS
    TROUBLESHOOTING
    HYDRAULIC SYSTEM INFORMATION
        Tighten Procedures
    LIFT CYLINDER(S)
        Checking The Lift Cylinder(s) For Internal Leakage
        Removal And Installation
    TILT CYLINDER
        Checking The Tilt Cylinder For Internal Leakage
        Removal And Installation
        Rod End Seal Replacement
    HYDRAULIC CYLINDER IDENTIFICATION
        Lift Cylinder Components
        Tilt Cylinder Components
    HYDRAULIC CYLINDERS
        Disassembly
        Assembly
    BICS™ VALVE (S/N 508694509 & Above, S/N 512727421 & Above, S/N 515811001 & Above & S/N 516211001 & Above)
        Removal
        Lift Arm By–Pass Orifice Disassembly
        Check Valve Disassembly
        Lock Valve Disassembly
        BICS™ Valve Solenoid Disassembly
        BICS™ Valve Solenoid Assembly
        Lock Valve Assembly
        Check Valve Assembly
        Lift Arm By–Pass Orifice Assembly
        Installation
    CONTROL VALVE (S/N 508694509 & Above, S/N 512727421 & Above, S/N 515811001 & Above & S/N 516211001 & Above)
        Removal And Installation
        Identification Chart
        Disassembly
        Lift Base End Restrictor Disassembly
        Load Check Valve Disassembly
        Main Relief Valve Disassembly
        Port Relief Valve Disassembly
        Anti–Cavitation Valve Disassembly
        Rubber Boot Disassembly
        Lift Spool And Detent Disassembly
        Tilt Spool And Centering Spring Disassembly
        Auxiliary Spool Disassembly
        Auxiliary Electric Solenoid Disassembly
        Port–Auxiliary Section Disassembly
        Port–Auxiliary Section Assembly
        Auxiliary Electric Solenoid Assembly
        Auxiliary Spool Assembly
        Tilt Spool And Centering Spring Assembly
        Lift Spool And Detent Assembly
        Rubber Boot Assembly
        Anti–Cavitation Valve Assembly
        Port Relief Valve Assembly
        Main Relief Valve Assembly
        Load Check Valve Assembly
        Spool Seal Installation
        Cleaning And Inspection
    CONTROL VALVE (S/N 508694508 & Below, S/N 512727420 & Below, S/N 511476001 & Above, S/N 5086300001 & Above & S/N 513911001 & Above)
        Removal And Installation
        Identification Chart
        Disassembly And Assembly
        Load Check Valve
        Main Relief Valve
        Port Relief Valve
        Anti–Cavitation Valve
        Rubber Boot
        Lift Spool Detent
        Tilt Centering Spring
        Auxiliary Spool
        Auxiliary Electric Solenoid
        Inspection
        Identification And Installation Of Spool Seal
    MAIN RELIEF VALVE
        Checking
        Adjustment
        Removal And Installation
    MAIN RELIEF VALVE (753H)
        Checking The Dual Pressure (Low Setting)
        Checking The Dual Pressure (High Setting)
        Adjusting The Dual Pressure (Low Setting)
        Adjusting The Dual Pressure (High Setting)
    HYDRAULIC PUMP
        Removal And Installation
        Checking The Output Of The Hydraulic Pump
        Checking The Output Of The HIgh Flow Hydraulic Pump (753H)
        Disassembly And Assembly
        Inspection
        Identification
        Removal And Installation (753H)
        Identification (753H)
        Disassembly And Assembly (753H)
    HYDRAULIC FILTER HOUSING
        Removal And Installation
    HYDRAULIC FLUID RESERVOIR
        Removal And Installation
    CONTROL PEDALS
        Removal And Installation
        Pedal Adjustment
    SELECT VALVE (753H)
        Checking the Main Relief Valve in High Horsepower Select Valve
        Removal and Installation
        Disassembly and Assembly (New Style Valve)
        Solenoid Testing (New Style Valve)
        Disassembly and Assembly (Old Style Valve)
        Solenoid Testing (Old Style Valve)
    CONTROL INTERLOCK LINKAGE (Pedal or Mechanical Hand)
        Removal And Installation
        Adjustment
    LIFT LOCK BY–PASS VALVE
        Removal And Installation (S/N 508694508 & Below, S/N 512727420 & Below, S/N 511476001 & Above, S/N 508630001 & Above & S/N 513911001 & Above)
        Disassembly and Assembly (S/N 508694508 & Below, S/N 512727420 & Below, S/N 511476001 & Above, S/N 508630001 & Above & 513911001 & Above)
        Removal And Installation (S/N 508694509 & Above, S/N 512727421 & Above, S/N 515811001 & Above & S/N 516211001 & Above)
        Disassembly And Assembly (S/N 508694509 & Above, S/N 512727421 & Above, S/N 515811001 & Above & S/N 516211001 & Above)
    TILT LOCK VALVE
        Removal And Installation (S/N 508694508 & Below,S/N 512727420 & Below, S/N 511476001 & Above, S/N 508630001 & Above & S/N 513911001 & Above)
        Disassembly And Assembly (S/N 508694508 & Below, S/N 512727420 & Below, S/N 511476001 & Above, S/N 508630001 & Above & S/N 513911001 &Above)
        
HYDROSTATIC SYSTEM
    TROUBLESHOOTING
    HYDROSTATIC SYSTEM INFORMATION
        Replenishing Valve Function
        Checking Charge Pressure
    CONTROL PANEL
        Removal And Installation
        Steering Shock Removal And Installation
        Steering Shaft Removal And Installation
        Steering Shaft Disassembly And Assembly
        Steering Lever Removal And Installation
        Rubber Boot Replacement
    STEERING LINKAGE
        Removal And Installation
        Steering Linkage Adjustment
        Steering Neutral Adjustment
    HYDROSTATIC DRIVE MOTOR
        Removal And Installation
        Identification (S/N 512716001 & Above, 508695347 & Below, 511476001 & Above, 508630001 & Above &  513911001 & Above)
        Disassembly And Assembly (S/N 512716001 & Above, 508695347 & Below, 511476001 & Above, 508630149 & Above & 513911001 & Above)
        Inspection
    HYDROSTATIC MOTOR
        Parts Identification – (S/N 515811001 & Above, 508695348 & Above & 516211001 & Above)
        Disassembly (S/N 515811001 & Above, 508695348 & Above & 516211001 & Above)
        Assembly (S/N 515811001 & Above, 508695348 & Above & 516211001 & Above)
    HYDROSTATIC PUMP
        Removal And Installation
        Identification
        Disassembly And Assembly
        Inspection
        Swashplate Pre–Load (Earlier Models Only)
    DRIVE BELT HOUSING
        Removal And Installation
    SPRING LOADED DRIVE BELT TENSIONER PULLEY
        Removal And Installation
        Identification
        Disassembly
        Assembly
    FIXED DRIVE BELT TENSIONER PULLEY
        Removal And Installation
        Identification
        Disassembly
        Assembly
        Checking Pulley End Play
    OIL COOLER
        Removal And Installation
        
DRIVE SYSTEM
    PARKING BRAKE
        Removal And Installation
        Disassembly And Assembly
    PARKING BRAKE DISC
        Removal And Installation
    TRACTION LOCK GUIDES
        Disassembly
        Assembly
    CHAINCASE FLUID
        Removing Oil From The Chaincase
    CHAINCASE COVERS
        Center Chaincase Cover Removal And Installation
        Front Chaincase Cover Removal And Installation
        Rear Chaincase Cover Removal And Installation
    MOTOR CARRIER
        Shaft Seal Replacement
        Removal And Installation
        Disassembly
        Assembly
    AXLE SEAL
        Removal And Installation
    AXLE, SPROCKET AND BEARINGS
        Removal And Installation
    DRIVE CHAIN
        Removal And Installation
        
MAIN FRAME
    SEAT BAR (W/GAS CYLINDER)
        Removal And Installation
        Assembly
        Compressing The Gas Cylinder
    SEAT BAR (W/COMPRESSION SPRING)
        Removal And Installation
        Assembling Components
        Compression Spring Disassembly And Assembly
    OPERATOR CAB GAS CYLINDER
        Removal And Installation
        Disassembly And Assembly
    OPERATOR CAB
        Removal And Installation
    OPERATOR SEAT
        Removal And Installation
    BOB–TACH
        Removal And Installation
        Bob–Tach Lever And Wedge
        Bob–Tach Stops
    LIFT ARMS
        Removal And Installation
    REAR GRILL
        Removal And Installation
    FUEL TANK
        Removal And Installation
        Fuel Level Sender
    REAR DOOR
        Removal And Installation (Two Piece Door)
        Removal And Installation (One Piece Door)
        Hood Removal And Installation (Two Piece Door)
        Bumper Removal And Installation (Two Piece Door)
        Door Latch Removal And Installation
        Door Latch And Catch Adjustment
    REAR LIGHTS
        Removal and Installation (One Piece Door)
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    TROUBLESHOOTING
    ELECTRICAL SYSTEM INFORMATION
        Description
    BATTERY
        Removal And Installation
        Servicing The Battery
        Using A Booster Battery (Jump Starting)
    ALTERNATOR
        Alternator Output Test
        Rectifier (Diode) Test
        Alternator Regulator Test
        Removal And Installation
        Adjusting The Alternator Belt
        Disassembly And Inspection
        Stator Continuity Test
        Stator Ground Test
        Rotor Continuity Test
        Rotor Ground Test
        Rectifier Continuity (Diode) Test
        Assembly
    STARTER (DELCO REMY)
        Checking The Starter
        Parts Identification
        Disassembly And Assembly
        Cleaning And Inspection
    STARTER (DENSO)
        Removal And Installation
        Parts Identification
        Disassembly
        Inspection And Repair
        No Load Test
        Assembly
    STANDARD INSTRUMENT PANEL
        Removal And Installation
    FRONT LIGHTS
        Removal And Installation
    RELAY SWITCHES
        Location
        
ENGINE SERVICE
    TROUBLESHOOTING
    ENGINE SPEED CONTROL
        Removal And Installation
        Disassembly
    RADIATOR
        Removal And Installation
    ENGINE MUFFLER
        Removal And Installation
    BLOWER HOUSING/FAN GEARBOX
        Removal And Installation
        Tension Pulley Removal And Installation
        Blower Fan Disassembly And Assembly
    FAN GEARBOX
        Identification
        Disassembly
        Assembly
        Checking Backlash
    AIR CLEANER
        Removal And Installation
    ENGINE
        Removal And Installation
        Engine Mount Replacement
    FLYWHEEL
        Removal And Installation
        Flywheel Ring Gear
    ENGINE COMPRESSION
        Checking
    GLOW PLUGS
        Checking The Glow Plugs
        Removal And Installation
    FUEL INJECTION PUMP
        Checking The Injection Pump
        Adjusting Shut–Off Linkage
    FUEL INJECTION PUMP
        Removal And Installation
        Timing The Injection Pump
    FUEL INJECTOR NOZZLES
        Removal And Installation
        Checking The Injector Nozzle
    CYLINDER HEAD
        Removal And Installation
        Disassembly And Assembly
        Servicing The Cylinder Head
        Top Clearance
    VALVE, VALVE SEAT AND GUIDE
        Checking The Valve Guide
        Valve Spring
    VALVE CLEARANCE
        Adjustment
    ROCKER ARM AND SHAFT
        Checking
    TIMING GEARCASE COVER
        Removal And Installation
    IDLER GEAR AND CAMSHAFT
        Removal And Installation
        Servicing The Camshaft
        Servicing The Idler Gear And Shaft
    TIMING GEARS
        Checking Backlash
    FUEL CAMSHAFT
        Removal And Installation
        Governor
    CRANKSHAFT GEAR
        Removal And Installation 
    OIL PUMP
        Removal And Installation
        Oil Pump Service
        Checking Engine Oil Pressure
        Relief Valve
    PISTON AND CONNECTING ROD
        Removal And Installation
        Servicing The Piston And Connecting Rod
        Connecting Rod Alignment
    CRANKSHAFT AND BEARINGS
        Removal And Installation
        Servicing the Crankshaft and Bearings
    CYLINDER BORE
        Checking The Cylinder Bore
    WATER PUMP
        Disassembly And Assembly
        
SYSTEMS ANALYSIS
    BICS™ (WITH PRESS TO OPERATE BUTTON)
        Inspecting The BICS™ Controller (Engine STOPPED - Key ON)
        Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
        Inspecting The Seat Bar Sensor (Engine RUNNING)
        Inspecting The Traction Lock (Engine RUNNING)
        Inspecting The Lift Arm By-Pass Control
        Additional Inspection For Loaders With Advanced Hand Controls
        Troubleshooting Chart
    BICS™ (Without Press To Operate Button)
        Inspecting The BICS Controller (Engine STOPPED –Key ON)
        Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED–Key ON)
        Inspecting The Seat And Seat Bar Sensors (EngineRUNNING)
        Inspecting The Traction Lock (Engine RUNNING)
        Inspecting The Lift Arm By–Pass Control
        Maintenance
        Troubleshooting Chart
    BICS™ SYSTEM CONTROLLER
        Troubleshooting Guide
        Removal And Installation
    SEAT BAR SENSOR
        Troubleshooting Guide
        Seat Bar Sensor Test
        Removal And Installation
        BICS™ Controller Seat Bar Sensor Circuit Test
    SEAT SENSOR
        Troubleshooting Guide
        Seat Sensor Test
        Removal And Installation
        BICS™ Controller Seat Sensor Circuit Test
    TRACTION LOCK
        Troubleshooting Guide
        Removal And Installation
    BOSS® DIAGNOSTIC TOOL
        Procedure
    SENDER AND SENSOR
        Service Checks
    RPM SENSOR
    MONITOR SERVICE CODES
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY
    BOSS® UNIT
        Removal And Installation
    BOSS® INSTRUMENT PANEL
        Removal And Installation
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
        Controls Identification Chart
        
SPECIFICATIONS
    SKID STEER LOADER SPECIFICATIONS
        753 - S/N 515811001 & Above, S/N 516211001 & Above
            PERFORMANCE
            CONTROLS
            ENGINE
            HYDRAULIC SYSTEM
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            FLOOR PRESSURE
        753, 753H - S/N 508693001 & Above, S/N 508630001 & Above, S/N 511476001 & Above, S/N 512716001 & Above, S/N 513911001 & Above
            PERFORMANCE
            CONTROLS
            ENGINE
            HYDRAULIC SYSTEM
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            FLOOR PRESSURE
        ENGINE SPECIFICATIONS
            Fuel Injection Nozzles
            Fuel Injection Pump
            Cylinder Head
            Valves
            Valve Springs
            Valve Timing
            Rocker Arms
            Camshaft
            Tappet
            Cylinders
            Piston Rings
            Pistons
            Connecting Rod
            Oil Pump
            Crankshaft
            Timing Gear
            Thermostat
            Crankshaft Re–Grind Data
            Torque For General Metric Bolts
        HYDRAULIC CONNECTION SPECIFICATIONS
            O–Ring Face Seal Connection
            Straight Thread O–Ring Fitting
            Tubelines And Hoses
            Flare Fitting
            O–Ring Flare Fitting
            Port Seal Fitting
        TORQUE SPECIFICATIONS FOR LOADER
        HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
        STANDARD TORQUE SPECIFICATIONS FOR BOLTS
        DECIMAL AND MILLIMETER EQUIVALENTS
        U.S. TO METRIC CONVERSION
        
ADVANCED HAND CONTROL SYSTEM (AHC)
    WIRING SCHEMATICS W/ADVANCED HAND CONTROL OPTIONS
    AHC COMPONENTS
        Identification
    TROUBLESHOOTING (AHC)
    ACTUATOR VOLTAGE TEST
        Procedure
    HANDLE CONTROL UNIT TEST
        Procedure
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
        Troubleshooting Chart
    ADVANCED HAND CONTROLS (AHC)
        Troubleshooting Chart
    AHC/PWM CONTROLLER
        Removal And Installation
        Description
        Conditions
        Troubleshooting Chart
        Handle Testing
        Solenoid Coil Testing
    CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)
        Control Handle Unit Removal And Installation
        Control Unit Connector
        Switch Handle Removal And Installation
        AHC Handle Removal And Installation
        AHC Handle Disassembly And Assembly
        AHC Steering Lever Removal And Installation
        AHC Steering Lever Boot
        Actuators Removal And Installation
        Actuators Disassembly And Assembly
        Components Identification
        Controller Connector And Wire Identification
        AHC/PWM Controller Removal And Installation
        Handle Sensor Removal And Installation
        Handle Sensor Connector
        Switch Handle Removal And Installation
        Control Handle Removal And Installation
        Control Handle Disassembly And Assembly
        Control Lever Removal And Installation
        Control Lever Boot
        Actuators Disassembly And Assembly
    BICS™ VALVE
        Lift Arm By–Pass Orifice
        Check Valve
        Lock Valve
        BICS™ Valve Solenoid
        Removal And Installation
    HYDRAULIC CONTROL VALVE
        Removal And Installation
        Identification Chart
        Disassembly And Assembly
        Load Check Valve
        Lift Base End Restrictor
        Main Relief Valve
        Port Relief Valve (Lift)
        Anti–Cavitation/Port Relief Valve
        Port Relief Valve (Tilt)
        Anti–Cavitation Valve
        Rubber Boot
        Lift And Tilt Spool
        Inspection
        Auxiliary Spool
        Auxiliary Electrical Solenoid
        Spool Seal Installation
        H–Port Auxiliary Section
        
SERVICE MANUAL REVISIONS
    753/753H–1
    753/753H–2
    753/753H–3
    753/753H–4
    753/753H–5
    
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