6900976 (4-03) Printed in U.S.A. © Bobcat Company 2003

18

Transcript of 6900976 (4-03) Printed in U.S.A. © Bobcat Company 2003

6900976 (4-03) Printed in U.S.A. © Bobcat Company 2003

MAINTENANCE SAFETY

Never service the Bobcat Skid-Steer Loader without instructions.

Have good ventilation whenwelding or grinding paintedparts.Wear dust mask when grindingpainted parts. Toxic dust and gascan be produced.Avoid exhaust fume leaks whichcan kill without warning. Exhaustsystem must be tightly sealed.

Stop, cool and clean engine offlammable materials beforechecking fluids.Never service or adjust loaderwith the engine running unlessinstructed to do so in themanual.Avoid contact with leakinghydraulic fluid or diesel fuelunder pressure. It can penetratethe skin or eyes.Never fill fuel tank with enginerunning, while smoking or whennear open flame.

Disconnecting or loosening anyhydraulic tubeline, hose, fitting,component or a part failure cancause lift arms to drop. Do not gounder lift arms when raisedunless supported by anapproved lift arm support device.Replace it if damaged.

Keep body, jewelry and clothingaway from moving parts,electrical contact, hot parts andexhaust.Wear eye protection to guardfrom battery acid, compressedsprings, fluids under pressureand flying debris when enginesare running or tools are used.Use eye protection approved fortype of welding.Keep rear door closed except forservice. Close and latch doorbefore operating the loader.

Never work on loader with liftarms up unless lift arms are heldby an approved lift arm supportdevice. Replace if damaged.Never modify equipment or addattachments not approved byBobcat Company.

Lead-acid batteries produceflammable and explosive gases.Keep arcs, sparks, flames andlighted tobacco away frombatteries.Batteries contain acid whichburns eyes or skin on contact.Wear protective clothing. If acidcontacts body, flush well withwater. For eye contact flush welland get immediate medicalattention.

Use the correct procedure to lift orlower operator cab.

Cleaning and maintenance arerequired daily.

MSW08-0805

WRONG

B-16102B-6589

B-10731a

CORRECT

B-15590

CORRECT

B-15591

CORRECT

B-15599

WRONGWRONG

B-15593

WRONG

B-15592

B-15600

WRONG WRONG

B-16102B-15601

WARNINGInstructions are necessary before operating or servicing machine. Read andunderstand the Operation & Maintenance Manual, Operator’s Handbook andsigns (decals) on machine. Follow warnings and instructions in the manualswhen making repairs, adjustments or servicing. Check for correct function afteradjustments, repairs or service. Untrained operators and failure to followinstructions can cause injury or death. W-2003-0903

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 & MaintenanceManual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcatreplacement parts. The Service Safety Training Course is available from your Bobcat dealer.

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

753 Bobcat LoaderService Manual

ALPHABETICAL INDEX

ADVANCED CONTROL SYSTEM (ACS) ADVANCE HAND CONTROL ............................... 60-01ADVANCED CONTROL SYSTEM (ACS) SELECTRABLE HAND/FOOT CONTROL............ 60-01ADVANCED HAND CONTROL (AHC) SYSTEM.... 60-01ADVANCED HAND CONTROL (AHC) SYSTEM (W/PUSH BUTTON FLOAT) ................. 60-01AIR CLEANER SERVICE ............................ 10-01, 70-01ALTERNATOR (55 AMP) ........................................ 60-01ALTERNATOR (90 AMP) ........................................ 60-01

BASIC TROUBLESHOOTING ................................ 80-01BATTERY................................................................ 60-01BICS™ SYSTEM .................................................... 60-01BOBCAT CONTROLLER ....................................... 60-01BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) ............................ 60-01BOB-TACH................................................... 10-01, 50-01BRAKE.................................................................... 40-01BUCKET POSITION VALVE.................................. 20-01

CHAINCASE ........................................................... 40-01CHARGE PRESSURE ........................................... 30-01COMPONENTS ..................................................... 80-01CONTROL HANDLE............................................... 50-01CONTROL HANDLE (ADVANCE HAND CONTROL) (AHC).................. 50-01CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) W/PUSH BUTTON FLOAT........................ 50-01CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL................. 50-01CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL... 50-01CONTROL PANEL.................................................. 50-01CONTROL PEDALS ............................................... 50-01CONTROL PEDALS (ACS) .................................... 50-01CONVERSIONS ................................................SPEC-01COOLING FAN ...................................................... 70-01CYLINDER (LIFT) ................................................... 20-01CYLINDER (POWER BOB-TACH).......................... 20-01CYLINDER (TILT) ................................................... 20-01

DIAGNOSTICS ....................................................... 60-01DRIVE BELT ........................................................... 30-01DRIVE COMPONENTS .......................................... 40-01

ELECTRICAL/HYD. CONTROLS REFERENCE .... 60-01ELECTRICAL SYSTEM INFORMATION ................ 60-01ENGINE .................................................................. 70-01ENGINE COMPONENTS AND TESTING .............. 70-01ENGINE COOLING SYSTEM................................. 10-01ENGINE LUBRICATION SYSTEM ......................... 10-01ENGINE SPECIFICATIONS...............................SPEC-01

ENGINE SPEED CONTROL ...................................70-01

FAN GEARBOX.......................................................10-01FINAL DRIVE TRANSMISSION (CHAINCASE)...... 10-01FLYWHEEL AND HOUSING ...................................70-01FRONT AUXILIARY HYDRAULIC COUPLER BLOCK ...............................................20-01FRONT AUXILIARY PRESSURE RELIEF BLOCK....................................................20-01FUEL SYSTEM........................................................10-01FUEL TANK .............................................................50-01

HEATER UNIT .........................................................80-01HEATER COIL.........................................................80-01HEATER FAN .........................................................80-01HEATER VALVE ......................................................80-01HYDRAULIC CONNECTION SPECS ............... SPEC-01HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) .................................20-01HYDRAULIC CONTROL VALVE (FOOT CONTROL)................................................20-01HYDRAULIC FLUID RESERVOIR ..........................20-01HYDRAULIC/HYDROSTATIC FILTER ....................20-01HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01HYDRAULIC/HYDROSTATIC SYSTEM..............10-01HYDRAULIC PUMP (ALUMINUM)..........................20-01HYDRAULIC SYSTEM INFORMATION 20-01HYDRAULIC PUMP (ALUMINUM)..........................20-01HYDRAULIC PUMP (CAST IRON) .........................20-01HYDROSTATIC MOTOR .........................................30-01HYDROSTATIC PUMP ............................................30-01HYDROSTATIC SYSTEM INFORMATION..............30-01

INSTRUMENT PANEL ............................................60-01

LIFT ARM ................................................................50-01LIFT ARM BY-PASS CONTROL VALVE..................20-01LIFT ARM SUPPORT DEVICE................................10-01LIFTING AND BLOCKING THE LOADER...............10-01LIGHTS....................................................................60-01LOADER SPECIFICATIONS ............................. SPEC-01LUBRICATION OF THE BOBCAT LOADER ...........10-01

MAIN RELIEF VALVE ..............................................20-01MUFFLER................................................................70-01

OIL COOLER...........................................................30-01OPERATOR CAB .........................................10-01, 50-01OPERATOR SEAT...................................................50-01OPERATOR SEAT (SUSPENSION)........................50-01

POWER BOB-TACH................................................50-01POWER BOB-TACH BLOCK...................................50-01

Continued On Next Page

753 Bobcat LoaderService Manual

ALPHABETICAL INDEX (CONT’D)

RADIATOR...............................................................70-01REAR AUXILIARY DIVERTER VALVE (DUAL SHUTTLE) .................................................50-01REAR AUXILIARY DIVERTER VALVE (SINGLE SHUTTLE)..............................................50-01REAR DOOR ..........................................................50-01REAR GRILL ..........................................................50-01RECONDITIONING THE ENGINE ..........................70-01REGULAR MAINTENANCE ....................................80-01REMOTE START.....................................................10-01RPM SENSOR.........................................................70-01

SEAT BAR............................................................... 50-01SEAT BAR SENSOR............................................... 60-01SELECT VALVE ......................................................20-01SERVICE SCHEDULE.............................................10-01SPARK ARRESTOR MUFFLER..............................10-01STARTER (NIPPONDENSO) ..................................60-01STARTER (VALEO) .................................................60-01SYSTEM TROUBLESHOOTING CHART ...............80-01

TIRE MAINTENANCE..............................................10-01TORQUE SPECIFICATIONS FOR BOLTS........SPEC-01TOWING THE LOADER ..........................................10-01TRACTION LOCK....................................................60-01TRANSPORTING THE LOADER ............................10-01TROUBLESHOOTING.............................................70-01

753 Bobcat LoaderI Service Manual

CONTENTS

FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X

SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01

SAFETY &

HYDROSTATIC

MAIN FRAME

SYSTEM

SYSTEMDRIVE

ELECTRICAL

MAINTENANCE

SYSTEM &ANALYSIS

ENGINESERVICEENGINE

SPECIFICATIONS

HEATER

SPECIFICATIONS

HYDRAULICSYSTEM

753 Bobcat LoaderII Service Manual

FOREWORDThis manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustmentprocedures 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(Including side screens) is ingood condition and is notmodified.

9. The parking brake mustfunction correctly.

2. Check that ROPS mountinghardware is tightened and isBobcat approved.

10. Enclosure door latches mustopen and close freely.

3. The seat belt must becorrectly installed, functionaland in good condition.

11. Bob-Tach wedges andlinkages must functioncorrectly and be in goodcondition.

4. The seat bar must becorrectly adjusted, clean andlubricated.

12. Safety treads must be in goodcondition.

5. Check lift arm support device,replace if damaged.

13. Check for correct function ofindicator lamps (Optional onsome models).

6. Machine signs must belegible and in the correctlocation.

14. Check hydraulic fluid level,engine oil level and fuelsupply.

7. Steering levers and footpedals must return to neutral.

15. Inspect for fuel, oil orhydraulic fluid leaks.

8. Check for correct function ofthe work lights

16. Lubricate the loader.

753 Bobcat LoaderIII Service Manual

17. Check the condition of thebattery and cables.

22. Operate the loader and checkall functions.

18. Inspect the air cleaner fordamage or leaks. Check thecondition of the element.

23. Check for any fieldmodification not completed.

19. Check the electrical chargingsystem.

24. Check for correct function ofthe Bobcat Interlock ControlSystem (BICS™) before themachine is returned to thecustomer.

20. Check tires for wear andpressure.

Recommend to the owner that all necessary corrections be made before the machine is returned to service.

21. Inspect for loose or brokenparts or connections.

CALIFORNIAPROPOSITION 65 WARNING

Diesel engine exhaust and some of itsconstituents are known to the State of California

to cause cancer, birth defects and otherreproductive harm.

753 Bobcat LoaderIV Service Manual

753 Bobcat LoaderV Service Manual

SAFETY INSTRUCTIONS

WARNINGInstructions are necessary before operating orservicing machine. Read and understand theOperation & Maintenance Manual, Operator’sHandbook and signs (decals) on machine. Followwarnings and instructions in the manuals whenmaking repairs, adjustments or servicing. Check forcorrect function after adjustments, repairs orservice. Untrained operators and failure to followinstructions can cause injury or death.

W-2003-0903

WARNINGWarnings on the machine and in the manuals are foryour safety. Failure to obey warnings can causeinjury or death.

W-2044-1285

IMPORTANTThis notice identifies procedures which must befollowed to avoid damage to the machine.

I-2019-0284

The following publications provide information on thesafe use and maintenance of the Bobcat machine andattachments:

• The Delivery Report is used to assure that completeinstructions have been given to the new owner andthat the machine is in safe operating condition.

• The Operation & Maintenance Manual delivered withthe machine or attachment contains operatinginformation as well as routine maintenance andservice procedures. It is a part of the machine and canbe stored in a container provided on the machine.Replacement Operation & Maintenance Manuals canbe ordered from your Bobcat dealer.

• Machine signs (decals) instruct on the safe operationand care of your Bobcat machine or attachment. Thesigns and their locations are shown in the Operation& Maintenance Manual. Replacement signs areavailable from your Bobcat dealer.

• An Operator’s Handbook fastened to the operatorcab. It’s brief instructions are convenient to theoperator. The handbook is available from your dealerin an English edition or one of many other languages.See your Bobcat dealer for more information ontranslated versions.

• The AEM Safety Manual delivered with the machinegives general safety information.

• The Service Manual and Parts Manual are availablefrom your dealer for use by mechanics to do shop-type service and repair work.

• The Skid-Steer Loader Operator Training Course isavailable through your local dealer or atwww.training.bobcat.com or www.bobcat.com.This course is intended to provide rules and practicesof correct operation of the Skid-Steer Loader. Thecourse is available in English and Spanish versions.

• Service Safety Training Courses are available fromyour Bobcat dealer or at www.training.bobcat.comor www.bobcat.com. They provide information forsafe and correct service procedures.

• The Skid-Steer Loader Safety Video is available fromyour Bobcat dealer or at www.training.bobcat.comor www.bobcat.com.

SI SSL-0206 SM

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

Safety Alert Symbol

753 Bobcat LoaderVI Service Manual

SAFETY INSTRUCTIONS (CONT’D)

The dealer and owner/operator review the recommendeduses of the product when delivered. If the owner/operatorwill be using the machine for a different application(s) heor she must ask the dealer for recommendations on thenew use.

Call Before You Dig1-888-258-0808

When you call, you will be directed to a location inyour state/city for information about buried lines(telephone, cable TV, water, sewer, gas, etc.)

SI SSL-0206 SM

753 Bobcat LoaderVII Service Manual

SAFETY INSTRUCTIONS (CONT’D)

Fire Prevention

The machine and attachments have components that areat high temperature under normal operating conditions.The primary source of high temperatures is the engineand exhaust system. The electrical system, if damagedor incorrectly maintained, can be a source of arcs orsparks.

Flammable debris (leaves, straw, etc.) must be removedregularly. If flammable debris is allowed to accumulate, itwill increase fire hazard. Clean often to avoid thisaccumulation. Flammable debris in the enginecompartment is a potential hazard.

The spark arrestor muffler is designed to control theemission of hot particles from the engine and exhaustsystem, but the muffler and the exhaust gases are stillhot.

• Do not use the machine where exhaust, arcs, sparksor hot components can contact flammable material,explosive dust or gases.

• The operator cab, engine compartment, and enginecooling system must be inspected every day andcleaned if necessary to prevent fire hazard andoverheating.

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

• Check fuel and hydraulic tubes, hoses and fittings fordamage and leakage. Never use open flame or bareskin to check for leaks. Tighten or replace any partsthat show leakage. Always clean fluid spills. Do notuse gasoline or diesel fuel for cleaning parts. Usecommercial nonflammable solvents.

• Do not use ether or starting fluids on any enginewhich has glow plugs. These starting aids can causeexplosion and injure you or bystanders.

• Always clean the machine, disconnect the battery,and disconnect the wiring from the controllers beforewelding. Cover rubber hoses, battery and all otherflammable parts. Keep a fire extinguisher near themachine when welding. Have good ventilation whengrinding or welding painted parts. Wear a dust maskwhen grinding painted parts. Toxic dust or gas can beproduced.

• Stop the engine and let it cool before adding fuel. NOSMOKING!

• Use the procedure in the Operation & MaintenanceManual for connecting the battery and for jumpstarting.

• Use the procedure in the Operation & MaintenanceManual for cleaning the spark arrestor muffler (ifequipped).

Figure 1

• Know where fire extinguishers and first aid kits arelocated and how to use them. Fire extinguishers areavailable from your Bobcat dealer [Figure 1].

SI SSL-0206 SM

753 Bobcat LoaderVIII Service Manual

753 Bobcat LoaderIX Service Manual

SERIAL NUMBER LOCATIONS

Always use the serial number of the loader whenrequesting service information or when ordering parts.Early or later models (identification made by serialnumber) may use different parts, or it may be necessaryto use a different procedure in doing a specific serviceoperation.

Loader Serial Number

Figure 2

The loader serial number plate is located on the outsideof the loader frame [Figure 2].

Explanation of loader Serial Number:

1. The four digit Model/Engine Combination Modulenumber identifies the model number and enginecombination.

2. The five digit Production Sequence Number identifiesthe order which the loader is produced.

Engine Serial Number

Figure 3

The engine serial number is in the location shown[Figure 3].

DELIVERY REPORT

Figure 4

The Delivery Report must be filled out by the dealer andsigned by the owner or operator when the Bobcat loaderis delivered. An explanation of the form must be given tothe owner. Make sure it is filled out completely [Figure4].

N-20515

XXXX XXXXX

Model 1.-Model/ Engine Combination

Model 2.-Production Sequence (Series)

N-20521

B-16315

753 Bobcat LoaderX Service Manual

LOADER IDENTIFICATION

▼ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)* TIRES - Flotation tires (Optional) are shown. The Bobcat loader is factory equipped with standard tires.+ BUCKET - Several different buckets and other attachments are available for the Bobcat loader.● ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structureper SAE J1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a standard operatorcab as shown. Extra insulated cab is available as an option (Reduced noise level).

SAFETY TREADBUCKET STEPS

+BUCKET

TILT CYLINDER

STEERING LEVER

GRAB HANDLES

FRONT LIGHTS

▼FRONT AUXILIARY QUICK COUPLERS

▼REAR AUXILIARY QUICK COUPLERS

OPERATOR SEAT WITH SEAT BELT

●OPERATOR CAB (ROPS & FOPS)

SEAT BAR

LIFT ARM

LIFT ARM SUPPORT DEVICE

LIFT CYLINDERS

*TIRESREAR DOOR

▼REAR LIGHT

▼TAIL

REAR GRILL

▼REAR WINDOW

753 Bobcat Loader10-01 Service Manual

SAFETY AND MAINTENANCE

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1Replacing Filter Element(s) . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2

BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 10-90-1Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-90-1Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

FAN GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1Removing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1Filling the Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2Fuel Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-3

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-4Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . 10-120-1Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . 10-120-1Replacing Hydrostatic Motor Case Drain Filter(s) . . . . . . 10-120-2

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1Installing Lift Arm Support Device . . . . . . . . . . . . . . . . . . . 10-20-1Removing The Lift Arm Support Device. . . . . . . . . . . . . . . 10-20-2

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

Continued On Next Page

SAFETY AND

SYSTEMDRIVE

ELECTRICALSYSTEM &ANALYSIS

ENGINESERVICE

SPECIFICATIONS

MAINTENANCE

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