Bobcat 7753 Loader Service Manual 6720899 (6–12)- PDF DOWNLOAD

Description

Bobcat 7753 Loader Service Manual 6720899 (6–12)- PDF DOWNLOAD

FILE DETAILS:

Bobcat 7753 Loader Service Manual 6720899 (6–12)- PDF DOWNLOAD

Language : English
Pages : 334
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 7753 Loader Service Manual 6720899 (6–12)- PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
SAFETY INSTRUCTIONS 9
SERIAL NUMBER LOCATIONS 10
LOADER SERIAL NUMBER 10
ENGINE SERIAL NUMBER 10
DELIVERY REPORT 10
BOBCAT LOADER IDENTIFICATION 11
PREVENTIVE MAINTENANCE 13
SERVICE SCHEDULE 15
LIFTING AND BLOCKING THE LOADER 16
Procedure 16
TRANSPORTING THE LOADER 17
Procedure 17
SINGLE POINT LIFT 17
LIFT ARM SUPPORT DEVICE 18
Installing Lift Arm Support Device 18
Removing Lift Arm Support Device 18
OPERATOR CAB 18
Description 18
Raising the Operator Cab 19
Lowering the Operator Cab 19
Emergency Exit 20
SEAT BAR RESTRAINT SYSTEM 20
Description 20
Seat Bar Inspection 20
Seat Bar Maintenance 20
AIR CLEANER 21
(Standard) 21
(Optional) 21
Replacing the Filter Element 21
FUEL SYSTEM 23
Fuel Specifications 23
Filling the Fuel Tank 23
Fuel Filter 23
Removing Air from the Fuel System 24
ENGINE LUBRICATION SYSTEM 25
Checking Engine Oil 25
Replacing of Oil and Filter 25
COOLING SYSTEM 27
Cleaning the Cooling System 27
Checking the Coolant Level 27
Removing Coolant from the Cooling System 28
ALTERNATOR BELT 29
Adjusting the Alternator Belt 29
USING A BOOSTER BATTERY (JUMP STARTING) 30
Procedure 30
BATTERY 30
Removal and Installation 30
HYDRAULIC/HYDROSTATIC SYSTEM 31
Checking and Adding Fluid 31
Replacing the Hydraulic/Hydrostatic Filter 31
Checking the Hydraulic Reservoir Breather Cap 32
Replacing the Hydraulic Fluid 33
SPARK ARRESTOR MUFFLER 34
Cleaning Procedure 34
TIRE MAINTENANCE 35
Wheel Nuts 35
Tire Rotation 35
Tire Mounting 35
FINAL DRIVE TRANSMISSION (CHAINCASE) 36
Checking and Adding Oil 36
Removing Oil from the Chaincase 36
FAN GEARBOX 36
Checking Grease Level 36
DRIVE BELT 37
Adjustment 37
Drive Belt Replacement 38
Adjusting the Drive Belt With The Spring Loaded Drive Idler 39
Replacing The Drive Belt With The Spring Loaded Drive Idler 40
LUBRICATION OF THE BOBCAT LOADER 41
Procedure 41
PIVOT PINS 43
REMOTE START SWITCH 44
Procedure 44
DIAGNOSTIC TOOL 45
Procedure 45
SENDER AND SENSOR 45
Service Checks 45
Component 45
MONITOR SERVICE CODES 46
TROUBLESHOOTING THE BOSS® & LCD DISPLAY 49
HYDRAULIC SYSTEM 51
HYDRAULIC / HYDROSTATIC SCHEMATICS 53
TROUBLESHOOTING 65
HYDRAULIC SYSTEM INFORMATION 66
Flare Connections 66
O–Ring Face Seal Connection 66
Straight Thread O–Ring Fitting 66
Tubelines and Hoses 66
LIFT CYLINDER(S) 67
Checking the Lift Cylinder(s) 67
Removal and Installation 67
TILT CYLINDER 69
Checking the Tilt Cylinder 69
Removal and Installation 69
Rod End Seal 70
Checking the Main Relief Valve 71
Main Relief Valve Removal and Installation 72
Removal and Installation 73
HYDRAULIC PUMP 74
Checking the Output of the Pump 74
Removal and Installation (Early Models) 75
Removal and Installation (Later Models) 78
HYDRAULIC FILTER HOUSING 80
Removal and Installation 80
HYDRAULIC FLUID RESERVOIR 82
Removal and Installation 82
CONTROL PEDALS 83
Removal and Installation 83
Adjustment 83
PEDAL INTERLOCK SHIELD AND LINKAGE 84
Removal and Installation 84
Adjustment 84
HYDROSTATIC SYSTEM 85
TROUBLESHOOTING 87
HYDROSTATIC SYSTEM INFORMATION 88
Replenishing Valve Function 88
FRONT PANEL 89
Removal and Installation 89
STEERING LEVERS 91
Disassembly and Assembly 91
STEERING LINKAGE (S/N 30758 & Below) 93
Steering Linkage Adjustment 93
Removal & Installation 95
Centering Plate 96
Pintle Arm Removal and Installation 97
Pintle Arm Lobe Removal and Installation 97
STEERING LINKAGE (S/N 30759 & Above) 98
Removal and Installation 98
Steering Linkage Adjustment 100
Steering Neutral Adjustment 102
HYDROSTATIC MOTOR 104
Removal and Installation 104
HYDROSTATIC PUMP 106
Removal and Installation 106
OIL COOLER 109
Removal and Installation 109
DRIVE BELT TENSIONER PULLEY 110
Disassembly 110
Assembly 112
Checking Pulley End Play 116
SPRING LOADED DRIVE BELT IDLER 117
Removal And Installation 117
Parts Identification 118
Disassembly 119
Assembly 121
DRIVE SYSTEM 123
PARKING BRAKE 125
Adjustment 125
Removal and Installation 126
Brake Block and Pads 128
Brake Discs 130
CENTER TRANSMISSION COVER 130
Installation 130
FRONT CHAINCASE COVER 131
Removal and Installation 131
MOTOR CARRIER (Later Models) 133
Shaft Seal Replacement 133
Early Models 133
Removal and Installation 134
Disassembly and Assembly 135
AXLE HUB AND SEAL 136
Removal and Installation 136
AXLE, SPROCKET AND BEARINGS 139
Removal and Installation 139
DRIVE CHAIN 143
Removal and Installation 143
CHAINCASE FLUID 144
Replacing the Chaincase Fluid 144
MAIN FRAME 145
OPERATOR CAB GAS CYLINDER 147
Removal and Installation 147
Disassembly and Assembly 149
OPERATOR CAB 149
Removal and Installation 149
REAR DOOR 150
Removal and Installation 150
REAR GRILL 151
Removal and Installation 151
SEAT BAR 154
Removal 154
Installation 154
BOB–TACH 155
Removal and Installation 155
Bob–Tach Lever and Wedge 157
LIFT ARM LINK 160
Removal and Installation 160
LIFT ARMS 162
Removal and Installation 162
FUEL TANK 164
Removal and Installation 164
Fuel Level Sender 165
ELECTRICAL SYSTEM 167
ELECTRICAL SCHEMATICS 170
ELECTRICAL SYSTEM INFORMATION 207
Description 207
TROUBLESHOOTING 207
BATTERY 208
Removal and Installation 208
ALTERNATOR 209
Checking the Alternator Output (Old Style) 209
Checking the Alternator Regulator (Old Style) 210
Alternator Output Test (New Style) 211
Rectifier (Diode) Test (New Style) 211
Alternator Regulator Test (New Style) 212
Removal and Installation (Old Style) 213
Disassembly (Old Style) 214
Checking The Rotor (Old Style) 214
Checking The Stator (Old Style) 215
Checking The Rectifier (Old Style) 215
Disassembly (New Style) 217
Stator Continuity Test (New Style) 217
Stator Ground Test (New Style) 217
Disassembly (New Style) 218
Rotor Ground Test (New Style) 218
Rectifier Continuity (Diode) Test (New Style) 218
STARTER 220
Checking the Starter 220
Removal and Installation 220
Disassembly and Assembly 221
Cleaning and Inspection 223
Parts Identification 225
OPERATING SYSTEM UNIT 226
Removal and Installation 226
INSTRUMENT PANEL 227
Removal and Installation 227
ENGINE SERVICE 229
TROUBLESHOOTING 231
RADIATOR 232
Removal and Installation 232
ENGINE MUFFLER 234
Removal and Installation 234
BLOWER HOUSING/FAN GEARBOX 235
Removal and Installation 235
FAN GEAR BOX 238
Disassembly 238
Long Housing 238
Short Housing 240
Assembly 243
Long Housing 243
Short Housing 245
Checking Backlash 248
Parts Identification 251
TENSION PULLEY 252
Removal and Installation 252
AIR CLEANER 253
Removal And Installation 253
ENGINE 254
Removal and Installation 254
FLYWHEEL 261
Removal and Installation 261
Flywheel Ring Gear 261
BELT SHIELD 262
Removal and Installation 262
VALVE CLEARANCE 263
Adjustment 263
ENGINE COMPRESSION 264
Checking 264
GLOW PLUGS 265
Removal and Installation 265
Checking 265
FUEL INJECTION PUMP 266
Checking the Injection Pump 266
Adjusting Shut–Off Linkage 266
Removal and Installation 267
Timing the Injection Pump 269
FUEL INJECTION NOZZLES 270
Removal and Installation 270
Checking the Injector Nozzle 272
CYLINDER HEAD 273
Removal and Installation 273
Disassembly and Assembly 274
Servicing the Cylinder Head 275
Top Clearance 275
VALVE, VALVE SEAT AND GUIDE 276
Checking the Valve Guide 276
Reconditioning the Valve and Valve Seat 277
Valve Spring 278
ROCKER ARM AND SHAFT 279
Checking 279
TIMING GEARCASE COVER 280
Removal and Installation 280
IDLER GEAR AND CAMSHAFT 282
Removal and Installation 282
Servicing the Camshaft 283
Servicing the Idler Gear and Shaft 284
TIMING GEARS 284
Checking Backlash 284
FUEL CAMSHAFT 285
Removal and Installation 285
Governor 285
CRANKSHAFT GEAR 286
Removal and Installation 286
OIL PUMP 286
Removal and Installation 286
Oil Pump Service 286
Checking Engine Oil Pressure 287
Relief Valve 287
PISTON AND CONNECTING ROD 288
Removal and Installation 288
Servicing the Piston and Connecting Rod 289
Connecting Rod Alignment 291
CRANKSHAFT AND BEARINGS 292
Removal and Installation 292
Servicing the Crankshaft and Bearings 293
CYLINDER BORE 297
Checking the Cylinder Bore 297
WATER PUMP 298
Disassembly and Assembly 298
SPECIFICATIONS 299
LOADER DIMENSIONS 301
OPERATIONS & PERFORMANCE 301
ENGINE 301
HYDRAULIC SYSTEM 302
ELECTRICAL 302
DRIVE SYSTEM 302
CAPACITIES 302
TIRES 302
ENGINE SPECIFICATIONS 303
Fuel Injector Nozzles 303
Fuel Injection Pump 303
Cylinder Head 303
Valves 303
Valve Springs 303
Valve Timing 303
Rocker Arms 303
Camshaft 304
Tappet 304
Cylinders 304
Piston Rings 304
Pistons 304
Connecting Rod 304
Oil Pump 304
Crankshaft 305
Timing Gear 305
Thermostat 305
Crankshaft Re–Grind Data 306
Torque For General Metric Bolts 306
TORQUE SPECIFICATIONS FOR LOADER 307
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 308
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 309
DECIMAL AND MILLIMETER EQUIVALENTS 310
U S TO METRIC CONVERSION 310
SERVICE MANUAL REVISIONS 311
7753–001 311
7753–002 313
7753–003 315
7753–004 317
7753–005 319
7753–006 321
7753–007 323
7753–008 325
7753–009 327
7753–010 329
7753–011 331
7753-012 333

DESCRIPTION:

Bobcat 7753 Loader Service Manual 6720899 (6–12)- PDF DOWNLOAD

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.

SAFETY INSTRUCTIONS:
The following publications provide information on the safe use 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 routin e
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold.
• 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 dealers.
• The EM Manual delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from Bobcat loader dealers for use by mechanics to do shop–type
service and repair work.

• Wear tight fitting clothing and any other required safety apparel when operating or servicing the loader.
• Wear safety glasses when maintaining or servicing the loader.
• Exhaust gases can kill, vent engine exhaust outdoors.
• Know where fire extinguisher and first aid kits are located and how to use them.
• Do not run the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.
• 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.
• Clean the loader before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fi re
extinguisher near the loader when welding.
• Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust
and gas can be produced.
• Stop the engine and let it cool before adding fuel. No smoking!
• Use the procedure in this Manual for connecting battery.
• Use the procedure in this Manual for cleaning the spark arrestor muffler after each 100 hours of operation.

Customer Support: [email protected]

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• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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