Service

Manual
G Series

Dealer Copy -- Not for Resale

(S/N 515830001 & Above)
(S/N 516220001 & Above)

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Bobcat Company or the products of
either.

EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6900976 (10-12) Printed in U.S.A. © Bobcat Company 2010

1 of 726
2 of 726
Dealer Copy -- Not for Resale
 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-15590 B-15591

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

Dealer Copy -- Not for Resale

B-15592 B-15593 B-15599
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-15600 B-15601 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 perfor med 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.
MSW08-0805

3 of 726
4 of 726
Dealer Copy -- Not for Resale
 ALPHABETICAL INDEX

ADVANCED CONTROL SYSTEM (ACS) ENGINE SPEED CONTROL ...................................70-01

ADVANCE HAND CONTROL ............................... 60-01
ADVANCED CONTROL SYSTEM (ACS) FAN GEARBOX .......................................................10-01
SELECTRABLE HAND/FOOT CONTROL............ 60-01 FINAL DRIVE TRANSMISSION (CHAINCASE)...... 10-01
ADVANCED HAND CONTROL (AHC) SYSTEM.... 60-01 FLYWHEEL AND HOUSING ...................................70-01
ADVANCED HAND CONTROL (AHC) FRONT AUXILIARY HYDRAULIC
SYSTEM (W/PUSH BUTTON FLOAT) ................. 60-01 COUPLER BLOCK ...............................................20-01
AIR CLEANER SERVICE ............................ 10-01, 70-01 FRONT AUXILIARY PRESSURE
ALTERNATOR (55 AMP) ........................................ 60-01 RELIEF BLOCK ....................................................20-01
ALTERNATOR (90 AMP) ........................................ 60-01 FUEL SYSTEM........................................................10-01
FUEL TANK .............................................................50-01
BASIC TROUBLESHOOTING ................................ 80-01
BATTERY................................................................ 60-01 HEATER UNIT .........................................................80-01
BICS™ SYSTEM .................................................... 60-01 HEATER COIL .........................................................80-01
BOBCAT CONTROLLER ....................................... 60-01 HEATER FAN .........................................................80-01
BOBCAT INTERLOCK HEATER VALVE ......................................................80-01
CONTROL SYSTEM (BICS™) ............................ 60-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01
BOB-TACH................................................... 10-01, 50-01 HYDRAULIC CONTROL VALVE (ADVANCED
BRAKE .................................................................... 40-01 CONTROL SYSTEM) (ACS) .................................20-01
BUCKET POSITION VALVE.................................. 20-01 HYDRAULIC CONTROL VALVE
(FOOT CONTROL)................................................20-01
CHAINCASE ........................................................... 40-01 HYDRAULIC FLUID RESERVOIR ..........................20-01

Dealer Copy -- Not for Resale

CHARGE PRESSURE ........................................... 30-01 HYDRAULIC/HYDROSTATIC FILTER ....................20-01
COMPONENTS ..................................................... 80-01 HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01
CONTROL HANDLE ............................................... 50-01 HYDRAULIC/HYDROSTATIC SYSTEM.............. 10-01
CONTROL HANDLE HYDRAULIC PUMP (ALUMINUM) ..........................20-01
(ADVANCE HAND CONTROL) (AHC).................. 50-01 HYDRAULIC SYSTEM INFORMATION 20-01
CONTROL HANDLE (ADVANCED HAND CONTROL) HYDRAULIC PUMP (ALUMINUM) ..........................20-01
(AHC) W/PUSH BUTTON FLOAT........................ 50-01 HYDRAULIC PUMP (CAST IRON) .........................20-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) HYDROSTATIC MOTOR .........................................30-01
(ACS) ADVANCED HAND CONTROL................. 50-01 HYDROSTATIC PUMP ............................................30-01
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) HYDROSTATIC SYSTEM INFORMATION..............30-01
(ACS) SELECTABLE HAND/FOOT CONTROL... 50-01
CONTROL PANEL .................................................. 50-01 INSTRUMENT PANEL ............................................60-01
CONTROL PEDALS ............................................... 50-01
CONTROL PEDALS (ACS) .................................... 50-01 LIFT ARM ................................................................50-01
CONVERSIONS ................................................SPEC-01 LIFT ARM BY-PASS CONTROL VALVE..................20-01
COOLING FAN ...................................................... 70-01 LIFT ARM SUPPORT DEVICE................................10-01
CYLINDER (LIFT) ................................................... 20-01 LIFTING AND BLOCKING THE LOADER...............10-01
CYLINDER (POWER BOB-TACH).......................... 20-01 LIGHTS....................................................................60-01
CYLINDER (TILT) ................................................... 20-01 LOADER SPECIFICATIONS ............................. SPEC-01
LUBRICATION OF THE BOBCAT LOADER ...........10-01
DIAGNOSTICS ....................................................... 60-01
DRIVE BELT ........................................................... 30-01 MAIN RELIEF VALVE ..............................................20-01
DRIVE COMPONENTS .......................................... 40-01 MUFFLER................................................................70-01

ELECTRICAL/HYD. CONTROLS REFERENCE .... 60-01 OIL COOLER...........................................................30-01

ELECTRICAL SYSTEM INFORMATION ................ 60-01 OPERATOR CAB .........................................10-01, 50-01
ENGINE .................................................................. 70-01 OPERATOR SEAT...................................................50-01
ENGINE COMPONENTS AND TESTING .............. 70-01 OPERATOR SEAT (SUSPENSION)........................50-01
ENGINE COOLING SYSTEM ................................. 10-01
ENGINE LUBRICATION SYSTEM ......................... 10-01 POWER BOB-TACH................................................50-01
ENGINE SPECIFICATIONS...............................SPEC-01 POWER BOB-TACH BLOCK...................................50-01

Continued On Next Page

753 Bobcat Loader

Service Manual
5 of 726
 ALPHABETICAL INDEX (CONT’D)

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

SEAT BAR............................................................... 50-01

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

TIRE MAINTENANCE..............................................10-01

Dealer Copy -- Not for Resale

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

753 Bobcat Loader

Service Manual
6 of 726
 SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II

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

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

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

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

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

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

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

MAIN FRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

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

Dealer Copy -- Not for Resale

ELECTRICAL
SYSTEM &
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
ENGINE
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01 SERVICE

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

HEATER

SPECIFICATIONS

SPECIFICATIONS

753 Bobcat Loader

I Service Manual
7 of 726
 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 side screens) 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.
Bobcat approved.

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

correctly installed, functional linkages must function
and in good condition. correctly and be in good

Dealer Copy -- Not for Resale

condition.

4. The seat bar must be 12. Safety treads must be in good

correctly adjusted, clean and condition.
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 14. Check hydraulic fluid level,

legible and in the correct engine oil level and fuel
location. supply.

7. Steering levers and foot 15. Inspect for fuel, oil or

pedals must return to neutral. hydraulic fluid leaks.

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

the work lights

753 Bobcat Loader

II Service Manual
8 of 726
17. Check the condition of the 22. Operate the loader and check
battery and cables. all functions.

18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.

19. Check the electrical charging 24. Check for correct fu nction of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and Recommend to the owner that all
pressure. necessary corrections be made
before the machine is returned to

Dealer Copy -- Not for Resale

service.

21. Inspect for loose or broken

parts or connections.

CALIFORNIA
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.

753 Bobcat Loader

III Service Manual
9 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

IV Service Manual
10 of 726
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.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the

Dealer Copy -- Not for Resale

W-2003-0903 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.
WARNING • The AEM Safety Manual delivered with the machine
gives general safety information.
Warnings on the machine and in the manuals are for
your safety. Failure to obey warnings can cause • The Service Manual and Parts Manual are available
injury or death. from your dealer for use by mechanics to do shop-
W-2044-1285 type service and repair work.

• The Skid-Steer Loader Operator Training Course is

available through your local dealer or at
IMPORTANT www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
of correct operation of the Skid-Steer Loader. The
This notice identifies procedures which must be
course is available in English and Spanish versions.
followed to avoid damage to the machine.
I-2019-0284
• Service Safety Training Courses are available from
your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.

• The Skid-Steer Loader Safety Video is available from

your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.

SI SSL-0206 SM

753 Bobcat Loader

V Service Manual
11 of 726
SAFETY INSTRUCTIONS (CONT’D)

The dealer and owner/operator review the recommended

uses of the product when delivered. If the owner/operator
will be using the machine for a different application(s) he
or she must ask the dealer for recommendations on the
new use.

Dealer Copy -- Not for Resale

Call Before You Dig
1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)

SI SSL-0206 SM

753 Bobcat Loader

VI Service Manual
12 of 726
SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.

The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of hi gh temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a s ource of ar cs or Figure 1
sparks.

Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to av oid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.

The spark arrestor muffler is designed to control the

emission of hot particles from the eng ine and exhaust
system, but the muffler and the ex haust gases are still
hot.

• Do not use the machine where exhaust, arcs, sparks

or hot c omponents can contact flammable material,

Dealer Copy -- Not for Resale

explosive dust or gases.

• The operator cab, engine compartment, and engine

cooling system must be inspected every day and • Know where fire extinguishers and first aid kits are
cleaned if nec essary to pr event fire hazard and located and how to use them. Fire extinguishers are
overheating. available from your Bobcat dealer [Figure 1].

• 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 no t
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.

• Do not use ether or starting fluids on any engine

which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.

• Always clean the machine, disconnect the battery,

and disconnect the wiring from the controllers before
welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fi re extinguisher near the
machine when welding. Have good ventilation when
grinding or welding painted parts. Wear a 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!
SI SSL-0206 SM

753 Bobcat Loader

VII Service Manual
13 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

VIII Service Manual
14 of 726
SERIAL NUMBER LOCATIONS Engine Serial Number

Always use the serial number of th e loader when Figure 3

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

Figure 2

N-20521

The engine serial number is in the location shown

[Figure 3].

DELIVERY REPORT

Dealer Copy -- Not for Resale

Figure 4
N-20515

The loader serial number plate is located on the outside

of the loader frame [Figure 2].

Explanation of loader Serial Number:

XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)

1. The four digit Model/Engine Combination Module

B-16315
number identifies the model number and engine
combination.
The Delivery Report must be filled out by the dealer and
2. The five digit Production Sequence Number identifies signed by the owner or operator when the Bobcat loader
the order which the loader is produced. is delivered. An explanation of the form must be given to
the owner. Make sure it i s filled out completely [Figure
4].

753 Bobcat Loader

IX Service Manual
15 of 726
LOADER IDENTIFICATION

FRONT LIGHTS

OPERATOR SEAT
WITH SEAT BELT

GRAB HANDLES

STEERING LEVER ▼REAR AUXILIARY

QUICK COUPLERS

TILT CYLINDER

+BUCKET

▼FRONT AUXILIARY

Dealer Copy -- Not for Resale

QUICK COUPLERS

BUCKET STEPS SAFETY TREAD

●OPERATOR CAB
▼REAR WINDOW (ROPS & FOPS)

REAR GRILL SEAT BAR

LIFT ARM
LIFT ARM
SUPPORT DEVICE

LIFT CYLINDERS
▼TAIL

▼REAR LIGHT

*TIRES
REAR DOOR

▼ 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 Structure
per SAE J1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base-equipped with a standard operator
cab as shown. Extra insulated cab is available as an option (Reduced noise level).

753 Bobcat Loader

X Service Manual
16 of 726
 SAFETY AND MAINTENANCE

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing Filter Element(s) . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2 SAFETY AND
MAINTENANCE
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2 DRIVE
SYSTEM
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 10-110-1
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1

FAN GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

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

Dealer Copy -- Not for Resale

ELECTRICAL
SYSTEM &
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1 ANALYSIS
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Removing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
ENGINE
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 SERVICE
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . 10-100-3 SPECIFICATIONS

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . 10-120-1

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

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing Lift Arm Support Device . . . . . . . . . . . . . . . . . . . 10-20-1
Removing The Lift Arm Support Device. . . . . . . . . . . . . . . 10-20-2

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

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

Continued On Next Page

753 Bobcat Loader

10-01 Service Manual
17 of 726
 SAFETY AND MAINTENANCE (CONT’D)

LUBRICATION OF THE BOBCAT LOADER . . . . . . . . . . . . . 10-160-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Dealer Copy -- Not for Resale

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

753 Bobcat Loader

10-02 Service Manual
18 of 726
LIFTING AND BLOCKING THE LOADER Figure 10-10-2

Procedure

Figure 10-10-1

P-31849

Put floor jack under the rear of the loader [Figure 10-10-
B-7023A 2].

Lift the rear of the lo ader and install jackstands [Figure

10-10-2].

WARNING

Dealer Copy -- Not for Resale

Figure 10-10-3

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

Always park the loader on a level surface.

P-3868

WARNING Put the floor jack under the front of the loader [Figure 10-
10-3].
Put jackstands under the front axles and rear corners
Lift the front of the loader and put ja ckstands under the
of the frame before running the engine for service.
axle tubes [Figure 10-10-3].
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
NOTE: Make sure the jackstands do not touch the
W-2017-0286
tires. Make sure tires clear floor or any
obstacles.

753 Bobcat Loader

10-10-1 Service Manual
19 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-10-2 Service Manual
20 of 726
LIFT ARM SUPPORT DEVICE Figure 10-20-1

Installing Lift Arm Support Device

1
2

WARNING P-31849 N-20526

Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm Put jackstands under the rear corners of the loader frame
support device. Failure to use an approved lift arm (Inset) [Figure 10-20-1].
support device can allow the lift arms or attachment
to fall and cause injury or death. Disconnect the s pring from the l ift arm support device
W-2059-0598 retaining pin (Item 1). Support the lift arm support device
(Item 2) [Figure 10-20-1] with your hand and remove the

Dealer Copy -- Not for Resale

retaining pin.

WARNING Figure 10-20-2

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 arms to drop
causing injury or death. 1
W-2271-1197

N-20525

Lower the lift arm support device on top of the lift

cylinder. Hook the free end of the spring (Item 1) [Figure
10-20-2] to the lift arm 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.

753 Bobcat Loader

10-20-1 Service Manual
21 of 726
LIFT ARM SUPPORT DEVICE (CONT’D) With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
Installing Lift Arm Support Device (Cont’d)
Raise the lift arms a small amount and the spring will lift
Figure 10-20-3 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.

Figure 10-20-5

1 2
N-20524

Raise the lift arms, until the lift arm support device drops
onto the lift cylinder rod [Figure 10-20-3].

Dealer Copy -- Not for Resale

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
N-20526
lock.

Install pin (Item 1) [Figure 10-20-3] into the rear of the lift Raise the support device into storage position and insert
arm support device below the cylinder rod. pin (Item 1) through lift arm support device (Item 2)
[Figure 10-20-5] and bracket. Connect spring to pin.
Removing The Lift Arm Support Device
Remove jackstands.
Figure 10-20-4

N-20523

Remove the pin from the lift arm support device.

Connect the spring (Item 1) [Figure 10-20-4] from the lift

arm support device to the bracket below the lift arms.

753 Bobcat Loader

10-20-2 Service Manual
22 of 726
OPERATOR CAB Figure 10-30-1

Description

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 I. Level II
is available.

Level I - Protection from falling bricks, small concrete P-31849

blocks, and hand tools encountered in operations such
as highway maintenance, landscaping, and other
construction site services. Install jackstands under the rear of the loader frame
[Figure 10-30-1].
Level II - Protection from falling trees, rocks; for machines
involved in site clearing, overhead demolition or forestry.

Raising The Operator Cab

Dealer Copy -- Not for Resale

Always stop the engine before raising or lowering the
cab.

Stop the loader on a level surface. Lower the lift arms. If

the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Installing Lift Arm
Support Device on Page 10-20-1.)

WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in injury or death.
W-2069-1299

753 Bobcat Loader

10-30-1 Service Manual
23 of 726
OPERATOR CAB (CONT’D) Advanced Control System (ACS) and Advanced Hand
Controls (AHC) Only
Raising The Operator Cab (Cont’d)
Lowering The Operator Cab
Figure 10-30-2
Figure 10-30-4

N-20520 N-20519
N-20120 N-20608

Loosen the nut (both sides) at th e front corners of th e

operator cab [Figure 10-30-2]. Always stop the engine before raising or lowering the

Dealer Copy -- Not for Resale

cab.
Remove the n uts and plates [Figure 10-30-2] (both
sides). NOTE: Make sure the seat bar is fully raised or
lowered when lowering the cab. Always use
Figure 10-30-3 the grab handles to lower the cab.

Pull down on the bottom of the operator cab until it stops

at the latching mechanism [Figure 10-30-4].

Release the latching mechanism (Inset) [Figure 10-30-4]

and pull the cab all the way down.

Figure 10-30-5

N-20608

Lift on the grab handle and bottom of the operator cab

slowly until the cab is all the w ay up an d the latching
mechanism engages [Figure 10-30-3].

N-20519 N-20519

Install the plates and nuts [Figure 10-30-5] (both sides).

Tighten the nuts to 40-50 ft.-lbs. (54-68 Nm) torque.

753 Bobcat Loader

10-30-2 Service Manual
24 of 726
OPERATOR CAB (CONT’D) Figure 10-30-8

Emergency Exit

Figure 10-30-6

N-20171

Front Door (If Equipped)

N-19386
NOTE: When an Operator Cab Enclosure Kit is
installed, the window of the front door can be
The front opening on the op erator cab and rear window used as an emergency exit. [Figure 10-30-8]
provide exits.

Dealer Copy -- Not for Resale

Pull the plastic loop at the top of the win dow in the front
Rear Window (If Equipped) door to remove the rubber cord [Figure 10-30-8].

Pull on the tag on the top of the rear window to remove Figure 10-30-9
the rubber cord [Figure 10-30-6].

Figure 10-30-7

X
P-30255

N-20606 Push the window out with your foot [Figure 10-30-9] at
any corner of the window.

Push the rear window out of the rear of the operator cab. Exit through the front door.

Exit through the rear of the operator cab [Figure 10-30-

7].

753 Bobcat Loader

10-30-3 Service Manual
25 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-30-4 Service Manual
26 of 726
TRANSPORTING THE BOBCAT LOADER Figure 10-40-2

Procedure

WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0494
N-19048A N-19073

Figure 10-40-1

Dealer Copy -- Not for Resale

1 N-20527 N-20659

Be sure the transport and towing vehicles are of

adequate size and capacity (See Machine Dimensions
on Page SPEC-10-1.)

A loader with an empty bucket or no attachment must be 6707867

loaded backward onto the transport vehicle [Figure 10-
40-1].
Use the following procedure to fasten the Bobcat loader
The rear of the trailer must be blocked or supported (Item to the transport vehicle to prevent the loader from moving
1) [Figure 10-40-1] when loading or unloading the loader during sudden stops or when going up o r down slopes
to prevent the front end of the trailer from raising up. [Figure 10-40-2].

• Lower the bucket or attachment to the floor.

• Stop the engine.

• Engage the parking brake.

• Install chains at the front and rear loader tie down

positions (Inset) [Figure 10-40-2].

• Fasten each end of the chain to the transport vehicle.

753 Bobcat Loader

10-40-1 Service Manual
27 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-40-2 Service Manual
28 of 726
TOWING THE LOADER Figure 10-50-2

Procedure

Figure 10-50-1

1
1

N-18409

• Press the TRACTION LOCK OVERRIDE Button

N-18410 (Item 1) [Figure 10-50-2].

• Tow the Bobcat at 2 MPH (3,2 km/hr) or less for not

To prevent damage to the loaders hydrostatic system, the more than 25 feet (7,6 meters).
loader must be towed only a short distance at slow
speed. (Example: Moving the loader onto a tr ansport

Dealer Copy -- Not for Resale

If the ele ctrical system is not functioning or the engine
vehicle). does not run part of the brake system must be
disassembled to move the loader. (See TRACTION
The towing chain (or cable) must be rated at 1 & 1/ 2 LOCK on Page 60-110-1.)
times the weight of the loader. (See Machine Dimensions
on Page SPEC-10-1.)

• Turn the key switch to RUN (Item 1) [Figure 10-50-1]

(Standard Panel) OR press the RUN/ENTER Button
(Deluxe Panel).

753 Bobcat Loader

10-50-1 Service Manual
29 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-50-2 Service Manual
30 of 726
REMOTE START Figure 10-60-3

Procedure

Figure 10-60-1

P-28823

Lift and block the loader. (See LIFTING AND BLOCKING

N-20862 THE LOADER on Page 10-10-1.)

Raise the lift arms (if required by the procedure) and

The tool listed will be ne eded to d o the following install an approved lift arm support device. (See Installing
procedure: Lift Arm Support Device on Page 10-20-1.)

Dealer Copy -- Not for Resale

MEL1563: Remote Start Tool Kit Raise the operator cab (if required by the procedure).
(See Raising The Operator Cab on Page 10-30-1.)
The remote start (Item 1) [Figure 10-60-1] is r equired
when the operator cab is in the raised position for service Open the rear door of the loader.
and the service technician needs to turn the key switch
on or start the engine. Example: adjusting the steering Remove the plug (Item 1) [Figure 10-60-2] /or
linkage. disconnect the attachment control harness (Item 1)
[Figure 10-60-3] if connected.
Figure 10-60-2

P-28793

753 Bobcat Loader

10-60-1 Service Manual
31 of 726
REMOTE START (CONT’D)

Procedure (Cont'd)
WARNING
Figure 10-60-4
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
1 service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899

Figure 10-60-5

P-28806

Connect the remote start tool to the en gine harness

connector (Item 1) [Figure 10-60-4].
1

Dealer Copy -- Not for Resale

NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Kit will not operate.

N-20861

The remote start tool (Item 1) [Figure 10-60-5] has three

rocker switches.

753 Bobcat Loader

10-60-2 Service Manual
32 of 726
REMOTE START (CONT’D) S/N 515842310 and Above

Procedure (Cont'd) Figure 10-60-7

Figure 10-60-6

2
3 1

P-43215

N-20863
If your loader is equipped with the front auxiliary coupler
block (Item 1) [Figure 10-60-7], push the couplers
The traction lock switch (Item 1) [Figure 10-60-6] is used towards the block and hold for five seconds to r elease
to turn traction lock on or off. Push the switch to the the front auxiliary pressure.
override position. The switch will illuminate to in dicate

Dealer Copy -- Not for Resale

traction lock OVERRIDE, in thi s position the whe els are To release the rear auxiliary coupler pressure, use the
able to turn. pressure release button (Item 3) [Figure 10-60-6] on the
remote start tool.
The maximum flow/variable flow switch (Item 2) [Figure
10-60-6] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to ind icate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.

S/N 515842309 and Below

The auxiliary pressure release (Item 3) [Figure 10-60-6]

is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.

NOTE: With the engine running; pushing and holding

the pressure release switch this will cause the
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.

753 Bobcat Loader

10-60-3 Service Manual
33 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-60-4 Service Manual
34 of 726
SERVICE SCHEDULE
Chart
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
WARNING 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

SERVICE SCHEDULE HOURS

ITEM SERVICE REQUIRED ■ ■ ■ ■
8-10 50 100 250 500 1000
Engine Oil Check the oil level and add oil as needed.
Engine Air Filter and Air System Check display panel for lighted icon and/or Service Code. Service only when
required. Check for leaks and damaged components.
Engine Cooling System Clean debris from oil cooler, radiator & grill. Check coolant level in recovery tank
when engine is cold. Add 53% propylene glycol premixed with 47% water as
needed.
Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure
shown on tire sidewall.
Seat Belt, Seat Bar and Control Check the condition of seat belt. Check the seat bar and control interlocks. Clean
Interlocks dirt and debris from moving parts.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or safety
treads that are damaged or worn.
Indicators & Lights (Opt.) Check for correct operation of all indicators and lights.

Dealer Copy -- Not for Resale

Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
Fuel Filter Remove the trapped water.
Heater Filters Clean or replace filters as needed during heating/cooling season.
Bobcat Interlock Control System Check the four (4) BICS™ indicator lights and functions are activated. See details in
(BICS™) this Manual.
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Final Drive Trans. (Chaincase), Check oil level. Check for correct operation. Repair or adjust as needed.
Foot Pedals or Hand Controls Check for correct operation. Repair or adjust as needed.
and Steering Levers
Wheel Nuts ❏ Check for loose wheel nuts and tighten to 105-115 ft.-lbs. (142-156 Nm) torque
Parking Brake Check operation.
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease two fittings.
Engine/Hydrostatic Drive Belt * Check for wear or damage. Adjust as needed.
Fan Drive Gearbox Check gear lube level. Add as needed.
Alternator Belt Check belt tension and adjust as needed.
Engine Oil and Filter ^ Replace oil and filter. Use CD or better grade oil and Bobcat filter.
Fuel Filter Replace the filter element.
Bobcat Interlock Control System Check the function of the lift arm by-pass control
(BICS™)
Hydraulic Reservoir Breather Cap Replace the reservoir breather cap.
Hyd./Hydro. Filter ● Replace the filter element.
Hydraulic Reservoir Replace the fluid
Final Drive Trans. (Chaincase) Replace the fluid
Case Drain Filters ■ Replace the filters

❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Replace filter element after the first 50 hours and when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 250 hours thereafter.
■ Or every 12 months.

753 Bobcat Loader

10-70-1 Service Manual
35 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-70-2 Service Manual
36 of 726
AIR CLEANER SERVICE Figure 10-80-2

Checking

Figure 10-80-1

1
2

N-18409

Press and hold the LIGHT Button (Item 1) [Figure 10-80-

P-21769A 2] for two seconds.

If the fi lter element needs replacement, the CODE [01-

It is important to change the air filter element only when 17] (Air Filter Plugged) will show in the HOURMETER /
the Air Cleaner icon in the right panel is ON (Item 1) CODE DISPLAY (Item 2) [Figure 10-80-2].
[Figure 10-80-1] and you hear three beeps from the

Dealer Copy -- Not for Resale

alarm.

Replace the inner filter every third time the outer filter is
replaced or as indicated. (See Replacing Filter
Element(s) on Page 10-80-2.)

753 Bobcat Loader

10-80-1 Service Manual
37 of 726
AIR CLEANER SERVICE (CONT’D) Figure 10-80-5

Replacing Filter Element(s)

OUTER FILTER

Figure 10-80-3

1 P-43240

Remove the outer filter element [Figure 10-80-5].

NOTE: Be sure all sealing surfaces are clean.

P-43243
Install the new filter element and washer. Tighten the
wing nut.
Remove the wing nut (Item 1) [Figure 10-80-3] and

Dealer Copy -- Not for Resale

remove the dust cover. NOTE: Be sure sealing washer is in place on each
wing nut [Figure 10-80-4].
Figure 10-80-4
Install the dust cover and tighten the wing nut.

Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.

P-43239

Remove the wing nut (Item 1) [Figure 10-80-4] from the

outer filter element.

753 Bobcat Loader

10-80-2 Service Manual
38 of 726
AIR CLEANER SERVICE (CONT’D) Figure 10-80-7

Replacing Filter Element(s) (Cont’d)

INNER FILTER

Figure 10-80-6

1 P-43242

Remove the inner filter [Figure 10-80-7].

Install a new filter and tighten the wing nut.

P-43241

Only replace the inner filter element under the following

Dealer Copy -- Not for Resale

conditions:

• Replace the in ner filter element every third time the

outer filter is replaced.

• After the outer element has been replaced, start the

engine and run at full RPM. If the HOURMETER /
CODE DISPLAY shows [01-17] (Air Filter Plugged),
replace the inner filter element.

Remove the inner filter wing nut (Item 1) [Figure 10-80-

6].

753 Bobcat Loader

10-80-3 Service Manual
39 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-80-4 Service Manual
40 of 726
ENGINE COOLING SYSTEM Figure 10-90-2

WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285

Check the cooling system every day to prevent over- N-20594

heating, loss of performance or engine damage.

Cleaning The Cooling System Raise the oil cooler. Clean the top of the radiator [Figure
10-90-2].
Figure 10-90-1
NOTE: Use low air pressure or low water pressure to
clean the radiator or damage to the radiator
fins may result.

Dealer Copy -- Not for Resale

Lower the oil cooler.

Check cooling system for leaks.

Lower the rear grill and close the rear door.

Checking The Coolant Level

Figure 10-90-3

N-20595

Open the rear door and raise the rear grill.

Use air pressure or water pressure to clean the top of the

oil cooler [Figure 10-90-1].

WARNING
Do not use your bare hands to remove debris from
the oil cooler. Cooling fins are sharp and may cause P-43238

injury.
W-2460-0303
Open the rear door.

Remove the cover from the coolant recovery tank (Item

1) [Figure 10-90-3]. Check the coolant level. The coolant
level must be between the MIN a nd MAX marks on th e
coolant recovery tank when the engine is cold.

Close the rear door before operating the loader.

753 Bobcat Loader
10-90-1 Service Manual
41 of 726
ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-5

Checking The Coolant Level (Cont’d)

IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze. 1

Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
damage.
P-43237
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
boiling point and freeze protection of the system. Connect a hose to the engine block drain valve (Item 1)
[Figure 10-90-5]. Open the dr ain valve and drain the
Always add a premixed solution. Adding full strength coolant into a container.
concentrated coolant can cause serious premature
engine damage. Drain coolant from recovery tank.
I-2124-0497

Dealer Copy -- Not for Resale

After all the coolant is removed, close the drain valve and
Replacing The Coolant remove the hose.

Recycle or dispose of used coolant in an environmentally

safe manner.
WARNING Mix the coolant in a separate container. (See Capacities
on Page SPEC-10-5.)
Do not remove radiator cap when the engine is hot.
You can be seriously burned. NOTE: The loader is factory filled with propylene
W-2070-1285
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Figure 10-90-4
Add premixed coolant, 47% water and 53% propylene
glycol to the recovery tank if the coolant level is low.

One gallon and one pint (4,3 L) of propylene glycol mixed

with one gallon (3,8 L) 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.

Fill the radiator with the premixed coolant. Install the

radiator cap.

N-21131

Open the rear door and raise the rear grill.

Remove the radiator cap (Item 1) [Figure 10-90-4].

753 Bobcat Loader

10-90-2 Service Manual
42 of 726
ENGINE COOLING SYSTEM (CONT’D)

Replacing The Coolant (Cont’d)

Remove the cover from the coolant recovery tank. Fill the
tank until it i s between the MIN and M AX marks on th e
coolant recovery tank.

Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level in the recovery tank
and radiator when cool. Add coolant as needed.

Lower the rear grill and close the rear door.

IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine

Dealer Copy -- Not for Resale

damage.

Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497

753 Bobcat Loader

10-90-3 Service Manual
43 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-90-4 Service Manual
44 of 726
FUEL SYSTEM Figure 10-100-1

Fuel Specifications

Use only clean, high quality diesel fuel, Grade No. 2 or

Grade No. 1. 1

The following is one suggested blending guideline which

should prevent fuel gelling during cold temperatures:

TEMP. Fº (Cº) NO. 2 NO. 1

+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
P-43244

Contact your fuel supplier for local recommendations.

Remove the fuel fill cap (Item 1) [Figure 10-100-1].
Filling the Fuel Tank
Figure 10-100-2

WRONG
WARNING

Dealer Copy -- Not for Resale

Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0887

WARNING
Always clean up spilled fuel or oil. Keep heat, flames, B-15602

sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause Use a clean, approved safety container to add fuel of the
explosion or fire which can result in injury or death. correct specifications. Add fuel only in an area that has
W-2103-1285
free movement of air and no open flames or sparks. NO
SMOKING![Figure 10-100-2].

Install and tighten the fuel fill cap (Item 1) [Figure 10-
100-1].

753 Bobcat Loader

10-100-1 Service Manual
45 of 726
FUEL SYSTEM (CONT’D)

Fuel Filter

Figure 10-100-3

P-43248

Open the rear door.

(See SERVICE SCHEDULE on Page 10-70-1.) for the

Dealer Copy -- Not for Resale

service interval for removing water from, or replacing the
fuel filter.

Loosen the drain (Item 1) [Figure 10-100-3] at the

bottom of the filter element to r emove water from the
filter.

Remove the filter element (Item 2) [Figure 10-100-3].

Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and
hand tighten.

Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-100- 3.)

753 Bobcat Loader

10-100-2 Service Manual
46 of 726
FUEL SYSTEM (CONT’D) Open the vent (Item 1) [Figure 10-100-4] on the fuel filter
housing.
Removing Air From The Fuel System
Squeeze the hand pump (priming bulb) (Item 2) [Figure
10-100-4] until fuel flows from the vent with no air
bubbles.
WARNING Close the vent (Item 1) [Figure 10-100-4] on the fuel filter
housing.
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
Open the vent (Item 3) [Figure 10-100-4] on the fuel
death. Fluid leaks under pressure may not be visible.
injection pump.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
Squeeze the hand pump (priming bulb) (Item 2) [Figure
enters skin or eyes, get immediate medical attention
10-100-4] until the pump feels solid.
from a physician familiar with this injury.
W-2072-0496
Tighten the vent plug (Item 3) [Figure 10-100-4].

After replacing the fi lter element or when the fuel tank Start the engine.
has run out of fuel, the air must be removed from the fuel
system before starting the engine. It may be nec essary to ope n the vent plug (Item 3)
[Figure 10-100-4] briefly while the engine is running.
Figure 10-100-4 Close the vent when the engine runs smoothly.

Dealer Copy -- Not for Resale

3

2
P-43247

753 Bobcat Loader

10-100-3 Service Manual
47 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-100-4 Service Manual
48 of 726
ENGINE LUBRICATION SYSTEM Replacing Oil And Filter

Checking Engine Oil Figure 10-110-2

Figure 10-110-1

P-43249

P-43247
(See SERVICE SCHEDULE on P age 10-70-1.)for the
service interval for replacing the engine oil and filter.
Check the engine oil level every day before starting the
engine for the work shift. Run the engine until it is at operating temperature. Stop

Dealer Copy -- Not for Resale

the engine.
Open the rear door and remove the dipstick (Item 1)
[Figure 10-110-1]. Open the rear door.

Keep the oil level between the marks on the dipstick. Remove the drain plug (Item 1) [Figure 10-110-2].

Use a good quality motor oil that meets API Service Drain the oil into a container and dispose of used oil in an
Classification of CD or better (See Oil Chart on Page 10- environmentally safe manner.
110-1.)

Oil Chart
RECOMMENDED SAE VISCOSITY NUMBER
C° (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)

F° TEMPERATURE RANGE ANTICIPATED

BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST
USE API CLASSIFICATION CD, CF-4, CG4)
*Can be used ONLY when available with appropriate diesel rating

753 Bobcat Loader

10-110-1 Service Manual
49 of 726
ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-4

Replacing Oil And Filter (Cont’d)

WARNING
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. 1
W-2103-1285

Figure 10-110-3 P-28804

Remove the fill cap (Item 1) [Figure 10-110-4].

Put oil in the engine. (See Capacities on Page SPEC-10-

5.) [Figure 10-110-4] (See Oil Chart on Page 10-110-1.)
1
Start the engine and let it run for several minutes.

Dealer Copy -- Not for Resale

Stop the engine and check for leaks at the oil filter.

Remove the dipstick and check the oil level.

Figure 10-110-5
P-43238

Remove the oil filter (Item 1) [Figure 10-110-3].

Clean the filter housing surface. 1

Put clean oil on the new oil filter gasket.

Install the filter and hand tighten.

Install and tighten the drain plug.

P-1575

Add oil as needed if it i s not at the t op mark (Item 1)

[Figure 10-110-5] on the dipstick.

Install the dipstick and close the rear door.

753 Bobcat Loader

10-110-2 Service Manual
50 of 726
HYDRAULIC/HYDROSTATIC SYSTEM Figure 10-120-3

Checking And Adding Fluid

Figure 10-120-1

2
1

P-28802

Remove the sc reen and clean with solvent as needed

P-43245 [Figure 10-120-3].

Install the fill cap.

Use only recommended fluid in the hydraulic system.
(See HYDRAULIC FLUID SPECIFICATIONS on Page Replacing Hydraulic/Hydrostatic Filter
SPEC-50-1.)

Dealer Copy -- Not for Resale

Figure 10-120-4
Stop the loader on a level surface,

Lower the lift arms and tilt the Bob-Tach fully back.

Stop the engine.

1
Remove the dipstick (Item 1) [Figure 10-120-1] and
check the fluid level.

Remove the fill cap (Item 2) [Figure 10-120-1].

Figure 10-120-2

P-28794

(See SERVICE SCHEDULE on Page 10-70-1.) for the

1 correct service intervals.

Open the rear door.

Remove the filter element (Item 1) [Figure 10-120-4].

Clean the gasket sealing surface on the filter housing.

Put clean oil on the seal of the new filter element.

P10303

Install and hand tighten the filter element.

Add the correct fluid to the reservoir until the fluid level is Close the rear door before operating the loader.
between the marks on the dipstick (Item 1) [Figure 10-
120-2]. Do not fill above the top mark on the dipstick Start the engine, check for leaks and the proper fluid level
in the reservoir.

753 Bobcat Loader

10-120-1 Service Manual
51 of 726
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-5

Replacing Hydrostatic Motor Case Drain Filter(s)

WARNING 1

Hydraulic fluid escaping under pressure can have

sufficient force to enter a person’s body by 1
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received 2
immediately.
W-2145-0290
P-43272

Disconnect the ho ses (Item 1) from the c ase drain filter

WARNING (Item 2) [Figure 10-120-5] located on the hydraulic
reservoir. Use plugs and caps to prevent leakage and
contamination.
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Figure 10-120-6
Failure to use care around combustibles can cause

Dealer Copy -- Not for Resale

explosion or fire which can result in injury or death.
W-2103-1285

(See SERVICE SCHEDULE on Page 10-70-1.), for the

1
service interval.

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)
2
Drain the hydraulic fluid reservoir. (See Replacing
Hydraulic Fluid on Page 10-120-3.)
1

P-28800

Disconnect the hoses (Item 1) [Figure 10-120-6] from

the case drain filter located on the l eft drive motor. Use
plugs and caps on th e filter and case drain hoses to
prevent leakage and contamination.

Remove and replace both hydrostatic motor case drain

filters (Item 2) [Figure 10-120-5] & [Figure 10-120-6].

753 Bobcat Loader

10-120-2 Service Manual
52 of 726
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)

Replacing Hydraulic Fluid

WARNING
(See SERVICE SCHEDULE on Page 10-70-1.), for the
service interval. Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
The fluid must be replaced if it becomes contaminated or penetrating the skin. This can cause serious injury
after major repairs. If the fluid is replaced, the hydrostatic and possible death if proper medical treatment by a
filter and both case drain filters must be replaced. physician familiar with this injury is not received
immediately.
Figure 10-120-7 W-2145-0290

1
WARNING
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

Dealer Copy -- Not for Resale

Lower the operator cab. (See Lowering The Operator
Cab on Page 10-30-2.)
P-43245
Start the e ngine and operate the l oader hydraulic
controls. Stop the engine and check for leaks.
Remove the reservoir fill cap (Item 1) [Figure 10-120-7]
Check the fluid level in the reservoir and add as needed.
Pump fluid from reservoir.

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

Replace the hydraulic/hydrostatic filter element. (See

Replacing Hydraulic/Hydrostatic Filter on P age 10-120-
1.)

Replace both hydrostatic motor case drain filters. (See

Replacing Hydrostatic Motor Case Drain Filter(s) on
Page 10-120-2.)

Add the correct fluid to the reservoir until the fluid level is
between the marks on the dipstick. DO NOT fill above the
top mark on the dipstick.

753 Bobcat Loader

10-120-3 Service Manual
53 of 726
HYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Figure 10-120-10

Breather Cap

Figure 10-120-8

EARLY STYLE
1

2
1

P-30011

Clean the filter (Item 1) [Figure 10-120-10] in the

P-28803 breather cap. Use solvent, or soap and water to clean the
filter. Thoroughly dry with compressed air before using.

Figure 10-120-9 NOTE: Be sure the rubber gasket (Item 2) [Figure 10-
120-10] is installed on the cap.

Dealer Copy -- Not for Resale

LATER STYLE
Install the breather cap.

P-43186

(See SERVICE SCHEDULE on Page 10-70-1.), for the

correct service interval.

Remove the breather cap (Item 1) [Figure 10-120-8] and

[Figure 10-120-9].

753 Bobcat Loader

10-120-4 Service Manual
54 of 726
FINAL DRIVE TRANSMISSION (CHAINCASE) Removing The Oil

Checking And Adding Oil Figure 10-130-2

Figure 10-130-1

1 1

P1616

P-3870
To drain the oil from the chaincase, remove the c over
(Item 1) [Figure 10-130-2] which is installed over the
The chaincase contains the final drive sprockets and drain plug at the rear of the chaincase.
chains and uses the same type of oil as the hydraulic/
hydrostatic system. (See Hydraulic System on P age

Dealer Copy -- Not for Resale

Installation: Tighten the cover bolts to 10-20 ft.-lbs. (24-
SPEC-10-3.) 27 Nm) torque.

To check the chaincase oil level, use the fol lowing Figure 10-130-3
procedure:

Drive the loader on a level surface. Stop the engine.

Remove the plug (Item 1) [Figure 10-130-1] from the

front of the chaincase housing.

If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
1
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.

P1619

Remove the dr ain plug (Item 1) [Figure 10-130-3] and

drain the oil into a container.

NOTE: When installing the drain plug into the

chaincase, always use a NEW drain plug
gasket.

753 Bobcat Loader

10-130-1 Service Manual
55 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-130-2 Service Manual
56 of 726
FAN GEARBOX

Checking And Maintaining

Figure 10-140-1

N-18460

(See SERVICE SCHEDULE on Page 10-70-1.), for the

correct service interval.

Dealer Copy -- Not for Resale

Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.).

Remove the plug (Item 1) [Figure 10-140-1] to check the

lubricant level.

If the level is low, add SAE 90W gear lubricant through

the check plug hole until lubricant flows from the hole.

Install and tighten the plug.

Lower the operator cab. (See Lowering The Operator

Cab on Page 10-30-2.)

753 Bobcat Loader

10-140-1 Service Manual
57 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-140-2 Service Manual
58 of 726
BOB-TACH Figure 10-150-3

Inspection And Maintenance

Bob-Tach
Figure 10-150-1 Wedge

Wedge Must Contact

N-17022
Lower Edge Of Hole
In The Attachment
B-15177

The spring loaded wedge (Item 1) [Figure 10-150-1]

N-17027 must contact the lower edge of the hole in the attachment
(Item 1) [Figure 10-150-2] and [Figure 10-150-3].

Move the Bob-Tach levers to engage the wedges [Figure If the wedge does not contact the lower edge of the hole
10-150-1]. The levers and wedges must move freely. [Figure 10-150-2] and [Figure 10-150-3], the

Dealer Copy -- Not for Resale

attachment will be loose and can come off the Bob-Tach.
The wedges must extend through the holes in th e
attachment mounting frame (Item 1) [Figure 10-150-1]. Figure 10-150-4

WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588

Figure 10-150-2

TS-1062

Inspect the mounting frame on th e attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-150-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.

Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.
1
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1 and See LUBRICATION OF THE BOBCAT
N-17023 LOADER on Page 10-160-1)

753 Bobcat Loader

10-150-1 Service Manual
59 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-150-2 Service Manual
60 of 726
POWER BOB-TACH Figure 10-151-3

Inspection And Maintenance

Figure 10-151-1

2
1

P-43832
2

Push and hold the BOB-TACH “WEDGES DOWN” switch

B-15891 (Item 2) [Figure 10-151-1], until the wedges (Item 1) and
levers (Item 2) [Figure 10-151-3] are fully down.

Figure 10-151-2 The levers and wedges must move freely.

Dealer Copy -- Not for Resale

WARNING
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
2 Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588

1
P-43831

Push and hold the BOB-TACH “WEDGES UP” switch

(Item 1) [Figure 10-151-1], until the wedges (Item 1) and
levers (Item 2) [Figure 10-151-2] are fully raised.

753 Bobcat Loader

10-151-1 Service Manual
61 of 726
POWER BOB-TACH (CONT’D) Figure 10-151-5

Inspection And Maintenance (Cont’d)

Figure 10-151-4

Bob-Tach
Wedge
1

B-17460

Wedge Must Contact

Lower Edge Of Hole Inspect the mounting frame on th e attachment and the
In The Attachment
B-15177 Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-151-5]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10- Look for cracked welds. Contact your Bobcat dealer for

Dealer Copy -- Not for Resale

151-4]. repair or replacement parts.

If the wedge does not contact the lower edge of the hole Lubricate the wedges. (See SERVICE SCHEDULE on
[Figure 10-151-4], the attachment will be loose and can Page 10-70-1 and See LUBRICATION OF THE BOBCAT
come off the Bob-Tach. LOADER on Page 10-160-1)

753 Bobcat Loader

10-151-2 Service Manual
62 of 726
LUBRICATION OF THE BOBCAT LOADER Figure 10-160-3

Procedure

Figure 10-160-1

N-20580

3. Lift Arm Pivot Pin (Both Sides) [Figure 10-160-3].

N-20576
Figure 10-160-4

Lubricate the loader as specified (See SERVICE

SCHEDULE on Page 10-70-1.) for the best performance
of the loader.

Dealer Copy -- Not for Resale

Record the operating hours each time you lubricate the
Bobcat loader.
4
Always use a good quality lithium based multi-purpose
grease. Apply lubricant until extra grease shows.

Lubricate the following locations on the loader:

1. Rod End Lift Cylinder (Both Sides) [Figure 10-160-1].

N-20574
Figure 10-160-2

4. Base End Tilt Cylinder [Figure 10-160-4].

N-20579

2. Base End Lift Cylinder (Both Sides) [Figure 10-160-

2].

763 Bobcat Loader

10-160-1 Service Manual
63 of 726
LUBRICATION OF THE BOBCAT LOADER (CONT’D) Figure 10-160-7

Procedure (Cont'd)

Figure 10-160-5

8 8

P-43829 P-43830

N-20573

5. Rod End Tilt Cylinder [Figure 10-160-5].

Dealer Copy -- Not for Resale

Figure 10-160-6

6 P-43831

8. Power Bob-Tach Pivot Pins (If Equipped) [Figure 10-

160-7].

7
P1564

6. Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-6].

7. Bob-Tach Wedge (Both Sides) [Figure 10-160-6].

753 Bobcat Loader

10-160-2 Service Manual
64 of 726
LUBRICATION OF THE BOBCAT LOADER (CONT'D)

Procedure (Cont'd)

Figure 10-160-8

N-20571

9. 250 Hours: Steering Lever Shaft (2) [Figure 10-160-

8].

Dealer Copy -- Not for Resale

Figure 10-160-9

N-20575

All lift arm and cylinder pivots have a la rge pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-160-9].

Check that the lock nuts are tightened to 18-20 ft.-lbs.

(24-27 Nm) torque.

763 Bobcat Loader

10-160-3 Service Manual
65 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-160-4 Service Manual
66 of 726
TIRE MAINTENANCE It is important to keep the same size tires on each side of
the loader. If di fferent sizes are used, each tire will be
Wheel Nuts turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Figure 10-170-1
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for the correct pressure before
operating the loader.

Mounting

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.

N-18514
The tire bead and rim flange must be lubricated with a
rubber lubricant before mounting the tire.
(See SERVICE SCHEDULE on Page 10-70-1.), for the
service interval to check the wheel nuts. The correct Avoid excessive pressure which can rupture the tire and
torque is 1 05-115 ft.-lbs. (142-156 Nm) torque [Figure

Dealer Copy -- Not for Resale

cause serious injury or death.
10-170-1].
During inflation of th e tire, check the tire pressure
Rotating frequently to avoid over inflation.
Figure 10-170-2

IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794

WARNING
B-9976 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.
Check the tires regularly for wear, damage and pressure. W-2078-1285
(See Tires on Page SPEC-10-5 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
to the front [Figure 10-170-2].

753 Bobcat Loader

10-170-1 Service Manual
67 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-170-2 Service Manual
68 of 726
SPARK ARRESTOR MUFFLER

Servicing
WARNING
Figure 10-180-1
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 e ngine and run for about 10 seconds while a

second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler.
1
This will force contaminants out through the c leanout
hole.

Stop the engine.

P-28794
Install and tighten the plug.

(See SERVICE SCHEDULE on Page 10-70-1.) for Close the rear door.
service interval for cleaning the spark arrestor muffler.

Dealer Copy -- Not for Resale

Do not operate the loader with a defective exhaust
system.
WARNING
When an engine is running in an enclosed area, fresh
IMPORTANT air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
This loader is factory equipped with a U.S.D.A. gases which can kill without warning.
Forestry Service approved spark arrestor muffler. It W-2050-1285
is necessary to do maintenance on this spark
arrestor muffler to keep it in working condition. The
spark arrestor muffler must be serviced by dumping
the spark chamber every 100 hours of operation.
WARNING
If this machine is operated on flammable forest,
brush or grass covered land, it must be equipped Stop engine and allow the muffler to cool before
with a spark arrestor attached to the exhaust system cleaning the spark chamber. Wear safety goggles.
and maintained in working order. Failure to do so will Failure to obey can cause serious injury.
be in violation of California State Law, Section 4442 W-2011-1285
PRC.

Make reference to local laws and regulations for

spark arrestor requirements.
I-2022-0595 WARNING
Stop the engine. Open the rear door. Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
Remove the plug (Item 1) [Figure 10-180-1] from the flammable material. Failure to obey warnings can
bottom of the muffler. cause injury or death.
W-2068-1285

753 Bobcat Loader

10-180-1 Service Manual
69 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

10-180-2 Service Manual
70 of 726
 HYDRAULIC SYSTEM

BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-1

Disassembly And Assembly 20-90-3
Removal And Installation 20-90-2 HYDRAULIC
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . .20-90-1 SYSTEM
Solenoid Testing 20-90-1

CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-4
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-3 DRIVE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-2 SYSTEM
CYLINDER (POWER BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . .20-22-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-5
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-2

Dealer Copy -- Not for Resale

ELECTRICAL
SYSTEM &
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-1 ANALYSIS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-6
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-5 ENGINE
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-4 SERVICE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-1
Rod End Pivot Pin Bushing And Seal Replacement . . . . . . .20-21-3

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK. . . . . . .20-121-1 SPECIFICATIONS

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . .20-121-1
Removal and Installation (S/N 515842310 & Above). . . . . .20-121-1

FRONT AUXILIARY PRESSURE RELIEF BLOCK. . . . . . . . . .20-120-1

Disassembly And Assembly (S/N 515842309 and Below) .20-120-2
Removal And Installation (S/N 515842309 and Below) . . . .20-120-1
Solenoid Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-120-3
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-120-3

Continued On Next Page

753 Bobcat Loader

20-01 Service Manual
71 of 726
 HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC CONTROL VALVE (FOOT CONTROL) . . . . . . . . . . . . . . . . .20-40-1

Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-19
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . 20-40-34
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . 20-40-34
BICS™ Valve Check Valve Disassembly And Assembly . . . . . . . . . . 20-40-12
BICS™ Valve Lift Arm By-Pass Orifice Disassembly And Assembly. .20-40-11
BICS™ Valve Lock Valve Disassembly And Assembly . . . . . . . . . . . 20-40-13
BICS™ Valve Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . 20-40-10
BICS™ Valve Solenoid Disassembly And Assembly . . . . . . . . . . . . . 20-40-14
BICS™ Valve Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-36
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Lift And Tilt Lock Block Removal And Installation . . . . . . . . . . . . . . . 20-40-22
Lift Spool and Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-23
Load Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-20
Port-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-35

Dealer Copy -- Not for Resale

Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-19
Removal And Installation (S/N 515840212 & Above) . . . . . . . . . . . . . 20-40-5
Removal And Installation (S/N 515840211 & Below) . . . . . . . . . . . . . . 20-40-1
Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-21
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32

Continued On Next Page

753 Bobcat Loader

20-02 Service Manual
72 of 726
 HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)20-41-

1
Actuator Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-8
Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Anti-Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . 20-41-20
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-25
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-41-9
BICS™ Valve, Lift Arm By-Pass Orifice Removal and Installation. . . . 20-41-10
BICS™ Valve, Check Valve Removal and Installation . . . . . . . . . . . . . 20-40-11
BICS™ Valve, Lock Valve Removal and Installation . . . . . . . . . . . . . . 20-41-12
BICS™ Valve, Solenoid Removal and Installation. . . . . . . . . . . . . . . . 20-40-13
BICS™ Valve, Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-2
Identification Chart (AHC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Identification Chart (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17

Dealer Copy -- Not for Resale

Lift And Tilt Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . .20-40-23
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-21
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-19
Port-Auxiliary Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Removal And Installation (S/N 515840211 & Below) . . . . . . . . . . . . . . . 20-41-1
Removal And Installation (S/N 515840212 & Above) . . . . . . . . . . . . . . 20-41-4
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-22

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

HYDRAULIC PUMP (ALUMINUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Checking The Output Of The Hydraulic Pump. . . . . . . . . . . . . . . . . . . . 20-60-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2

HYDRAULIC PUMP (CAST IRON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Check The Output Of The Hydraulic Pump With Power Bob-Tach.. . . . 20-61-3
Check The Output Of The Hydraulic Pump Without Power Bob-Tach. . 20-61-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5

Continued On Next Page

753 Bobcat Loader

20-03 Service Manual
73 of 726
 HYDRAULIC SYSTEM (CONT’D)

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . .20-10-1

Glossary Of Hydraulic/Hydrostatic Symbols . . . . . . . . . . . . .20-10-1
Tighten Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-5
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-6

HYDRAULIC/HYDROSTATIC FILTER . . . . . . . . . . . . . . . . . . . .20-70-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-70-1

LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . . .20-50-1

Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-1

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-2
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-3

POWER BOB-TACH BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . .20-110-2

Dealer Copy -- Not for Resale

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1

REAR AUXILIARY DIVERTER VALVE (DUAL SHUTTLE) . . . .20-101-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-101-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-7
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-7

REAR AUXILIARY DIVERTER VALVE (SINGLE SHUTTLE) . .20-100-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (See TORQUE SPECIFICATIONS FOR BOLTS on Page
SPEC-30-1.) UNLESS OTHERWISE SPECIFIED.

753 Bobcat Loader

20-04 Service Manual
74 of 726
 HYDRAULIC/HYDROSTATIC SCHEMATIC
753 (S/N 515830001 - 515845424)
(S/N 516220001 - 516226372)
Printable Version Click Here

(PRINTED APRIL 2003)

V-0264legend
LEGEND
1 RESERVOIR: 14 LOAD CHECK VALVE 27 PILOT ACTIVATED DIRECTIONAL 40 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . . 14 Qts. (13,2 L) CONTROL VALVE - FOR REAR CONTROL VALVE - BUCKET POSITION
2 SPRING LOADED FILTER BY-PASS 15 ONE WAY RESTRICTOR VALVE AUXILIARY - NORMALLY OPEN VALVE (ON/OFF)
VALVE: 45-55 PSI (311-379 kPa) (Optional - ADVANCED HAND ("D2" and "P2")
CONTROLS ONLY) 41 CHECK VALVE - BICS CONTROL VALVE
3 DIFFERENTIAL PRESSURE SWITCH: 28 FILTER - DIVERTER VALVE
36-44 PSI (250-300 kPa) 16 SOLENOID ACTIVATED DIRECTIONAL 42 MUFFLER (If equipped)
(SINTERED BRONZE)
Normally Closed CONTROL VALVE - BICS CONTROL
29 SOLENOID ACTIVATED DIRECTIONAL
4 DRIVE MOTOR SHUTTLE VALVE 43 LOAD SHUTTLE VALVE - AUXILIARY
17 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TO ACTIVATE
CONTROL VALVE - TILT CONTROL BLEED VALVE (USED ON MACHINES
5 RELIEF/REPLENISHING VALVE - HIGH REAR AUXILIARY ("SV1")
WITHOUT REAR AUXILIARY)
PRESSURE: 5000 PSI (34475 kPa) 18 PILOTED ACTIVATED DIRECTIONAL 30
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL 44 ANTICAVITATION VALVE (TILT BASE
6 RELIEF VALVE - CHARGE INLET: CONTROL VALVE - FOR REAR
155-165 PSI (1069-1138 kPa) 19 PULL BUTTON ACTIVATED AUXILIARY - NORMALLY CLOSED END)
at 14.3 GPM (54 L/min.) Dealer Copy -- Not ("P1"
DIRECTIONAL CONTROL VALVE - LIFT and "F1")
for Resale
at 2800 RPM ARM BY-PASS 45 SOLENOID ACTIVATED DIRECTIONAL
31 FILTER - HYDRAULIC (CANISTER)
With 140 degrees F. (60 degrees C.) Fluid CONTROL VALVE - AUXILIARY BLEED
20 PILOTED ACTIVATED DIRECTIONAL
7 RELIEF/REPLENISHING VALVE - HIGH CONTROL VALVE - UNLOADING VALVE (USED ON MACHINES WITHOUT
32 FILTER - CASE DRAIN (SINTERED
PRESSURE: 5000 PSI (34475 kPa) SPOOL REAR AUXILIARY)
BRONZE)
8 HYDRAULIC PUMP . . . . . . . Gear Type 21 PILOTED ACTIVATED DIRECTIONAL
14.3 GPM (54 L/min.) at 2800 RPM CONTROL VALVE - FLOW CONTROL 33 FILTER - BICS CONTROL VALVE
at 1150 PSI (7929 kPa) SPOOL (SCREEN)
9 RELIEF VALVE - MAIN: 22 FLOW DIVIDER ADJUSTMENT VALVE 34 CHECK VALVE - BUCKET POSITION
2500-2600 PSI (17236-17926 kPa)
VALVE
at Front Quick Couplers
23 SOLENOID ACTIVATED DIRECTIONAL 35 RESTRICTION
10 RELIEF VALVE - PORT: . . . . . (Optional) CONTROL VALVE - BLEED OFF REAR
3500 PSI (24132 kPa) AUXILIARY ("SV2") 36 VARIABLE CAPACITY DISPLACEMENT
11 ANTICAVITATION VALVE BIDIRECTIONAL HYDROSTATIC PUMP
24 LOAD SHUTTLE VALVE - BLEED OFF
37 SHUTTLE RELIEF VALVE
12 SOLENOID ACTIVATED DIRECTIONAL 25 PILOT ACTIVATED DIRECTIONAL (Not Adjustable - Factory Set)
CONTROL VALVE - AUXILIARY CONTROL VALVE - FOR REAR 65 PSI (448 kPa)
AUXILIARY - NORMALLY CLOSED
13 RELIEF VALVE - PORT: . . . . . (Optional) 38 FIXED CAPACITY DISPLACEMENT
("P2" and "F2")
3500 PSI (24132 kPa) BIDIRECTIONAL HYDROSTATIC
26 PILOT ACTIVATED DIRECTIONAL MOTOR
CONTROL VALVE - FOR REAR
39 ONE WAY RESTRICTOR VALVE NOTE: Unless otherwise specified
AUXILIARY - NORMALLY OPEN
("D1" and "P1") springs have NO significant
pressure value.

Printed in U.S.A. V-0264legend (4-9-03)

75 of 726
 DIVERTER VALVE (OPTIONAL)

28
HYDRAULIC/HYDROSTATIC SCHEMATIC 29
PILOT
753 (S/N 515830001 - 515845424)
(S/N 516220001 - 516226372)
Printable Version Click Here
(FRONT AUXILIARY
30 26 LEFT SIDE LIFT ARM)
(PRINTED APRIL 2003) FEMALE
F1 D1
V-0264 A
FEMALE

43 AUXILIARY
BLEED
DRIVE MOTOR 24 VALVE
(REAR QUICK
1 COUPLERS)
T
27 45
MALE 23 25
F2 D2 B
4 MALE
37

DRAIN P1 P2
32

BUCKET POSITION VALVE (OPTIONAL)

38
D
HYDRAULIC FILTER 34

31

OIL
2 22
COOLER
B HYDROSTATIC PUMPS A

5 36
7
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21

20

Dealer Copy -- Not for Resale

12 12
13 B
CHARGE
INLET A B

AUXILIARY
SPOOL

36 39
TILT CYLINDERS
44 BICS CONTROL VALVE
5 8 7
INLET OUTLET

D C

A B 17
TILT
CYLINDER
SPOOL

11 14
DRIVE MOTOR

10 15 LIFT CYLINDERS
38
18

A B
LIFT
CYLINDER
SPOOL 35

14
4 37

9 16 WORKING CIRCUITS
42 PILOT CIRCUITS
33 41 33
DRAIN CIRCUITS
COMPONENTS

LIFT ARM BY PASS VALVE

32
19

Printed in U.S.A. V-0264 (4-9-03)

76 of 726
 HYDRAULIC/HYDROSTATIC SCHEMATIC
753 (S/N 515845425 AND ABOVE)
(S/N 516226373 AND ABOVE)
Printable Version Click Here

(PRINTED APRIL 2003)

V-0258legend
LEGEND
1 RESERVOIR: 14 LOAD CHECK VALVE 27 PILOT ACTIVATED DIRECTIONAL 40 SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . . . 14 Qts. (13,2 L) CONTROL VALVE - FOR REAR CONTROL VALVE - BUCKET POSITION
2 SPRING LOADED FILTER BY-PASS 15 LIFT CYLINDER SPOOL - MADE TO AUXILIARY - NORMALLY OPEN VALVE (ON/OFF)
VALVE: 45-55 PSI (311-379 kPa) RESTRICT FLOW DURING BOOM ("D2" and "P2")
DOWN BUT NOT DURING BOOM UP 41 CHECK VALVE - BICS CONTROL VALVE
3 DIFFERENTIAL PRESSURE SWITCH: 28 FILTER - DIVERTER VALVE (SCREEN)
36-44 PSI (250-300 kPa) 16 SOLENOID ACTIVATED DIRECTIONAL 42 PRESSURE COMPENSATED FLOW
INTEGRATED IN SOLENOID
Normally Closed CONTROL VALVE - BICS CONTROL CONTROL
29 SOLENOID ACTIVATED DIRECTIONAL
4 DRIVE MOTOR SHUTTLE VALVE 43 RELIEF VALVE - PORT:
17 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TO ACTIVATE
CONTROL VALVE - TILT CONTROL 3500 PSI (24132 kPa)
5 RELIEF/REPLENISHING VALVE - HIGH REAR AUXILIARY ("SV1")
PRESSURE: 5000 PSI (34475 kPa) 18 PILOTED ACTIVATED DIRECTIONAL 44 RELIEF/ANTICAVITATION VALVE -
30
PILOT ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL PORT (TILT BASE END)
6 RELIEF VALVE - CHARGE INLET: CONTROL VALVE - FOR REAR
3500 PSI (24132 kPa)
205-215 PSI (1416-1482 kPa) 19 PULL BUTTON ACTIVATED AUXILIARY - NORMALLY CLOSED
at 15.9 GPM (60 L/min.) Dealer Copy -- Not ("P1"
DIRECTIONAL CONTROL VALVE - LIFT and "F1")
for Resale 45 PILOT ACTIVATED DIRECTIONAL
at 2800 RPM ARM BY-PASS CONTROL VALVE - HYDRAULIC
31 FILTER - HYDRAULIC (CANISTER)
With 140 degrees F. (60 degrees C.) Fluid POWERED BOB-TACH
20 PILOTED ACTIVATED DIRECTIONAL
7 FRONT AUXILIARY MANUAL CONTROL VALVE - UNLOADING 46 TWO-STAGE RELIEF
32 FILTER - CASE DRAIN (SINTERED
PRESSURE SPOOL BRONZE) 1000/2000 PSI (6895/13790 kPa)
8 BLEED-OFFPUMP
HYDRAULIC VALVE . . . . . . . Gear Type 21 PILOTED ACTIVATED DIRECTIONAL 47 SOLENOID ACTIVATED DIRECTIONAL
15.9 GPM (60 L/min.) at 2800 RPM CONTROL VALVE - FLOW CONTROL 33 FILTER - BICS CONTROL VALVE CONTROL VALVE (TWO COIL)
at 1150 PSI (7929 kPa) SPOOL (SCREEN)
48 RELIEF VALVE - 1200 PSI (8268 kPa)
9 RELIEF VALVE - MAIN: 22 FLOW DIVIDER ADJUSTMENT VALVE 34 CHECK VALVE - BUCKET POSITION
2500-2600 PSI (17236-17926 kPa)
VALVE 49 RESTRICTION - 0.015 inch (0.381 mm)
at Front Quick Couplers
23 SOLENOID ACTIVATED DIRECTIONAL 35 RESTRICTION
10 RELIEF VALVE - PORT: . . . . . (Optional) CONTROL VALVE - BLEED OFF REAR
3500 PSI (24132 kPa) AUXILIARY ("SV2") 36 VARIABLE CAPACITY DISPLACEMENT
11 ANTICAVITATION VALVE BIDIRECTIONAL HYDROSTATIC PUMP
24 LOAD SHUTTLE VALVE - BLEED OFF
37 SHUTTLE RELIEF VALVE
12 SOLENOID ACTIVATED DIRECTIONAL 25 PILOT ACTIVATED DIRECTIONAL (Not Adjustable - Factory Set)
CONTROL VALVE - AUXILIARY CONTROL VALVE - FOR REAR 65 PSI (448 kPa)
AUXILIARY - NORMALLY CLOSED
13 RELIEF VALVE - PORT: . . . . . (Optional) 38 FIXED CAPACITY DISPLACEMENT
("P2" and "F2")
3500 PSI (24132 kPa) BIDIRECTIONAL HYDROSTATIC
26 PILOT ACTIVATED DIRECTIONAL MOTOR
CONTROL VALVE - FOR REAR
39 ONE WAY RESTRICTOR VALVE NOTE: Unless otherwise specified
AUXILIARY - NORMALLY OPEN
("D1" and "P1") springs have NO significant
pressure value.

Printed in U.S.A. V-0258legend (3-25-03)

77 of 726
 DIVERTER VALVE (OPTIONAL)

28
HYDRAULIC/HYDROSTATIC SCHEMATIC 29
PILOT
753 (S/N 515845425 AND ABOVE)
(S/N 516226373 AND ABOVE)
Printable Version Click Here
INTEGRATED QUICK
30 26
(PRINTED APRIL 2003) FEMALE COUPLER BLOCK
F1 D1
V-0258 FEMALE

7 (FRONT AUXILIARY
MALE
24 7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
(REAR QUICK
1 COUPLERS)
MALE

23 25 27
MALE
F2 D2
4 37

DRAIN P1 P2

32 BUCKET POSITION VALVE (OPTIONAL)

38
D
HYDRAULIC FILTER 34

31

OIL
2 22
COOLER
B HYDROSTATIC PUMPS A

5 36
5
A
6 3 40 C
HYDRAULIC CONTROL VAVLE 21

20

Dealer Copy -- Not for Resale

12 12
BOB-TACH 13 B
CHARGE
INLET CYLINDER A B
(OPTIONAL)

HYDRAULIC
AUXILIARY
POWERED
SPOOL
BOB-TACH
(OPTIONAL)
36 39
44 TILT CYLINDERS
BICS CONTROL VALVE
5 8 5
INLET OUTLET

D C
48
47
A B 17
43 TILT
46 CYLINDER
SPOOL
42
11
DRIVE MOTOR 14
DR 49
10 LIFT CYLINDERS
38
P1 P2 18
45
A B
LIFT
CYLINDER
PP SPOOL 35

15

14
4 37

9 16 WORKING CIRCUITS
33 41 33 PILOT CIRCUITS
DRAIN CIRCUITS
COMPONENTS

LIFT ARM BY PASS VALVE

32
19

Printed in U.S.A. V-0258 (3-25-03)

78 of 726
HYDRAULIC SYSTEM INFORMATION

Glossary Of Hydraulic/Hydrostatic Symbols

Dealer Copy -- Not for Resale

753 Bobcat Loader

20-10-1 Service Manual
79 of 726
HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic/Hydrostatic Symbols (Cont’d)

Dealer Copy -- Not for Resale

753 Bobcat Loader

20-10-2 Service Manual
80 of 726
HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic/Hydrostatic Symbols (Cont’d)

Dealer Copy -- Not for Resale

753 Bobcat Loader

20-10-3 Service Manual
81 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

20-10-4 Service Manual
82 of 726
HYDRAULIC SYSTEM INFORMATION (CONT’D)

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Tighten Procedures

For tightening torques for hydraulic fittings,

tubelines etc., - Hydraulic Connection Specifications.
(See HYDRAULIC CONNECTION SPECIFICATIONS on
Page SPEC-40-1.).

Dealer Copy -- Not for Resale

753 Bobcat Loader

20-10-5 Service Manual
83 of 726
HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of t he recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. 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, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4
By-pass valve stuck. 12
By-pass valve stem bent or broke. 13

KEY TO CORRECT THE CAUSE

Dealer Copy -- Not for Resale

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 LOADER SPECIFICATIONS (753) on Page
SPEC-10-1.)
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.
12. Rotate shaft.
13. Replace manual spool cartridge.

753 Bobcat Loader

20-10-6 Service Manual
84 of 726
CYLINDER (LIFT) Figure 20-20-2

Checking

Figure 20-20-1
1

3
2
1

N-20952

Install a p lug in the hose (Item 1) [Figure 20-20-2] and

N-20951 tighten.

Connect the ho se (Item 2) [Figure 20-20-2] to the lift

Lower the lift arms. Stop the engine. Pull up on the li ft cylinder rod end port.
arm by-pass control. Raise the seat bar.

Dealer Copy -- Not for Resale

Engage the parking brake. Lower the seat bar. Start the
Check only one cylinder at a time. engine. Press the PRESS TO OPERATE BUTTON. Push
the top ( toe) of th e lift pedal or move left hand lever
Disconnect the hose (Item 1) [Figure 20-20-1] from the towards the operator.
lift cylinder rod end port to allow access to the hose (Item
2) [Figure 20-20-1]. If there is any leakage from the base end cylinder port
(Item 3) [Figure 20-20-2], remove the lift cylinder for
Disconnect the hose (Item 2) [Figure 20-20-1] from the repair.
lift cylinder base end port.
Repeat the procedure to check the other lift cylinder.

WARNING
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

WARNING
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

753 Bobcat Loader

20-20-1 Service Manual
85 of 726
CYLINDER (LIFT) (CONT’D) Figure 20-20-5

Removal And Installation

Figure 20-20-3

1
N-20954

Remove the lift arm pivot pin (Item 1) [Figure 20-20-5]

N-20951 (both sides).

Figure 20-20-6
Stop the engine. Pull up on the lift arm by-pass control
and move the lift pedal to release the hydraulic pressure.

Dealer Copy -- Not for Resale

1
Disconnect the hoses (Item 1) [Figure 20-20-3] from the
lift cylinder.

Install plugs in the hoses and tighten.

2
Figure 20-20-4

P-28796

1 Remove the retainer bolt (Item 1) [Figure 20-20-6] and

nut from the lift cylinder rod end pivot pin (both sides).

Installation: Tighten the bolt and nut to 18-20 ft.-lbs. (24-

27 Nm) torque.

N-20953 Remove the lift cylinder rod end pivot pin (Item 2) [Figure
20-20-6].

Remove the retainer bolt (Item 1) [Figure 20-20-4] and Remove the l ift cylinder (Item 3) [Figure 20-20-6] from
nut from the lift arm pin (both sides). the loader.

Installation: Tighten the bolt and nut to 18-20 ft.-lbs. (24-

27 Nm) torque.

NOTE: Remove the air cleaner (See AIR CLEANER

SERVICE on Page 10-80-1.) to remove the left
rear pivot pin. The pin must be driven out from
the engine compartment.

753 Bobcat Loader

20-20-2 Service Manual
86 of 726
CYLINDER (LIFT) (CONT’D)

Identification

1. Rod 9. O-ring
2. Case 10. Washer
3. O-ring 11. Head
4. Nut 12. Seal
5. Piston 13. Seal
6. Ring 14. Plug
7. O-ring 15. O-ring
8. Spacer

Dealer Copy -- Not for Resale

7

1
5

14 4
15
3

13

12
14
15 2 11

10

TS-1060

753 Bobcat Loader

20-20-3 Service Manual
87 of 726
CYLINDER (LIFT) (CONT’D) Figure 20-20-9

Disassembly

Figure 20-20-7 3
1 2

N-20610

Piston: Remove the seal (Item 1), and O-ring (Item 2)

N-20615 from the piston (Item 3) [Figure 20-20-9].

Figure 20-20-10
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook 5

Dealer Copy -- Not for Resale

3
Spanner Wrench 4
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder. 2
1
Put the base end of the cylinder in a vise.

Use a spanner wrench to loosen the head [Figure 20-20-

7].

Figure 20-20-8
N-20611

2 1 Remove the wi per seal (Item 1), and rod seal (Item 2),
3
4 the back up washer (Item 3) the thin O-ring (Item 4) and
the thick O-ring (Item 5) [Figure 20-20-10] from the
head.

N-20552

Remove the head and the rod assembly from the cylinder
[Figure 20-20-8]. Put the rod end in a vise.

Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-8].

753 Bobcat Loader

20-20-4 Service Manual
88 of 726
CYLINDER (LIFT) (CONT’D) Figure 20-20-12

Assembly

Figure 20-20-11 3
1 2

N-20610

Piston: Install the O-ring (Item 1) and seal (Item 2) on the

P7424 piston (Item 3) [Figure 20-20-12].

NOTE: The piston center hole (Item 4) [Figure 20-20-

Use the following tools to assembly the cylinder: 12] has a bevel on one end. The bevel goes
toward the rod.
MEL1396 - Seal Installation Tool

Dealer Copy -- Not for Resale

MEL1033 - Rod Seal Installation Tool Figure 20-20-13
Piston Ring Compressor
Spanner Wrench

Wash the cylinder parts in solvent and air dry them.

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

installation.

Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-11]. N-20612

Allow the seal to stretch for 30 seconds before installing it

on the piston. Install the rod seal on the rod seal tool [Figure 20-20-13].

NOTE: During installation the O-ring side of the seal

must be toward the inside of the cylinder.

753 Bobcat Loader

20-20-5 Service Manual
89 of 726
CYLINDER (LIFT) (CONT’D) Figure 20-20-16

Assembly (Cont'd)

Figure 20-20-14

2
3

P7422

Install the thin O-ring (Item 1) [Figure 20-20-16].

N-20613
Install the back-up washer (Item 2) and thick O-ring (Item
3) [Figure 20-20-16] into the groove on the head.
Rotate the handles to co llapse the r od seal [Figure 20-
20-14]. NOTE: Clean and dry the threads before installing the

Dealer Copy -- Not for Resale

nut. Install the new nut from the seal kit.
Figure 20-20-15

P7425

Install the rod seal in the head [Figure 20-20-15].

Install the wiper seal with the wiper toward the outside of
the head.

753 Bobcat Loader

20-20-6 Service Manual
90 of 726
CYLINDER (LIFT) (CONT’D) Figure 20-20-18

Assembly (Cont'd)

Figure 20-20-17

3
4
2
1

P7429
5

Put the base end of the hydraulic cylinder in a vise.

N-20552
Tighten the head using a spanner wrench [Figure 20-20-
18].
Install the head (Item 1), and spacer (Item 2) [Figure 20-
20-17].

Dealer Copy -- Not for Resale

Install the piston (Item 3) [Figure 20-20-17].

NOTE: The piston center hole (Item 5) [Figure 20-20-

17] has a bevel on one end. The bevel goes
toward the rod.

Grease the piston where the nut contacts the piston. Do

not get grease on the threads. Install the new nut (Item 4)
[Figure 20-20-17].

Tighten the nut (Item 4) [Figure 20-20-17] to 300 ft.-lbs.

(407 Nm) torque.

753 Bobcat Loader

20-20-7 Service Manual
91 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

20-20-8 Service Manual
92 of 726
CYLINDER (TILT) Removal And Installation

Checking

Remove the attachment. Roll the Bob-Tach fully back.

Stop the engine. Raise the seat bar.
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
WARNING Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
Figure 20-21-2
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

Figure 20-21-1

Dealer Copy -- Not for Resale

N-20733

1 Remove the attachment. Roll the Bob-Tach forward and

lower the lift arms.

Place the Bob-Tach flat on a pallet to allow the tilt cylinder

N-20732 base end pin enough clearance to be r emoved [Figure
20-21-2].

Disconnect the hose (Item 1) [Figure 20-21-1] which Stop the engine. Move the tilt pedal to release the
goes to the base end of the tilt cylinder. hydraulic pressure. Raise the seat bar.

Install a cap on the fitting and tighten.

Engage the parking brake. Lower the seat bar.

Start the engine and push the Press to Operate button.

Push the bottom (heel) of the tilt pedal.

If there is leakage from the open port, remove the tilt

cylinder for repair.

753 Bobcat Loader

20-21-1 Service Manual
93 of 726
CYLINDER (TILT) (CONT’D) Figure 20-21-5

Removal And Installation (Cont’d)

Figure 20-21-3
1

N-20739

1 Remove the grease fitting from the r od end pivot pin

N-20731 (Item 1) [Figure 20-21-5].

Remove the rod end pivot pin.

Disconnect both hydraulic hoses (Items 1 & 2 ) [Figure
20-21-3].

Dealer Copy -- Not for Resale

Figure 20-21-4
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
1 Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285

Figure 20-21-6

N-20734

1
Remove the retainer nut (Item 1) [Figure 20-21-4] from
the cylinder rod end pivot pin.

Installation: Tighten the retainer nut to 18-20 ft.-lbs. (24-

27 Nm) torque.

N-20737

Remove the r etainer nut (Item 1) [Figure 20-21-6] and

bolt from the base end pivot pin.

Installation: Tighten the retainer nut and bolt to 18-20 ft.-

lbs. (24-27 Nm) torque.

753 Bobcat Loader

20-21-2 Service Manual
94 of 726
CYLINDER (TILT) (CONT’D) Rod End Pivot Pin Bushing And Seal Replacement

Removal And Installation (Cont’d) Figure 20-21-8

Figure 20-21-7

1
1
1

N-18556

N-00845
Remove the old seal (both sides) from the end of the tilt
cylinder [Figure 20-21-8].
Remove the base end pivot pin (Item 1) [Figure 20-21-7].
Apply a li ght coat of grease on the new seals (Item 1)
Remove the tilt cylinder from the loader.

Dealer Copy -- Not for Resale

[Figure 20-21-8].

Install the new seals with the lip facing in [Figure 20-21-
8].

Install the rod end of the tilt cylinder into the Bob-Tach.

Be careful not to damage the n ew seals during

installation.

Reserve the removal procedure to install the tilt cylinder.

753 Bobcat Loader

20-21-3 Service Manual
95 of 726
CYLINDER (TILT) (CONT’D)

Identification

1. Cylinder 11. O-ring

2. Case 12. Seal
3. Piston 13. Seal
4. Head 14. Bushing
5. Rod 15. Tube
6. Nut 16. O-ring
7. O-ring 17. Plug
8. Seal 18. Clamp
9. O-ring 19. Nut
10. Washer 20. Seal

1
15

Dealer Copy -- Not for Resale

18
16 17
6
4
3
19

7 12

13
8

5
10

14
20

11

MS1797

753 Bobcat Loader

20-21-4 Service Manual
96 of 726
CYLINDER (TILT) (CONT’D) Figure 20-21-10

Disassembly
2
Figure 20-21-9 3 1

N-20554

Remove the he ad and rod assembly from the c ylinder

N-20615 [Figure 20-21-10]. Put the rod end in a vise.

Remove the nut (Item 1), piston (Item 2) and head (Item
Use the following tools to disassemble the cylinder: 3) [Figure 20-21-10].

MEL1074 - O-ring Seal Hook

Dealer Copy -- Not for Resale

Figure 20-21-11
Spanner Wrench
3
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
1 2
Put the base end of the cylinder in a vise.

Use a spanner wrench to loosen the head [Figure 20-21-

9].

N-20609

Piston: Remove the seal (Item 1), and O-ring (Item 2)

from the piston (Item 3) [Figure 20-21-11].

753 Bobcat Loader

20-21-5 Service Manual
97 of 726
CYLINDER (TILT) (CONT’D) Assembly

Disassembly (Cont’d) Figure 20-21-13

Figure 20-21-12

5
3
4

2
1

P7424

N-20611
Use the following tools to assembly the cylinder:

Remove the wi per seal (Item 1), and rod seal (Item 2), MEL1396 - Seal Installation Tool
the back up washer (Item 3), the thin O-ring (Item 4) and MEL1033 - Rod Seal Installation Tool
the thick O-ring (Item 5) [Figure 20-21-12] from the

Dealer Copy -- Not for Resale

Piston Ring Compressor
head. Spanner Wrench

Wash the cylinder parts in solvent and air dry them.

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

installation.

Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-21-13].

Allow the seal to stretch for 30 seconds before installing it

on the piston.

753 Bobcat Loader

20-21-6 Service Manual
98 of 726
CYLINDER (TILT) (CONT’D) Figure 20-21-16

Assembly (Cont'd)

Figure 20-21-14

N-20613

Rotate the han dles to co llapse the r od seal [Figure 20-

N-20609 21-16].

Figure 20-21-17
Install the O-ring and seal on the piston (Item 1) [Figure
20-21-14].

Dealer Copy -- Not for Resale

Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
three minutes.

Figure 20-21-15

P7425

Install the rod seal in the head [Figure 20-21-17].

Install the wiper seal with the wiper toward the outside of
the head.

N-20612

Install the rod seal on the rod seal tool [Figure 20-21-15].

NOTE: During installation the O-ring side of the seal

must be toward the inside of the cylinder.

753 Bobcat Loader

20-21-7 Service Manual
99 of 726
CYLINDER (TILT) (CONT’D) Figure 20-21-20

Assembly (Cont'd)

Figure 20-21-18

2
3
P7429

Put the base end of the hydraulic cylinder in a vise.

P7422
Tighten the head using a spanner wrench [Figure 20-21-
20].
Install the thin O-ring (Item 1) [Figure 20-21-18].

Install the back-up washer (Item 2) and thick O-ring (Item

Dealer Copy -- Not for Resale

3) [Figure 20-21-18] into the groove on the head.

NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the seal kit.

Figure 20-21-19

2
1 3

N-20554

Install the head (Item 1), and the piston (Item 2) [Figure
20-21-19]. The small diameter of the piston goes into the
cylinder tube first.

Grease the piston where the nut contacts the piston. Do

not get grease on the threads. Install the new nut (Item 3)
[Figure 20-21-19].

Tighten nut (Item 3) [Figure 20-21-19] to 8 50 ft.-lbs.

(1153 Nm) torque.

753 Bobcat Loader

20-21-8 Service Manual
100 of 726
CYLINDER (POWER BOB-TACH)

Checking
WARNING
Figure 20-22-1
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

WARNING
1 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.
P-31514
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
Tilt the B ob-Tach forward, so it i s parallel to th e floor from a physician familiar with this injury.
[Figure 20-22-1]. W-2072-0496

Dealer Copy -- Not for Resale

Disconnect the hose (Item 1) [Figure 20-22-1] from the
power Bob-Tach cylinder base end port.

Figure 20-22-2

1
2

P-43211

Install a p lug in th e hose (Item 1) [Figure 20-22-2] and

tighten.

Engage the parking brake. Lower the seat bar. Start the
engine.

Push and hold the BOB-TACH “WEDGES UP” Switch

(Front Accessory Panel).

If there is any leakage from the base end cylinder port

(Item 2) [Figure 20-22-2], remove the lift cylinder for
repair.

753 Bobcat Loader

20-22-1 Service Manual
101 of 726
CYLINDER (POWER BOB-TACH) (CONT’D) Figure 20-22-4

Removal And Installation

Figure 20-22-3

1 1

1 2 P-31513

Remove the bolts (Item 1) [Figure 20-22-4].

P-31514
Installation: Tighten the bolts to 25- 28 ft.-lbs. (34-38
Nm) torque.
Disconnect the hoses (Items 1 & 2) [Figure 20-22-3]
from the cylinder fittings. Remove the washers and cylinder from the lever pivots.

Dealer Copy -- Not for Resale

Install plugs and cap in fittings.

753 Bobcat Loader

20-22-2 Service Manual
102 of 726
CYLINDER (POWER BOB-TACH) (CONT’D)

Parts Identification

1. Cylinder
2. Plug
3. O-Ring
4. Nut
5. Piston
6. O-Ring
7. Ring
8. Spacer
9. O-Ring
10. Ring
11. O-Ring
12. Head
13. Seal
14. Seal
15. Rod

Dealer Copy -- Not for Resale

3
2
14
13 12
11
10
9
8 7 6
5
4

15

PE1064

753 Bobcat Loader

20-22-3 Service Manual
103 of 726
CYLINDER (POWER BOB-TACH) (CONT’D) Figure 20-22-6

Disassembly
2
3 1
Use the following tools to disassemble the cylinder:

MEL 1074 - O-ring Seal Hook

Spanner Wrench

Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.

Put the base end of the cylinder in a vise.

Figure 20-22-5
P-16294

Remove the he ad and rod assembly from the c ylinder

[Figure 20-22-6].

Put the rod end in a vise.

Remove the nut (Item 1), piston (Item 2) and head (Item

Dealer Copy -- Not for Resale

3) [Figure 20-22-6] from the rod.

Figure 20-22-7

3
P-43212
2
1

Use a spanner wrench to loosen the head [Figure 20-22-

5].

P-16295

Piston: Remove the O-ring (Item 1), and seal (Item 2)

from the piston (Item 3) [Figure 20-22-7].

753 Bobcat Loader

20-22-4 Service Manual
104 of 726
CYLINDER (POWER BOB-TACH) (CONT’D) Assembly

Disassembly (Cont’d) Use the following tools to assemble the cylinder:

Figure 20-22-8 MEL 1396 - Seal Installation Tool

MEL 1033 - Rod Seal Installation Tool
5 Piston Ring Compressor
3 Spanner Wrench
4
Wash the cylinder parts in solvent and air dry them.
2
Inspect the cylinder parts for nicks, scratches or other
1 damage. Replace any damaged parts.

Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during

installation.

N-20611 Figure 20-22-9

Remove the wi per seal (Item 1), and rod seal (Item 2),
the back-up washer (Item 3), the thin O-ring (Item 4) and
the thick O-ring (Item 5) [Figure 20-22-8] from the head.

Dealer Copy -- Not for Resale

P-7424

Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-9].

Allow the seal to stretch for 30 seconds before installing it

on the piston.

753 Bobcat Loader

20-22-5 Service Manual
105 of 726
CYLINDER (POWER BOB-TACH) (CONT’D) Figure 20-22-12

Assembly (Cont’d)

Figure 20-22-10

3
1
2

4
N-20613

Rotate the han dles to co llapse the r od seal [Figure 20-

P-16295 22-12].

Figure 20-22-13
Piston: Install the O-ring (Item 1) and seal (Item 2) on the
piston (Item 3) [Figure 20-22-10].

Dealer Copy -- Not for Resale

NOTE: The piston center hole (Item 4) [Figure 20-22-
10] has a bevel on one end. The bevel goes
toward the rod.

Figure 20-22-11

P-7425

Install the rod seal in the head [Figure 20-22-13].

Install the wiper seal with the wiper toward the outside of
the head.

N-20612

Install the rod seal on the rod seal tool [Figure 20-22-11].

NOTE: During installation the O-ring side of the seal

must be toward the inside of the cylinder.

753 Bobcat Loader

20-22-6 Service Manual
106 of 726
CYLINDER (POWER BOB-TACH) (CONT’D) Figure 20-22-15

Assembly (Cont’d)
1 3
2 4
Figure 20-22-14

2
3

P-16294

Install the head (Item 1), and spacer (Item 2) [Figure 20-
P-7422 22-15].

Install the piston (Item 3) [Figure 20-22-15].

Install the thin O-ring (Item 1) [Figure 20-22-14].
Lift Cylinder: Grease the piston where the nut contacts
Install the back-up washer (Item 2) and thick O-ring (Item

Dealer Copy -- Not for Resale

the piston, do not get grease on the threads. Install the
3) [Figure 20-22-14] into the groove on the head. new nut (Item 4) [Figure 20-22-15].

NOTE: Clean and dry the threads before installing the Tighten the nut to 90 ft.-lbs. (122 Nm) torque.
nut. Install the new nut from the seal kit.
Figure 20-22-16

P-43212

Put the base end of the hydraulic cylinder in a vise.

Tighten the head using a spanner wrench [Figure 20-22-

16].

753 Bobcat Loader

20-22-7 Service Manual
107 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

20-22-8 Service Manual
108 of 726
MAIN RELIEF VALVE Figure 20-30-2

Checking OLD STYLE NEW STYLE

WARNING
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

Figure 20-30-1 P-43215

N-20538

• Press the AUXILIARY PRESSURE RELEASE Button

(Item 1) [Figure 20-30-1]. Hold it for two seconds.
The engine will stop and release auxiliary hydraulic
pressure on Loaders S/N 515842309 and Below .

• Pressing the AUXILIARY HYDRAULIC RELEASE

Dealer Copy -- Not for Resale

Button with the instrument panel power on and the
1 engine stopped, will also release hydraulic pressure
on Loaders S/N 515842309 and Below..

Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.)
N-18409

The tools listed will be nee ded to do the fol lowing

procedure: WARNING
MEL10003 - Hydraulic Tester Put jackstands under the front axles and rear corners
MEL10006 - Hydraulic Test Kit of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
NOTE: The procedure listed below should be used for fall or move and cause injury or death.
all loaders (With either the new or old style W-2017-0286
front hydraulic couplers) [Figure 20-30-2].

Loaders S/N 515842310 and Above, with the

new front hydraulic couplers, release the
auxiliary pressure when the coupler is pushed IMPORTANT
in. This can be done manually, or
automatically when the operator pushes the The hydraulic tester must be in the fully open
hose on to the coupler to make the position before you start the engine.
connection. The engine must be stopped I-2024-0284
before making this connection.

753 Bobcat Loader

20-30-1 Service Manual
109 of 726
MAIN RELIEF VALVE (CONT’D) The correct pressure for the main relief is 2500-2600 PSI
(17237-17926 kPa).
Checking (Cont’d)
Press the auxiliary pressure release (Item 2) [Figure 20-
Figure 20-30-3 30-4] and hold the switch for three seconds to r elease
hydraulic pressure to the fr ont and/or rear auxiliary
couplers on Loaders S/N 515842309 & Below. On
Loaders S/N 515842310 & Above, push the front
hydraulic couplers in to r elease the pr essure before
servicing the main relief valve.
1
2

Adjustment

IMPORTANT
P-28807
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Connect the IN por t (Item 1) [Figure 20-30-3] of th e parts clean. Always use caps and plugs on hoses,
hydraulic tester to the bo ttom (female) quick coupler on tubelines and ports to keep dirt out. Dirt can quickly
the loader.

Dealer Copy -- Not for Resale

damage the system.
I-2003-0888
Connect the OUT port (Item 2) [Figure 20-30-3] of the
hydraulic tester to the top (male) quick coupler on the
Figure 20-30-5
loader.

Figure 20-30-4

O-ring

1
1
2 Back-up

B-6764

N-20863 If the relief pressure is not correct, adjust the main relief
valve. Remove the end cap (Item 1) [Figure 20-30-5].
Connect the remote start tool. (See REMOTE START on
Turn the adjusting screw in or out until the pressure is
Page 10-60-1.) correct.
Start the engine with the remote start tool. NOTE: If the correct pressure can not be reached,
replace the main relief valve. Check the
Press the maximum flow/variable flow switch (Item 1) pressure setting of the new relief valve.
[Figure 20-30-4] twice to a ctivate maximum flow. The Release the pressure from the auxiliarys
switch will illuminate to indicate the maximum flow rate is before removing the main relief valve for
active. replacement.

753 Bobcat Loader

20-30-2 Service Manual
110 of 726
MAIN RELIEF VALVE (CONT’D)

Removal and Installation

Figure 20-30-6

N-20909

Remove the four motor cover mounting bolts (Item 1)

[Figure 20-30-6].

Dealer Copy -- Not for Resale

Clean the area around the control valve. Loosen and
remove the main relief valve (Item 1) [Figure 20-30-7].

Remove the O-rings and back-up washers [Figure 20-

30-5].

Clean the main relief valve in clean solvent. Use air

pressure to dry the valve.

Figure 20-30-7

N-20907

Install new O-rings and back-up washers. Install the main

relief valve (Item 1) [Figure 20-30-7] and tighten. Check
the pressure again. (See MAIN RELIEF VALVE
(CONT’D) on Page 20-30-3.)

Installation: Tighten the main relief valve to 35-40 ft.-lbs.

(47-54 Nm) torque.

753 Bobcat Loader

20-30-3 Service Manual
111 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

20-30-4 Service Manual
112 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-1

Removal And Installation (S/N 515840211 & Below) 1

1

2
3

N-15066

WARNING
Disconnect the wire harness connectors (Item 1) [Figure
Never work on a machine with the lift arms up unless 20-40-1] from the solenoid connectors.
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Disconnect the wire harness connector (Item 2) [Figure
support device can allow the lift arms or attachment 20-40-1] from the BICS™ valve solenoid connector.
to fall and cause injury or death.

Dealer Copy -- Not for Resale

W-2059-0598 Disconnect the drain hoses (Item 3) [Figure 20-40-1]
from the main control valve.
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.) Disconnect the hose (Item 4) [Figure 20-40-1] from the
lift arm by-pass control valve.
Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device Figure 20-40-2
on Page 10-20-1.)

Stop the engine. Raise the seat bar.

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

Remove control panel. (See Removal and Installation on

Page 50-100-1.)
1
Thoroughly clean the area around the control valve.

Drain the hydraulic reservoir. (See Replacing Hydraulic

Fluid on Page 10-120-3.)
N-15065
Mark all tubelines and hoses for correct installation.
Disconnect the tubeline (Item 1) [Figure 20-40-2] from
the control valve.

753 Bobcat Loader

20-40-1 Service Manual
113 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-5
(CONT’D)

Removal And Installation (S/N 515840211 & Below)

(Cont'd)

Figure 20-40-3

1 1 P-28894

2 Disconnect the three tubelines (Item 1) [Figure 20-40-5]

from the lift section of the control valve.

N-15064 Disconnect the drain hose (Item 2) [Figure 20-40-5].

Figure 20-40-6
Disconnect the tubeline (Item 1) [Figure 20-40-3] from

Dealer Copy -- Not for Resale

the auxiliary section of the control valve.

Disconnect and remove the tubeline (Item 2) [Figure 20-

40-3] from the auxiliary section of the control valve.

Figure 20-40-4
1

P-28895

1
Remove the two mounting bolts (Item 1) [Figure 20-40-
6] from the lift arm by-pass control bracket.

P-28893

Disconnect the tilt tubelines (Item 1) [Figure 20-40-4].

753 Bobcat Loader

20-40-2 Service Manual
114 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-9
(CONT’D)

Removal And Installation (S/N 515840211 & Below) 2

1
(Cont'd)

Figure 20-40-7

P-28897
1
2
Locate the drive motor cover (Item 1) and the access
cover (Item 2) [Figure 20-40-9] on the right side of th e
loader frame.
N-15061
Figure 20-40-10
Remove the clevis pin (Item 1) [Figure 20-40-7] from the

Dealer Copy -- Not for Resale

tilt spool linkage.

Remove the clevis pin (Item 2) [Figure 20-40-7] from the

lift spool linkage.

Figure 20-40-8

P-28899

Remove the dr ive motor cover and loosen the rear

mounting bolt and remove the front mounting bolt from
the rectangular access cover [Figure 20-40-10].

Rotate the cover to expose the access slot in the loader

P-28900 [Figure 20-40-10].

Connect a hoist to the control valve [Figure 20-40-8].

753 Bobcat Loader

20-40-3 Service Manual
115 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-12
(CONT’D)

Removal And Installation (S/N 515840211 & Below)

(Cont'd)

Figure 20-40-11
1

P-28901

Remove the two control valve mounting bolts/nuts (Item

1) [Figure 20-40-12] from the loader frame.

P-28898 Remove the control valve from the loader.

Installation: Tighten the mounting bolt & nut to 18-20 ft.-

Disconnect the inlet hose from the control valve through

Dealer Copy -- Not for Resale

lbs. (24-27 Nm) torque.
the access slot [Figure 20-40-11].
Reverse the removal procedure to install the control
valve.

753 Bobcat Loader

20-40-4 Service Manual
116 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-13
(CONT’D)

Removal And Installation (S/N 515840212 & Above)

P-28861

The fixed end main valve hose assembly (Item 1) [Figure

WARNING 20-40-13] is connected to a fix ed end fitting on th e
control valve. The hose is routed to the upright where the
hose is connected to a tee fitting that feeds the base end
Never work on a machine with the lift arms up unless of both lift cylinders. The hose can only be removed by
the lift arms are secured by an approved lift arm first removing it from the tee fitting located at the

Dealer Copy -- Not for Resale

support device. Failure to use an approved lift arm rear of the loader.
support device can allow the lift arms or attachment
to fall and cause injury or death. Disconnect hose (Item 1) [Figure 20-40-13] at fitting.
W-2059-0598

Mark all tubelines and hoses for correct installation.

Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.) Cap all hoses and fittings.

Raise the lift arms and install an approved lift arm Figure 20-40-14
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Stop the engine. Raise the seat bar.

Raise the operator cab. (See Raising The Operator Cab 1

on Page 10-30-1.)

Remove the control panel. (See Removal and Installation

on Page 50-100-1.)

Thoroughly clean the area around the control valve.

Drain the hydraulic reservoir. (See Replacing Hydraulic

Fluid on Page 10-120-3.) P-28862

Open the rear door.

Remove the tubeline clamp (Item 1) [Figure 20-40-14]
holding the fixed end main valve hose assembly. Clamp
is located behind fuel fill tube.

753 Bobcat Loader

20-40-5 Service Manual
117 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-17
(CONT’D)

Removal And Installation (S/N 515840212 & Above)

(Cont'd)

Figure 20-40-15 1

1
2

P-28858
1

Disconnect the harness connector (Item 1) from auxiliary

solenoids connectors. Disconnect the harness connector
(Item 2) [Figure 20-40-17] from BICS™ valve solenoid
P-28863 connector.

Figure 20-40-18
Disconnect and remove the two tubelines (Item 1)

Dealer Copy -- Not for Resale

[Figure 20-40-15] at lift arm by-pass valve.

Figure 20-40-16

1 2

P-28866

Remove the clevis pin (Item 1) [Figure 20-40-18] from

P-28895 the tilt spool linkage.

Remove the clevis pin (Item 2) [Figure 20-40-18] from

Remove the two mo unting bolts and nuts (Item 1) the lift spool linkage.
[Figure 20-40-16] from the lift arm by-pass mount.

753 Bobcat Loader

20-40-6 Service Manual
118 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-21
(CONT’D)

Removal And Installation (S/N 515840212 & Above)

(Cont'd)

Figure 20-40-19

1
1 2 P-28870

Disconnect the tubelines (Item 1) [Figure 20-40-21] from

the control valve and the C & D por ts on the bucket
position valve. (If so equipped.)
P-28867
Disconnect the tubelines (Item 2) [Figure 20-40-21] from
the control valve.
Disconnect and remove the auxiliary tubelines (Item 1)

Dealer Copy -- Not for Resale

[Figure 20-40-19] from the control valve. Figure 20-40-22
Figure 20-40-20

1
1

P-28871

P-28869
Disconnect drain hose (Item 1) [Figure 20-40-22].

Disconnect the tilt tubelines (Item 1) [Figure 20-40-20]

from the control valve.

753 Bobcat Loader

20-40-7 Service Manual
119 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-25
(CONT’D)

Removal And Installation (S/N 515840212 & Above)

(Cont'd)
1
Figure 20-40-23

P-28874

1 Disconnect the tubeline from control valve (Item 1)

[Figure 20-40-25].

P-28873 Figure 20-40-26

Disconnect the control valve drain hose (Item 1) [Figure

Dealer Copy -- Not for Resale

20-40-23].

Figure 20-40-24
1

P-28877

Install the chain hoist (Item 1) [Figure 20-40-26] as

shown.

P-28872

Disconnect the drive motor case drain hose (Item 1)

[Figure 20-40-24].

753 Bobcat Loader

20-40-8 Service Manual
120 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-29
(CONT’D)

Removal And Installation (S/N 515840212 & Above)

(Cont'd)

Figure 20-40-27

1
2 1

P-43310

Remove the two control valve mounting bolts/nuts (Item

1) [Figure 20-40-29] from the loader frame.

P-43309 Installation: Tighten the mounting bolt & nut to 18-20 ft.-
lbs. (24-27 Nm) torque.
Remove the access covers (Items 1 & 2) [Figure 20-40-

Dealer Copy -- Not for Resale

27] on the right side of the loader frame.

Figure 20-40-28

P-43308

Disconnect the inlet hose from the control valve through

the access slot [Figure 20-40-28].

753 Bobcat Loader

20-40-9 Service Manual
121 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-32
(CONT’D)

Removal And Installation (S/N 515840212 & Above)

(Cont'd)

Figure 20-40-30

N-21005

Remove the BICS™ valve assembly from the top of th e

control valve [Figure 20-40-32].

P-28879 Figure 20-40-33

Lower the chain hoist and valve to allow clearance

Dealer Copy -- Not for Resale

between valve spools and tubelines [Figure 20-40-30].

Rotate the valve upward until the valve spools are above
the tubelines. 1
1
Reverse the removal procedure to install the control
valve.

BICS™ Valve Removal And Installation 2

Figure 20-40-31
N-21006

1 1
Remove the four large O-rings (Item 1) and the small O-
ring (Item 2) [Figure 20-40-33] from the top of the control
valve.

1 1 Install the four large O-rings (Item 1) and the small O-ring
(Item 2) [Figure 20-40-33] on the top of the control valve.
1

N-21004

Remove the c ontrol valve. (See BICS™ Valve Removal

And Installation on Page 20-40-10.)

To remove the BICS™ from the control valve loosen and

remove the six mounting bolts (Item 1) [Figure 20-40-
31].

753 Bobcat Loader

20-40-10 Service Manual
122 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) BICS™ Valve Lift Arm By-Pass Orifice Disassembly
(CONT’D) And Assembly

BICS™ Valve Removal And Installation (Cont’d) Figure 20-40-35

Figure 20-40-34

3 6

1 2
1

5 4
N-21013

N-21004
Remove the fi tting (Item 1) [Figure 20-40-35] from the
valve.
Install the six mounting bolts [Figure 20-40-34].

Dealer Copy -- Not for Resale

The chart below lists the c orrect torque specifications
and tightening sequence when reinstalling the BICS™
valve assembly to the control valve. Thoroughly clean
and dry bolts and threads in valve. Use liquid adhesive
LOCTITE #242 or equivalent.

STEP TORQUE SEQUENCE

1 110-130 in.-lbs.
(12,4-14,7Nm)
2 190-210 in.-lbs.
1,2,3,4,5 & 6
(21,5-23,7Nm)
3* 190-210 in.-lbs.
(21,5-23,7 Nm)

*Torque must be 19 0-210 in.-lbs. (21,5-23,7 Nm) for

every bolt or repeat step 3.

753 Bobcat Loader

20-40-11 Service Manual
123 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) BICS™ Valve Check Valve Disassembly And
(CONT’D) Assembly

BICS™ Valve Lift Arm By-Pass Orifice Disassembly Figure 20-40-38

And Assembly (Cont’d)

Figure 20-40-36

N-21010

N-21015 Remove the check valve (Item 1) [Figure 20-40-38].

Installation: Tighten the v alve to 20 f t.-lbs. (27 Nm)

Figure 20-40-37

Dealer Copy -- Not for Resale

torque.

Figure 20-40-39

1 2
1

N-18685

N-18684
Using a flat blade screw driver, remove the l ift arm by-
pass orifice (Item 1) [Figure 20-40-36] & [Figure 20-40-
37]. Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-40-39].
Orifice size is 0.078 inch.
Install new O-rings (Item 1) and back-up ring (Item 2)
* Reverse the removal procedure to install the lift arm [Figure 20-40-39] on the check valve.
by-pass orifice.
Check valve (Item 3) [Figure 20-40-39] has a rating of 5-
10 PSI.

753 Bobcat Loader

20-40-12 Service Manual
124 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-42
(CONT’D)

BICS™ Valve Check Valve Disassembly And

Assembly (Cont’d)

Figure 20-40-40

N-21017

Figure 20-40-43

P-8956

Clean and inspect the screen (Item 1) [Figure 20-40-40]

Dealer Copy -- Not for Resale

on the end of the valve.

Reverse the removal procedure to install the BICS™

check valve.
1
BICS™ Valve Lock Valve Disassembly And Assembly

Figure 20-40-41
N-21013

Remove the lock valves (Item 1) [Figure 20-40-41],

[Figure 20-40-42] & [Figure 20-40-43] from the BICS™
1 valve.
1
Installation: Tighten the lock valves to 25 ft.-lbs. (34 Nm)
torque.

N-21004

753 Bobcat Loader

20-40-13 Service Manual
125 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-46
(CONT’D)

BICS™ Valve Lock Valve Disassembly And Assembly

1
(Cont’d)

Figure 20-40-44 1

1 N-18693A

2 Remove the O-rings (Item 1) [Figure 20-40-46] from

2 both ends of the solenoid.
2
N-18690 Figure 20-40-47

Remove the O-rings (Item 1) and back-up rings (Item 2)

Dealer Copy -- Not for Resale

[Figure 20-40-44] from both the tilt and lift lock valves.

Install new O-rings (Item 1) and b ack-up rings (Item 2) 1

[Figure 20-40-44] on the tilt and lift lock valves.
Reverse the removal procedure to install the lock valve.

BICS™ Valve Solenoid Disassembly And Assembly

Figure 20-40-45

N-21011
1

Remove the solenoid cartridge (Item 1) [Figure 20-40-

47].

Installation: Tighten the cartridge to 20 ft.-lbs. (27 Nm)

2 torque.

N-21010

Remove the mounting nut (Item 1) [Figure 20-40-45]

from the solenoid cartridge.
Installation: Tighten the mounting nut to 53 in.-lbs. (6
Nm) torque.
Remove the solenoid (Item 2) [Figure 20-40-45].
NOTE: The solenoid resistance valve is (8-10 ohms).

753 Bobcat Loader

20-40-14 Service Manual
126 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) BICS™ Valve Solenoid Testing
(CONT’D)
Figure 20-40-49
BICS™ Valve Solenoid Disassembly And Assembly
(Cont’d)

Figure 20-40-48

3
2

P9175
1

Use an Ohm meter to measure coil resistance [Figure

N-18694 20-40-49].

Coil wires do not have polarity.

Remove the O-rings (Item 1) and back-up rings (Item 2)

Dealer Copy -- Not for Resale

[Figure 20-40-48] from the cartridge. Correct resistance for the au xiliary, lift and tilt lock coils
are 7-10 ohms.
Clean all parts in solvent and dry with compressed air.
The other coils (BICS, diverter, select valve) are 5-8
Inspect all parts for wear and r eplace any showing ohms.
excessive wear.

NOTE: The screen (Item 3) [Figure 20-40-48] may be

cleaned with solvent. If it is torn or worn it
needs to be replaced.

Use only new O-rings and apply oil to al l O-rings and

back-up rings before installation.

Install new O-rings (Item 1) [Figure 20-40-46] & [Figure

20-40-48] and new back-up rings (Item 2) [Figure 20-40-
48] on the solenoid cartridge.

753 Bobcat Loader

20-40-15 Service Manual
127 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-50
(CONT’D)
H1
H3 H2
Identification Chart

Item 753 Loader

G3
A1 Lift Cylinder Base End C4
B3 A3
D3
A2 Tilt Cylinder Base End
C3
A3 Auxiliary Hydraulics G2 B2 A2 E2 D2
F2 C2
B1 Lift Cylinder Rod End G1 E1 D1
B1 A1
B2 Tilt Cylinder Rod End F1 C1
B3 Auxiliary Hydraulics MR
C1 Load Check Valve/Lift Function
TS-1918
C2 Load Check Valve/Tilt Function
C3 Orificed Load Check Valve/ Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs

Dealer Copy -- Not for Resale

E1 Port Relief Valve-3500 PSI
E2 Anti-Cavitation-Valve
F1 Anti-Cavitation Valve
F2 Plug
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional)-3500 PSI
H3 Auxiliary Electric Solenoid
MR Main Relief Valve-2600 PSI

753 Bobcat Loader

20-40-16 Service Manual
128 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)

Lift Base End Restrictor IMPORTANT

Figure 20-40-51 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1

Figure 20-40-53

N-21159
1
Remove the BICS valve assembly from the control valve.
(See BICS™ Valve, Removal And Installation on Page

Dealer Copy -- Not for Resale

20-41-9.)

Remove the restrictor (Item 1) [Figure 20-40-51] from

the lift section base end port. N-21007

Load Check Valves

Mark each valve section, spool and related parts so that
they will be r eturned to its original valve section during
Figure 20-40-52
assembly.

Use bolts to fasten the control valve to a work bench for

easier disassembly and assembly procedures.
1 1
Loosen the load check valve plugs (Item 1) [Figure 20-
40-53].

1 1 Installation: Always use new O-ring. tighten the plug to

35-40 ft.-lbs. (47-54 Nm) torque.

N-21006

Remove the BICS valve assembly from the control valve.

(See BICS™ Valve, Removal And Installation on Page
20-41-9.)

Remove the fo ur large O-rings (Item 1) [Figure 20-40-

52] and small O-ring (Item 2) [Figure 20-40-52]. Always
replace these O-rings before installing the BICS valve
assembly.

753 Bobcat Loader

20-40-17 Service Manual
129 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL Main Relief Valve
(CONT’D)
Figure 20-40-56
Load Check Valves (Cont’d)
1
Figure 20-40-54

1
2
N-21018

3
2 N-21008 Loosen the main relief valve (Item 1) [Figure 20-40-56].

Remove the main relief valve.

Remove the load check plugs (Item 1) [Figure 20-40-54].

Dealer Copy -- Not for Resale

Installation: Always use new O-rings, sleeve, and glide
Remove the spring (Item 2) and poppet (Item 3) [Figure ring. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
20-40-54].
Figure 20-40-57
Figure 20-40-55
2 3
1 4 5

1
B-6764

1. Relief Valve
2. O-ring
3. Sleeve
4. Glide Ring
5. O-ring

2
CD-15092
N-21009

Remove the O-rings, sleeve, and glide ring from the main
The auxiliary section (Item 1) uses an orifice load check relief valve [Figure 20-40-57].
poppet (Item 2) [Figure 20-40-55].

NOTE: For correct port locations and valve

component valves. (See Identification Chart
on Page 20-40-16.)

753 Bobcat Loader

20-40-18 Service Manual
130 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Anti-Cavitation Valve
(CONT’D)
Figure 20-40-60
Port Relief Valve

Figure 20-40-58

N-21013

N-21013 Remove the anti-cavitation valve (Item 1) [Figure 20-40-

60] (Port E2) from the control valve for the tilt section.
Loosen the p ort relief valve (Item 1) [Figure 20-40- Installation: Always use new O-rings and back-up
58](Port E1).

Dealer Copy -- Not for Resale

washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
Installation: Always use new O-rings and back-up
washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.

Remove the port relief valve.

Figure 20-40-59

4
3

1. O-ring
2. Backup Washer
3. O-ring
4. Relief Valve

N-18844

Remove the O-rings and b ack-up washer from the p ort

relief valve [Figure 20-40-59].

753 Bobcat Loader

20-40-19 Service Manual
131 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-63
(CONT’D)
1 2 3
4
Anti-Cavitation Valve (Cont’d)

Figure 20-40-61

2 E-01509

1. Anti-Cavitation Valve
2. O-ring
3. Backup Washer
4. O-ring

N-18839

1
Remove the O -rings and back-up washer from the an ti-
cavitation valve [Figure 20-40-63].
N-21018
Plug
Figure 20-40-62 Figure 20-40-64

Dealer Copy -- Not for Resale

2

N-21019
N-21018

Remove the lift lock solenoid (Item 1) [Figure 20-40-61] Remove the plug (Item 1) [Figure 20-40-64] (Port F2).or
& [Figure 20-40-62] (Port F1). optional port relief valve from the control valve.

Remove the anti-cavitation valve (Item 2) [Figure 20-40- Installation: Always use new O-rings and back-up
61] & [Figure 20-40-62] (Port F1). from the control valve washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
for the lift section.

753 Bobcat Loader

20-40-20 Service Manual
132 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-67
(CONT’D)
2
Plug (Cont’d) 1

Figure 20-40-65

Plug

1 2

N-21020

1
Remove the rubber boot (Item 1) and retainer (Item 2)
1
[Figure 20-40-67].
N-18800

Remove the O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-40-65] from the plug.

Dealer Copy -- Not for Resale

Rubber Boot

Figure 20-40-66

N-21018

Remove the two screws (Item 1) [Figure 20-40-66] on

the rubber boot retainer.

Installation: Tighten the screws to 90-100 in.-lbs. (10,2-

11,3 Nm) torque.

753 Bobcat Loader

20-40-21 Service Manual
133 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-70
(CONT’D)

Lift And Tilt Lock Block Removal And Installation

Figure 20-40-68

1
N-21022
2

1 Remove the block [Figure 20-40-70].

N-21018 NOTE: The lock block must be clean and oil free. (Oil
can cause the solenoids not to function
properly.)
Figure 20-40-69

Dealer Copy -- Not for Resale

1

2
1
N-21021

Remove the lock solenoids (Item 1) [Figure 20-40-68] &

[Figure 20-40-69] from the lock block.

Remove the rubber Boot (Item 2) [Figure 20-40-68] &

[Figure 20-40-69]. (See Rubber Boot on Page 20-40-
21.)

753 Bobcat Loader

20-40-22 Service Manual
134 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-73
(CONT’D)

Lift Spool and Detent

Figure 20-40-71

1
N-21013

2
1 Remove the end cap (Item 1) [Figure 20-40-73].

N-21018 Figure 20-40-74

The tool listed will be ne eded to d o the following

procedure:

Dealer Copy -- Not for Resale

MEL1278 - Detent Tool
MEL1285 - Detent Spring Tool
1
Remove the lift and tilt lock block (Item 1) [Figure 20-40-
71] from the control valve. (See Lift And Tilt Lock Block
Removal And Installation on Page 20-40-22.)

Figure 20-40-72 2

N-21031

Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-74].
1 2
Remove the washer (Item 2) [Figure 20-40-74].

N-21023

Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-72] from the lift spool.

753 Bobcat Loader

20-40-23 Service Manual
135 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-77
(CONT’D)

Lift Spool and Detent (Cont'd)

Figure 20-40-75
3
2
1

1
N-21035
2

Remove the detent sleeve (Item 1), detent balls (Item 2)

1 and spring (Item 3) [Figure 20-40-77].
N-21033
Figure 20-40-78
Remove the screws (Item 1) [Figure 20-40-75] from the
detent bonnet.

Dealer Copy -- Not for Resale

Remove the detent bonnet (Item 2) [Figure 20-40-75].

IMPORTANT
1
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
N-21036

Figure 20-40-76
Remove the s pool assembly and seal (Item 1) [Figure
20-40-78] from the control valve.

N-21034

Put a rag around the detent assembly [Figure 20-40-76].

This will prevent the detent balls and s pring from being
lost when the detent sleeve is removed.

753 Bobcat Loader

20-40-24 Service Manual
136 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-81
(CONT’D)

Lift Spool and Detent (Cont'd)

2
Figure 20-40-79

1 N-18915

Install the spring tool (Item 1) [Figure 20-40-81] over the

centering spring.
N-21027
NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-81] from the centering
Remove the spool seal (Item 1) [Figure 20-40-79] from spring, as it is under spring pressure.
the linkage end of the valve.

Dealer Copy -- Not for Resale

Figure 20-40-82
Figure 20-40-80

1
2
N-18916
P-8988

Put a rag around the detent assembly [Figure 20-40-82].

Clamp the linkage end of the spool in a vise [Figure 20- This will prevent the detent balls and spring from being
40-80]. lost when the detent adapter is removed.

Remove the detent adapter with an allan wrench.

Remove the back-up washer (Item 1) and spool seal

(Item 2) [Figure 20-40-82].

753 Bobcat Loader

20-40-25 Service Manual
137 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-85
(CONT’D)

Lift Spool and Detent (Cont'd) 1

2
3
Figure 20-40-83
4
1

N-18919A

Inspect the adapter (Item 1), collar (Item 2), spring (Item
3), and washer (Item 4) [Figure 20-40-85].
N-19004
Figure 20-40-86
Remove the detent adapter (Item 1) [Figure 20-40-83]
from the spring assembly.

Dealer Copy -- Not for Resale

Figure 20-40-84

N-18918

Remove the stud from the end of the spool [Figure 20-
40-86].
N-19009

Remove spring tool (Item 1) [Figure 20-40-84] from the

spring assembly.

753 Bobcat Loader

20-40-26 Service Manual
138 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-89
(CONT’D)

Lift Spool and Detent (Cont'd)

Figure 20-40-87

N-18963
1

Install the plastic plug and O-ring in the spool [Figure 20-
40-89].
N-18920
Figure 20-40-90
Removal of the plastic plug:
O-ring

Dealer Copy -- Not for Resale

Make a center point in the plug using a 1/16 inch drill.

Drill a hole all the way through the plug using a 7/64 inch
tap drill.

Turn a 6-32 tap (Item 1) [Figure 20-40-87] into the plug.

Pull the tap and plug out of the spool. Be careful, do not Plastic
break the tap. Plug
.60 inch
Clean all the debris from inside the spool bore. (15,2 mm)

NOTE: DO NOT USE LOCTITE ON THE STUD

B-14712
THREADS.

Figure 20-40-88 Install the stud and tighten until the other end of the stud
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-40-90].

2
1

N-18961

Install the O-ring (Item 1) over the nipple on th e plastic

plug (Item 2) [Figure 20-40-88].

753 Bobcat Loader

20-40-27 Service Manual
139 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-93
(CONT’D)

Lift Spool and Detent (Cont'd)

1
Figure 20-40-91

N-18968

Install the detent adapter to the collar [Figure 20-40-93].

N-18967 NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
Clamp the collar (Item 1) [Figure 20-40-91] in a vise. detent adapter and collar together to prevent

Dealer Copy -- Not for Resale

the detent balls and spring from falling out.
Figure 20-40-92
Figure 20-40-94

1
3
2

N-18958

N-19004

Apply grease on all the detent component surfaces

before assembly [Figure 20-40-92]. Install the spring tool (Item 1) [Figure 20-40-94] over the
washer, spring, collar and detent adapter.
Install the spring (Item 1) and detent balls (Item 2) into
the adapter (Item 3) [Figure 20-40-92] and compress
with the detent pliers (Item 1) [Figure 20-40-93].

753 Bobcat Loader

20-40-28 Service Manual
140 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-97
(CONT’D)

Lift Spool and Detent (Cont'd)

Figure 20-40-95

CD-15051
1
Install the detent balls and spring [Figure 20-40-97].

N-18917 Figure 20-40-98

Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-40-95].

Dealer Copy -- Not for Resale

Figure 20-40-96

N-19007

Hold the detent balls in place with the detent pliers

[Figure 20-40-98].

N-19005

Install the spring assembly to the lift spool hand tight

[Figure 20-40-96].

Remove the spring tool.

Check the alignment of the detent adapter and the

washer.

Tighten the adapter to 90-100 in.-lbs. (10,2-11,3 Nm).

NOTE: The adapter must fit in the center of the

washer (Item 1) [Figure 20-40-96].

753 Bobcat Loader

20-40-29 Service Manual
141 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-101
(CONT’D)

Lift Spool and Detent (Cont'd)

Figure 20-40-99

1
N-21031

Install the washer (Item 1) and snap ring (Item 2) [Figure

20-40-101].
N-19008
Figure 20-40-102
Install the detent sleeve (Item 1) [Figure 20-40-99] to the
detent adapter.

Dealer Copy -- Not for Resale

Figure 20-40-100

N-21013
1

Install the end cap (Item 1) [Figure 20-40-102].

2
N-21033

Install the lift spool assembly in the spool bore[Figure

20-40-100].

Install the detent bonnet (Item 1) [Figure 20-40-100].

Install the mounting screws (Item 2) [Figure 20-40-100].

Installation: Tighten the screws to 90-100 in.-lbs. (10,2-

11,3 Nm) torque.

753 Bobcat Loader

20-40-30 Service Manual
142 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-105
(CONT’D)

Lift Spool and Detent (Cont'd)

Figure 20-40-103

1 N-21018

Install the li ft and tilt lock block (Item 1) [Figure 20-40-

105]. (See Lift And Tilt Lock Block Removal And
N-21027 Installation on Page 20-40-22.)

Install the spool seal (Item 1) [Figure 20-40-103] on the

linkage end of the valve.

Dealer Copy -- Not for Resale

Figure 20-40-104

2
1

N-21023

Install the spacer (Item 1) and O-ring (Item 2) [Figure 20-

40-104] on the linkage end of the lift spool.

753 Bobcat Loader

20-40-31 Service Manual
143 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-108
(CONT’D)

Tilt Spool Removal And Installation

Figure 20-40-106

N-21013

1 Remove the screws (Item 1) [Figure 20-40-108] from the

end cap.
N-21018
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
Remove the lift and tilt lock block (Item 1) [Figure 20-40-
106] from the control valve. (See Lift And Tilt Lock Block

Dealer Copy -- Not for Resale

Figure 20-40-109
Removal And Installation on Page 20-40-22.)

Figure 20-40-107

2
1

N-21037

N-21024 Remove the spool, centering spring, back-up washer and

spool seal [Figure 20-40-109].

Remove the spacer (Item 1) and O-ring (Item 2) [Figure Assembly: Always use a new spool seal.
20-40-107] from the tilt spool.

753 Bobcat Loader

20-40-32 Service Manual
144 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-112
(CONT’D)

Tilt Spool Removal And Installation (Cont'd) 2 1

3
Figure 20-40-110
4

N-18944A

Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-112].
N-18942
N-18942
Figure 20-40-113
Put the linkage end of the spool in t he vise [Figure 20-
40-110]. 2

Dealer Copy -- Not for Resale

1
Install the spring tool (Item 1) [Figure 20-40-110] over
the centering spring.

Figure 20-40-111

N-21027 N-18943

Remove the spool seal(s) (Item 1) and the back-up

washer (Item 2) [Figure 20-40-113].

Assembly: Always use a new spool seal.

N-19014

Remove the bolt (Item 1) [Figure 20-40-111] holding the

centering spring to the spool.

Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3

Nm) torque.

Remove spring tool from the spring assembly.

753 Bobcat Loader

20-40-33 Service Manual
145 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Auxiliary Electric Solenoid Disassembly
(CONT’D)
Figure 20-40-116
Auxiliary Spool Removal And Installation

Figure 20-40-114

1 1

N-21040

N-21030 Remove the nut (Item 1) [Figure 20-40-116] from both

solenoids.
Remove the screws (Item 1) [Figure 20-40-114] from the Installation: Tighten the nut to 8-12 ft.-lbs. (11-16 Nm)
end cap (both sides).

Dealer Copy -- Not for Resale

torque.
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3 Figure 20-40-117
Nm) torque.

Figure 20-40-115

2 1

N-21041

N-21038 Remove the coil (Item 1) [Figure 20-40-117].

Remove the solenoid valve (Item 2) [Figure 20-40-117].

Remove the end cap, O-ring, springs and washer, (both
sides) [Figure 20-40-115]. Installation: Tighten valve to 8-12 ft.-lbs. (11-16 Nm)
torque.
Remove the spool [Figure 20-40-115].

Assembly: Put grease on all the centering spring

component parts. Always use a new spool seal.

753 Bobcat Loader

20-40-34 Service Manual
146 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Port-Auxiliary Section Disassembly
(CONT’D)
Figure 20-40-119
Auxiliary Electric Solenoid Disassembly (Cont’d)

Figure 20-40-118

1
1

N-21042

N-18795 Remove the plug (Item 1) [Figure 20-40-119] or optional

port relief valve from the control valve.
Remove the O -rings (Item 1) [Figure 20-40-118] from NOTE: Optional port relief (Item 1) [Figure 20-40-119]
the solenoid valves.

Dealer Copy -- Not for Resale

is a 3500 PSI valve.

753 Bobcat Loader

20-40-35 Service Manual
147 of 726
HYDRAULIC CONTROL VALVE (FOOT CONTROL) Cleaning And Inspection
(CONT’D)
Clean all components with clean solvent and dry with
Port-Auxiliary Section Disassembly (Cont’d) compressed air.

Figure 20-40-120 Check the spools for wear or scratches.

Plug Check that the spools are not loose in their bore.

Check that the centering springs are not broken.

2
Check that the load check valve seats are not worn.

Check the load check poppets for damage.

Check the rubber boots and retainers.

1
Replace the parts as needed.
1
Use new O-rings and back-up rings.
N-18800

Apply oil to all new O-rings and back-up rings before

installation.
Figure 20-40-121

Dealer Copy -- Not for Resale

Port Relief (Optional)

1
1

N-18843

Remove the O-rings (Item 1) [Figure 20-40-120] &

[Figure 20-40-121] and back-up ring (Item 2) [[Figure
20-40-120] & [Figure 20-40-121] from the plug.

753 Bobcat Loader

20-40-36 Service Manual
148 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-1
CONTROL SYSTEM) (ACS)

Description

The Advanced Control System (ACS) includes the 3 1

Advanced Hand Controls (AHC) and/or the Selectable
Hand/Foot Control.

Removal And Installation (S/N 515840211 & Below)

4

4
2

N-21135

Disconnect the wire harness connectors (Item 1) [Figure

20-41-1] from the auxiliary solenoids connectors.

Disconnect the wire harness connector (Item 2) [Figure

WARNING 20-41-1] from the BICS™ valve solenoid connector.

Dealer Copy -- Not for Resale

Disconnect the hose (Item 3) [Figure 20-41-1] from the
Never work on a machine with the lift arms up unless lift arm by-pass control valve.
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Disconnect the drain hoses (Item 4) [Figure 20-41-1]
support device can allow the lift arms or attachment from the main control valve.
to fall and cause injury or death.
W-2059-0598
Figure 20-41-2

Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.)

Raise the lift arms and install an approved lift arm

support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
1
Stop the engine. Raise the seat bar.

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

Clean the area around the control valve.

P-30148
Drain the hydraulic reservoir. (See Replacing Hydraulic
Fluid on Page 10-120-3.)
Disconnect the wire harness connector (Item 1) [Figure
Mark all tubelines for correct installation. 20-41-2] from the control valve actuators.

Cap and plug all hoses, tubelines, and fittings.

Remove the control panel. (See Removal and Installation

on Page 50-100-1.)

753 Bobcat Loader

20-41-1 Service Manual
149 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-5
CONTROL SYSTEM) (ACS) (CONT'D)

Removal And Installation (S/N 515840211 & Below)

(Cont’d)
1
Figure 20-41-3

P-28893

1
Disconnect the tilt tubelines (Item 1) [Figure 20-41-5].

Figure 20-41-6
P-28891

Disconnect the o utlet tubeline (Item 1) [Figure 20-41-3]

Dealer Copy -- Not for Resale

from the control valve. 2

Figure 20-41-4

1 2
1

1
P-28894

Disconnect the three tubelines (Item 1) [Figure 20-41-6]

from the lift section of the control valve.

Disconnect the drain hose (Item 2) [Figure 20-41-6].

P-28892

Disconnect the tubeline (Item 1) [Figure 20-41-4] from

the auxiliary section of the control valve.

Disconnect and remove the tubeline (Item 2) [Figure 20-

41-4] from the auxiliary section of the control valve.

753 Bobcat Loader

20-41-2 Service Manual
150 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-9
CONTROL SYSTEM) (ACS) (CONT'D)

Removal And Installation (S/N 515840211 & Below)

(Cont’d) 1 1

Figure 20-41-7

P-28897

Locate the access covers (Item 1) [Figure 20-41-9] on

the right side of the loader frame.

P-28895 Figure 20-41-10

Remove the two mounting bolts (Item 1) [Figure 20-41-

Dealer Copy -- Not for Resale

1
7] from the lift arm by-pass control bracket.

Figure 20-41-8

P-28899

Remove the drive motor cover [Figure 20-41-10].

Loosen the rear mounting bolt and remove the front

N-21145 mounting bolt from the rectangular access cover (Item 1)
[Figure 20-41-10].

Connect a hoist to the control valve [Figure 20-41-8]. Rotate the cover to expose the access slot in the loader
[Figure 20-41-10].

753 Bobcat Loader

20-41-3 Service Manual
151 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Removal And Installation (S/N 515840212 & Above)
CONTROL SYSTEM) (ACS) (CONT'D)

Removal And Installation (S/N 515840211 & Below)

(Cont’d)

Figure 20-41-11

WARNING
Never work on a machine with the lift arms up 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 lift arms or attachment
to fall and cause injury or death.
P-28898 W-2059-0598

Disconnect the inlet hose from the control valve through Lift and block the loader. (See LIFTING AND BLOCKING

Dealer Copy -- Not for Resale

the access slot [Figure 20-41-11]. THE LOADER on Page 10-10-1.)

Figure 20-41-12 Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Stop the engine. Raise the seat bar.

1
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)

Clean the area around the control valve.

Drain the hydraulic reservoir. (See Replacing Hydraulic

Fluid on Page 10-120-3.)

Mark all tubelines for correct installation.

P-28901
Cap and plug all hoses, tubelines, and fittings.

Remove the two control valve mounting bolts/nuts (Item Remove the control panel. (See Removal and Installation
1) [Figure 20-41-12] from the loader frame. on Page 50-100-1.)

Remove the control valve from the loader. Open the rear door.

Installation: Tighten the mounting bolt & nut to 18-20 ft.-

lbs. (24-27 Nm) torque.

Reverse the removal procedure to install the control

valve.

753 Bobcat Loader

20-41-4 Service Manual
152 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-15
CONTROL SYSTEM) (ACS) (CONT'D)

Removal And Installation (S/N 515840212 & Above)

(Cont’d)
2
Figure 20-41-13
1

P-34986

Label and disconnect the actuator electrical connectors

(Item 1) [Figure 20-41-15].
1
P-28861 Label and disconnect the electrical connectors (Item 2)
[Figure 20-41-15].
The fixed end main valve hose assembly (Item 1) [Figure

Dealer Copy -- Not for Resale

Label and disconnect the BICS™ electrical connector
20-41-13] is connected to a fix ed end fitting on th e (Item 3) [Figure 20-41-15].
control valve. The hose is routed to t he back upright
where the hose is connected to a tee fitting that fe eds Figure 20-41-16
the base end of both lift cylinders. The hose must be
removed at the back tee fitting, located in the right side
upright.
3
NOTE: Remember the hose routing for ease of
control valve installation.
1
Figure 20-41-14

P-34987

1
Disconnect the tubeline (Item 1) [Figure 20-41-16] from
the lift arm by-pass valve.

Remove the drain tubeline (Item 2) [Figure 20-41-16]

from the lift arm by-pass valve.
P-28862
Remove the bolts (Item 3) [Figure 20-41-16] from the lift
arm by-pass control valve bracket.
Remove the tubeline clamp (Item 1) [Figure 20-41-14]
holding the fixed end main valve hose. The clamp is Remove the lift arm by-pass control valve from the
located behind fuel fill tube. loader.

753 Bobcat Loader

20-41-5 Service Manual
153 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-19
CONTROL SYSTEM) (ACS) (CONT'D)

Removal And Installation (S/N 515840212 & Above)

(Cont’d)

Figure 20-41-17

P-34990

Disconnect the tilt tubeline (Item 1) [Figure 20-41-19]

from the control valve.

P-34989 Disconnect the dr ain hose (Item 2) [Figure 20-41-19]

from the control valve.
Remove the tubeline clamp (Item 1) [Figure 20-41-17]

Dealer Copy -- Not for Resale

Figure 20-41-20
on the left fender to allow the auxiliary tubelines to move
during the removal and installation of the control valve.
1
Figure 20-41-18

1
2 3
3
2

P-34991

Disconnect the dr ain hose (Item 1) [Figure 20-41-20]

P-34988 from the control valve.

Disconnect the lift tubeline (Item 2) [Figure 20-41-20]

Disconnect the outlet tubeline (Item 1) [Figure 20-41-18] from the control valve.
from the control valve.
Disconnect the tilt tubeline (Item 3) [Figure 20-41-20]
Disconnect the tubeline (Item 2) [Figure 20-41-18] from from the control valve.
the auxiliary section of the control valve.

Disconnect the dr ain hose (Item 3) [Figure 20-41-18]

from the control valve.

753 Bobcat Loader

20-41-6 Service Manual
154 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-23
CONTROL SYSTEM) (ACS) (CONT'D)

Removal And Installation (S/N 515840212 & Above)

(Cont’d)

Figure 20-41-21

P-43308

Disconnect the inlet hose from the control valve through

the access slot [Figure 20-41-23].

P-34992

Connect a hoist to the control valve (Item 1) [Figure 20-

Dealer Copy -- Not for Resale

41-21].

Figure 20-41-22

1 1

P-43309

Remove the access covers (Item 1) [Figure 20-41-22] on

the right side of the loader frame.

753 Bobcat Loader

20-41-7 Service Manual
155 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Actuator Removal And Installation
CONTROL SYSTEM) (ACS) (CONT'D)
Figure 20-41-25
Removal And Installation (S/N 515840212 & Above)
(Cont’d)

Figure 20-41-24

1
1

2 1

N-19112

Remove the two screws (Item 1) [Figure 20-41-25] on

P-43310 the actuator retainer.

Installation: Tighten the bolt and nut to 90-100 in.-lbs.

Remove the two control valve mounting bolts/nuts (Item

Dealer Copy -- Not for Resale

(10,2-11,3 Nm) torque.
1) [Figure 20-41-24] from the loader frame.
Pull the actuator (Item 2) [Figure 20-41-25] away from
Remove the control valve from the loader. the control valve.
Installation: Tighten the mounting bolt & nut to 18-20 ft.- Figure 20-41-26
lbs. (24-27 Nm) torque.

Reverse the removal procedure to install the control

valve.

N-19113

Use a dr ift pin and hammer to r emove the ac tuator pin

(Item 1) [Figure 20-41-26] from the actuator and the lift
or tilt spool.

753 Bobcat Loader

20-41-8 Service Manual
156 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-29
CONTROL SYSTEM) (ACS) (CONT'D)

Actuator Removal And Installation (Cont’d)

Figure 20-41-27

3 N-18695
2

Remove the BICS™ valve assembly from the top of the

control valve [Figure 20-41-29].
1 N-19114
Figure 20-41-30
Remove the actuator (Item 1) [Figure 20-41-27].

Dealer Copy -- Not for Resale

Remove and replace the O-ring (Item 2) [Figure 20-41-
27].

Remove the spacer block (Item 3) [Figure 20-41-27]. 1

1
Remove and replace the O-ring (Item 4) [Figure 20-41-
27].

BICS™ Valve, Removal And Installation

2
Figure 20-41-28
N-18697

1 Remove the four large O-rings (Item 1) and the small O-

1
ring (Item 2) [Figure 20-41-30] from the top of the control
valve.

1 1 Installation: Install the four new large O-rings (Item 1)

and the new small O-ring (Item 2) [Figure 20-41-30] on
1 the top of the control valve.

N-18679

Remove the hydraulic control valve. (See BICS™ Valve,

Removal And Installation on Page 20-41-9.)

To remove the BICS™ from the control valve loosen and

remove the six mounting bolts (Item 1) [Figure 20-41-
28].

753 Bobcat Loader

20-41-9 Service Manual
157 of 726
HYDRAULIC CONTROL VALVE (ADVANCED BICS™ Valve, Lift Arm By-Pass Orifice Removal and
CONTROL SYSTEM) (ACS) (CONT'D) Installation

BICS™ Valve, Removal And Installation (Cont’d) Figure 20-41-32

Figure 20-41-31

6
3

1 2
1

5
4
N-18686

N-18679
Remove the fi tting (Item 1) [Figure 20-41-32] from the
valve.
Install the six mounting bolts [Figure 20-41-31].

Dealer Copy -- Not for Resale

Figure 20-41-33
The chart below lists the c orrect torque specifications
and tightening sequence when reinstalling the B ICS™]
valve assembly to the c ontrol valve. Thoroughly clean
and dry bolts and threads in valve. Use liquid adhesive
LOCTITE #242 or equivalent.

STEP TORQUE SEQUENCE

1
1 110-130 in.-lbs.
(12,4-14,7 Nm)
2 190-210 in.-lbs.
1,2,3,4,5 &6
(21,5-23,7 Nm)
3* 190-210 in.-lbs.
(21,5-23,7 Nm)
N-18687

*Torque must be 19 0-210 in.-lbs. (21,5-23,7 Nm) for

every bolt or repeat step 3.
Figure 20-41-34

N-18685

753 Bobcat Loader

20-41-10 Service Manual
158 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-36
CONTROL SYSTEM) (ACS) (CONT'D)

BICS™ Valve, Lift Arm By-Pass Orifice Removal and

Installation (Cont’d)

Using a flat blade screw driver, remove the l ift arm by-
3
pass orifice (Item 1) [Figure 20-41-33] & [Figure 20-41-
34].

Orifice size is 0.078 inch. 2

1
Reverse the removal procedure to install the lift arm by-
pass orifice.

BICS™ Valve, Check Valve Removal and Installation

N-18684

Figure 20-41-35
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-41-36].

Install new O-rings (Item 1) and back-up ring (Item 2)

[Figure 20-41-36] on the check valve.

Dealer Copy -- Not for Resale

Check valve (Item 3) [Figure 20-41-36] has a rating of 5-
10 PSI.

Figure 20-41-37
1

N-18683 1

Remove the check valve (Item 1)[Figure 20-41-35].

Installation: Tighten the v alve to 20 f t.-lbs. (27 Nm)

torque.

P-8956

Clean and inspect the screen (Item 1) [Figure 20-41-37]

on the end of the valve.

Reverse the removal procedure to i nstall the

BICS™check valve.

753 Bobcat Loader

20-41-11 Service Manual
159 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-40
CONTROL SYSTEM) (ACS) (CONT'D)

BICS™ Valve, Lock Valve Removal and Installation

Figure 20-41-38

1
1

N-18689

Remove the lock valves (Item 1)[Figure 20-41-38],

[Figure 20-41-39] & [Figure 20-41-40] from the BICS]
N-18682 valve.

Installation: Tighten the lock valves to 25 ft.-lbs. (34 Nm)

Figure 20-41-39 torque.

Dealer Copy -- Not for Resale

Figure 20-41-41

1 1

N-18688 2
2
2 N-18690

Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-41-41] from both the tilt and lift lock valves.

Install new O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-41-41] on the tilt and lift lock valves.

Reverse the removal procedure to install the lock valve.

753 Bobcat Loader

20-41-12 Service Manual
160 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-44
CONTROL SYSTEM) (ACS) (CONT'D)

BICS™ Valve, Solenoid Removal and Installation

1
Figure 20-41-42

N-18692

Remove the solenoid cartridge (Item 1) [Figure 20-41-

44].
N-18691
Installation: Tighten the cartridge to 20 ft.-lbs. (27 Nm)
torque.
Remove the mounting nut (Item 1) [Figure 20-41-42]
from the solenoid cartridge.

Dealer Copy -- Not for Resale

Installation: Tighten the mounting nut to 53 in.-lbs. (6
Nm) torque.

Remove the solenoid (Item 2) [Figure 20-41-42].

NOTE: The solenoid resistance valve is (8-10 ohms).

Figure 20-41-43

N-18693A

Remove the O -rings (Item 1) [Figure 20-41-43] from

both ends of the solenoid.

753 Bobcat Loader

20-41-13 Service Manual
161 of 726
HYDRAULIC CONTROL VALVE (ADVANCED BICS™ Valve, Solenoid Testing
CONTROL SYSTEM) (ACS) (CONT'D)
Figure 20-41-46
BICS™ Valve, Solenoid Removal and Installation
(Cont’d)

Figure 20-41-45

3
2

P9175

1
Use an Ohm meter to measure coil resistance [Figure
N-18694 20-41-46].

Coil wires do not have polarity.

Remove the O-rings (Item 1) and back-up rings (Item 2)

Dealer Copy -- Not for Resale

[Figure 20-41-45] from the cartridge. Correct resistance for the au xiliary, lift and tilt lock coils
are 7.7 ohms
Clean all parts in solvent and dry with compressed air.
The other coils (BICS, diverter, select valve) are 7.5
Inspect all parts for wear and r eplace any showing ohms.
excessive wear.

NOTE: The screen (Item 3) [Figure 20-41-45] may be

cleaned with solvent. If it is torn or worn it
needs to be replaced.

Use only new O-rings and apply oil to al l O-rings and

back-up rings before installation.

Install new O-rings (Item 1) [Figure 20-41-43] & [Figure

20-41-45] and new back-up rings (Item 2) [Figure 20-41-
45] on the solenoid cartridge.

753 Bobcat Loader

20-41-14 Service Manual
162 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-47
CONTROL SYSTEM) (ACS) (CONT'D)
H3 H2 H1
Identification Chart (AHC)

ITEM 753 AHC LOADER

C4
A1 Lift Cylinder Base End/Restrictor B3 A3
G3 D3
A2 Tilt Cylinder Base End C3
G2 B2 A2 E2 D2
A3 Auxiliary Hydraulics
C2
B1 Lift Cylinder Rod End F2
G1 B1 A1 E1 D1
B2 Tilt Cylinder Rod End F1 C1
MR
B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function MC-2419
C2 Load Check Valve/Tilt Function
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Centering Spring
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs

Dealer Copy -- Not for Resale

E1 Port Relief Valve-3500 PSI
E2 Anti-Cavitation/Port Relief Valve-3500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve-3500 PSI
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional)-3500 PSI
H3 Auxiliary Electric Solenoid
MR Main Relief Valve-2600 PSI

753 Bobcat Loader

20-41-15 Service Manual
163 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-48
CONTROL SYSTEM) (ACS) (CONT'D)
H3 H2 H1
Identification Chart (ACS)

ITEM 753 ACS LOADER

A1 Lift Cylinder Base End/Restrictor
C41
A2 Tilt Cylinder Base End B3 A3 D3
A3 Auxiliary Hydraulics G3
C3 D2
B1 Lift Cylinder Rod End G2 B2 A2 E2
B2 Tilt Cylinder Rod End F2 C2
G1 B1 A1 E1 D1
B3 Auxiliary Hydraulics F1 C1
C1 Load Check Valve/Lift Function MR
PE-1339
C2 Load Check Valve/Tilt Function
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Centering Spring
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs

Dealer Copy -- Not for Resale

E1 Port Relief Valve-3500 PSI
E2 Anti-Cavitation/Port Relief Valve-3500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve-3500 PSI
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional)-3500 PSI
H3 Auxiliary Electric Solenoid
MR Main Relief Valve-2600 PSI

753 Bobcat Loader

20-41-16 Service Manual
164 of 726
HYDRAULIC CONTROL VALVE (ADVANCED
CONTROL SYSTEM) (ACS) (CONT'D)

Lift Base End Restrictor IMPORTANT

Figure 20-41-49 When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1

Figure 20-41-51

N-21159

1
Remove the BICS valve assembly from the control valve.
(See BICS™ Valve, Removal And Installation on Page

Dealer Copy -- Not for Resale

20-41-9.)

Remove the restrictor (Item 1) [Figure 20-41-49] from

the lift section base end port. N-19100

Load Check Valve

Mark each valve section, spool and related parts so that
they will be returned to their original valve section during
Figure 20-41-50
assembly.

Use bolts to fasten the control valve to a work bench for

easier disassembly and assembly procedures.

1 1 Loosen the load check valve plugs (Item 1) [Figure 20-

41-51].

1 Installation: Always use new O-ring. tighten the plug to

1
35-40 ft.-lbs. (47-54 Nm) torque.

2
N-19099

Remove the BICS valve assembly from the control valve.

(See BICS™ Valve, Removal And Installation on Page
20-41-9.)

Remove the four large O-rings (Item 1) and small O-ring

(Item 2)[Figure 20-41-50]. Always replace these O-rings
before installing the BICS valve assembly

753 Bobcat Loader

20-41-17 Service Manual
165 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Main Relief Valve
CONTROL SYSTEM) (ACS) (CONT'D)
Figure 20-41-54
Load Check Valve (Cont’d)

Figure 20-41-52

1
1

N-19034

3
2 N-19101 Loosen the main relief valve (Item 1) [Figure 20-41-54].

Figure 20-41-55
Remove the load check plugs (Item 1) [Figure 20-41-52].

Dealer Copy -- Not for Resale

Remove the spring (Item 2) and poppet (Item 3) [Figure
20-41-52].

Figure 20-41-53

N-19035

Remove the main relief valve (Item 1) [Figure 20-41-55].

2

N-19102

The auxiliary section (Item 1) uses an orifice load check

poppet (Item 2) [Figure 20-41-53].

753 Bobcat Loader

20-41-18 Service Manual
166 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-57
CONTROL SYSTEM) (ACS) (CONT'D)

Main Relief Valve (Cont’d)

Figure 20-41-56

1
2
3 4
1
1

B-06764

1. Relief Valve
2. O-ring
3. Sleeve N-19000

4. Glide Ring
5. O-ring
Figure 20-41-58

CD-15092

Remove the O-rings, sleeve, and glide ring from the main
relief valve [Figure 20-41-56]. 1

Dealer Copy -- Not for Resale

Installation: Always use new O-rings, sleeve, and glide
ring. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.

Port Relief Valve

N-19034

Loosen the port relief valve (Item 1) [Figure 20-41-57] & [Figure 20-41-58] (Port E1 or F2).
(See Port Relief Valve on Page 20-40-19.)
Installation: Always use new O-rings and back-up HYDRAULIC CONTROL VALVE (ADVANCED
washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque. CONTROL SYSTEM) (ACS) (CONT'D)

Figure 20-41-59 Port Relief Valve (Cont’d)

Figure 20-41-60

4
3

2
1
1

1. O-ring
2. Back-up Washer
3. O-ring
4. Relief Valve
N-18981

N-18844
Remove the port relief valve (Item 1) [Figure 20-41-59].
753 Bobcat Loader
20-41-19 Service Manual
167 of 726
Remove and install new O-rings and check back-up Figure 20-41-63
washer from the port relief valve [Figure 20-41-60].

Anti-Cavitation Valve/Port Relief Valve

Figure 20-41-61
1

N-18843

Remove and install new O-rings (Item 1) [Figure 20-41-

63] from the anti-cavitation/port relief valve.
N-19003

Loosen the anti-cavitation valve (Item 1) [Figure 20-41-

Dealer Copy -- Not for Resale

61].

Installation: Always use new O-rings and back-up

washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.

Figure 20-41-62

N-18980

Remove the anti-cavitation/port relief valve (Item 1)

[Figure 20-41-62] from the control valve for the til t
section.

753 Bobcat Loader

20-41-20 Service Manual
168 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-66
CONTROL SYSTEM) (ACS) (CONT'D) 1 3 4
2

Anti-Cavitation Valve

Figure 20-41-64

E-1509
1

1. Anti-Cavitation Valve
2. O-ring
3. Back-up Washer
4. O-ring

N-18839

Remove and install new O-rings and check back-up

washer from the anti-cavitation valve [Figure 20-41-66].
N-19034

Figure 20-41-65

Dealer Copy -- Not for Resale

1

N-19036

Remove the anti-cavitation valve (Item 1) [Figure 20-41-

64] and (Item 1) [Figure 20-41-65] from the control
valve.

753 Bobcat Loader

20-41-21 Service Manual
169 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-67
CONTROL SYSTEM) (ACS) (CONT'D)

Lift Spool Removal And Installation

1
N-19112

Remove the actuator (Item 1) [Figure 20-41-67] from the control valve. (See Lift Spool
Removal And Installation on Page 20-41-22.)
Figure 20-41-68 Figure 20-41-69

Dealer Copy -- Not for Resale

1

N-19003 N-18983

Remove the screws (Item 1) [Figure 20-41-68] from the Remove the spool assembly (Item 1)[Figure 20-41-69]
cap. and seal from the control valve.

Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3 Assembly: Always use a new spool seal and new O-
Nm) torque. rings.

753 Bobcat Loader

20-41-22 Service Manual
170 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-72
CONTROL SYSTEM) (ACS) (CONT'D)

Tilt Spool Removal And Installation

Figure 20-41-70
1

N-18985

Remove the spool assembly (Item 1) [Figure 20-41-72]

and seal from the control valve.
N-19112
Assembly: Always use a new spool seal and new O-
rings.
Remove the actuators (Item 1) [Figure 20-41-70] from
the control valve. (See Actuator Removal And Installation

Dealer Copy -- Not for Resale

on Page 20-41-8.)

Figure 20-41-71

1
1

N-19003

Remove the screws (Item 1) [Figure 20-41-71] from the

end cap.

Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3

Nm) torque.

753 Bobcat Loader

20-41-23 Service Manual
171 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-75
CONTROL SYSTEM) (ACS) (CONT'D)

Lift And Tilt Spool Disassembly And Assembly 2 1

3
Figure 20-41-73
4

N-18944A

NOTE: The centering spring (Item 3) [Figure 20-41-75]

is white on all 700 series loaders.
N-18942
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-41-75].
Put the linkage end of the spool in t he vice [Figure 20-
41-73].

Dealer Copy -- Not for Resale

Figure 20-41-76
Install the spool tool (Item 1) [Figure 20-41-73] over the
2
centering spring.
1
Figure 20-41-74

N-18943 N-18943

Remove the spool seal (Item 1) and the back-up washer

(Item 2) [Figure 20-41-76].
N-19014
Assembly: Always use a new spool seal.

Remove the bolt (Item 1) [Figure 20-41-74] holding the

centering spring to the spool.

Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3

Nm) torque.

Remove spring tool from the spring assembly.

753 Bobcat Loader

20-41-24 Service Manual
172 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-79
CONTROL SYSTEM) (ACS) (CONT'D)

Auxiliary Spool Removal And Installation

Figure 20-41-77 1

1
N-18988

Remove the spool (Item 1) [Figure 20-41-79].

N-19003 Assembly: Put grease on all the centering spring

component parts.
Remove the screws (Item 1) [Figure 20-41-77] from the
end cap (both sides).

Dealer Copy -- Not for Resale

Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.

Figure 20-41-78

N-18987

Remove the end cap, O-ring, springs and washer (both

sides) [Figure 20-41-78].

Assembly: Always use a new spool seal and new O-

rings

753 Bobcat Loader

20-41-25 Service Manual
173 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-82
CONTROL SYSTEM) (ACS) (CONT'D)

Auxiliary Electric Solenoid

Figure 20-41-80

3 2

1 N-18992

Remove the coil (Item 1) and end plate (Item 2) [Figure

1 20-41-82].
N-18996
Remove the solenoid valve (Item 3) [Figure 20-41-82].
Remove the nut (Item 1) [Figure 20-41-80] from both Installation: Tighten valve to 8-12 ft.-lbs. (11-16 Nm)
solenoids.

Dealer Copy -- Not for Resale

torque.
Installation: Tighten the nut to 8 -12 ft.-lbs. (11-16 Nm) Figure 20-41-83
torque.

Figure 20-41-81

1
N-18795

N-18823 Remove and install new O-rings (Item 1) [Figure 20-41-

83] on the solenoid valves.

Remove the end plate (Item 1) and housing (Item 2)

[Figure 20-41-81].

753 Bobcat Loader

20-41-26 Service Manual
174 of 726
HYDRAULIC CONTROL VALVE (ADVANCED Figure 20-41-86
CONTROL SYSTEM) (ACS) (CONT'D)

Port-Auxiliary Section Port Relief (Optional)

Figure 20-41-84

1 2

N-18843
1

Remove the O -rings (Item 1) [Figure 20-41-85] &

[Figure 20-41-86] and back-up ring (Item 2) [Figure 20-
N-18996 41-85] & [Figure 20-41-86] from the plug.

Cleaning And Inspection

Remove the plug (Item 1) [Figure 20-41-84] or optional
port relief valve from the control valve.

Dealer Copy -- Not for Resale

Clean all components with clean solvent and dry with
compressed air.
NOTE: Optional port relief (Item 1) [Figure 20-41-84]
is 3500 PSI. Check the spools for wear or scratches.
Figure 20-41-85 Check that the spools are not loose in their bore.

Plug Check that the centering springs are not broken.

Check that the load check valve seats are not worn.
2
Check the load check poppets for damage.

Check the rubber boots and retainers.

Replace the parts as needed.

1
Use new O-rings and back-up rings.
1
Apply oil to all new O-rings and back-up rings before
N-18800 installation.

753 Bobcat Loader

20-41-27 Service Manual
175 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

20-41-28 Service Manual
176 of 726
LIFT ARM BY-PASS CONTROL VALVE Figure 20-50-1

Inspecting
2

WARNING
4
Never work on a machine with the lift arms up unless 1
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment 5
to fall and cause injury or death.
W-2059-0598

P-43322
Raise the lift arms 6 feet (2 m) off the ground. Stop the
engine. Turn the Lift Arm By-Pass Control Knob
clockwise 1/4 turn. Then pull up and hold the Lift Arm By- Raise the operator cab. (See Raising The Operator Cab
Pass Control Knob while the lift arms slowly lower. on Page 10-30-1.)

Removal And Installation The lift lock by-pass valve (Item 1) [Figure 20-50-1] is
located under the right side of the control panel.
Install jackstands under the rear corners of the loader.

Dealer Copy -- Not for Resale

Hold the by-pass control knob (Item 2) and loosen the
Raise the lift arms and install an approved lift arm jam nut (Item 3) [Figure 20-50-1] on the b y-pass valve
support device. (See Installing Lift Arm Support Device shaft.
on Page 10-20-1.)
Remove the by-pass control knob and jam nut from the
valve shaft.

Remove the rubber washer (Item 4) [Figure 20-50-1].

Disconnect the two tub elines (Item 5) [Figure 20-50-1]

from the lift lock by-pass valve.

Cap or plug all open hydraulic connections.

753 Bobcat Loader

20-50-1 Service Manual
177 of 726
LIFT ARM BY-PASS CONTROL VALVE (CONT’D) Disassembly And Assembly

Removal And Installation (Cont’d) Figure 20-50-3

Figure 20-50-2

1
P-43324

P-43323
Remove the by-pass valve (Item 1) [Figure 20-50-3] from
the valve block. Inspect the by-pass valve for damage
Remove the two mounting bolts (Item 1) [Figure 20-50- and replace if necessary.
2].

Dealer Copy -- Not for Resale

Installation: Tighten the valve to 33 -37 ft.-lbs. (45-50
Installation: Tighten the mounting bolts to 180-200 in.- Nm) torque.
lbs. (21-23 Nm) torque.
Inspect the hydraulic fittings on t he valve block for
Remove the lift arm by-pass valve. damage and replace if necessary.

753 Bobcat Loader

20-50-2 Service Manual
178 of 726
HYDRAULIC PUMP (ALUMINUM) Figure 20-60-1

Checking The Output Of The Hydraulic Pump

The tools listed will be nee ded to do the fol lowing

procedure:
2
MEL1563 - Remote Start Tool
MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit 1

WARNING
N-15482
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 Disconnect the OUTLET hose (Item 1) from the OUTLET
fall or move and cause injury or death. fitting (Item 2) [Figure 20-60-1] on the pump.
W-2017-0286

Figure 20-60-2
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)

Dealer Copy -- Not for Resale

Raise the lift arms and install an approved lift arm 1
support device. (See Installing Lift Arm Support Device 2
on Page 10-20-1.)

WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
P-28826
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 Connect the INLET hose (Item 1) [Figure 20-60-2] from
the tester to the OUTLET fitting (Item 2) [Figure 20-60-1]
Raise the operator cab. (See Raising The Operator Cab of the pump. Connect the OUTLET hose (Item 2) [Figure
on Page 10-30-1.) 20-60-2] from the tester to the hose (Item 1) [Figure 20-
60-1] which was disconnected from the pump.
Open the rear door of the loader.

Connect the remote start switch. (See REMOTE START

on Page 10-60-1.)
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

753 Bobcat Loader

20-60-1 Service Manual
179 of 726
HYDRAULIC PUMP (ALUMINUM) (CONT’D) Removal And Installation

Check The Output Of The Pump (Cont'd)

Figure 20-60-3

EXAMPLE: TESTER
Reservoir CONNECTION

Hydraulic Pump WARNING

Out In
Hydraulic Control
Valve Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
1 support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
B-16277
to fall and cause injury or death.
W-2059-0598
Sample tester connection shown [Figure 20-60-3].
Raise the lift arms and install an approved lift arm
Start the engine and run at low idle RPM. Make sure the

Dealer Copy -- Not for Resale

support device. (See Installing Lift Arm Support Device
tester is connected correctly. If no flow is indicated on the on Page 10-20-1.)
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to f ull Stop the engine. Move the hydraulic controls to release
RPM*. the hydraulic pressure.

Warm the fluid to 140°F. (60°C.) by turning the restrictor Raise the seat bar.
control (Item 1) [Figure 20-60-3] on the te ster to about
1000 PSI (6895 kPa). DO NOT exceed system relief Lift and block the rear of the loader. (See LIFTING AND
pressure. Open the restrictor control and record the free BLOCKING THE LOADER on Page 10-10-1.)
flow (GPM) at full RPM.
Raise the operator cab. (See Raising The Operator Cab
Push the maximum/variable flow switch (on the remote on Page 10-30-1.)
start tool) to en gage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right steering
lever) for fluid flow to the quick coupler (fluid pressure will
go over main relief). Record the hi ghest pressure (PSI)
and flow (GPM). The high pressure flow must be at least
80% of free flow.

HIGH PRESSURE FLOW (GPM)

%= x100
FREE FLOW (GPM)

A low percentage may indicate a failed pump.

*Refer to SPECIFICATIONS Section SPEC-01 for system

relief pressure and full RPM.

753 Bobcat Loader

20-60-2 Service Manual
180 of 726
HYDRAULIC PUMP (ALUMINUM) (CONT’D) Figure 20-60-6

Removal And Installation (Cont’d)

Figure 20-60-4
2

1
N-20873

Disconnect the inlet hose (Item 1) from the hydraulic

N-20871 pump (Item 2) [Figure 20-60-6].

Disconnect the h ydraulic pump outlet tubeline (Item 3)

Disconnect the case drain hose (Item 1) [Figure 20-60-4] [Figure 20-60-6] from the outlet fitting.
from the right drive motor.

Dealer Copy -- Not for Resale

Figure 20-60-7
Drain the hydraulic fluid (using the case drain hose) from
the reservoir.

Figure 20-60-5
1

N-22037

Remove the two mounting bolts (Item 4) [Figure 20-60-6]

N-20869 & (Item 1) [Figure 20-60-7] from the hydraulic pump with
a 5/16 inch allen wrench.

Disconnect the h ydraulic pump inlet hose (Item 1) NOTE: The allen wrench will need to be modified for
[Figure 20-60-5] from the reservoir and drain as much the procedure.
fluid from the ho se as possible. Reconnect the ho se to
the reservoir. Installation: Tighten the mounting bolts to 27-37 ft.-lbs.
(37-50 Nm) torque.

Remove the hydraulic pump from the hydrostatic pump.

753 Bobcat Loader

20-60-3 Service Manual
181 of 726
HYDRAULIC PUMP (ALUMINUM) (CONT’D) Figure 20-60-8

Removal And Installation (Cont'd)

Remove the coupler (Item 1) [Figure 20-60-8] from the

hydraulic pump shaft.

Remove the large O-ring (Item 2) [Figure 20-60-8].

Installation: Use a new O-ring when installing the

hydraulic pump.

WARNING 2
N-22036

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

Parts Identification

Dealer Copy -- Not for Resale

1. BOLT
2. END HOUSING
3. O.-RING SEAL
4. SEAL
5. RING
6. BODY
7. BEARING HOUSING
8. DRIVE GEAR
1 9. IDLER GEAR
2 10. BOLT
3 11. END HOUSING
4 12. RETAINER RING
5 6 13. O.-RING

9
7 5
4
10 12

11 13

TS-2046B

753 Bobcat Loader

20-60-4 Service Manual
182 of 726
HYDRAULIC PUMP (ALUMINUM) (CONT’D) Figure 20-60-10

Disassembly And Assembly

1

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

2 N-22024
Figure 20-60-9

Remove the end housing (Item 1) [Figure 20-60-10].

Remove the O-ring (Item 2) [Figure 20-60-10].

Figure 20-60-11
1

Dealer Copy -- Not for Resale

1

1 1

N-22023

Mark the pump sections for correct assembly [Figure 20-

60-9].

Remove the pump housing bolts (Item 1) [Figure 20-60- N-22025

9].

Installation: Tighten bolts to 35 ft.-lbs. (47,5 Nm) torque. Remove the bearing housing (Item 1) [Figure 20-60-11]
from the pump body.

753 Bobcat Loader

20-60-5 Service Manual
183 of 726
HYDRAULIC PUMP (ALUMINUM) (CONT’D) Figure 20-60-14

Disassembly And Assembly (Cont'd)

1
Figure 20-60-12

2 1

2 N-22027

Remove the other end bearing housing (Item 1) [Figure

N-21918 20-60-14].

Remove the O-ring (Item 2) [Figure 20-60-14].

Remove the seal (Item 1) and back-up seal (Item 2)
[Figure 20-60-12] from the bearing housing. Figure 20-60-15

Dealer Copy -- Not for Resale

Figure 20-60-13

2 N-22028

N-22026
Remove the bearing housing (Item 1) [Figure 20-60-15]
from the pump body.
Remove the dr ive gear (Item 1) and i dler gear (Item 2)
[Figure 20-60-13].

753 Bobcat Loader

20-60-6 Service Manual
184 of 726
HYDRAULIC PUMP (ALUMINUM) (CONT’D) Figure 20-60-18

Disassembly And Assembly (Cont'd)

Figure 20-60-16

1 2

N-22026A

Check the gear(s) for wear [Figure 20-60-18].

N-22031
Figure 20-60-19

Remove the seal (Item 1) and back-up seal (Item 2)

[Figure 20-60-16] from the bearing housing.

Dealer Copy -- Not for Resale

Inspection

Figure 20-60-17

N-22031

Check the b ushings in the bearing housing [Figure 20-

60-19].

If excessive wear or damage is visible on any of th e

N-22028A parts, the pump must be replaced.

Reverse the disassembly procedure to as semble the

Wash all parts in clean solvent and use air pressure to hydraulic pump.
dry them.

Check the body [Figure 20-60-17].

753 Bobcat Loader

20-60-7 Service Manual
185 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

20-60-8 Service Manual
186 of 726
HYDRAULIC PUMP (CAST IRON) Figure 20-61-1

Check The Output Of The Hydraulic Pump Without

Power Bob-Tach

1
WARNING
Put jackstands under the front axles and rear corners 2
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

P-37545

WARNING Disconnect the O UTLET hose (Item 1) from the fitting

(Item 2) [Figure 20-61-1].
Never work on a machine with the lift arms up unless
Figure 20-61-2
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment

Dealer Copy -- Not for Resale

to fall and cause injury or death.
W-2059-0598

The tools listed will be nee ded to do the fol lowing

procedure:
2 1
MEL1563 - Remote Start Tool
MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit

Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.) P-37416

Raise the lift arms and install an approved lift arm

support device. (See Installing Lift Arm Support Device Place the hydraulic tester as shown in [Figure 20-61-2].
on Page 10-20-1.)
Route the inlet hose (Item 1) [Figure 20-61-2] from the
Raise the operator cab. (See Raising The Operator Cab tester, between the hydraulic reservoir and the blower
on Page 10-30-1.) housing to the gear pump.

Open the rear door of the loader.

Connect the remote start tool. (See REMOTE START on

Page 10-60-1.)

753 Bobcat Loader

20-61-1 Service Manual
187 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D)

Check The Output Of The Hydraulic Pump Without

Power Bob-Tach (Cont'd) IMPORTANT
Figure 20-61-3 The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

Figure 20-61-5
EXAMPLE: TESTER
1
CONNECTION
Reservoir
2

Hydraulic Pump
Out In
P-37418
Hydraulic Control
Valve
Connect the INL ET hose (Item 1) [Figure 20-61-2] & 1
[Figure 20-61-3] from the tes ter to the O UTLET fitting

Dealer Copy -- Not for Resale

B-16277
(Item 2) [Figure 20-61-3] on the pump.

Figure 20-61-4 Sample tester connection shown [Figure 20-61-5].

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*.

2 Warm the fluid to 140°F. (60°C.) by turning the restrictor

1
control (Item 1) [Figure 20-61-5] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM.

Turn the restrictor control (Item 1) [Figure 20-61-5] on

P-37417
the tester to the system relief pressure.

Connect the OUTLET hose (Item 2) [Figure 20-61-2] & NOTE: Do not exceed system relief pressure,
[Figure 20-61-4] from the tester to the hose (Item 1) damage to the hydraulic system may occur if
[Figure 20-61-4] which was disconnected from the gear pressure is exceeded.
pump.
Record the flow (GPM) at system relief pressure. The
high pressure flow must be at least 80% of free flow.

%= HIGH PRESSURE FLOW (GPM) X100

FREE FLOW (GPM)

A low percentage may indicate a failed pump.

*Refer to SPECIFICATIONS Section SPEC-01 for system

relief pressure and full RPM.
753 Bobcat Loader
20-61-2 Service Manual
188 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D) Figure 20-61-6

Check The Output Of The Hydraulic Pump With

Power Bob-Tach.
1

WARNING
2
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

P-37330

WARNING Disconnect the O UTLET hose (Item 1) from the fitting

(Item 2) [Figure 20-61-6].
Never work on a machine with the lift arms up unless
Figure 20-61-7
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment

Dealer Copy -- Not for Resale

to fall and cause injury or death.
W-2059-0598

The tools listed will be nee ded to do the fol lowing

procedure:
2 1
MEL1563 - Remote Start Tool
MEL10103 - Hydraulic Tester
MEL10106 - Hydraulic Test Kit

Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.) P-37416

Raise the lift arms and install an approved lift arm

support device. (See Installing Lift Arm Support Device Place the hydraulic tester as shown in [Figure 20-61-7].
on Page 10-20-1.)
Route the inlet hose (Item 1) [Figure 20-61-7] from the
Raise the operator cab. (See Raising The Operator Cab tester, between the hydraulic reservoir and the blower
on Page 10-30-1.) housing to the gear pump.

Open the rear door of the loader.

Connect the remote start tool. (See REMOTE START on

Page 10-60-1.)

753 Bobcat Loader

20-61-3 Service Manual
189 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D)

Check The Output Of The Hydraulic Pump With

Power Bob-Tach. (Cont'd) IMPORTANT
Figure 20-61-8 The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284

1 Figure 20-61-10
EXAMPLE: TESTER
CONNECTION
Reservoir

Hydraulic Pump
Out In
P-37415
Hydraulic Control
Valve
Connect the INL ET hose (Item 1) [Figure 20-61-7] & 1
[Figure 20-61-8] from the tes ter to the O UTLET fitting

Dealer Copy -- Not for Resale

B-16277
(Item 2) [Figure 20-61-8] on the Power Bob-tach block.

Figure 20-61-9 Sample tester connection shown [Figure 20-61-10].

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*.

2 Warm the fluid to 140°F. (60°C.) by turning the restrictor

1
control (Item 1) [Figure 20-61-10] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM.

Turn the restrictor control (Item 1) [Figure 20-61-10] on

P-37417
the tester to the system relief pressure.

Connect the OUTLET hose (Item 2) [Figure 20-61-7] & NOTE: Do not exceed system relief pressure,
[Figure 20-61-9] from the tester to the hose (Item 1) damage to the hydraulic system may occur if
[Figure 20-61-9] which was disconnected from the pressure is exceeded.
Power Bob-tach block.
Record the flow (GPM) at system relief pressure. The
high pressure flow must be at least 80% of free flow.

%= HIGH PRESSURE FLOW (GPM) X100

FREE FLOW (GPM)

A low percentage may indicate a failed pump.

*Refer to SPECIFICATIONS Section SPEC-01 for system

relief pressure and full RPM.
753 Bobcat Loader
20-61-4 Service Manual
190 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D) Figure 20-61-11

Removal And Installation

4 2
3

N-21044

WARNING
Remove the nut from the speed control linkage (Item 1)
Never work on a machine with the lift arms up unless [Figure 20-61-11].
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Unplug the rear lights electrical connector (Item 2)
support device can allow the lift arms or attachment [Figure 20-61-11].
to fall and cause injury or death.

Dealer Copy -- Not for Resale

W-2059-0598 Remove the belt shield mounting bolts (Item 3) [Figure
20-61-11].
Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device Remove the belt shield.
on Page 10-20-1.)
Remove the coolant recover tank and mount (Item 4)
Stop the engine. Raise the seat bar. [Figure 20-61-11].

Lift and block the loader. (See LIFTING AND BLOCKING Figure 20-61-12
THE LOADER on Page 10-10-1.)

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

Drain the hydraulic fluid from the reservoir. (See 1

Replacing Hydraulic Fluid on Page 10-120-3.)

Remove the hydraulic fluid reservoir from the loader.

(See Housing Removal And Installation on Page 20-70-
1.)

Open the rear door of the loader.

Remove the Power Bob-Tach block if so equipped. (See P-37545

Removal And Installation on Page 20-110-1.)

Disconnect and cap the outlet hose (Item 1) [Figure 20-

61-12] from the back of the hydraulic pump.

753 Bobcat Loader

20-61-5 Service Manual
191 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D) Figure 20-61-15

Removal And Installation (Cont’d)

Figure 20-61-13

1
1

P-37357

Remove the inlet hose (Item 1) [Figure 20-61-15] from

P-37334 the front of the hydraulic pump.

Figure 20-61-16
Remove the right rear engine mount (Item 1) [Figure 20-
61-13].

Dealer Copy -- Not for Resale

Installation: Tighten the engine mount bolt to 70 ft.-lbs.
(95 Nm) torque.

Figure 20-61-14

P-37353

1 Loosen the hose clamps and remove the f uel fill hose
(Item 1) and the fuel vent hose (Item 2) from the loader
[Figure 20-61-16]

N-19423

Remove the left rear engine mount (Item 1) [Figure 20-

61-14].

Installation: Tighten the engine mount bolt to 70 ft.-lbs.

(95 Nm) torque.

753 Bobcat Loader

20-61-6 Service Manual
192 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D) Figure 20-61-19

Removal And Installation (Cont’d)

Figure 20-61-17

1
1
N-21114

Loosen the left front engine mount (Item 1) [Figure 20-

P-37338 61-19] but do not remove.

Installation: Tighten the engine mount bolt to 70 f t.-lbs.

Remove the engine speed control rod and the rod guide (95 Nm) torque.
(Item 1) [Figure 20-61-17].

Dealer Copy -- Not for Resale

Figure 20-61-20
Figure 20-61-18

P-37339
P-37352

Use a port-a-power (Item 1) [Figure 20-61-20] to push

Remove the right front engine mount (Item 1) [Figure 20- the engine/hydrostatic pump assembly away from the
61-18]. mainframe.

Installation: Tighten the engine mount bolt to 70 ft.-lbs. NOTE: A shaft (Item 2) [Figure 20-61-20] with the
(95 Nm) torque. dimensions of 1.5” diameter by 2.125” long
will be needed to push the engine/hydrostatic
pump assembly.

NOTE: Push the engine/hydrostatic pump assembly

only as far as needed to remove the gear
pump.

753 Bobcat Loader

20-61-7 Service Manual
193 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D)

Removal And Installation (Cont’d) Figure 20-61-22

Figure 20-61-21

P-26347

1 2
1

P-26347

P-37336
Remove the O-ring (Item 1) [Figure 20-61-22].

Remove the two mounting bolts (Item 1) [Figure 20-61- Remove the coupler (Item 2) [Figure 20-61-22] from the
21] from the hydraulic pump. hydraulic pump shaft.

Dealer Copy -- Not for Resale

Installation: Tighten the mounting bolts to 2 7-37 ft.-lbs. Reverse the removal procedure to i nstall the hydraulic
(37-50 Nm) torque. pump.

Remove the hydraulic pump (Item 2) [Figure 20-61-21] Installation: Use a ne w O-ring (Item 1) [Figure 20-61-
from the loader. 22] when installing the hydraulic pump.

753 Bobcat Loader

20-61-8 Service Manual
194 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D)

Identification

15

8
7

Dealer Copy -- Not for Resale

6

14

12
13
11
7 9 10
1 4 5
3

B-16050A

REF. DESCRIPTION REF. DESCRIPTION

1 RETAINING RING 9 IDLER GEAR
2 PUMP END SECTION 10 PUMP SECTION
3 PRE-LOAD SEAL 11 WEAR PLATE
4 LOAD SEAL 12 SECTION SEAL
5 SECTION SEAL 13 PUMP END SECTION
6 WEAR PLATE 14 BOLT (4)
7 PINS 15 BOLT (4)
8 DRIVE GEAR

753 Bobcat Loader

20-61-9 Service Manual
195 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D) Figure 20-61-24

Disassembly And Assembly

1
Figure 20-61-23

P-26352
2

2
P-26353
1

Remove the pump end section (Item 1) [Figure 20-61-

P-26351 24].

Mark the pump sections for correct assembly [Figure 20-

61-23].

Dealer Copy -- Not for Resale

Remove the four smaller pump housing bolts (Item 1)
[Figure 20-61-23].

Remove the four larger pump housing bolts (Item 2)

[Figure 20-61-23].

Installation: Tighten the four smaller bolts (Item 1) to 30

ft.-lbs. (40,7 Nm) torque. Tighten the four larger bolts
(Item 2) [Figure 20-61-23] to 54 ft.-lbs. (73,2 Nm) torque.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

753 Bobcat Loader

20-61-10 Service Manual
196 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D) Figure 20-61-27

Disassembly And Assembly (Cont'd)

Figure 20-61-25 1

P-26358

2
Figure 20-61-28
P-26354

1
Figure 20-61-26

Dealer Copy -- Not for Resale

4
3

1
P-26359

2 Remove the pump center section (Item 1) [Figure 20-61-

P-26355 27] & [Figure 20-61-28] from the pump end section.

NOTE: Inspect the pump center section (Item 1)

Remove the we ar plate (Item 1) [Figure 20-61-25] & [Figure 20-61-28]. If excessive wear or
[Figure 20-61-26] and section seal (Item 2) [Figure 20- damage is visible, the pump must be
61-25] & [Figure 20-61-26] from the pump end section. replaced.

NOTE: Position wear plate (Item 1) [Figure 20-61-26]

inlets and traps as shown with bronze side
toward gears.

NOTE: Inspect the pump end section (Item 3) and

bushings (Item 4) [Figure 20-61-26]. If
excessive wear or damage is visible, the
pump must be replaced.

753 Bobcat Loader

20-61-11 Service Manual
197 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D) Figure 20-61-31

Disassembly And Assembly (Cont'd)

Figure 20-61-29

1
P-26391

Figure 20-61-32
P-26389

Figure 20-61-30

Dealer Copy -- Not for Resale

1

P-26362

1
1

P-26362

To remove the drive gear (Item 1) [Figure 20-61-31] from

P-26390 the pump end section, locate and remove the retaining
ring (Item 1) [Figure 20-61-32] from the spline end of the
drive gear.
Remove the idler gear (Item 1) [Figure 20-61-29] &
[Figure 20-61-30].

NOTE: Inspect the idler gear (Item 1) [Figure 20-61-

30]. If excessive wear or damage is visible, the
pump must be replaced.

753 Bobcat Loader

20-61-12 Service Manual
198 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D) Figure 20-61-35

Disassembly And Assembly (Cont'd)

Figure 20-61-33

P-26394

NOTE: Position wear plate (Item 1) [Figure 20-61-35]

P-26392 inlets and traps as shown with bronze side
toward gears.

Remove the dr ive gear (Item 1) [Figure 20-61-33] from Figure 20-61-36
the pump end section.

Dealer Copy -- Not for Resale

1
NOTE: Inspect the drive gear (Item 1) [Figure 20-61-
33]. If excessive wear or damage is visible, the
pump must be replaced.
P-26396
Figure 20-61-34
1

1 P-26395

Remove the load seal (Item 1) [Figure 20-61-36].

2

P-26393

Remove the we ar plate (Item 1) [Figure 20-61-34] &

[Figure 20-61-35] and section seal (Item 2) [Figure 20-
61-34] & [Figure 20-61-35] from the pump end section.

753 Bobcat Loader

20-61-13 Service Manual
199 of 726
HYDRAULIC PUMP (CAST IRON) (CONT'D)

Disassembly And Assembly (Cont'd)

Figure 20-61-37

P-26398

P-26397

Remove the pre-load seal (Item 1) [Figure 20-61-37].

Dealer Copy -- Not for Resale

Figure 20-61-38

P-26374

NOTE: Inspect the pump end section (Item 1) and

bushings (Item 2) [Figure 20-61-38] . If
excessive wear or damage is visible, the
pump must be replaced.

Reverse the disassembly procedure to assemble the

hydraulic pump.

753 Bobcat Loader

20-61-14 Service Manual
200 of 726
HYDRAULIC/HYDROSTATIC FILTER Figure 20-70-2

Housing Removal And Installation 1

2
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-28831
Stop the engine and open the rear door.

Figure 20-70-1 Disconnect the oil cooler tubeline (Item 1) [Figure 20-70-
2] from the filter housing.

Disconnect the hose (Item 2) [Figure 20-70-2] from the

filter housing outlet.

Dealer Copy -- Not for Resale

Figure 20-70-3

3
1
2

1 1

P-28830

Disconnect the charge pressure sender connector (Item

1), temperature sender connector (Item 2) and differential
pressure switch connector (Item 3) [Figure 20-70-1] from
the filter housing. P-28832

Remove the two mounting bolts (Item 1) [Figure 20-70-3]

from the filter housing mounting bracket.

Installation: Tighten the mounting bolts to 190-240 ins.-

lbs. (29,2-36,7 Nm) torque.

753 Bobcat Loader

20-70-1 Service Manual
201 of 726
HYDRAULIC/HYDROSTATIC FILTER (CONT’D)

Housing Removal And Installation (Cont’d)

Figure 20-70-4

1 1

P-28833

Remove the hydraulic filter housing (Item 1) [Figure 20-

70-4] from the mounting brackets.

Dealer Copy -- Not for Resale

Installation: Tighten the mounting bolts to 375-400 ins.-
lbs. (42,4-45,2 Nm) torque.

Remove the filter from the hydraulic filter housing.

Reverse the removal procedure to install the filter

housing and filter.

753 Bobcat Loader

20-70-2 Service Manual
202 of 726
HYDRAULIC FLUID RESERVOIR Figure 20-80-2

Removal And Installation

1
1

P-43185
WARNING
Mark and disconnect the hoses (Item 1) [Figure 20-80-2]
Never work on a machine with the lift arms up unless from the hydraulic fluid reservoir.
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Figure 20-80-3
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598

Dealer Copy -- Not for Resale

Start the engine. Raise the lift arms and install an
approved lift arm support device. (See Installing Lift Arm
Support Device on Page 10-20-1.)
1
Stop the engine.

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)
2
Figure 20-80-1
P-43186

Remove the hydraulic reservoir bracket (Item 1) by

removing the two mounting bolts (Item 2) [Figure 20-80-
3] .

Remove the reservoir.

P-43186

Drain the hydraulic fluid reservoir [Figure 20-80-1]. (See

Replacing Hydraulic Fluid on Page 10-120-3.)

753 Bobcat Loader

20-80-1 Service Manual
203 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

20-80-2 Service Manual
204 of 726
BUCKET POSITION VALVE Installation: Put oil on O-rings and back-up washers and
tighten the solenoid stem to 30-35 ft.-lbs. (40,8-47,6 Nm)
Solenoid Removal And Installation torque.

Figure 20-90-1 Figure 20-90-3

1 1
2
2

P-30526 N-18191

Raise the operator cab. (See Raising The Operator Cab Inspect the solenoid stem and replace the O-rings (Item
on Page 10-30-1.) 1) and the back-up washer (Item 2) [Figure 20-90-3].

Dealer Copy -- Not for Resale

Remove the Bobcat controller mount from the frame. Solenoid Testing
(See Removal And Installation on Page 60-70-4.)
Figure 20-90-4
Disconnect the wire harness connector (Item 1) [Figure
20-90-1] from the bucket position shutoff solenoid.

Remove the solenoid nut (Item 2) [Figure 20-90-1].

Installation: Tighten the solenoid nut to 60 in.-lbs. (6,78

Nm) torque.

Figure 20-90-2

P9175

Use a test meter to measure coil resistance [Figure 20-

90-4]. Coil wires do not have polarity. Correct resistance
for the coil is 5-8 ohms.

P-30527

Remove the solenoid stem (Item 1) [Figure 20-90-2]

from the bucket position valve.

753 Bobcat Loader

20-90-1 Service Manual
205 of 726
BUCKET POSITION VALVE (CONT’D) Figure 20-90-6

Removal And Installation

A
1 B

C
D

WARNING P-28882

Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm Disconnect tubelines (Item 1) [Figure 20-90-6] from the
support device. Failure to use an approved lift arm B, C, and D port.
support device can allow the lift arms or attachment
to fall and cause injury or death. Figure 20-90-7
W-2059-0598

Dealer Copy -- Not for Resale

Figure 20-90-5

1 1

P-28884

Disconnect tubeline (Item 1) [Figure 20-90-7] at te e

P-28883 fitting.

This line is connected to A port on bucket position valve.

Start the engine. Raise the lift arms and install an
approved lift arm support device. (See Installing Lift Arm
Support Device on Page 10-20-1.)

Stop the engine.

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

Disconnect solenoid connector harness (Item 1) [Figure

20-90-5].

753 Bobcat Loader

20-90-2 Service Manual
206 of 726
BUCKET POSITION VALVE (CONT’D) Figure 20-90-10

Removal And Installation (Cont’d)

Figure 20-90-8 2

N-19070

Remove the solenoid (Item 1) and the solenoid stem

P-28887 (Item 2) [Figure 20-90-10].

Installation: Tighten the s olenoid stem to 30-35 ft.-lbs.

Remove bucket position valve mounting bolts (Item 1) (40,8-47,6 Nm) torque.
[Figure 20-90-8]. Remove valve from loader.

Dealer Copy -- Not for Resale

Figure 20-90-11
Disassembly And Assembly

Figure 20-90-9

1
N-19072

N-19069 Remove the flow adjustment valve and O-ring (Item 1)

[Figure 20-90-11]

Remove the solenoid nut (Item 1) [Figure 20-90-9]. NOTE: Always install new O-rings before any parts
are installed into the valve. Check the parts
Installation: Tighten the nut to 60 in.-lbs. (6,78 Nm) for wear or damage and replace as needed.
torque.

753 Bobcat Loader

20-90-3 Service Manual
207 of 726
BUCKET POSITION VALVE (CONT’D) Figure 20-90-14

Disassembly And Assembly (Cont'd)

Figure 20-90-12

3
N-19042

Remove the tilt cylinder check valve (Item 1) spring (Item

N-19041 2) and plug (Item 3) [Figure 20-90-14]. Check for wear,
check the O-ring and replace as needed.

Remove the plug [Figure 20-90-12]. Figure 20-90-15

Dealer Copy -- Not for Resale

Figure 20-90-13

N-19045

N-18339
Remove the plug [Figure 20-90-15].

Remove the plug (Item 1), and flow control spool (Item 2)
[Figure 20-90-13].

Check the flow control spool for wear, check the O-ring
on the plug and replace as needed.

753 Bobcat Loader

20-90-4 Service Manual
208 of 726
BUCKET POSITION VALVE (CONT’D)

Disassembly And Assembly (Cont'd)

Figure 20-90-16

1
N-19046

Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-90-16].

Dealer Copy -- Not for Resale

Check all parts and replace as needed. Install a new O-
ring on the plug before installing.

Reverse the dissasembly procedure to assemble the

bucket position valve.

753 Bobcat Loader

20-90-5 Service Manual
209 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

20-90-6 Service Manual
210 of 726
REAR AUXILIARY DIVERTER VALVE (SINGLE Figure 20-100-1
SHUTTLE)

Removal And Installation

WARNING P-30004

Never work on a machine with the lift arms up unless Disconnect pilot line (Item 1) [Figure 20-100-1] from
the lift arms are secured by an approved lift arm diverter block.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Remove the battery. (See Removal And Installation on
to fall and cause injury or death. Page 60-20-1.)
W-2059-0598

Dealer Copy -- Not for Resale

Figure 20-100-2
NOTE: The single shuttle rear auxiliary diverter valve
is a silver color block.

Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.) 1

Raise the lift arms and install an approved lift arm

support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

Remove air cleaner. (See Removal And Installation on

Page 70-40-1.) P-30080

Remove drive belt shield. (See Shield Removal And

Loosen the bolt on clamp (Item 1) [Figure 20-100-2] to
Installation on Page 30-50-1.)
aid in tubeline removal.

753 Bobcat Loader

20-100-1 Service Manual
211 of 726
REAR AUXILIARY DIVERTER VALVE (SINGLE Figure 20-100-5
SHUTTEL) (CONT’D)

Removal And Installation (Cont'd)

1
Figure 20-100-3
3

2
P-30079

1
Disconnect the “Drain Line” (Item 1) [Figure 20-100-5]
from the control valve.
P-30075
Disconnect tubeline (Item 2) [Figure 20-100-5] from “P1”
port.
Disconnect the yellow marked frame harness (item 1)
[Figure 20-100-3] from the yellow marked diverter

Dealer Copy -- Not for Resale

Disconnect tubeline (Item 3) [Figure 20-100-5] from “P2”
harness. port.
Disconnect the green marked frame harness (Item 2) Figure 20-100-6
[Figure 20-100-3] from the gr een marked diverter
harness.

Figure 20-100-4
1

2
2

P-30084

1
Disconnect hose (Item 1) from diverter block. Remove
P-30076 fitting (Item 2) [Figure 20-100-6] from diverter valve.

Disconnect the hose (Item 1) [Figure 20-100-4] on “F1”

port.

Disconnect the hose (Item 2) [Figure 20-100-4] on the

“F2” port.

753 Bobcat Loader

20-100-2 Service Manual
212 of 726
REAR AUXILIARY DIVERTER VALVE (SINGLE Disassembly
SHUTTLE) (CONT’D)
Clean the diverter block to r emove dirt before
Removal And Installation (Cont'd) disassembly. Block ports are labeled for correct
assembly.
Figure 20-100-7

1 IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 20-100-9

P-30085

Disconnect hose (Item 1) [Figure 20-100-7] from diverter

block.

Dealer Copy -- Not for Resale

Figure 20-100-8

1
1 1
N-00527

Remove the l ogic cartridge valves from block ports LC1

and LC2 (Item 1) [Figure 20-100-9].

P-30086

Remove jam nuts (Item 1) [Figure 20-100-8].

Remove the diverter valve from the loader.

Reverse the removal procedure to install the diverter

valve.

753 Bobcat Loader

20-100-3 Service Manual
213 of 726
REAR AUXILIARY DIVERTER VALVE (SINGLE Inspection
SHUTTLE) (CONT’D)
Inspect cartridges, check valves, solenoid valves and
Disassembly (Cont’d) sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure for drying them.
Figure 20-100-10 Install new O-rings and back-up washers.

Inspect diverter block cavities for contamination. Wash

block in clean solvent. Use air pressure to dry.

Solenoid Testing

Figure 20-100-12

1
2
N-00529

Remove the pilot check valves from block ports PC1 and
PC2 (Item 1) [Figure 20-100-10].

Dealer Copy -- Not for Resale

Remove the s huttle check valve from block port SH1
(Item 2) [Figure 20-100-10].
P9137

Figure 20-100-11
Use a test meter to measure coil resistance [Figure 20-
100-12]. Coil wires do not have polarity. Correct
resistance is 6-9 ohms.
4
Replace the test meter with 12 v olt power. You can see
2 and hear the spool shift.
3 Assembly
5 2
Put oil on O-rings and back-up washers.
2
Tighten the Logic cartridge valves (Item 1) [Figure 20-
100-9] to 65 ft. lbs. (88 Nm) torque.
3
2 1 N-00528 Tighten the pilot check valves (Item 1), and shuttle check
valve (Item 2) [Figure 20-100-10] to 35 ft. lbs. (47 Nm)
torque.
Remove the nuts (Item 1), seal washers (Item 2), and
solenoid valve coils (Item 3) [Figure 20-100-11].
Tighten the s olenoid valves (Items 4 & 5) to 1 2 ft. lbs.
(16,3 Nm) torque. Install the se aling washers (Item 2)
Remove the diverter control solenoid valve (Item 4) from
and coils (Item 3). Tighten the nuts (Item 1) [Figure 20-
port SV1. Remove the pressure relieving solenoid valve
100-11] to 10 in. lbs. (1,13 Nm) torque.
(Item 5) [Figure 20-100-11] from block port SV2.

753 Bobcat Loader

20-100-4 Service Manual
214 of 726
REAR AUXILIARY DIVERTER VALVE (DUAL Figure 20-101-1
SHUTTLE)

Removal And Installation

WARNING P-30004

Never work on a machine with the lift arms up unless Disconnect pilot line (Item 1) [Figure 20-101-1] from
the lift arms are secured by an approved lift arm diverter block.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Remove the battery. (See Removal And Installation on
to fall and cause injury or death. Page 60-20-1.)
W-2059-0598

Dealer Copy -- Not for Resale

Figure 20-101-2
NOTE: The dual shuttle rear auxiliary diverter valve is
a gold color block.

Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.) 1

Raise the lift arms and install an approved lift arm

support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

Remove air cleaner. (See Removal And Installation on

Page 70-40-1.) P-30080

Remove drive belt shield. (See Shield Removal And

Loosen the bolt on clamp (Item 1) [Figure 20-101-2] to
Installation on Page 30-50-1.)
aid in tubeline removal.

753 Bobcat Loader

20-101-1 Service Manual
215 of 726
REAR AUXILIARY DIVERTER VALVE (DUAL Figure 20-101-5
SHUTTLE) (CONT’D)

Removal And Installation (Cont'd)

1
Figure 20-101-3
3

2
P-30079

1
Disconnect the dr ain hose (Item 1) [Figure 20-101-5]
from the control valve.
P-30075
Disconnect tubeline (Item 2) [Figure 20-101-5] from “P1”
port.
Disconnect the yellow marked frame harness (Item 1)
[Figure 20-101-3] from the yellow marked diverter

Dealer Copy -- Not for Resale

Disconnect tubeline (Item 3) [Figure 20-101-5] from “P2”
harness. port.
Disconnect the green marked frame harness (Item 2) Figure 20-101-6
[Figure 20-101-3] from the gr een marked diverter
harness.

Figure 20-101-4
1

2
2

P-30084

1
Disconnect hose (Item 1) from diverter block. Remove
P-30076 fitting (Item 2) [Figure 20-101-6] from diverter valve.

Disconnect the hose (Item 1) [Figure 20-101-4] on “F1”

port.

Disconnect the hose (Item 2) [Figure 20-101-4] on the

“F2” port.

753 Bobcat Loader

20-101-2 Service Manual
216 of 726
REAR AUXILIARY DIVERTER VALVE (DUAL Figure 20-101-8
SHUTTLE) (CONT’D)

Removal And Installation (Cont'd)

Figure 20-101-7

1
1

P-30086

Remove jam nuts (Item 1) [Figure 20-101-8].

P-30085 Remove the diverter valve from the loader.

Reverse the removal procedure to in stall the d iverter

Disconnect hose (Item 1) [Figure 20-101-7] from diverter valve.
block.

Dealer Copy -- Not for Resale

753 Bobcat Loader

20-101-3 Service Manual
217 of 726
REAR AUXILIARY DIVERTER VALVE (DUAL Remove the lo gic cartridge valves (Item 1) [Figure 20-
SHUTTLE) (CONT’D) 101-9] & [Figure 20-101-10] from block ports LC1 an d
LC2.
Disassembly And Assembly
Installation: Put oil on O-rings and back-up
washers.Tighten to 60-65 ft.-lbs. (81,4-88 Nm) torque.

IMPORTANT Figure 20-101-11

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Clean the diverter block to remove dirt before

disassembly. Block ports are labeled for correct 1
assembly.

Figure 20-101-9
P16315

Dealer Copy -- Not for Resale

Figure 20-101-12

1
P16312

Figure 20-101-10
P16314
1

Remove the shuttle check valve (Item 1) [Figure 20-101-

11] & [Figure 20-101-12]from SH1 port.

Installation: Put oil on O-rings and ba ck-up washers.

Tighten to 30-35 ft.-lbs. (40,7-47,5 Nm) torque.

P16313

753 Bobcat Loader

20-101-4 Service Manual
218 of 726
REAR AUXILIARY DIVERTER VALVE (DUAL Figure 20-101-15
SHUTTLE) (CONT’D)

Disassembly And Assembly (Cont'd)

Figure 20-101-13

P16319

1 Remove the nuts (Item 1) [Figure 20-101-15] & [Figure

1 20-101-16] from the solenoid valve.
P16316
Installation: Tighten the nuts to 50 -55 in.-lbs. (5,6-6,2
Nm) torque.
Figure 20-101-14

Dealer Copy -- Not for Resale

Figure 20-101-16

3
2
2
1
1

2
P16317
2 1
P16321

Remove the pilot check valves (Item 1) [Figure 20-101-

13] & [Figure 20-101-14] from block ports PC1 and PC2. Remove the seal washers (Item 2) and solenoid valve
coils (Item 3) [Figure 20-101-16].
Installation: Put oil on O -ring and back-up washers.
Tighten to 30-35 ft.-lbs. (40,7-47,5 Nm) torque.

753 Bobcat Loader

20-101-5 Service Manual
219 of 726
REAR AUXILIARY DIVERTER VALVE (DUAL Figure 20-101-19
SHUTTLE) (CONT’D)

Disassembly And Assembly (Cont'd)

Figure 20-101-17

1
P16322

Figure 20-101-20

P16323

Figure 20-101-18 1

Dealer Copy -- Not for Resale

1

P16325

Remove the pressure relieving solenoid valve (Item 1)

[Figure 20-101-19] & [Figure 20-101-20] from the SV 2
P16324 port.

Installation: Put oil on O-rings and ba ck-up washers.

Remove the diverter control solenoid valve (Item 1) Tighten to 12-15 ft.-lbs. (16,3-20,3 Nm) torque.
[Figure 20-101-17] & [Figure 20-101-18] from the SV1
port.

Installation: Put oil on O-rings and back-up washers.

Tighten to 12-15 ft.-lbs. (16,3-20,3 Nm) torque.

753 Bobcat Loader

20-101-6 Service Manual
220 of 726
REAR AUXILIARY DIVERTER VALVE (DUAL Solenoid Testing
SHUTTLE) (CONT’D)
Figure 20-101-23
Disassembly And Assembly (Cont'd)

Figure 20-101-21

P9137

P16326 Use a test meter to measure coil resistance [Figure 20-

101-23]. Coil wires do not have polarity. Correct
resistance is 6-9 ohms.
Figure 20-101-22

Dealer Copy -- Not for Resale

Replace the test meter with 12 v olt power. You can see
and hear the spool shift.

Inspection

Inspect cartridges, check valves, solenoid valves and

sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.

Inspect diverter block cavities for contamination. Wash

block in clean solvent. Use air pressure to dry.
1

P16327

Remove the shuttle check valve (Item 1) [Figure 20-101-

21] & [Figure 20-101-22] from the SH2 port.

Installation: Put oil on O -ring and back-up washers.

Tighten to 30-35 ft.-lbs. (40,7-47,5 Nm) torque.

753 Bobcat Loader

20-101-7 Service Manual
221 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

20-101-8 Service Manual
222 of 726
POWER BOB-TACH BLOCK Figure 20-110-1

Removal And Installation

4
2
3

WARNING N-21044

Never work on a machine with the lift arms up unless Remove the nut from the speed control linkage (Item 1)
the lift arms are secured by an approved lift arm [Figure 20-110-1].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Unplug the rear lights electrical connector (Item 2)
to fall and cause injury or death. [Figure 20-110-1].
W-2059-0598

Dealer Copy -- Not for Resale

Remove the belt shield mounting bolts (Item 3) [Figure
20-110-1].

Remove the belt shield.

IMPORTANT
Remove the coolant recover tank and mount (Item 4)
When repairing hydrostatic and hydraulic systems, [Figure 20-110-1]
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Figure 20-110-2
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.)

Raise the lift arms and install an approved lift arm

support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
1
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)

Open the rear door. P-34141

Drain the hydraulic reservoir. (See Replacing Hydraulic

Disconnect the wire harness connectors (Item 1) [Figure
Fluid on Page 10-120-3.)
20-110-2].
Remove the e ngine speed control. (See Removal And
Installation on Page 70-20-1.)

753 Bobcat Loader

20-110-1 Service Manual
223 of 726
POWER BOB-TACH BLOCK (CONT’D) Figure 20-110-5

Removal and Installation (Cont’d)

Figure 20-110-3

1
2

P-37331

1
Remove the four mounting bolts (Item 1) [Figure 20-110-
P-37330 5] holding the Power Bob-tach block.

Installation: Replace the O-ring and tighten the

Disconnect the hose (Item 1) [Figure 20-110-3] from the mounting bolts (Item 1) [Figure 20-110-5] to 2 5-28 ft.-
“DR” port on the Power Bob-tach block. lbs. (34-38 Nm) torque.

Dealer Copy -- Not for Resale

Disconnect the ou tlet hose (Item 2) [Figure 20-110-3] Remove the Power Bob-tach block.
from the top of the Power Bob-tach block.
Disassembly And Assembly
Figure 20-110-4
Figure 20-110-6

2 2

P-37329
P-26100

Disconnect the hose (Item 1) [Figure 20-110-4] from the

“BASE” port on the Power Bob-tach block. Clean the block (Item 1) [Figure 20-110-6] to remove dirt
before disassembly. Block ports are labeled for correct
Disconnect the hose (Item 2) [Figure 20-110-4] from the assembly.
“ROD” port on the Power Bob-tach block.
Remove the plug (Item 2) [Figure 20-110-6].

Installation: Tighten the plug to 46 ft.-lbs. (62,4 Nm)

torque.

753 Bobcat Loader

20-110-2 Service Manual
224 of 726
POWER BOB-TACH BLOCK (CONT'D) Installation: Tighten the plug to 120 in.-lbs. (13,6 Nm)
torque.
Disassembly And Assembly (Cont'd)
Figure 20-110-9

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
2
1
Figure 20-110-7 3

P-26107

Remove the spring (Item 1) and check ball (Item 2)

[Figure 20-110-9].

Dealer Copy -- Not for Resale

Check the O-ring (Item 3) [Figure 20-110-9] on the plug
and replace as needed.

2 Figure 20-110-10

3
P-26103

Remove the spring (Item 1) and compensator (Item 2)

[Figure 20-110-7].

Check the O-ring (Item 3) [Figure 20-110-7] on the plug

and replace as needed.

Figure 20-110-8 1

P-26109

Remove the pressure reducing valve plug (Item 1)

[Figure 20-110-10] & [Figure 20-110-11].

Installation: Tighten the pressure reducing valve plug to

to 46 ft.-lbs. (62,4 Nm) torque.

P-26105

Remove the plug (Item 1) [Figure 20-110-8].

753 Bobcat Loader

20-110-3 Service Manual
225 of 726
POWER BOB-TACH BLOCK (CONT'D) Figure 20-110-13

Disassembly And Assembly (Cont'd)

Figure 20-110-11

P-26208
3

3 2 1
2 P-26114
1

4 Remove the plug (Item 1) [Figure 20-110-12] & [Figure

5 P-26112 20-110-13].

Installation: Tighten the plug to 32 in.-lbs. (3,6 Nm)

Remove the relief piston (Item 2), spring (Item 3), ball torque.
seat spring guide (Item 4) [Figure 20-110-11].

Dealer Copy -- Not for Resale

Check the O-ring (Item 2) [Figure 20-110-13] on the plug
Check the O-ring (Item 5) [Figure 20-110-11] on the and replace as needed.
pressure reducing valve plug and replace as needed.
Check the O-ring (Item 3) [Figure 20-110-13] and
NOTE: The relief valve seat (Item 6) [Figure 20-110- replace as needed.
11] is a non-serviceable part. If seat is
damaged, order a new power Bob-Tach block Figure 20-110-14
from Bobcat parts.

Figure 20-110-12

1 P-26116

P-26113 Remove the nut ( Item 1) [Figure 20-110-14] & [Figure

20-110-15].

Installation: Tighten the nut to 5 ft.-lbs. (6,8 Nm) torque.

753 Bobcat Loader

20-110-4 Service Manual
226 of 726
POWER BOB-TACH BLOCK (CONT'D) Figure 20-110-17

Disassembly And Assembly (Cont'd)

1
Figure 20-110-15

4
3
2
2

1
P-26122

Check the O-rings and back-up washers (Item 1) [Figure

P-26117 20-110-17] and replace as needed.

Installation: Put oil on O-rings and back-up washers.

Remove the first solenoid coil (Item 2), spacer (Item 3)
and the second solenoid coil (Item 4) [Figure 20-110- Check the O-ring (Item 2) [Figure 20-110-17] and

Dealer Copy -- Not for Resale

15]. replace as needed.

NOTE: Remember the solenoid coil orientation for

ease of installation.

Figure 20-110-16

P-26120

Remove the solenoid valve stem (Item 1) [Figure 20-

110-16].

Installation: Tighten the solenoid valve stem to 20 ft.-lbs.

(27,1 Nm) torque.

753 Bobcat Loader

20-110-5 Service Manual
227 of 726
POWER BOB-TACH BLOCK (CONT'D) Figure 20-110-20

Disassembly And Assembly (Cont'd)

Figure 20-110-18

P-26125

Figure 20-110-21
1 P-26123

Figure 20-110-19

Dealer Copy -- Not for Resale

2
1

3 P-26127
2
1
Remove the plug (Item 1) [Figure 20-110-20] & [Figure
3 20-110-21].
P-26309

Installation: Tighten the plug to 198 in.-lbs. (22,4 Nm)

Remove the plug (Item 1) [Figure 20-110-18] & [Figure torque.
20-110-19].
Remove the pilot piston (Item 2) [Figure 20-110-21].
Installation: Tighten the plug to 120 in.-lbs. (13,6 Nm)
torque. Check the O-ring (Item 3) [Figure 20-110-21] and
replace as needed.
Remove the dowel pin shuttle (Item 2) [Figure 20-110-
19].

Check the O-ring (Item 3) [Figure 20-110-19] and

replace as needed.

753 Bobcat Loader

20-110-6 Service Manual
228 of 726
POWER BOB-TACH BLOCK (CONT'D) Figure 20-110-24

Disassembly And Assembly (Cont'd)

Figure 20-110-22

P-26130

Figure 20-110-25
P-26128

Figure 20-110-23

Dealer Copy -- Not for Resale

2
1

3
P-26132
1

Remove the plug (Item 1) [Figure 20-110-24] & [Figure

2
P-26129 20-110-25].

Installation: Tighten the plug to 32 in.-lbs. (3,6 Nm)

Remove the plug (Item 1) [Figure 20-110-22] & [Figure torque.
20-110-23].
Remove the orifice (Item 2) [Figure 20-110-25] with a 5/
Installation: Tighten the plug to 198 in.-lbs. (22,4 Nm) 32 inch allen wrench.
torque.
Installation: Tighten the orifice to 5 ft.-lbs. (6,8 Nm)
Check the O-ring (Item 2) [Figure 20-110-23] and torque.
replace as needed.

753 Bobcat Loader

20-110-7 Service Manual
229 of 726
POWER BOB-TACH BLOCK (CONT'D) Figure 20-110-28

Disassembly And Assembly (Cont'd)

Figure 20-110-26

3
2
1

4 P-26136

Remove the plug (Item 1) [Figure 20-110-27] & [Figure

P-26133 20-110-28].

Installation: Tighten the plug to 198 in.-lbs. (22,4 Nm)

Make sure orifice is clean and not plugged [Figure 20- torque.
110-26].

Dealer Copy -- Not for Resale

Remove the relief spring (Item 2) [Figure 20-110-28].
Figure 20-110-27
Remove the ball seat spring guide (Item 3) [Figure 20-
110-28].

Check the O-ring (Item 4) [Figure 20-110-28] and

replace as needed.

1 P-26134

753 Bobcat Loader

20-110-8 Service Manual
230 of 726
POWER BOB-TACH BLOCK (CONT'D) Figure 20-110-31

Disassembly And Assembly (Cont'd)

Figure 20-110-29

P-26140

1
Figure 20-110-32
P-26137

Remove the plug (Item 1) [Figure 20-110-29].

Installation: Tighten the plug to 120 in.-lbs. (13,6 Nm)

Dealer Copy -- Not for Resale

torque.

Figure 20-110-30

2
1

P-26141

Remove the plug (Item 1) [Figure 20-110-31] & [Figure

1 20-110-32].

Installation: Tighten the plug to 32 in.-lbs. (3,6 Nm)

torque.

2 P-26139 Check the O-ring (Item 2) [Figure 20-110-32] and

replace as needed.

Remove the d owel pin orifice (Item 1) [Figure 20-110-

30].

Check the O-ring (Item 2) [Figure 20-110-30] and

replace as needed.

753 Bobcat Loader

20-110-9 Service Manual
231 of 726
POWER BOB-TACH BLOCK (CONT'D)

Disassembly And Assembly (Cont'd)

Figure 20-110-33

P-26141A

Remove the plug (Item 1) [Figure 20-110-33].

Installation: Tighten the plug to 32 in.-lbs. (3,6 Nm)

Dealer Copy -- Not for Resale

torque.

Figure 20-110-34

2
1

3
P-26143

Remove the flow control spring (Item 1) [Figure 20-110-

34].

Remove the flow control (Item 2) [Figure 20-110-34].

Check the O-ring (Item 3) [Figure 20-110-34] and

replace as needed.

753 Bobcat Loader

20-110-10 Service Manual
232 of 726
FRONT AUXILIARY PRESSURE RELIEF BLOCK Figure 20-120-2

Removal And Installation (S/N 515842309 and Below)

1
WARNING 2
P-28815

Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm Mark the hydraulic hoses on the front auxiliary pressure
support device. Failure to use an approved lift arm relief block for proper installation.
support device can allow the lift arms or attachment
to fall and cause injury or death. Remove and cap the hydraulic tubeline (Item 1) [Figure
W-2059-0598 20-120-2] that goes from the hydraulic reservoir to th e
front auxiliary pressure relief block.

Dealer Copy -- Not for Resale

Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device Remove and cap the two hydraulic hoses (Item 2)
on Page 10-20-1.) [Figure 20-120-2] that go from the fr ont auxiliary
pressure relief block to the front auxiliary tubelines.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) Figure 20-120-3

Drain the hydraulic reservoir. (See Replacing Hydraulic

Fluid on Page 10-120-3.)

Figure 20-120-1

P-28817

1
Remove the two mounting bolts (Item 1) [Figure 20-120-
3] fastening the front auxiliary pressure relief block to the
bracket.
P-28816

Remove the front auxiliary pressure relief block from the

Disconnect the electrical wire harness connector (Item 1) loader.
[Figure 20-120-1].

753 Bobcat Loader

20-120-1 Service Manual
233 of 726
FRONT AUXILIARY PRESSURE RELIEF BLOCK Figure 20-120-6
(CONT'D)

Disassembly And Assembly (S/N 515842309 and

Below)

Figure 20-120-4

P-24995
1

Inspect the O-rings and back-up washer on the solenoid

valve and replace as needed [Figure 20-120-6].

P-30110 Assembly: Tighten the solenoid valve to 120-144 in.-lbs.

(13,6-16,3 Nm) torque.
Loosen the electrical brake solenoid nut (Item 1) [Figure

Dealer Copy -- Not for Resale

Figure 20-120-7
20-120-4].

Assembly: Tighten the solenoid nut to 15-45 in.-lbs.

(1,7-5,1 Nm) torque.

Figure 20-120-5

1
P-30112

Remove the shuttle valve (Item 1) [Figure 20-120-7]

3 from the block.
2
1 P-30111 Assembly: Tighten the s huttle valve to 30 ft.-lbs. (40,7
Nm) torque.

Remove the solenoid nut (Item 1) and solenoid coil (Item

2) [Figure 20-120-5].

Remove the solenoid valve (Item 3) [Figure 20-120-5]

from the block.

753 Bobcat Loader

20-120-2 Service Manual
234 of 726
FRONT AUXILIARY PRESSURE RELIEF BLOCK Solenoid Testing
(CONT'D)
Figure 20-120-9
Disassembly And Assembly (S/N 515842309 and
Below) (Cont'd)

Figure 20-120-8

P-26006

Use a test meter to measure coil resistance [Figure 20-

P-24998 120-9]. Coil wires do no t have polarity. Correct
resistance is 11 ± 1 ohms.
Inspect the O-rings and back-up washers on the shuttle

Dealer Copy -- Not for Resale

Replace the test meter with 12 v olt power. You can see
valve and replace as needed [Figure 20-120-8].
and hear the spool shift.

Solenoid Inspection

Inspect cartridges, check valves, solenoid valves and

sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.

Inspect the diverter block cavities for contamination.

Wash the block in clean solvent. Use air pressure to dry.

753 Bobcat Loader

20-120-3 Service Manual
235 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

20-120-4 Service Manual
236 of 726
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly

Removal and Installation (S/N 515842310 & Above) Figure 20-121-2

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all 2
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 4
damage the system.
3
I-2003-0888

Figure 20-121-1
P-34661

2 Figure 20-121-3

Dealer Copy -- Not for Resale

1
3

6 2
4
5 3
P-43215

Disconnect the auxiliary tubelines (Item 1) and drain

tubeline (Item 2) [Figure 20-121-1] from the co upler P-34760
block.

Remove the two mounting bolts (Item 3) [Figure 20-121- Remove the male coupler (Item 1) [Figure 20-121-2] &
1]. [Figure 20-121-3].

Installation: Tighten the male coupler (Item 1) [Figure

20-121-2] & [Figure 20-121-3] to 59 ft.lbs. (80 Nm)

Remove the dr ain coupler (Item 2) [Figure 20-121-2] &

[Figure 20-121-3].

Installation: Tighten the drain coupler (Item 2) [Figure

20-121-2] & [Figure 20-121-3] to 37 ft.lbs. (50 Nm)

Remove the female coupler (Item 3) [Figure 20-121-2] &

[Figure 20-121-3].

Installation: Tighten the female coupler (Item 3) [Figure

20-121-2] & [Figure 20-121-3] to 59 ft.lbs. (80 Nm)

Remove the fi ttings (Item 4), check the O-rings (Item 5)

[Figure 20-121-3] and replace as needed.

Remove the springs (Item 6) [Figure 20-121-3].

753 Bobcat Loader

20-121-1 Service Manual
237 of 726
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-121-6
(CONT’D)

Disassembly And Assembly (S/N 515842310 &

1
Above) (Cont’d)

Figure 20-121-4

1 2

P-34665

Check the O-rings (Item 1) backup O-rings (Item 2)

[Figure 20-121-6] for damage and replace as needed.

P-34663 Figure 20-121-7

Check the O-ring (Item 1) [Figure 20-121-4] for damage

Dealer Copy -- Not for Resale

1
and replace as needed.

Figure 20-121-5

P-34664

Check the O-rings (Item 1) backup O-rings (Item 2)

[Figure 20-121-7] for damage and replace as needed.

P-34701

Press center of male couplers down and check the O-ring

(Item 1) [Figure 20-121-5] for damage and replace as
needed.

753 Bobcat Loader

20-121-2 Service Manual
238 of 726
 HYDROSTATIC SYSTEM

HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 HYDROSTATIC
SYSTEM
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-9
Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-21
Carrier Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-20
Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 30-20-19
Carrier Removal And Installation . . . . . . . . . . . . . . . . . . . 30-20-17
Carrier Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . 30-20-15 DRIVE
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4 SYSTEM
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-2
Checking Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Sender Removal And Installation. . . . . . . . . . . . . . . . . . . . 30-30-1

Dealer Copy -- Not for Resale

ELECTRICAL
SYSTEM &
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 ANALYSIS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9
Hydraulic Pump Removal And Installation. . . . . . . . . . . . . 30-40-8 ENGINE
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . 30-40-6 SERVICE
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . 30-40-4
Pump Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . 30-40-1 SPECIFICATIONS

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-50-1
Tensioner Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-50-7
Tensioner Pulley Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-50-6
Tensioner Pulley Parts Identification . . . . . . . . . . . . . . . . . 30-50-5
Tensioner Pulley Removal And Installation . . . . . . . . . . . . 30-50-4

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (See TORQUE SPECIFICATIONS FOR BOLTS on Page
SPEC-30-1.) UNLESS OTHERWISE SPECIFIED.

753 Bobcat Loader

30-01 Service Manual
239 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

30-02 Service Manual
240 of 726
HYDROSTATIC SYSTEM INFORMATION

Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285

PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7
The hydrostatic system is overheating. 8, 9, 10, 11
Service code HP2 appears. (Warnings, low charge pressure.) 8, 11, 12, 13

KEY TO CORRECT THE CAUSE

1. The hydrostatic pump replenishing valves not seating.
2. The steering linkage needs adjustment.

Dealer Copy -- Not for Resale

3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The temperature sending switch is not operating correctly.
11. The loader is not being operated at the correct RPM.
12. The hydraulic charge pressure sender is defective.
13. Pump is defective or worn hydrostatics.

753 Bobcat Loader

30-10-1 Service Manual
241 of 726
HYDROSTATIC SYSTEM INFORMATION Replenishing Valve Function

Figure 30-10-1

IMPORTANT CHARGE OIL

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

FUNCTION 1 Valve Moves for Charge

Oil Replacement

Valve Stays on Seat to

Hold High Pressure for Drive

Dealer Copy -- Not for Resale

FUNCTION 2

B-2804

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 [Figure
30-10-1].

2. To keep high pressure fluid out of th e low pressure

side of the hydrostatic circuitry; Function 2 [Figure
30-10-1].

753 Bobcat Loader

30-10-2 Service Manual
242 of 726
HYDROSTATIC MOTOR Figure 30-20-1

Removal And Installation

WARNING P-43309

Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm Remove the fou r motor cover mounting bolts (Item 1)
support device. Failure to use an approved lift arm [Figure 30-20-1].
support device can allow the lift arms or attachment
to fall and cause injury or death. Installation: Tighten the drive motor mounting bolts to
W-2059-0598 25-28 ft.-lbs. (34-38 Nm) torque.

Dealer Copy -- Not for Resale

Figure 30-20-2

3
WARNING 3
1
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 3
explosion or fire which can result in injury or death.
W-2103-1285

Raise the lift arms and install an approved lift arm

support device. (See Installing Lift Arm Support Device 2
on Page 10-20-1.)

Lift and block the loader. (See LIFTING AND BLOCKING 3 N-20908

THE LOADER on Page 10-10-1.)

Mark the two hoses (Item 1) [Figure 30-20-2] before
Raise the operator cab. (See Raising The Operator Cab disconnecting them from the HYDROSTATIC MOTOR for
on Page 10-30-1.) correct installation.
Remove the front and rear wheel/tire assemblies. (See Remove the two hoses (Item 1) [Figure 30-20-2] from
TIRE MAINTENANCE on Page 10-170-1.) the drive motor.

Remove the drain hose (Item 2) [Figure 30-20-2] from

the drive motor.

Remove the four drive motor mounting bolts (Item 3)

[Figure 30-20-2].

Installation: Tighten the drive motor mounting bolts to

90-100 ft.-lbs. (122-136 Nm) torque.

753 Bobcat Loader

30-20-1 Service Manual
243 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-5

Removal And Installation (Cont’d)

Figure 30-20-3

RH

P-39644

Carriers that ne ed the spacer washer (Item 1) [Figure

P-4141 30-20-4] are marked with “RH” (Item 1) [Figure 30-20-5]
stamped on the face.

Remove the drive motor from the ac cess hole in th e If the carrier shaft is replaced and the same carrier
loader frame [Figure 30-20-3]. housing is re-used, stamp over the ”RH” with an “XX”.

Dealer Copy -- Not for Resale

Figure 30-20-4 NOTE: Eliminating the washer when it is required will
result in drive motor failure at very low hours.
Attempting to install a washer when it is not
required will result in interference. The motor
will not seat against the carrier and damage
1 will result if tightened.

*Refer to Bobcat Technical Informational Bulletin #345 for

more information on the spacer washer if needed.

Reverse the removal procedure to i nstall the

HYDROSTATIC MOTOR.

PE1054

NOTE: If your loader has a spacer washer (Item 1)

[Figure 30-20-4], it must be re-installed if:

1. You are replacing only the drive motor.

The spacer washer must be discarded if:

1. You are replacing the entire motor carrier

assembly.

2. You are replacing the carrier shaft and

keeping the carrier housing.

753 Bobcat Loader

30-20-2 Service Manual
244 of 726
HYDROSTATIC MOTOR (CONT’D)

Parts Identification

10
11
9
8
13

3 16

5
14

6
15 3

Dealer Copy -- Not for Resale

7
21 6
22
20
17
19
18
19
17
20
1

24 26
12 23 25 2 D-3431A

Ref. Description Ref. Description

1. HOUSING 15. SHAFT, drive
2. O-RING 16. BOLT
3. SEAL, square 17. SPRING
4. VALVE, plate 18. PISTON
5. GEROLER 19. POPPET
6. BALL 20. SLEEVE
7. PLATE, balance 21. PLUG
8. RING, back-up 22. O-RING
9. SEAL 23. O-RING
10. RING, back-up 24. SPRING
11. O-RING 25. SHIM
12. PLUG 26. POPPET
13. FLANGE, mounting
14. SEAL, face

753 Bobcat Loader

30-20-3 Service Manual
245 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-8

Disassembly 1

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Drain the oil from the motor. N-00623

Seal all open ports and clean the motor with solvent.
Lift and remove the mounting flange (Item 1) [Figure 30-
Figure 30-20-6 20-8] from the motor.

NOTE: Do not scratch or damage the surfaces of the

motor sections. Always put them on a soft
surface.

Dealer Copy -- Not for Resale

Figure 30-20-9

1
2
3

N-00621

Put a mar k across the sections of the motor for correct

assembly [Figure 30-20-6].
Figure 30-20-7
N-00624

Turn the mounting flange over and remove the O-ring and
1 back-up ring (Item 1), the seal and back-up ring (Item 2),
and the square-cut seal (Item 3) [Figure 30-20-9].

N-00622

Remove the nine bolts (Item 1) [Figure 30-20-7] from the

motor.

753 Bobcat Loader

30-20-4 Service Manual
246 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-12

Disassembly (Cont'd)
1
Figure 30-20-10

N-00627

Remove the main drive (Item 1) [Figure 30-20-12] from

N-00625 the gerolor assembly.

Figure 30-20-13
Turn the mounting flange backover and remove the seal
(Item 1) [Figure 30-20-10] from the mounting flange.

Dealer Copy -- Not for Resale

Figure 30-20-11

N-00628

Remove the two check balls (Item 1) [Figure 30-20-13]

N-00626 from the gerolor.

Remove the ba lance plate (Item 1) [Figure 30-20-11]

from the gerolor assembly.

753 Bobcat Loader

30-20-5 Service Manual
247 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-16

Disassembly (Cont'd)

Figure 30-20-14

N-00631
1

Carefully turn the gerolor assembly over and remove the

N-00629 square cut seal (Item 1) [Figure 30-20-16].

Figure 30-20-17
Remove the square cut seal (Item 1) [Figure 30-20-14]
from the gerolor.
1

Dealer Copy -- Not for Resale

Figure 30-20-15

N-00632

Remove the valve plate (Item 1) [Figure 30-20-17] from

N-00630 the end cap.

Remove the gerolor assembly (Item 1) [Figure 30-20-

15].

NOTE: Care should be taken to keep the gerolor

assembly together.

NOTE: If rollers are removed, put them back in their

original bore with the correct orientation.

753 Bobcat Loader

30-20-6 Service Manual
248 of 726
HYDROSTATIC MOTOR (CONT'D) Figure 30-20-20

Disassembly (Cont'd)
1
Figure 30-20-18

N-00635

Remove the poppet and shuttle valve (Item 1) [Figure

N-00633 30-20-20].

Figure 30-20-21
Remove the square cut seal (Item 1) and small O-ring
(Item 2) [Figure 30-20-18] from the end cap.

Dealer Copy -- Not for Resale

Figure 30-20-19

1
2

N-00636

Turn the end cover over and remove the shuttle valve
N-00634 plug from the end cover [Figure 30-20-21].

Remove the spring seat (Item 1) and spring (Item 2)

[Figure 30-20-19].

753 Bobcat Loader

30-20-7 Service Manual
249 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-24

Disassembly (Cont'd)
3
Figure 30-20-22

2
1
1
2
3

N-00640

Remove the spring (Item 1) and poppet (Item 2) from the

N-00637 end cover (Item 3) [Figure 30-20-24].

NOTE: The relief pressure is factory set and must not

Remove the spring sleeve (Item 1), spring (Item 2) and be changed. Shims may or may not have been
poppet (Item 3) [Figure 30-20-22]. used at the factory for setting the pressure. If

Dealer Copy -- Not for Resale

shims are present, make sure they are
Figure 30-20-23 reinstalled during assembly.

Figure 30-20-25

2
1

N-00639

N-00641
Remove the low pressure relief valve plug from the side
of the end cover [Figure 30-20-23].
The low pressure relief valve is made up of the poppet
(Item 1), the spring (Item 2) and the plug assembly (Item
3) [Figure 30-20-25].

753 Bobcat Loader

30-20-8 Service Manual
250 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-27

Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

N-00643
Prior to assembly:

Clean all parts with solvent and dry with compressed air. Install the new O-ring on the plug and tighten to 300 in.-
lbs. (34 Nm) torque [Figure 30-20-27].
Put grease on O-rings.
Figure 30-20-28
Lubricate parts with oil.

Dealer Copy -- Not for Resale

Figure 30-20-26 3
2

2
1
1

N-00644

Install the poppet (Item 1), the spring (Item 2) and the
N-00642
spring sleeve (Item 3) [Figure 30-20-28] in the end cover.

Install the poppet (Item 1) and spring (Item 2) [Figure 30- NOTE: The tapered end of the poppet must face
20-26] in the low pressure relief port in the end cover. towards the shuttle valve.

753 Bobcat Loader

30-20-9 Service Manual
251 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-31

Assembly (Cont'd)
1
Figure 30-20-29

N-00648

Install the square cut seal (Item 1) and small O-ring (Item
N-00646 2) [Figure 30-20-31] in the end cover.

Figure 30-20-32
Install a new O-ring on the plug [Figure 30-20-29] and
tighten to 260 in.-lbs. (41 Nm) torque.

Dealer Copy -- Not for Resale

NOTE: Always use new O-rings and seals when
assembling the motor. Put a small amount of
grease on all the O-rings and seals for easier
installation.

Figure 30-20-30

N-00649
3 1

Mark the c ase drain port location on the ou tside of th e

end cover for ease of assembly [Figure 30-20-32].

N-00647

Install the shuttle valve (Item 1), poppet (Item 2), spring
(Item 3) and spring sleeve (Item 4) [Figure 30-20-30] in
the port hole in the end cap.

NOTE: The tapered end of the poppet must face

towards the shuttle valve.

753 Bobcat Loader

30-20-10 Service Manual
252 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-35

Assembly (Cont'd)

Figure 30-20-33

N-00652

Mark the case drain port location on the outside edge of

N-00650 the valve plate as shown [Figure 30-20-35].

Figure 30-20-36
Align the case drain ports in the valve plate with the case
drain port in the end cover [Figure 30-20-33].
1

Dealer Copy -- Not for Resale

Figure 30-20-34

N-00653

Install the gerolor assembly (Item 1) [Figure 30-20-36]

N-00651 by aligning the case drain hole with the case drain hole in
the valve plate.

Install the large square cut seal (Item 1) [Figure 30-20-

34] in gerolor assembly.

753 Bobcat Loader

30-20-11 Service Manual
253 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-39

Assembly (Cont'd) 1

Figure 30-20-37

N-00656

Install the ma in drive (Item 1) [Figure 30-20-39] in the

N-00654 gerolor (as shown).

NOTE: Whenever the main drive is not symmetrical,

Install the square cut seal (Item 1) [Figure 30-20-37] in the smallest end of the main drive must be
the gerolor outer ring. installed into the gerolor star.

Dealer Copy -- Not for Resale

Figure 30-20-38 Figure 30-20-40

N-00655 N-00657

Install the two check balls (Item 1) [Figure 30-20-38] in Mark the case drain hole on the outer ring of the gerolor
their bores in the gerolor star. (as shown) [Figure 30-20-40].

753 Bobcat Loader

30-20-12 Service Manual
254 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-43

Assembly (Cont'd)
1
Figure 30-20-41 2

3
4
5

N-00660

1 Install the square cut seal (Item 1), seal (Item 2), back-up
N-00658 seal (Item 3), seal (Item 4) and back-up ring (Item 5)
[Figure 30-20-43] in the mounting flange.

Align the case drain holes and install the balance plate Figure 30-20-44
(Item 1) [Figure 30-20-41] on the gerolor assembly.

Dealer Copy -- Not for Resale

Figure 30-20-42

N-00661

N-00659 Mark the case drain holes on the side of t he balance

plate [Figure 30-20-44].

Install the seal (Item 1) [Figure 30-20-42] (as shown).

753 Bobcat Loader

30-20-13 Service Manual
255 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-47

Assembly (Cont'd)

Figure 30-20-45

N-00664

Install the nine bolts into the motor. Make sure all the
N-00662 parts are in correct alignment [Figure 30-20-47].

Figure 30-20-48
Align the case drain port (Item 1) [Figure 30-20-45] in
the mounting flange with the case drain port in th e
balance plate (as shown).

Dealer Copy -- Not for Resale

Figure 30-20-46

MC-2230

1. Tighten the bolts to 45-55 ft.-lbs. (61-75 Nm) torque

as shown [Figure 30-20-48].
N-00663
2. Tighten the bolts to 55-65 ft.-lbs. (75 -88 Nm) torque
as shown [Figure 30-20-48].
Align the case drain port (Item 1) [Figure 30-20-46] and
install the mounting flange on the balance plate. NOTE: To prevent damage to the balance plate, never
lift or support the motor by the center shaft.
Be careful not to displace the seals and back-up rings.

753 Bobcat Loader

30-20-14 Service Manual
256 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-50

Carrier Shaft Seal Replacement

WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
P-4456

The tool listed is necessary for the following procedure:

Drill a.125 inch (3 mm) hole in the motor carrier seal
MEL1420 - Carrier Seal Tool [Figure 30-20-50].

Remove the hy drostatic motor. (See Removal And Figure 30-20-51

Installation on Page 30-20-1.)

Dealer Copy -- Not for Resale

Figure 30-20-49

P-4455

P-4153 Use a s lide hammer to remove the seal from the motor
carrier shaft [Figure 30-20-51].

The motor carrier seal (Item 1) [Figure 30-20-49] is

located on the outside of the motor carrier shaft.

753 Bobcat Loader

30-20-15 Service Manual
257 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-54

Carrier Shaft Seal Replacement (Cont'd)

Figure 30-20-52

P-4149

Photo [Figure 30-20-54] shows the motor carrier seal

P-4454 correctly installed.

NOTE: Before reinstalling the hydrostatic motor,

Installation: Install a new seal over the motor carrier check the plug (Item 1) [Figure 30-20-54]
shaft [Figure 30-20-52]. located in the center of the carrier shaft for

Dealer Copy -- Not for Resale

tightness. If the plug becomes loosened, case
Figure 30-20-53 drain lubrication oil from the hydrostatic
motor can leak into the chaincase.

P-4150

Installation: Install MEL1420 Carrier Seal Tool over the

carrier seal [Figure 30-20-53].

Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-20-53].

753 Bobcat Loader

30-20-16 Service Manual
258 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-55

Carrier Removal And Installation

WARNING
1
Never work on a machine with the lift arms up 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 lift arms or attachment
to fall and cause injury or death.
W-2059-0598

P-4152
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Remove the parking brake disc (Item 1) [Figure 30-20-
55]. (See Disc Removal And Installation on Page 40-10-
Lift and block the loader. (See LIFTING AND BLOCKING 2.)
THE LOADER on Page 10-10-1.)
Remove the six motor carrier mounting bolts (Item 2)
Raise the l oader operator cab. (See Raising The [Figure 30-20-55] from the inside of the chaincase.

Dealer Copy -- Not for Resale

Operator Cab on Page 10-30-1.)
Installation: Tighten the motor carrier mounting bolts to
Drain the fluid from the chaincase. (See Removing The 125-140 ft.-lbs. (170-190 Nm) torque.
Oil on Page 40-30-1.)
Figure 30-20-56
Remove the e ngine speed control. (See Removal And
Installation on Page 70-20-1.)

Remove the control panel. (See Removal and Installation

on Page 50-100-1.)

Remove the lift arm by-pass control valve. (See Removal

And Installation on Page 20-50-1.) 1

Remove the traction lock assembly. (See TRACTION

LOCK on Page 60-110-1.)

Remove the center chaincase cover. (See Center Cover

Removal And Installation on Page 40-30-3.)
P-4167
Remove the front chaincase cover. (See Front Cover
Removal And Installation on Page 40-30-2.)
For ease of r emoval, fasten the front drive chain
Remove the front axle and sprocket. (See Axle Sprocket (previously removed) to the chaincase as shown [Figure
And Bearings Removal And Installation on P age 40-20- 30-20-56].
3.)
Tip the end of the sprocket toward the rear of the loader
Remove the hy drostatic motor. (See Removal And and remove the rear drive chain (Item 1) [Figure 30-20-
Installation on Page 30-20-1.) 56] from the sprocket.

753 Bobcat Loader

30-20-17 Service Manual
259 of 726
Figure 30-20-57 Figure 30-20-58

1
1

P-4165 P-4168

Slide the motor carrier out of the chaincase [Figure 30- Use one of the motor carrier mounting bolts (Item 1)
20-57]. [Figure 30-20-58] and install partially into one mounting
hole on the carrier.
Installation: Check the motor carrier gasket (Item 1)
[Figure 30-20-57] for wear or damage and r eplace if Fasten a chain hoist to the bolt on the motor carrier and
necessary. remove the carrier from the loader.

Dealer Copy -- Not for Resale

Reverse the removal procedure to install the motor
carrier.

753 Bobcat Loader

30-20-18 Service Manual
260 of 726
HYDROSTATIC MOTOR (CONT’D)

Carrier Parts Identification

Dealer Copy -- Not for Resale

2 8
3 4

4
3 7
6

1. Mount Assy.
2. Shaft
3. Bearing
4. Race
5. Housing
6. Snap Ring
7. Seal
8. Plug

MC-1937

753 Bobcat Loader

30-20-19 Service Manual
261 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-61

Carrier Disassembly

Figure 30-20-59

3,000” O.D. Diameter

(76,2 mm)

2.530” I.D. Diameter

(64,26 mm)

7.000”
Length
(177,8 mm) P-4176

Put the motor carrier in the hy draulic press as shown

MC-2102 [Figure 30-20-61].

Use 2-1/4 inch driver tool and press the sprocket shaft
It is necessary to locate or fabricate a press tool for this out of the motor carrier housing [Figure 30-20-61].
procedure. Refer to ph oto [Figure 30-20-59] for the
correct dimensions of the tool needed.

Dealer Copy -- Not for Resale

NOTE: The outer bearing will now be free from the
sprocket shaft.
A hydraulic press, slide hammer with puller end and snap
ring pliers are also recommended for this procedure. Figure 30-20-62

Remove the motor carrier shaft seal. (Refer to

Disassembly on Page 30-20-4)

Figure 30-20-60
2
1

P-4365

Remove the housing from the press and install a bearing

puller (Item 1) [Figure 30-20-62] on the sprocket shaft.
1
P-4372
Put the assembly in the hydraulic press. Use the same
tool driver and remove the bearing (Item 2) [Figure 30-
Remove the snap ring (Item 1) [Figure 30-20-60] from 20-62] from the shaft.
the motor carrier shaft using the snap ring pliers.

753 Bobcat Loader

30-20-20 Service Manual
262 of 726
HYDROSTATIC MOTOR (CONT’D) Carrier Assembly

Carrier Disassembly (Cont'd) Figure 30-20-65

Figure 30-20-63

P-4369

P-4373
Put the motor carrier housing in the press as shown
[Figure 30-20-65].
Fasten the carrier motor housing to the work surface
securely with the inner bearing race (Item 1) [Figure 30- Use 4-5/16 inch driver tool and press the new inner
20-63] facing up.

Dealer Copy -- Not for Resale

bearing race into the motor carrier housing [Figure 30-
20-65].
Install the slide hammer with puller end (Item 2) [Figure
30-20-63] on the bottom side of the bearing race. Press the bearing race in until it is fully seated in the
carrier housing.
Remove the bearing race from the carrier housing
[Figure 30-20-63]. Figure 30-20-66

Figure 30-20-64

P-4368

P-4370
Turn the motor carrier housing over as shown [Figure 30-
20-66].
Put the motor carrier housing in the hydraulic press as
shown [Figure 30-20-64]. Use 4-5/16 inch driver tool and press the new ou ter
bearing race into the motor carrier housing [Figure 30-
Use a 3-7/8 inch driver tool and press the outer bearing 20-66].
race from the housing.
Press the bearing race in until it is fully seated in the
Check all parts for wear and damage. Replace the carrier housing.
bearing race when new bearings are to be installed.

753 Bobcat Loader

30-20-21 Service Manual
263 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-68

Carrier Assembly (Cont'd)

Figure 30-20-67

1
1

Dealer Copy -- Not for Resale

P-4371
P-4366

Put the motor carrier housing (Item 1) [Figure 30-20-68]

Use the fabricated press tool (Item 1) and 3.0 inch driver over the sprocket shaft as shown.
tool, install the new inner bearing (Item 2) [Figure 30-20-
67] on the sprocket shaft as shown. Put the outer bearing over the end of the sprocket shaft
and press the bearing on with the press tool and driver
Remove the press and drive tools from the sprocket tool [Figure 30-20-68].
shaft.
Remove the press and driver tools from the s procket
shaft.

753 Bobcat Loader

30-20-22 Service Manual
264 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-71

Carrier Assembly (Cont'd)

Figure 30-20-69

P-4374 1

Put the snap ring (Item 1) [Figure 30-20-69] over the end
of the sprocket shaft.

Dealer Copy -- Not for Resale

NOTE: Use the snap ring pliers to spread the snap
ring so it will fit over the sprocket shaft.

Using the press and driver tools, press the s nap ring
(Item 1) [Figure 30-20-69] over the sprocket.

Press the snap ring on until it snaps into the groove on

the shaft.

Figure 30-20-70 P-4375

Use MEL1420 Carrier Seal Tool (Item 1) [Figure 30-20-

71] and install the shaft seal.

Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [Figure 30-20-71].
1
Refer to Carrier Shaft Seal Replacement on Page 30-20-
15 for complete shaft seal installation procedure.

P-4376

Put a new shaft seal (Item 1) [Figure 30-20-70] on th e

sprocket shaft.

753 Bobcat Loader

30-20-23 Service Manual
265 of 726
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-73

Carrier Assembly (Cont'd)

Figure 30-20-72

N-15088

1
Check the end play of the motor carrier as follows:

Use a rubber mallet [Figure 30-20-72], tap down on the

Dealer Copy -- Not for Resale

cluster shaft.

N-15087

Install a dial indicator as shown in Photo [Figure 30-20-

73].

Use a pry bar (Item 1) [Figure 30-20-73] to lift the carrier

shaft and read the end play on the dial indicator.

The carrier shaft must turn freely with end play not to
exceed 0.007 inch (0,17 mm).

753 Bobcat Loader

30-20-24 Service Manual
266 of 726
CHARGE PRESSURE Install a gauge where the charge pressure sender was
removed.
Sender Removal And Installation
Start the engine.
Figure 30-30-1
The gauge must read as follows:

For S/N 515844250 and Above: 240-260 PSI (1379

kPa) with approximately 140° F (49° C) fluid @ 27 10-
2850 RPM .

For S/N 515844249 and Below: 155-165 PSI (1276-

1345 kPa) with approximately 140° F (49° C) fluid @
2710-2850 RPM.
2

P-28849 P-28804

Open the rear door.

Disconnect the wires (Item 1) [Figure 30-30-1] from the

Dealer Copy -- Not for Resale

charge pressure sender.

Remove the charge pressure sender (Item 2) [Figure 30-

30-1] from the fitting.

Installation: Tighten the mounting bolts and nuts to 15

ft.-lbs. (20 Nm) torque.

Checking Charge Pressure

WARNING
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

Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.)

Open the rear door.

Disconnect the wires (Item 1) [Figure 30-30-1] from the

charge pressure sender.

Remove the charge pressure sender (Item 2) [Figure 30-

30-1] from the fitting.

Installation: Tighten the mounting bolts and nuts to 15

ft.-lbs. (20 Nm) torque.
753 Bobcat Loader
30-30-1 Service Manual
267 of 726
CHARGE PRESSURE (CONT’D) Figure 30-30-3

Adjusting

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

N-17231
Figure 30-30-2

1 Remove the plug, spring and poppet [Figure 30-30-3].

Check the poppet and spring for wear or damage.

Figure 30-30-4

Dealer Copy -- Not for Resale

N-19567

1
If the charge pressure is not c orrect loosen the c harge
relief valve plug (Item 1) [Figure 30-30-2].

Assemble: Always use a new O-ring. Tighten the plug to N-19568

30-50 ft.-lbs. (41-68 Nm) torque.

There are several different thickness of the shims (Item 1)

[Figure 30-30-4] and are used to adjust the charge
pressure.

NOTE: 0.010 inch (0,254 mm) is 8 PSI (55.16 kPa)

increase in pressure.

The charge pressure should be set at:

For S/N 515844250 and Above: 240-260 PSI (1379

kPa) with approximately 140°F (49°C) fluid @ 2710-2850
RPM .

For S/N 515844249 and Below: 155-165 PSI (1276-

1345 kPa) with approximately 140°F (49°C) fluid @ 2710-
2850 RPM.

753 Bobcat Loader

30-30-2 Service Manual
268 of 726
HYDROSTATIC PUMP Figure 30-40-2

Replenishing/High Pressure Relief Valve

1
Figure 30-40-1

1 2

N-19566

Remove the high pressure relief valve (Item 1) [Figure

N-19565 30-40-2] from the pump.

Assemble: Tighten the plug to 30-50 ft.-lbs. (41-68 Nm)

There are four replenishing/high pressure relief valves torque.
(Item 1) [Figure 30-40-1] in the hydrostatic pump
assembly. Two are located at the top of the pumps and

Dealer Copy -- Not for Resale

Check for damage and replace as needed.
two at the bottom of the pumps.
Check the O-rings (Items 2 & 3) [Figure 30-40-2] for
(See HYDROSTATIC SYSTEM INFORMATION on Page damage and replace as needed.
30-10-1.)
If the high pressure relief valve must be replaced, it must
NOTE: The two top valves are for the forward drive be replaced as a complete unit.
loop and the two bottom valves are for the
reverse drive loop. The pressure setting for a new high pressure relief valve
is 5000 PSI (34475 kPa).

753 Bobcat Loader

30-40-1 Service Manual
269 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-4

Removal And Installation

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

P-4235
Remove the engine/hydrostatic pump assembly from the
loader. (See Hydraulic Pump Removal And Installation
on Page 30-40-8.) Install a p uller on the h ydrostatic pump drive pulley and
remove the pulley from the pump shaft [Figure 30-40-4].
Figure 30-40-3

1
WARNING

Dealer Copy -- Not for Resale

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

P-4236

Loosen the drive belt tensioner (Item 1) [Figure 30-40-3]

and remove the drive belt.

Remove the hydrostatic pump drive pulley mounting nut

(Item 2) [Figure 30-40-3] and washer.

Installation: Tighten the pump pulley mounting nut to

175-200 ft.-lbs. (237-271 Nm) torque.

753 Bobcat Loader

30-40-2 Service Manual
270 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-6

Removal And Installation (Cont'd)

Figure 30-40-5

P-28850
2

Hold the nut ( Item 1) [Figure 30-40-6]on the two

P-4238 hydrostatic pump mounting bolts (Item 2) [Figure 30-40-
5].

Installation: Install the key in the hydrostatic pump shaft Remove the two hy drostatic pump mounting bolts (Item
(Item 1) [Figure 30-40-5] before installing the pump drive 2) [Figure 30-40-5] from the pump and drive belt
pulley.

Dealer Copy -- Not for Resale

housing.

Installation: Tighten the pump mounting bolts to 65-70

ft.-lbs. (88-95 Nm) torque.

Reverse the removal procedure to install the hydrostatic

pump assembly.

753 Bobcat Loader

30-40-3 Service Manual
271 of 726
HYDROSTATIC PUMP (CONT’D)

Parts Identification (Right Half)

5
8
7 4
6 3
2
9 1

13 14
10 15

11 12
17

19
21
16

Dealer Copy -- Not for Resale

18
23
20
25
27

22
29
24
26

28
38
30 33
36
34
32
31
37
35
46
47 48

40
42 45

39 44

49
41

43
D-2427

753 Bobcat Loader

30-40-4 Service Manual
272 of 726
HYDROSTATIC PUMP (CONT’D)

Parts Identification (Right Half) (Cont'd)

Ref. Description Ref. Description

1. BOLT 26. RETAINER

2. END CAP 27. RETAINER
3. PLUG 28. PISTON ASSEMBLY
4. O-RING 29. PLATE
5. PLUG 30. SWASHPLATE
6. O-RING 31. PIN
7. O-RING 32. HOUSING
8. RELIEF VALVE 33. PLUG
9. BOLT 34. BEARING
10. GASKET 35. SEAL
11. BEARING 36. O-RING
12. PLUG 37. COVER
13. O-RING 38. BOLT
14. O-RING 39. SHAFT
15. RELIEF VALVE 40. SNAP RING

Dealer Copy -- Not for Resale

16. PIN 41. BEARING
17. VALVE PLATE 42. SNAP RING
18. RETAINER 43. SNAP RING
19. WASHER 44. PLUG
20. SPRING 45. O-RING
21. WASHER 46. BEARING
22. BLOCK 47. O-RING
23. RETAINER 48. PLATE
24. PIN 49 BOLT
25. WASHER

753 Bobcat Loader

30-40-5 Service Manual
273 of 726
HYDROSTATIC PUMP (CONT’D)

Parts Identification (Left Half)

4
17 6
16
8 1
11
14 13 10 3 2
12
5
7
15 9
22
23

19
18 21

20
24

Dealer Copy -- Not for Resale

28

30
25
32
26
34 27
29
36 31
38

35 33
47
37

39 46
45

44
48
43
49
42
50 40
51
58
52 41
53

57
52
53
59
54 55 56
D-2428

753 Bobcat Loader

30-40-6 Service Manual
274 of 726
HYDROSTATIC PUMP (CONT’D)

Parts Identification (Left Half) (Cont'd)

Ref. Description Ref. Description

1. SNAP RING 31. PIN

2. WASHER 32. RETAINER
3. SEAL 33. BLOCK
4. SNAP RING 34. WASHER
5. SNAP RING 35. SPRING
6. BEARING 36. WASHER
7. SNAP RING 37. WASHER
8. KEY 38. VALVE PLATE
9. SHAFT 39. PIN
10. HOUSING 40. GASKET
11. PLUG 41. BEARING
12. O-RING 42. PLUG
13. BEARING 43. POPPET
14. SEAL 44. SPRING
15. O-RING 45. SHIM

Dealer Copy -- Not for Resale

16. COVER 46. O-RING
17. BOLT 47. PLUG
18. PIN 48. RELIEF VALVE
19. O-RING 49. O-RING
20. PLUG 50. O-RING
21. BEARING 51. PLUG
22. O-RING 52. PIN
23. PLATE 53. O-RING
24. BOLT 54. COUPLER
25. SWASH PLATE 55. O-RING
26. WEAR PLATE 56. BOLT
27. PISTON ASSEMBLY 57. O-RING
28. PISTON RETAINER 58. O-RING
29. RETAINER 59. RELIEF VALVE
30. WASHER

753 Bobcat Loader

30-40-7 Service Manual
275 of 726
HYDROSTATIC PUMP (CONT’D) Pump Separation

Hydraulic Pump Removal And Installation Figure 30-40-9

Figure 30-40-7
1

1
2
1

1 N-19569
1
N-22038
Remove the four mounting bolts (Item 1) [Figure 30-40-
9].
Remove the pump mounting bolts (Item 1) [Figure 30-
40-7] (both sides). Figure 30-40-10

Dealer Copy -- Not for Resale

Installation: Tighten the mounting bolts to 2 7-37 ft.-lbs.
(37-50 Nm) torque.

Remove the hydraulic pump (Item 2) [Figure 30-40-7]

from the hydrostatic pumps.

Figure 30-40-8

2
N-19570
1

Separate the two hydrostatic pumps [Figure 30-40-10].

N-22036

Remove the gasket (Item 1) and coupler (Item 2) [Figure

30-40-8] with the hydraulic pump.

753 Bobcat Loader

30-40-8 Service Manual
276 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-13

Pump Separation (Cont’d)

Figure 30-40-11

3
1

1 N-19551

2
3 Remove the pump housing end cap (Item 1) [Figure 30-
N-19571 40-13].

Remove the gasket (Item 2) [Figure 30-40-13].

Remove the pump coupler (Item 1) [Figure 30-40-11].
Figure 30-40-14
Remove the large O-ring (Item 2) [Figure 30-40-11].

Dealer Copy -- Not for Resale

1
Remove the two small O-rings (Item 3) [Figure 30-40-
11].

Disassembly

Figure 30-40-12

1 1

N-17193

Remove the valve plate (Item 1) [Figure 30-40-14].

Check the valve plate for wear. (Both Sides.)

N-19550

Remove the four bolts (Item 1) [Figure 30-40-12] from

the pump housing end cap.

753 Bobcat Loader

30-40-9 Service Manual
277 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-17

Disassembly (Cont'd) 1

Figure 30-40-15

2
1

N-17198

Remove the slipper guide and pistons (Item 1) [Figure

N-17194 30-40-17] from the cylinder block.

Check all the pistons (Item 2) [Figure 30-40-17] for wear

Check the valve plate locating pin (Item 1) [Figure 30-40- and replace the rotating group as needed.
15] for wear and replace if needed.

Dealer Copy -- Not for Resale

Figure 30-40-18
Check the needle bearing (Item 2) [Figure 30-40-15] for
wear and replace if needed. 1

Figure 30-40-16

N-17199

Remove the ball guide retainer (Item 1) [Figure 30-40-

N-17197 18] from the cylinder block.

Remove the rotating group (Item 1) [Figure 30-40-16]

from the pump.

753 Bobcat Loader

30-40-10 Service Manual
278 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-21

Disassembly (Cont'd)

Figure 30-40-19 1

4 3
4 2

4 2 1
4
3
N-17481

Remove the driveshaft key (Item 1), snap ring (Item 2)

N-17200 and support washer (Item 3) [Figure 30-40-21] from the
drive shaft end of the pump.

Check the ball guide retainer (Item 1) and washer (Item Figure 30-40-22
2) [Figure 30-40-19] for wear and replace as needed.

Dealer Copy -- Not for Resale

1
Remove the pin retainer (Item 3) [Figure 30-40-19].

Remove the four pins (Item 4) [Figure 30-40-19] from the

cylinder block.

Check the cylinder block for wear and replace as needed.

Check pins (Item 4) [Figure 30-40-19] to see if they are

all the same length.

Figure 30-40-20

N-17239

Use a s eal puller and remove the seal (Item 1) [Figure

30-40-22] from the pump housing.

N-17201

Remove the thrust plate (Item 1) [Figure 30-40-20] from

the pump housing.

753 Bobcat Loader

30-40-11 Service Manual
279 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-25

Disassembly (Cont'd)
1
Figure 30-40-23

1
N-17242

Check the bearing for wear and replace if worn.

N-17240
Check the pump shaft (Item 1) [Figure 30-40-25] for
wear and replace if needed.
Remove the snap ring (Item 1) [Figure 30-40-23] from
the pump housing and remove the driveshaft and bearing Figure 30-40-26
from the housing.

Dealer Copy -- Not for Resale

Figure 30-40-24

1 1

1
N-17243

N-17241 Remove the four mount bolts (Item 1) [Figure 30-40-26]

from the lower trunnion cover. Remove the cover.

Remove the snap ring (Item 1) [Figure 30-40-24] from

the driveshaft and remove the bearing.

753 Bobcat Loader

30-40-12 Service Manual
280 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-29

Disassembly (Cont'd)

Figure 30-40-27

1 1

1
N-17246

Remove the four mount bolts (Item 1) from the pump

N-17244 housing and remove the steering bracket (Item 2) [Figure
30-40-29].

Remove the O-ring (Item 1) and bearing race (Item 2) Figure 30-40-30
[Figure 30-40-27] from the pump housing.

Dealer Copy -- Not for Resale

Figure 30-40-28

1
2

N-17247

N-17245 Remove the upper trunnion cover (Item 1) [Figure 30-40-

30].

Check the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-40-28] for wear and replace as needed.

753 Bobcat Loader

30-40-13 Service Manual
281 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-33

Disassembly (Cont'd)

Figure 30-40-31

1 N-17249

Inspect the bearing race (Item 1) and O-ring (Item 2)

N-17250 [Figure 30-40-33] and replace as needed.

Figure 30-40-34
Inspect the seal (Item 1) [Figure 30-40-31] in the upper
trunnion cover and replace if needed.

Dealer Copy -- Not for Resale

Figure 30-40-32

1 N-17251

2 Slide the swashplate from side to side and remove the

N-17248 tapered roller bearing (Item 1) [Figure 30-40-34] from
the swashplate shaft.

Remove the O-ring (Item 1) and bearing race (Item 2)

[Figure 30-40-32] from the pump housing.

753 Bobcat Loader

30-40-14 Service Manual
282 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-37

Disassembly (Cont'd)

Figure 30-40-35

N-17252

Install the swashplate and bearing into the pump housing

N-17252 [Figure 30-40-37].

Tilt the swashplate (Item 1) [Figure 30-40-35] and

remove the swashplate and lower bearing from the pump
housing.

Dealer Copy -- Not for Resale

Assembly

Figure 30-40-36

N-17253

Install the lo wer bearing (Item 1) [Figure 30-40-36] on

the swashplate.

753 Bobcat Loader

30-40-15 Service Manual
283 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-40

Assembly (Cont'd)

Figure 30-40-38

1 1

N-17247

3
Install the upper trunnion seal (Item 1) [Figure 30-40-40]
N-17249 and cover.

Figure 30-40-41
Figure 30-40-39

Dealer Copy -- Not for Resale

1

N-17246
N-17248

Install the steering bracket (Item 1) [Figure 30-40-41]

Install the tapered bearing (Item 1) [Figure 30-40-38] on and the four mounting bolts and tighten to 1 8-22 ft.-lbs.
the swashplate shaft. (24-30 Nm) torque.

Install the bearing race (Item 2) and O-ring (Item 3)

[Figure 30-40-38] as shown in [Figure 30-40-39].

753 Bobcat Loader

30-40-16 Service Manual
284 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-44

Assembly (Cont'd)

Figure 30-40-42

2
N-17243

Align the marks on the lower trunnion cover and pump

N-17245 housing as shown in [Figure 30-40-44].

Install the four mounting bolts and tighten to 18-22 ft.-lbs.

Figure 30-40-43 (24-30 Nm) torque.

Dealer Copy -- Not for Resale

Figure 30-40-45

N-17244

N-17242
Install the bearing race (Item 1) and O-ring (Item 2)
[Figure 30-40-42] at the lower trunnion as shown in
[Figure 30-40-43]. Install the snap ring (Item 1) [Figure 30-40-45] on th e
pump shaft.

753 Bobcat Loader

30-40-17 Service Manual
285 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-48

Assembly (Cont'd) 1 2 1
Figure 30-40-46

3 4
1
1

1
N-17200

Install the four slipper pins (Item 1) into the cylinder

N-17241 block. Use the retaining ring (Item 2) [Figure 30-40-48]
to hold the pins in place.

Install the bearing and snap ring (Item 1) [Figure 30-40- Apply a small amount of grease to t he washer (Item 3)
46] on the pump shaft. and install into the ball guide retainer (Item 4) [Figure 30-

Dealer Copy -- Not for Resale

40-48].
Figure 30-40-47
Figure 30-40-49

N-17240
N-17199

Install the pump shaft into the pump housing [Figure 30-
40-47]. Install the ball guide retainer and washer (Item 1) [Figure
30-40-49] onto the slipper holddown pins.
Install the snap ring (Item 1) [Figure 30-40-47].

753 Bobcat Loader

30-40-18 Service Manual
286 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-52

Assembly (Cont'd)
2 1
Figure 30-40-50

N-17194

Replace the needle bearing (Item 1) and valve plate

N-17198 locating pin (Item 2) [Figure 30-40-52] in the pump.

Figure 30-40-53
Assemble the piston assemblies into the slipper guide.
Lubricate the pistons and cylinder block bores and insert
the piston assemblies into the cylinder bores [Figure 30-

Dealer Copy -- Not for Resale

40-50].
2
Figure 30-40-51 1

N-17196

The bearing cage (Item 1) [Figure 30-40-53] will

protrude from 0.08-0.10 inch (2,0-2,5 mm) from the
surface of the pump.
N-17197
The valve plate locating spring pin (Item 2) [Figure 30-
40-53] will protrude from 1.65-0.185 inch (4,19-4,70 mm)
Lay the pump housing on its side and install the cylinder from the surface of the charge pump.
block, piston assembly into the housing.

Place the pump on a w ork surface with the end cap

opening up [Figure 30-40-51].

753 Bobcat Loader

30-40-19 Service Manual
287 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-56

Assembly (Cont'd) 1 1
Figure 30-40-54

N-19550

Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-40-56] to 35-45 ft.-
lbs. (47-61 Nm) torque.

Coat the backside of the valve plate with petroleum jelly Figure 30-40-57
to hold it in po sition and install the valve plate onto the
pump, bronze face up [Figure 30-40-54].

Dealer Copy -- Not for Resale

The notch (Item 1) [Figure 30-40-54] on the valve plate
must engage the locating pin.

Figure 30-40-55 1

2 1

N-19571

1
Install the two small O-rings (Item 1) [Figure 30-40-57].

Install the large new O-ring (Item 2) [Figure 30-40-57].

N-19551 Install the pump coupler (Item 3) [Figure 30-40-57].

Coat a new end cap gasket (Item 1) [Figure 30-40-55]

with petroleum jelly and install onto the end cap.

753 Bobcat Loader

30-40-20 Service Manual
288 of 726
HYDROSTATIC PUMP (CONT’D) Figure 30-40-59

Assembly (Cont'd)
1
Figure 30-40-58

1 N-19569

Tighten the four bolts (Item 1) [Figure 30-40-59] to 35-45

N-19570 ft.-lbs. (47-61 Nm) torque.

Install the two pumps together [Figure 30-40-58].

Dealer Copy -- Not for Resale

753 Bobcat Loader

30-40-21 Service Manual
289 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

30-40-22 Service Manual
290 of 726
DRIVE BELT Figure 30-50-3

Shield Removal And Installation

Figure 30-50-1
1

P-8760

Loosen the bolt (Item 1) [Figure 30-50-3] on the spring

P-28852 loaded drive idler.

NOTE: The pointer (Item 2) [Figure 30-50-3] will be at

Remove the th ree drive belt shield mounting clips (Item the 1 o'clock position when the idler is not
1) [Figure 30-50-1]. under spring tension.

Dealer Copy -- Not for Resale

Adjusting

Figure 30-50-2

P-43217

To adjust the drive belt between the flywheel and the

hydrostatic pump pulley, use the following procedure:

Stop the engine. Open the rear door.

Disconnect the negative (-) battery cable.

Remove the belt shield (Item 1) [Figure 30-50-2].

The pulley tensioner is located between the flywheel and

pump pulley.

753 Bobcat Loader

30-50-1 Service Manual
291 of 726
DRIVE BELT (CONT’D) NOTE: Do not set the idler against the travel stop in
the 3 o'clock position.
Adjusting (Cont’d)
Run the engine for a few minutes.
Figure 30-50-4
Stop the engine and recheck the pointer position.

Readjust if necessary.

After the idler has been in service, readjust when the

pointer reaches the 1 o'clock position.
1
Install the belt shield using the fasteners.

Reconnect the negative (-) battery cable.

Close the rear door.

Drive Belt Replacement

P-8762
Figure 30-50-6
Using the B elt Tensioner Bar (MEL1405) or a p ry bar,
push the id ler assembly against the belt. The pointer
(Item 1) [Figure 30-50-4] will be at the 3 o'clock position

Dealer Copy -- Not for Resale

when the idler stop is bottomed out. Do not pry directly
on the pulley, pry on the tensioner bracket the pulley is
mounted on.

NOTE: If the pointer does not move when prying on

the tensioner mounting bracket, manually
move the arrow towards the 3 o’clock position
with a screwdriver while putting tension on
the bracket to help get it started.

Figure 30-50-5
P-43217

Stop the engine. Open the rear door.

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

1 Remove the negative (-) cable from the battery. The

battery may be removed for additional working clearance.
(See Removal And Installation on Page 60-20-1.)

Remove the belt shield [Figure 30-50-6]. (See Shield

Removal And Installation on Page 30-50-1.)

P-8761

Raise the idler assembly slightly so that the pulley is

operating on spring tension and not against the stop.

Tighten the mounting bolt (Item 1) [Figure 30-50-5] to

25-28 ft.-lbs. (34-38 Nm) torque.

753 Bobcat Loader

30-50-2 Service Manual
292 of 726
DRIVE BELT (CONT’D) Figure 30-50-8

Drive Belt Replacement (Cont’d)

Figure 30-50-7

1
2

P-4064

Remove the drive belt from the pump pulley and flywheel.
P-8760 Remove the drive belt from the loader [Figure 30-50-8].

Install the new drive belt. Install the belt tensioner

Remove the fan drive belt (Item 1) [Figure 30-50-7]. assembly.

The belt tensioner is located between the flywheel and

Dealer Copy -- Not for Resale

Install the fan drive belt.
pump pulley. Loosen and remove the bolt (Item 2)
[Figure 30-50-7] from the belt tensioner. Adjust the drive belt. (See Adjusting on Page 30-50-1.)

Remove the belt tensioner assembly. Reinstall belt shield and connect the negative (-) cable to
the battery.

753 Bobcat Loader

30-50-3 Service Manual
293 of 726
DRIVE BELT (CONT’D) Figure 30-50-10

Tensioner Pulley Removal And Installation

1
Figure 30-50-9

P-8760

Loosen and remove the tensioner pulley mounting bolt

P-43217 (Item 1) [Figure 30-50-10].

Installation: Tighten the bolt to 25-28 ft.-lbs. (34-38 Nm)

Stop the engine. Open rear door. torque.

Remove the negative (-) cable from the battery. the

Dealer Copy -- Not for Resale

Remove the belt tensioner pulley from the housing.
battery may be removed for additional working clearance.
(See Removal And Installation on Page 60-20-1.) Reverse the removal procedure to install the dr ive belt
tensioner.
Remove the belt shield [Figure 30-50-9]. (See Shield
Removal And Installation on Page 30-50-1.)

753 Bobcat Loader

30-50-4 Service Manual
294 of 726
DRIVE BELT (CONT’D)

Tensioner Pulley Parts Identification

1. Cover
2. Bolt 1
3. Washer
4. Pins
5. Washer
6. Spring
2
7. Snap Ring
8. Snap Ring
9. Bearing
10. Dust Shield 11
11. Pulley 3
12. Bushing
13. Hub 12
4
14. Washer
15. Seal
16. Arrow Indicator Plate 5
17. Locating Pin
18. Spring

Dealer Copy -- Not for Resale

19. Shaft 6 13
20. Bracket

NOTE: Drive idler parts are not 5 14

available individually. Consult
parts catalog for available 15
sub-assemblies. 7

8 16

17
9

18
10

19

20

E-2296

753 Bobcat Loader

30-50-5 Service Manual
295 of 726
DRIVE BELT (CONT’D) Figure 30-50-13

Tensioner Pulley Disassembly

Figure 30-50-11

3
1

1
4

P-8861

Remove the two pin s (Item 1) from the hub assembly

P-8858 (Item 2) [Figure 30-50-13] only if the y have been
damaged.

Remove the grease cover (Item 1) [Figure 30-50-11]. Remove the bracket assembly (Item 3) by tapping on the
shaft (Item 4) [Figure 30-50-13] with a plastic hammer.

Dealer Copy -- Not for Resale

Figure 30-50-12
Figure 30-50-14

2
3 2

1 4
P-8859
P-8862

Remove the bolt (Item 1), the flat washer (Item 2), the
retainer washer (Item 3), the spring washer (Item 4) and Remove the spring (Item 1) from the bracket (Item 2)
the second retainer washer (Item 3) from the pulley [Figure 30-50-14].
assembly (Item 5) [Figure 30-50-12].

753 Bobcat Loader

30-50-6 Service Manual
296 of 726
DRIVE BELT (CONT’D) Figure 30-50-17

Tensioner Pulley Assembly

Figure 30-50-15

1
1

P-8873
2

Turn the pulley assembly over and install the two pins
P-8871 (Item 1) [Figure 30-50-17] into the hub.

Figure 30-50-18
Install the s pring (Item 1) on the pulley (Item 2) [Figure
30-50-15] as shown.

Dealer Copy -- Not for Resale

Figure 30-50-16

2
3
P-8874

Install a pu nch as shown and turn clockwise while

P-8872 applying down pressure on the pulley.

Turn until the pu lley snaps down into place; this

Install the s haft from the bracket assembly (Item 1) into procedure winds the spring and retains the end of th e
the pulley assembly (Item 2) and align the spring (Item 3) spring in proper location [Figure 30-50-18].
[Figure 30-50-16] over the alignment pin on the bracket.

753 Bobcat Loader

30-50-7 Service Manual
297 of 726
DRIVE BELT (CONT’D) Figure 30-50-21

Tensioner Pulley Assembly (Cont'd)

Figure 30-50-19

1
1

P-8877

Press the grease cap (Item 1) onto the pulley assembly

P-8875 (Item 2) [Figure 30-50-21]. Press on the outer formed
edge of the grease cap.

Install the first retainer washer (Item 1) and spring NOTE: When pressing the grease cap onto the pulley
washer (Item 2) [Figure 30-50-19] over the roll pins. assembly, do not press down on the arrow

Dealer Copy -- Not for Resale

indicator plate. Support the hub assembly so
Figure 30-50-20 that it contacts only the hub and not the arrow
indicator plate.

2
1

P-8876

Install the second retainer washer (Item 1), the washer

(Item 2) and the bolt (Item 3) [Figure 30-50-20]. Tighten
the bolt to 28-32 ft.-lbs. (38-45 Nm) torque.

Fill the grease cap 1/4 full (approximately 1/2-3/4 oz.) of

grease.

753 Bobcat Loader

30-50-8 Service Manual
298 of 726
OIL COOLER Figure 30-60-2

Removal and Installation

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

N-19345
Following tool is necessary to perform this procedure:

MEL1558 Install tool MEL1558 (Item 1) to outside of rubber sleeve

(Item 1) [Figure 30-60-2].
Open the rear door of the loader.

Figure 30-60-1

Dealer Copy -- Not for Resale

2 3 1
N-20727

Raise the rear grill [Figure 30-60-1].

Disconnect the inlet and outlet hoses (Items 1 & 2) from

the oil cooler (Item 3) [Figure 30-60-1].

753 Bobcat Loader

30-60-1 Service Manual
299 of 726
OIL COOLER (CONT’D) Figure 30-60-4

Removal and Installation (Cont’d)

Figure 30-60-3

N-19346

Slide the rubber sleeve in toward the radiator. The

N-21153 connector will release [Figure 30-60-3] & [Figure 30-60-
4].

NOTE: When installing the cooler hoses, the fittings

should make a clicking sound when pushed

Dealer Copy -- Not for Resale

together.

Lift up t he oil cooler and remove the cooler from the

loader.

Reverse the removal procedure to install the oil cooler.

753 Bobcat Loader

30-60-2 Service Manual
300 of 726
 DRIVE SYSTEM

BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-2
Pedal Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . 40-10-1 DRIVE
Pedal Removal And Installation (S/N 515834999 & Below) . . . 40-10-1 SYSTEM
Switch Operated Parking Brake (S/N 515835000 & Above) . . . 40-10-3

CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation. . . . . . . . . . . . . . . . . . . 40-30-3
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-30-2
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-30-4
Removing The Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Sprocket And Bearings Removal And Installation . . . . . . . 40-20-3
Chain Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8

Dealer Copy -- Not for Resale

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (See TORQUE SPECIFICATIONS FOR BOLTS on Page
SPEC-30-1.) UNLESS OTHERWISE SPECIFIED.

753 Bobcat Loader

40-01 Service Manual
301 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

40-02 Service Manual
302 of 726
BRAKE Reverse the r emoval procedure to i nstall the parking
brake assembly in the loader.
Pedal Removal And Installation (S/N 515834999 &
Below) Pedal Disassembly And Assembly
Figure 40-10-5 Figure 40-10-7

5
6

1
4
1

N-20720
2
3 P-4189

Raise the l oader operator cab. (See Raising The

Loosen and remove the mounting bolt (Item 1) and nut
Operator Cab on Page 10-30-1.)
from the spring mounting bracket (Item 2) [Figure 40-10-

Dealer Copy -- Not for Resale

7].
Remove the two mounting bolts (Item 1) [Figure 40-10-5]
from the brake pedal mounting bracket.
Remove the brake pedal spring (Item 3) from the tension
spring mounting bracket (Item 2) and from the brake
Disconnect the e lectrical connector from the parking
pedal mounting bracket (Item 4) [Figure 40-10-7].
brake pedal sensor. The connector is located behind the
control panel.
Remove the two mounting bolts, washers and nuts (Item
5) [Figure 40-10-7] from the brake pedal sensor.
Installation: Tighten the mounting bolts to 2 5-28 ft.-lbs.
(34-38 Nm) torque.
Remove the harness mounting clamp (Item 1) [Figure
40-10-8] from the pedal mounting bracket (Item 4)
Figure 40-10-6
[Figure 40-10-7].

Remove the s ensor harness from the pedal mounting

bracket.

Remove the pedal mounting bolt (Item 6) [Figure 40-10-

7], plastic spacers and bushing nut from the brake pedal.

Remove the pedal from the pedal mounting bracket.

N-20658

Remove the fuse mount bracket (Item 1) [Figure 40-10-

6] from the front of the control panel.

Remove the parking brake assembly from the loader.

753 Bobcat Loader

40-10-1 Service Manual
303 of 726
BRAKE (CONT’D) Disc Removal And Installation

Pedal Disassembly And Assembly (Cont’d)

Figure 40-10-8
WARNING
Never work on a machine with the lift arms up unless
1
the lift arms are secured by an approved 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.
W-2059-0598

Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Raise the l oader operator cab. (See Raising The

P-4156 Operator Cab on Page 10-30-1.)

Disconnect and remove the engine speed control. (See

Photo [Figure 40-10-8] shows the p arking brake Removal And Installation on Page 70-20-1.)
disassembled to i dentify the existing parts in the brake
assembly.

Dealer Copy -- Not for Resale

Remove the control panel from the loader. (See Removal
and Installation on Page 50-100-1.)

Remove the center chaincase cover. (See Center Cover Removal And Installation on
Page 40-30-3.)
Remove the front chaincase cover. (See Front Cover Removal And Installation on
Page 40-30-2.)
Remove the traction lock assembly. (See TRACTION Figure 40-10-10
LOCK on Page 60-110-1.)

Figure 40-10-9

N-19105

1
N-19081
Inspect the traction lock guides (Item 1) [Figure 40-10-
10] and the brake disc for damage or wear and r eplace
as necessary.
The parking brake discs (Item 1) [Figure 40-10-9] are
located beneath the center chaincase cover. A snap ring pliers with 90° tips are necessary for
removing the parking brake disc.

753 Bobcat Loader

40-10-2 Service Manual
304 of 726
BRAKE (CONT’D) Switch Operated Parking Brake (S/N 515835000 &
Above)
Disc Removal And Installation (Cont’d)
Figure 40-10-13
Figure 40-10-11

2 1

P-21944
N-19082

The parking brake switch in the front panel (Item 1)

Figure 40-10-12 [Figure 40-10-13] replaced the pedal parking brake.
(See Removal And Installation on Page 60-50-9.)

Dealer Copy -- Not for Resale

1

N-19083

Remove the s nap ring (Item 1) [Figure 40-10-11] from

the end of the sprocket on the hydrostatic motor carrier.

Slide the disc (Item 2) [Figure 40-10-11] off the sprocket

(Item 1) [Figure 40-10-12] and remove the disc through
the front chaincase cover.

Reverse the r emoval procedure to install the disc in the

loader.

Refer to Page 60-01 for the traction lock inspection

procedure.

753 Bobcat Loader

40-10-3 Service Manual
305 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

40-10-4 Service Manual
306 of 726
DRIVE COMPONENTS Figure 40-20-2

Axle Seal Removal And Installation

Figure 40-20-1

1 1

P-4159

2 Install the puller tool (Item 1) [Figure 40-20-2] on the

P-4157 axle hub.

A driver tool (Item 2) [Figure 40-20-2] can be used for

The tools listed are needed for the following procedure: centering the threaded rod of the puller.
Axle Hub Puller Tool

Dealer Copy -- Not for Resale

MEL1399 - Seal Driver Tool

MEL1242 - Power Ram (may be used if desired)

WARNING
To loosen the axle hub mounting bolt (Item 1) [Figure 40- NEVER STAND IN-LINE OF THE HUB WHEN
20-1], use the following procedure: REMOVING A HUB FROM AN AXLE. The hub has a
Before lifting and blocking the loader, loosen the hub tapered fit on the axle end and can come off the axle
mounting bolt (Item 1) [Figure 40-20-1]. with great force and cause serious injury.
W-2186-0395
NOTE: If the axle and bearings are being replaced,
also loosen the sprocket mounting bolt inside
the chaincase before lifting and blocking the Use a wrench with the puller and remove the axle hub
loader. (See Axle Sprocket And Bearings from the axle tube. A spacer and a powe r ram can be
Removal And Installation on Page 40-20-3.) used between the axle and the tool if available, instead of
the wrench, threaded rod and driver tool.
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.)

Remove the front tire/wheel assembly.

Installation: Tighten the wheel mounting nuts to 105-115

ft.-lbs. (142-156 Nm) torque.
Remove the hub mounting bolt (Item 1) [Figure 40-20-1]
and washer from the axle.
Installation: Tighten the h ub mounting bolt to 5 75-625
ft.-lbs. (780-848 Nm) torque.

Remove two of the wheel mounting studs (Item 2)

[Figure 40-20-1].
Use a wheel mounting nut on each stud and remove the
two studs with a hammer.
Installation: Support the flange of th e axle hub and
install the two studs with a h ammer. A hydraulic press
can also be used to install the studs.

753 Bobcat Loader

40-20-1 Service Manual
307 of 726
DRIVE COMPONENTS (CONT’D) Figure 40-20-5

Axle Seal Removal And Installation (Cont'd)

Figure 40-20-3

P-4160

Installation: MEL1399 seal driver tool is necessary for

1
P-4161 the following procedure:

Clean the seal area and inspect the shaft for wear.
Remove the key (Item 1) [Figure 40-20-3] from the axle.
NOTE: If the shaft is damaged or worn, an axle repair

Dealer Copy -- Not for Resale

Figure 40-20-4 sleeve kit is available from Bobcat Parts Sales
in Chicago.

Place the new axle seal over the axle and into the axle
tube.

Install MEL1399 seal driver tool over the axle and put
against the axle seal [Figure 40-20-5].

Hit the seal driver tool with a hammer until the too l is
flush with the edge of the axle tube [Figure 40-20-5].
1
Reverse removal procedure to install the axle hub and
wheel assembly.

P-4181

Drill a small hole in the axle seal.

Install a s lide hammer (Item 1) [Figure 40-20-4] with a

screw tip end in the axle seal.

Remove the axle seal.

753 Bobcat Loader

40-20-2 Service Manual
308 of 726
DRIVE COMPONENTS (CONT’D) Figure 40-20-6

Axle Sprocket And Bearings Removal And

Installation

The tools listed are needed for the following procedure:

MEL1242 - Power Ram

MEL1202B - Axle Bearing Service Set

NOTE: The procedure shown is for removing the

front axle, bearings and sprocket. This
procedure can also be used for the rear axle,
bearings and sprocket. (See Rear Cover
Removal And Installation on Page 40-30-4.) 1
P-4147

WARNING Loosen the axle sprocket mounting bolt (Item 1) [Figure

40-20-6].
Never work on a machine with the lift arms up unless Lift and block the loader. (See LIFTING AND BLOCKING
the lift arms are secured by an approved lift arm THE LOADER on Page 10-10-1.)
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment

Dealer Copy -- Not for Resale

Remove the fluid from the chaincase. (See Removing
to fall and cause injury or death. The Oil on Page 40-30-1.)
W-2059-0598

Remove the axle hub. (See DRIVE COMPONENTS on

Raise the lift arms and install an approved lift arm Page 40-20-1.)
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.) Remove the sprocket mounting bolt (Item 1) [Figure 40-
20-6].
Lift and block the loader. (See LIFTING AND BLOCKING
THE LOADER on Page 10-10-1.) Installation: Tighten the sprocket mounting bolt to 220-
245 ft.-lbs. (298-332 Nm) torque.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)

Remove the control panel. (See Removal and Installation

on Page 50-100-1.).

Remove the b rake pedal. (If so equipped.) (See Pedal

Removal And Installation (S/N 515834999 & Below) on
Page 40-10-1.).

Remove the front chaincase cover. (See Front Cover

Removal And Installation on Page 40-30-2.).

753 Bobcat Loader

40-20-3 Service Manual
309 of 726
DRIVE COMPONENTS (CONT’D) Figure 40-20-9

Axle Sprocket And Bearings Removal And

Installation (Cont'd)

Figure 40-20-7 1

P-4170

A bearing puller (Item 1) [Figure 40-20-9] is needed for

the following procedure:
1 P-4158
Put the axle/outer bearing assembly in the bearing puller
as shown and put in the hy draulic press [Figure 40-20-
Install the MEL1242 power ram (Item 1) [Figure 40-20-7] 9].
between the two sprockets.

Dealer Copy -- Not for Resale

Be sure the bearing puller makes good contact with the
Put a spacer between the power ram and axle. Push the
inner race of the be aring and press the bearing off the
axle out to the end of the power ram stroke. Add another
mounting surface of the axle.
spacer and push the axle again. Repeat this procedure
until the axle is free from the sprocket and inner bearing.
Be sure to hol d onto the axle during removal as it wi ll
Figure 40-20-8 slide freely along the axle shaft after removal from the
bearing mounting surface and until the bearing contacts
the spline on the shaft.

Figure 40-20-10

2
1

P-4162

Remove the drive chain from the sprocket (Item 1)

[Figure 40-20-8] and remove the sprocket from the P-4171
chaincase.

Installation: Pack both axle bearings with grease before Press the splined end of the axle free from the bearing
installing them. [Figure 40-20-10].
Remove the inner bearing (Item 2) [Figure 40-20-8] and
remove the axle from the axle tube. (See Axle Sprocket
And Bearings Removal And Installation on P age 40-20-
3.)

753 Bobcat Loader

40-20-4 Service Manual
310 of 726
DRIVE COMPONENTS (CONT’D) Figure 40-20-12

Axle Sprocket And Bearings Removal And

Installation (Cont'd)

Figure 40-20-11

4
3

P-4175

2 When the bearing reaches the bearing mounting surface,

continue the installation until the bearing is fully seated
P-4169 [Figure 40-20-12].

Figure 40-20-13
Installation: A piece of round tubing (Item 1) [Figure 40-
20-11] is needed to install the bearing on the axle shaft.

Dealer Copy -- Not for Resale

The tubing needs to me asure approximately 0.500 inch
(12,7 mm) to 1.0 inch (25,4 mm) in length. The inside
diameter of the tubing should not be under 2.100 inches
(53,3 mm) and the outside diameter should not be over
2.400 inches (60 mm),

A bearing puller (Item 2) [Figure 40-20-11] is also

needed to install the bearing on the axle.

Put the tubing (Item 1) on the bearing puller (Item 2)

[Figure 40-20-11].

Put the bearing (Item 3) [Figure 40-20-11] on the tube as P-4172

shown.

Put the spline end of the axle shaft (Item 4) [Figure 40- Use the tools provided in the MEL1202B Axle Bearing
20-11] in the bearing and press the bearing onto the axle. Service Set for bearing cup removal and ins tallation. A
slide hammer is also necessary for this procedure.
Be sure to hold onto the axle during installation, as it will
slide freely along the axle shaft after the spline end has Use the long rod and bearing cup tool to r emove the
passed through the bearing and until it reaches the inner bearing cup [Figure 40-20-13].
bearing mounting surface on the axle.
Hit the long rod with a hammer to remove the bearing cup
from the axle tube [Figure 40-20-13].

753 Bobcat Loader

40-20-5 Service Manual
311 of 726
DRIVE COMPONENTS (CONT’D) Figure 40-20-15

Axle Sprocket And Bearings Removal And

Installation (Cont'd)

Figure 40-20-14

P-4180

2
Use the slide hammer and remove the bearing cup from
1 the axle tube [Figure 40-20-15].
P-4179

To remove the outer bearing cup, place the bearing cup

tool (Item 1) [Figure 40-20-14] on the slide hammer.

Dealer Copy -- Not for Resale

Leave the bearing cup tool loose until the tool is installed
inside the tube [Figure 40-20-14].

After the bearing cup tool is inside the axle tube, pull the
tool against the bearing cup and tighten the nut (Item 2)
[Figure 40-20-14] on the tool.

753 Bobcat Loader

40-20-6 Service Manual
312 of 726
DRIVE COMPONENTS (CONT’D) Put the installation tool (Item 1) [Figure 40-20-17] in the
axle tube with the thr eaded rod through the hole in the
Axle Sprocket And Bearings Removal And tool.
Installation (Cont'd)
Secure the tool to the threaded rod with a nut [Figure 40-
Figure 40-20-16 20-17].

Hold the inside nut (Item 3) [Figure 40-20-16] with a

1 wrench and tighten the outside nut as shown in photo
2 [Figure 40-20-17].

Tighten the nut until the bearing cup is seated.

Figure 40-20-18

P-4174

Figure 40-20-17

Dealer Copy -- Not for Resale

1

P-4173

To install the outer bearing cup, use the short rod and the
bearing cup tool used for removing the bearing cups.

Put the bearing cup tool on the short rod.

2
Put the bearing cup in the axle tube and put the tool into
the tube over the bearing cup [Figure 40-20-18].
P-4164
Hit the short rod with a ham mer until the bearing cup is
seated inside the axle tube.
Use the be aring cup installation tools (Item 1) [Figure
40-20-16] and (Item 1) [Figure 40-20-17] and the long
threaded rod (Item 2) [Figure 40-20-17] from the service
set to install the inner and outer bearing cups.

Put the inner bearing cup in the axle tube (Item 2)

[Figure 40-20-16].

Put the installation tool (Item 1) [Figure 40-20-16] in the

axle tube.

Install the long threaded rod (Item 2) [Figure 40-20-17]

into the axle tube and through the installation tool (Item
1) [Figure 40-20-16].

Secure the tool to the thr eaded rod with a nut ( Item 3)
[Figure 40-20-16].

753 Bobcat Loader

40-20-7 Service Manual
313 of 726
DRIVE COMPONENTS (CONT’D) Figure 40-20-19

Chain Removal And Installation

2

WARNING
DO NOT exceed the recommended torque of 130 ft.-
lbs. (176 Nm). The tool may fail under too much
1
torque. Put cloth around the tool to protect yourself
from flying debris.
W-2233-0296

P-4152

WARNING Remove the parking brake disc (Item 1) [Figure 40-20-

19]. (See Disc Removal And Installation on Page 40-10-
Never work on a machine with the lift arms up unless
2.)
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
Remove the six carrier mounting bolts (Item 2) [Figure
support device can allow the lift arms or attachment
40-20-19] from inside the chaincase.
to fall and cause injury or death.

Dealer Copy -- Not for Resale

W-2059-0598
Installation: Tighten the motor carrier mounting bolts to
125-140 ft.-lbs. (170-190 Nm) torque.
Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device Figure 40-20-20
on Page 10-20-1.)

Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.)

Raise the l oader operator cab. (See Raising The

Operator Cab on Page 10-30-1.)

Drain the fluid from the chaincase. (See Removing The 1

Oil on Page 40-30-1.)

Remove the e ngine speed control. (See Removal And

Installation on Page 70-20-1.)

Remove the control panel. (See Removal and Installation P-4167

on Page 50-100-1.)

Remove the traction lock assembly. (See TRACTION Tip the end of the sprocket on the mo tor carrier toward
LOCK on Page 60-110-1.) the rear of the loader and remove the r ear drive chain
from the sprocket.
Remove the center chaincase cover. (See Center Cover
Removal And Installation on Page 40-30-3.) NOTE: It may be necessary to tie the front drive chain
up as shown in photo [Figure 40-20-20], so the
Remove the front (or rear) chaincase cover. (See carrier/motor assembly can be moved enough
CHAINCASE on Page 40-30-1.) to free the rear drive chain (Item 1) [Figure 40-
20-20] from the sprocket.
Remove the front (or rear) axle and sprocket. (See
DRIVE COMPONENTS on Page 40-20-1.) Remove the front drive chain from the chaincase.

753 Bobcat Loader

40-20-8 Service Manual
314 of 726
DRIVE COMPONENTS (CONT’D)

Chain Removal And Installation (Cont’d)

Figure 40-20-21

B-13504

The tool listed is needed for the following procedure:

MEL1037 - Chain Link Tool

Dealer Copy -- Not for Resale

Installation: If a new chain is installed, a connector link
must be used to connect the chain together.

Use MEL1037 Chain Link Tool and #80 chain adapter.

Secure the tool and place the connector link in the tool as
shown [Figure 40-20-21].

Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-21]. Tighten the
threaded rod of the chain link tool to 130 ft.-lbs. (176 Nm)
torque.

753 Bobcat Loader

40-20-9 Service Manual
315 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

40-20-10 Service Manual
316 of 726
CHAINCASE Removing The Oil

Checking And Adding Oil Figure 40-30-2

Figure 40-30-1

1 1

P1616

P-3870
To drain the oil from the chaincase, remove the c over
(Item 1) [Figure 40-30-2] which is installed over the drain
The chaincase contains the final drive sprockets and plug at the rear of the chaincase.
chains and uses the same type of oil as the hydraulic/
hydrostatic system. (See Hydraulic System on P age

Dealer Copy -- Not for Resale

Installation: Tighten the cover bolts to 10-20 ft.-lbs. (24-
SPEC-10-3.) 27 Nm) torque.

To check the chaincase oil level, use the fol lowing Figure 40-30-3
procedure:

Drive the loader on a level surface. Stop the engine.

Remove the plug (Item 1) [Figure 40-30-1] from the front

of the chaincase housing.

If oil can be reached with the tip of the your finger through
the hole the oil level is correct. 1

If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.

P1619

Remove the drain plug (Item 1) [Figure 40-30-3] and

drain the oil into a container.

NOTE: When installing the drain plug into the

chaincase, always use a NEW drain plug
gasket.

753 Bobcat Loader

40-30-1 Service Manual
317 of 726
CHAINCASE (CONT’D) Figure 40-30-5

Front Cover Removal And Installation

1 1 1

1 1
1

WARNING P-4144

Never work on a machine with the lift arms up unless Remove the eight front chaincase cover mounting bolts
the lift arms are secured by an approved lift arm (Item 1) [Figure 40-30-5].
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Installation: Tighten the mounting bolts to 25-28 ft.-lbs.
to fall and cause injury or death. (34-38 Nm) torque.
W-2059-0598

Dealer Copy -- Not for Resale

Remove the front chaincase cover (Item 2) [Figure 40-
Figure 40-30-4 30-5] from the loader.

Installation: The front chaincase cover (Item 2) [Figure

40-30-5] has a gasket installed between the cover and
the chaincase. Install new gasket if necessary.

N-19075A

Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Raise the l oader operator cab. (See Raising The

Operator Cab on Page 10-30-1.)

Remove the brake pedal (If equipped) (Item 1) [Figure

40-30-4]. (See Pedal Removal And Installation (S/N
515834999 & Below) on Page 40-10-1.).

753 Bobcat Loader

40-30-2 Service Manual
318 of 726
CHAINCASE (CONT’D) Figure 40-30-7

Center Cover Removal And Installation EARLIER

Figure 40-30-6

LATER 3

3
2 4

4 P-4132

Disconnect and remove the engine speed control from

P-28856 the control panel. (See Removal And Installation on Page
70-20-1.)

Remove the control panel from the loader. (See Removal

and Installation on Page 50-100-1.)

Dealer Copy -- Not for Resale

Disconnect the lift control cross bar (Item 1) [Figure 40-
30-6] from the lift pedal linkage.

Disconnect the lift control cross bar (Item 2) [Figure 40-

30-6] from the lift spool on the main control valve.

Disconnect the electrical connector (Item 3) [Figure 40-

30-6] & [Figure 40-30-7] from the p arking brake pedal
sensor.

Remove the ten center chaincase cover mounting bolts

(Item 4) [Figure 40-30-6] and [Figure 40-30-7].

Installation: Tighten the mounting bolts to 25-28 ft.-lbs.

(34-38 Nm) torque.

Remove the center chaincase cover from the loader.

Installation: The center chaincase cover has a gasket

installed between the c over and the chaincase. Install
new gasket if necessary.

753 Bobcat Loader

40-30-3 Service Manual
319 of 726
CHAINCASE (CONT’D) Figure 40-30-9

Rear Cover Removal And Installation

Figure 40-30-8
1
1

P-4147

2 Installation: The rear chaincase cover (Item 2) [Figure

1 P-28857 40-30-8] has a gasket (Item 1) [Figure 40-30-9] installed
between the cover and the chaincase. Install a ne w
gasket if necessary. (See Linkage Neutral Adjustment on
Disconnect the front steering linkage bars from the rear Page 50-110-8.)
linkage bars. (See Linkage Removal And Installation on
Page 50-110-3.)

Dealer Copy -- Not for Resale

Move the li nkage bars to allow adequate space to
remove the rear chaincase cover.

Remove the front auxiliary bleed block, if equipped. (See

Removal And Installation (S/N 515842309 and Below) on
Page 20-120-1.)

Remove the ei ght rear chaincase cover mounting bolts

(Item 1) [Figure 40-30-8].

Installation: Tighten the mounting bolts to 2 5-28 ft.-lbs.

(34-38 Nm) torque.

Remove the rear chaincase cover (Item 2) [Figure 40-

30-8] from the loader.

753 Bobcat Loader

40-30-4 Service Manual
320 of 726
 MAIN FRAME

BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Bob-Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4 MAIN
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1 FRAME

CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-110-2
Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-5
Linkage Neutral Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 50-110-8
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . 50-110-3
Rubber Boot Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-2 DRIVE
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 50-110-1 SYSTEM
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-110-1

CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) . . 50-111-1

Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Control Handle Disassembly And Assembly . . . . . . . . . . . . . 50-111-5
Control Handle Removal And Installation . . . . . . . . . . . . . . . 50-111-5

Dealer Copy -- Not for Resale

ELECTRICAL
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-7 SYSTEM &
Control Lever Removal And Installation. . . . . . . . . . . . . . . . . 50-111-6 ANALYSIS
Handle Control Unit Removal And Installation. . . . . . . . . . . . 50-111-2

CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) W/PUSH ENGINE

BUTTON FLOAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1 SERVICE
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-6
Control Lever Removal And Installation. . . . . . . . . . . . . . . . 50-112-5
Control Handle Disassembly And Assembly . . . . . . . . . . . . 50-112-4 SPECIFICATIONS
Control Handle Removal And Installation . . . . . . . . . . . . . . 50-112-3
Handle Sensor Removal And Installation . . . . . . . . . . . . . . 50-112-1

CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS)

ADVANCED HAND CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . 50-113-1
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 50-113-1
Control Handle Disassembly and Assembly . . . . . . . . . . . . 50-113-6
Control Handle Removal and Installation. . . . . . . . . . . . . . . 50-113-5
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-113-7
Control Lever Removal and Installation . . . . . . . . . . . . . . . . 50-113-6
Handle Sensor Removal And Installation . . . . . . . . . . . . . . 50-113-1

Continued On Next Page

753 Bobcat loader

50-01 Service Manual
321 of 726
 MAIN FRAME (CONT’D)

CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS)

SELECTABLE HAND/FOOT CONTROL. . . . . . . . . . . . . . . . 50-114-1
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 50-114-1
Control Handle Disassembly and Assembly . . . . . . . . . . 50-114-6
Control Handle Removal and Installation. . . . . . . . . . . . . 50-114-5
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-114-7
Control Lever Removal and Installation . . . . . . . . . . . . . . 50-114-6
Handle Sensor Removal And Installation . . . . . . . . . . . . 50-114-1

CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Crossbar Linkage Removal And Installation . . . . . . . . . . . 50-90-2
Lift Foot Pedal Linkage Removal And Installation . . . . . . . 50-90-3
Pedal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Tilt Foot Pedal Linkage Removal And Installation . . . . . . . 50-90-3

CONTROL PEDALS (ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Foot Pedal Linkage Disassembly And Assembly. . . . . . . . 50-91-2
Foot Pedal Removal And Installation . . . . . . . . . . . . . . . . . 50-91-2

Dealer Copy -- Not for Resale

Foot Sensor Removal And Installation. . . . . . . . . . . . . . . . 50-91-1

CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

LIFT ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Cylinder Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . 50-20-3
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . 50-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-4

OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . 50-30-1

OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . 50-31-1

Back Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-31-3
Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . 50-31-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . 50-31-4
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . 50-31-2

Continued On Next Page

753 Bobcat Loader

50-02 Service Manual
322 of 726
 MAIN FRAME (CONT’D)

POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Power Bob-Tach Lever And Wedge. . . . . . . . . . . . . . . . . . . . 50-41-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Door Latch and Catch Adjustment . . . . . . . . . . . . . . . . . . . . . 50-70-3
Latch Removal and Installation (S/N 515840618 & Below) . . 50-70-4
Latch Removal and Installation (S/N 515840619 & Above). . 50-70-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 50-70-2

REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . 50-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-2

SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
Compression Spring Disassembly And Assembly . . . . . . . . . 50-10-5

Dealer Copy -- Not for Resale

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

753 Bobcat loader

50-03 Service Manual
323 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

50-04 Service Manual
324 of 726
SEAT BAR Figure 50-10-3

Removal And Installation

Figure 50-10-1

P10564 P10563

Loosen the nut ( both sides) at th e front corners of th e

P-43383 operator cab [Figure 50-10-3].

Remove the nuts and plates (both sides) [Figure 50-10-

Raise the seat bar (Item 1) [Figure 50-10-1]. 3].

Dealer Copy -- Not for Resale

Figure 50-10-2 Installation: Tighten the nuts to 40-50 ft.-lbs. (54-68 Nm)
torque.

Figure 50-10-4

N-18463

Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]

P-30151
from the cab harness.

Lower the seat bar. Lift on the grab handle and bottom of t he operator cab
slowly until the cab is all the way up a nd the latching
mechanism engages [Figure 50-10-4].

753 Bobcat Loader

50-10-1 Service Manual
325 of 726
SEAT BAR (CONT’D) Figure 50-10-6

Removal And Installation (Cont'd)

Figure 50-10-5
1

P-43382

Remove the seat bar (Item 1) [Figure 50-10-6] from the

N-20632 operator cab.

Reverse the above procedure to install the seat bar into

Remove the seat bar mounting nuts (Item 1) [Figure 50- the operator cab.
10-5] (both sides).

Dealer Copy -- Not for Resale

Installation: Tighten the nuts to 28 ft.-lbs. (38 Nm)
torque.

Lower the operator cab. (See Lowering The Operator

Cab on Page 10-30-2.)

753 Bobcat Loader

50-10-2 Service Manual
326 of 726
SEAT BAR (CONT’D) Figure 50-10-8

Assembling Components

Figure 50-10-7

4 5 6
7
9
4 8
3 5

3 6

2 9 8
10 2 10
1

7
N-19383

Assemble the parts as shown for the left side of the seat 1
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].

Dealer Copy -- Not for Resale

Seat Bar Mount (Item 1)
Mounting Bolt (Item 2)
Keyed Plastic Bushing (Item 3)
Seat Bar (Item 4)
Magnetic Bushing Assembly (Item 5)
Pivot Bushing (Item 6)
Sensor Bracket (Item 7)
Sensor Mounting Nut (Item 8)
N-19219
Sensor Mounting Bolt (Item 9)
Mounting Nut (Item 10)
Installation: Tighten the mou nting bolt (Item 2) [Figure
50-10-7] & [Figure 50-10-8] to 50- 70 in.-lbs. (5,6-7,9
Nm) torque.

753 Bobcat Loader

50-10-3 Service Manual
327 of 726
SEAT BAR (CONT’D) Figure 50-10-10

Assembling Components (Cont'd)

Figure 50-10-9

5
4 6

3
4
5
2 7 2 3 6

1
N-19340 1

Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-9] & [Figure 50-10-

Dealer Copy -- Not for Resale

10].

Seat Bar Mount (Item 1)

Mounting Nut (Item 2)
Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Seat Bar (Item 5)
Keyed Plastic Bushing (Item 6)
Mounting Bolt (Item 7)
N-19220

Installation: Tighten the mou nting bolt (Item 7) [Figure

50-10-9] & [Figure 50-10-10] to 50 -70 in.-lbs. (5,6-7,9
Nm) torque.

753 Bobcat Loader

50-10-4 Service Manual
328 of 726
SEAT BAR (CONT’D) Figure 50-10-12

Compression Spring Disassembly And Assembly 6 7

Figure 50-10-11

4 5
2

2
1 N-19384

Disassemble and assemble the seat bar compression

spring and parts as shown in Fig. [Figure 50-10-12].

Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)

Dealer Copy -- Not for Resale

Clevis (Item 4)
Retaining Pin (Item 5)
Pin (Item 6)
Bushing (Item 7)

N-19222

Turn the bolt (Item 1) [Figure 50-10-11] & [Figure 50-10-

12] out of the clevis.

Assembly: Apply LOCTITE #242 adhesive to the bolt

threads. Adjust the compression spring by turning the
bolt in past the end of the clevis three turns.

NOTE: For procedures requiring the use of LOCTITE

#242 adhesive, thoroughly clean and dry
affected parts before the application of
LOCTITE #242.

753 Bobcat Loader

50-10-5 Service Manual
329 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

50-10-6 Service Manual
330 of 726
OPERATOR CAB Figure 50-20-2

Gas Cylinder Removal And Installation

WARNING 1

Cylinder contains high pressure gas. Do not open.

Opening cylinder can release rod and cause injury or
death.
W-2113-0288

P1518 P1528
WARNING
Remove the cab nut and holddown plate (Item 1) [Figure
Never work on a machine with the lift arms up unless
50-20-2] (both sides).
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm Installation: Tighten the nut to 40-50 ft.-lbs. (54-68 Nm)
support device can allow the lift arms or attachment torque.
to fall and cause injury or death.
W-2059-0598 Figure 50-20-3

Dealer Copy -- Not for Resale

Figure 50-20-1 1

N-20616

Remove the operator cab stop (Item 1) (both sides)

[Figure 50-20-1].

N-20617

Install a strap (Item 1) [Figure 50-20-3] to the cab

handles to prevent the cab from falling forward.

Raise the operator cab (See Raising The Operator Cab

on Page 10-30-1.), to release the tension on the gas
cylinder.
753 Bobcat Loader
50-20-1 Service Manual
331 of 726
OPERATOR CAB (CONT’D) Figure 50-20-6

Gas Cylinder Removal And Installation (Cont'd) EARLY STYLE

2
Figure 50-20-4

EARLY STYLE 1

N-20631

Figure 50-20-7
N-20618
LATER STYLE

Figure 50-20-5

Dealer Copy -- Not for Resale

LATER STYLE 2

P-43354

Remove the retaining pin(s) (Item 1) [Figure 50-20-6]

P-39601 and [Figure 50-20-7] from the bottom pivot pin(s).

Remove the gas cylinder(s) (Item 2) [Figure 50-20-6]

Remove the retaining pin(s) (Item 1) [Figure 50-20-4] and [Figure 50-20-7] from the operator cab.
and [Figure 50-20-5] from the top pivot pin(s).
Reverse the above procedure to install the gas cylinders
onto the operator cab.

753 Bobcat Loader

50-20-2 Service Manual
332 of 726
OPERATOR CAB (CONT’D) Removal And Installation

Gas Cylinder Disassembly

Figure 50-20-8
WARNING
AVOID INJURY OR DEATH
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
cylinders. If the operator cab is tilted forward without
the gas cylinders operational, the cab will fall and
2 could cause injury or death.
1 W-2245-0796

Figure 50-20-10

P1008

Remove the clevis (Item 1) and washer (Item 2) [Figure

50-20-8] from the end of the gas cylinder.

Dealer Copy -- Not for Resale

Remove the gas cylinder from the outer housing.

Figure 50-20-9

P1006

Assembly: Install a r eplacement cylinder inside the

cylinder housing.

Apply a small amount of LOCTITE 242 on the threads of N-20617

the cylinder rod [Figure 50-20-9].

Reinstall the washer and clevis on the cylinder rod. Remove the operator cab gas cylinder(s). (See Gas
Cylinder Removal And Installation on Page 50-20-1.)

Remove the heater unit from the cab (if equipped). (See
Removal And Installation on Page 80-50-1.)

Use the hoist connected to the operator cab grab handles

to lower or (raise) the operator cab when the gas
cylinders are disconnected [Figure 50-20-10].
753 Bobcat Loader
50-20-3 Service Manual
333 of 726
OPERATOR CAB (CONT’D) Figure 50-20-13

Removal And Installation (Cont'd)

Figure 50-20-11

1
1
1

P-43358 P-43357

Figure 50-20-14
P-43362

Remove bolt (Item 1) [Figure 50-20-11] from the cab

ground.

Dealer Copy -- Not for Resale

1
Remove any sta-straps connected to the harness
[Figure 50-20-11].

Figure 50-20-12

P-43356

Disconnect all harness(s) (Item 1) [Figure 50-20-12]

[Figure 50-20-13] [Figure 50-20-14] that c onnects the
mainframe to the cab. The number of connectors will vary
1 1 depending on the options equipped on your loader.

P-43355

753 Bobcat Loader

50-20-4 Service Manual
334 of 726
OPERATOR CAB (CONT’D) Figure 50-20-17

Removal And Installation (Cont'd)

1
Figure 50-20-15

P-39601

Remove the operator cab gas cylinder(s) (Item 1)

[Figure 50-20-15]. (See Gas Cylinder Removal And
Installation on Page 50-20-1.)

Dealer Copy -- Not for Resale

3

Lower the cab.

Figure 50-20-16

N-20628 N-20628

1 Connect the slings (Items 1, 2 and 3) [Figure 50-20-17]

to a chain hoist.

Remove the operator cab from the loader.

Reverse the above procedure to install the operator cab.

N-20619

Remove the rear mounting bolts (Item 1) [Figure 50-20-

16] (both sides) and nut from the operator cab.

Installation: Tighten the bolt and nut to 25-35 ft.-lbs. (34-

47 Nm) torque.

753 Bobcat Loader

50-20-5 Service Manual
335 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

50-20-6 Service Manual
336 of 726
OPERATOR SEAT Seat Belt Removal And Installation

Removal And Installation Figure 50-30-3

Figure 50-30-1

1
1

1
2

N-20729A

N-20729
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) Locate the seat belt bolts under seat pan i nsulation

Dealer Copy -- Not for Resale

(Items 1 & 2) [Figure 50-30-3] and peel back or cut
Remove the four seat mounting nuts (Item 1) [Figure 50- insulation to gain access to the head.
30-1] and washers from the operator seat mounting
studs. Figure 50-30-4

Installation: Tighten the mounting nuts to 20 ft.-lbs. (27

Nm) torque.

NOTE: Ensure the washers are installed.

Figure 50-30-2

2 N-20655

Remove the two nuts (Items 1 & 2) [Figure 50-30-4].

Installation: Tighten nut ( Item 1) to 54 f t.-lbs. (73 Nm)

torque. Tighten nut (Item 2) [Figure 50-30-4] to 34 ft.-lbs.
P10564 P10563 (46 Nm) torque.

Repeat for other half of seat belt and guide.

Lower the cab and install one of the m ounting washers
and nuts [Figure 50-30-2].

NOTE: With the seat removed the cab will raise.

Reverse the removal procedure to install the ope rator

seat.

753 Bobcat Loader

50-30-1 Service Manual
337 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

50-30-2 Service Manual
338 of 726
OPERATOR SEAT (SUSPENSION) Figure 50-31-3

Removal And Installation

Figure 50-31-1

1 1

1
2
N-20974

NOTE: Assure seat tethers are securely fastened to

N-20647 seat belt studs (Item 1) and seat rail studs
(Item 2) [Figure 50-31-3].

Raise the operator cab. (See Raising The Operator Cab Figure 50-31-4
on Page 10-30-1.)

Dealer Copy -- Not for Resale

Remove the four seat mounting nuts (Item 1) [Figure 50-
31-1] and washers from the operator seat mounting
studs.

Installation: Tighten the mounting nuts to 20 ft.-lbs. (27

Nm) torque.

Figure 50-31-2

N-20973

NOTE: Verify the front two seat rail studs have

washers attached (Item 1) [Figure 50-31-4].

P10564 P10563

Lower the cab and install one of the m ounting washers

and nuts [Figure 50-31-2].

NOTE: With the seat removed the cab will raise.

Reverse the removal procedure to install the ope rator

seat.

753 Bobcat Loader

50-31-1 Service Manual
339 of 726
OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-7

Slide Rail Removal And Installation 2

Figure 50-31-5 1 1

1
2
2

1 1
N-18582

Figure 50-31-8
N-18587

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.) 1

Dealer Copy -- Not for Resale

Remove the operator seat. (See Removal And
Installation on Page 50-31-1.)

Remove the two slide rail mounting bolts (Item 1) [Figure

50-31-5].

Remove the slide rail (Item 2) [Figure 50-31-5] from the

bottom of the seat frame.
N-18581
Reverse the removal procedure to install the ope rator
seat slide rail.
Remove the cushion (Item 2) [Figure 50-31-7] from the
Cushion Removal And Installation seat frame (Item 1) [Figure 50-31-8].

Figure 50-31-6

N-18579

Press the two buttons (Item 1) [Figure 50-31-6] &

[Figure 50-31-7] and lift the seat cushion.

753 Bobcat Loader

50-31-2 Service Manual
340 of 726
OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-11

Cushion Removal And Installation (Cont’d)

Figure 50-31-9

1 1

N-18578

Remove the two mo unting screws (Item 1) [Figure 50-

N-18580 31-11] from the seat back and remove the back.

Reverse the removal procedure to install the ope rator

Inspect the seat ride adjustment [Figure 50-31-9]. seat back.

Reverse the removal procedure to install the ope rator

Dealer Copy -- Not for Resale

seat back.

Back Removal And Installation

Figure 50-31-10

N-18583

Pull the seat back adjustment lever (Item 1) [Figure 50-

31-10] and tilt the seat back all the way forward.

753 Bobcat Loader

50-31-3 Service Manual
341 of 726
OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-14

Shock Removal And Installation

1
Figure 50-31-12

1
1

1 2 N-18586

NOTE: The seat block mounting studs (Item 1)

N-18584 [Figure 50-31-14] are replaceable.

Reverse the removal procedure to install the ope rator

Figure 50-31-13 seat shock.

Dealer Copy -- Not for Resale

1

N-18585

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

Remove the operator seat. (See Removal And

Installation on Page 50-31-1.)

Remove the seat shock retaining pin (Item 1) [Figure 50-

31-12] & [Figure 50-31-13] (Both ends.)

Remove the seat shock (Item 2) [Figure 50-31-12] &

[Figure 50-31-13].

753 Bobcat Loader

50-31-4 Service Manual
342 of 726
BOB-TACH Figure 50-40-3

Removal And Installation

Figure 50-40-1

N-20739

1
Remove the rod end pivot pin (Item 1) [Figure 50-40-3].
N-20733
Remove the tilt cylinder rod end.

Tilt the Bob-Tach forward, so it is parallel to the floor. Put

blocks (Item 1) approximately 3 inches thick under each
side of the B ob-Tach. Lower the Bob-Tach onto the

Dealer Copy -- Not for Resale

blocks [Figure 50-40-1].

Figure 50-40-2

N-20734

Remove the retainer bolt (Item 1) [Figure 50-40-2] from

the pivot pin.

Installation: Tighten the retainer bolt to 18- 20 ft.-lbs.

(24-27 Nm) torque.

753 Bobcat Loader

50-40-1 Service Manual
343 of 726
BOB-TACH (CONT’D) Figure 50-40-5

Removal And Installation (Cont'd)

Figure 50-40-4

1
1

P-3908

NOTE: Use tapered ream MEL1233 to clean the

P-3913 tapered hole in the lift arms. The tapered hole
must be clean and free of debris to provide a
good contact surface for the pivot pin.
NOTE: Removal procedure is shown for the right
side. Left side procedure is the same. Slowly back the loader away to r emove the Bob-Tach

Dealer Copy -- Not for Resale

frame [Figure 50-40-5].
Remove the grease fitting (Item 1) [Figure 50-40-4] from
the Bob-Tach frame for the pivot pin (both sides). Remove the seal dust cup (Item 1) [Figure 50-40-5].

NOTE: The grease fitting (Item 1) [Figure 50-40-4] Figure 50-40-6

must be removed to prevent the pivot pin from
being locked in the Bob-Tach frame.

Loosen the bolt (Item 2) [Figure 50-40-4] at the Bob-

1
Tach pivot pin.

Strike the head of th e bolt (Item 2) [Figure 50-40-4] to

push the pivot pin into the Bob-Tach frame.

Remove the bolt (Item 2) [Figure 50-40-4].

Installation: Tighten the bolt to 175-190 ft.-lbs. (240-255

Nm) torque.

Use a pun ch to push the pivot pin all the way into the P-3909
Bob-Tach frame.

Installation: A longer bolt is necessary to install through Remove the rubber seal (Item 1) [Figure 50-40-6].
lift arms into the pivot pin, to pull the pivot pin into the lift
arms.

753 Bobcat Loader

50-40-2 Service Manual
344 of 726
BOB-TACH (CONT’D) Figure 50-40-9

Removal And Installation (Cont'd)

Figure 50-40-7

3 3
2 1 2 P-3928
1

Remove the lever mounting bolt and nut (Item 1), washer
P-3912 (Item 2) and spring (Item 3) [Figure 50-40-9].

Installation: Tighten the nut to 25-28 ft.-lbs. (34-38 Nm)

Install the Bob-Tach mounting bolt (Item 1) into the pivot torque.
pin (Item 2) [Figure 50-40-7]. Remove the pivot pin from
the Bob-Tach frame.

Dealer Copy -- Not for Resale

Figure 50-40-10

Check for wear and damage. Replace the pivot pins as

needed.

Installation: Push the pivot pin (Item 2) into the Bob-

Tach frame. Position the end of the pin flush with the end
of the Bob-Tach bushing (Item 3) [Figure 50-40-7].

Installation: Reverse the removal procedure to install

the Bob-Tach.

Bob-Tach Lever And Wedge

Figure 50-40-8 1
P-3924A

Remove the Bob-Tach lever (Item 1) [Figure 50-40-10].

1
N-20735

Use the following procedure to remove and install the

Bob-Tach lever (Item 1) [Figure 50-40-8], spring and
wedge.

753 Bobcat Loader

50-40-3 Service Manual
345 of 726
BOB-TACH (CONT’D) Figure 50-40-13

Bob-Tach Lever And Wedge (Cont'd)

Figure 50-40-11

1
2

4
3 P-3929

If the bolt (Item 1), handle pivot (Item 2), spring (Item 3)
P-3925 or clevis (Item 4) are damaged, put the assembly in the
vise. Loosen and remove the bolt (Item 1) [Figure 50-40-
13] with a 5/16 inch allen wrench.
Use a punch and hammer, remove the r oll pin (Item 1)
[Figure 50-40-11] from the Bob-Tach wedge and spring, Replace the worn or damaged parts as needed.
bolt and clevis assembly.

Dealer Copy -- Not for Resale

Installation: Reverse the removal procedure to install
Figure 50-40-12 the Bob-Tach Lever and Wedge.

Bob-Tach Stops

Figure 50-40-14

1 1
P-3926

Remove the spring, bolt and c levis assembly (Item 1)

[Figure 50-40-12].
P-3914

Remove the wedge (Item 2) [Figure 50-40-12] from the

Bob-Tach frame. Remove and replace the Bob-Tach stop (Item 1) [Figure
50-40-14] (both sides) if worn or damaged.
Always replace bent or broken wedges.
NOTE: The Bob-Tach stop (Item 1) [Figure 50-40-14]
must contact the lift arm at the same time the
tilt cylinder reaches full extension. Use
available shims to adjust the Bob-Tach stop
and tilt cylinder sequence as closely as
possible.

753 Bobcat Loader

50-40-4 Service Manual
346 of 726
POWER BOB-TACH Remove the pivot pin (Item 2) [Figure 50-41-2] from the
tilt cylinder rod end.
Removal And Installation
Remove the tilt cylinder rod end (Item 3) [Figure 50-41-
Figure 50-41-1 2] from the Bob-Tach.

Figure 50-41-3

1
1 2
2
3
P-43823

P-3913
Tilt the Bob-Tach forward, so it is parallel to the floor. Put
blocks (approximately 3 i nches) under each side of th e
Bob-Tach [Figure 50-41-1].

Dealer Copy -- Not for Resale

Remove the grease fitting (Item 1) [Figure 50-41-3]
(Both sides). This will allow grease to c ome out in the
Lower the Bob-Tach onto the blocks. next step. Not letting grease escape will prevent the pin
from going into the Bob-Tach far enough to remove the
Remove the hoses on the c ylinder fittings (Item 1) Bob-Tach from the lift arms.
[Figure 50-41-1].
Loosen the bolt (Item 2) [Figure 50-41-3] at the Bob-
Remove the ho se clamp on the hoses and use the bolt Tach pivot pin. (Both sides)
(Item 2) [Figure 50-41-1] on the Bob-Tach lever to
secure the clamp. Strike the head of t he bolt (Item 2) [Figure 50-41-3] to
push the pivot pin into the Bob-Tach frame. (Both sides)
Figure 50-41-2
Remove the bolt. (Both sides)

Installation: A longer bolt will be needed to reach

through the lift arms into the pins to seat them into the lift
arms. Tighten the bolts to 175-190 ft.-lbs. (240-255 Nm)
1 torque.

Use a punch to push the pivot pins all the way inside the
Bob-Tach frame.

Remove the Bob-Tach from the lift arms.

2
3
Remove the dust cup (Item 3) [Figure 50-41-3] (Both
sides) when the Bob-Tach is free from the loader.
N-20734

Remove the retainer bolt (Item 1) [Figure 50-41-2] and

nut from the tilt cylinder rod end pin.

Installation: Tighten the retainer bolt and nut to 18-20 ft.-

lbs. (24-27 Nm) torque.

753 Bobcat Loader

50-41-1 Service Manual
347 of 726
POWER BOB-TACH (CONT’D) Power Bob-Tach Lever And Wedge

Removal And Installation (Cont’d) Figure 50-41-6

Figure 50-41-4

1 P-43823

P-3909
Use the following procedure to remove and install the
Bob-Tach lever (Item 1) [Figure 50-41-6], spring and
Remove the rubber seal (Item 1) [Figure 50-41-4] (Both wedge.
sides).

Dealer Copy -- Not for Resale

Figure 50-41-7
Installation: Use a new seal when assembling.

Figure 50-41-5

2 1 3
P-43824

P-3912 Use a punc h and hammer, remove the r oll pin (Item 1)
[Figure 50-41-7] from the Bo b-Tach Wedge and spring
clevis.
Remove the Bob-Tach pivot pin (Item 1). (Both sides)
Thread the bolt (Item 2) [Figure 50-41-5] into the pivot
pins and pull.

Check for wear and damage on the pins and the Bo b-

Tach bushings (Item 3) [Figure 50-41-5]. Replace as
needed.

Installation: Reverse the removal procedure to install

the Bob-Tach.

753 Bobcat Loader

50-41-2 Service Manual
348 of 726
POWER BOB-TACH (CONT’D) Figure 50-41-10

Power Bob-Tach Lever And Wedge (Cont’d)

Figure 50-41-8
4

1
1

3 2

N-20625

If the bolt (Item 1), handle pivot (Item 2), spring (Item 3)
N-18560 or clevis (Item 4) [Figure 50-41-10] are damaged, put the
assembly in a vise.

Remove the Wedge (Item 1) [Figure 50-41-8]. Remove the bolt and replace the damaged parts as
needed.
Always replace bent or broken wedges.

Dealer Copy -- Not for Resale

Figure 50-41-11
Figure 50-41-9

1
2

5
N-18563
P-43824

Use a pun ch and h ammer to dr ive the roll pin (Item 1)

Remove the washer and bolt (Item 1) [Figure 50-41-9]. [Figure 50-41-11] flush with the face of the Bob-Tach.

Installation: Tighten the bolts to 25-28 ft.-lbs. (34-38 Installation: Reverse the removal procedure to install
Nm) torque. the Power Bob-Tach lever and wedge [Figure 50-41-11].

Remove the cylinder off the lever pivots. Position the rod
end to the left with the grease fitting holes to the bottom
[Figure 50-41-9].

Remove the lever mounting nut (Item 2), washer (Item 3),
spring (Item 4) and lever (Item 5) [Figure 50-41-9].

Installation: Tighten the nut to 25-28 ft.-lbs. (34-38 Nm)

torque.

753 Bobcat Loader

50-41-3 Service Manual
349 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

50-41-4 Service Manual
350 of 726
LIFT ARM Figure 50-50-3

Removal And Installation

Figure 50-50-1

2
1

N-20771

Remove the tubeline clamps (Item 1) [Figure 50-50-3]

P-31849 under the lift arms.

Pull the tubelines (Item 2) [Figure 50-50-3] down .

Roll the Bob-Tach fully forward. Stop the engine.

Remove the Bob-Tach frame from the lift arms. (See

Dealer Copy -- Not for Resale

Removal And Installation on Page 50-40-1.)

Install jackstands under the rear of the loader [Figure 50-

50-1].

Figure 50-50-2

P-43215

Remove the front auxiliary mount mounting bolts (Item 1)

[Figure 50-50-2].

753 Bobcat Loader

50-50-1 Service Manual
351 of 726
LIFT ARM (CONT’D) Figure 50-50-6

Removal And Installation (Cont'd)

Figure 50-50-4
1

N-20768

1
Remove the tubeline clamps (Item 1) [Figure 50-50-6]
N-20766 under the lift arms.

Figure 50-50-7
Right Side

Remove the mounting bolt (Item 1) [Figure 50-50-4] from

Dealer Copy -- Not for Resale

the tilt tubeline clamp.

Figure 50-50-5
2
1

N-20769

Remove the lift arm support device mounting bolt (Item 1)

[Figure 50-50-7] spacer and nut.

N-20767 Installation: Tighten the mounting bolt and nut to 25 -28

ft.-lbs. (34-38 Nm) torque.

Remove the lift arm support device (Item 1) [Figure 50- Remove the retainer bolt (Item 2) [Figure 50-50-7] and
50-5]. nut from the lift cylinder rod end pivot pin.

Installation: Tighten the mounting bolt and nut to 25 -28

ft.-lbs. (34-38 Nm) torque.

753 Bobcat Loader

50-50-2 Service Manual
352 of 726
LIFT ARM (CONT’D) Figure 50-50-10

Removal And Installation (Cont'd)

Figure 50-50-8
1

1 2
P-4345

Wrap one of the 7 ft. lifting straps around the lift arm
N-20846 crossmember as shown [Figure 50-50-10].

Both loops of the lifting strap should be supported by the

Raise the operator cab. (See Raising The Operator Cab chain hoist [Figure 50-50-10].
on Page 10-30-1.)

Dealer Copy -- Not for Resale

Use a chain hoist and lifting strap to r aise the lift arms
Remove the r ight side lift cylinder pivot pin (Item 1) enough to remove the tilt cylinder base end pivot pin
[Figure 50-50-8]. (Item 1) [Figure 50-50-10].

NOTE: Put a piece of cardboard under the rod end of Remove the tilt cylinder (Item 2) [Figure 50-50-10] from
the lift cylinders to protect the fender from the lift arm crossmember and put on the blocking.
scratches.
Figure 50-50-11
Remove the lift arm support device (Item 2) [Figure 50-
50-8].

Figure 50-50-9

1 2
P-4348

Put the middle of the second lifting strap (Item 1) [Figure

N-20865 50-50-11] up into the lift arm as shown.

Install the lift cylinder pivot pin (Item 2) [Figure 50-50-11]

Remove the left side lift cylinder pivot pin (Item 1) [Figure and secure the pin with the mounting bolt and nut.
50-50-9].
Wrap both ends of the strap around the top of the lift arm
and down the back of the lift arm [Figure 50-50-11].

753 Bobcat Loader

50-50-3 Service Manual
353 of 726
LIFT ARM (CONT’D) Installation: Tighten the pivot pin mounting bolt and nut
to 25-28 ft.-lbs. (34-38 Nm) torque.
Removal And Installation (Cont'd)
Remove the upright pivot pin (Item 2) [Figure 50-50-13].
Figure 50-50-12 (Both sides.)

Figure 50-50-14

P-4346

Continue to wr ap the lifting strap around the lift arm a

second time [Figure 50-50-12].

Dealer Copy -- Not for Resale

Fasten both loops of th e lifting strap to a second chain
attached to the chain hoist.

Use the wrapping procedure on the third strap which

should be installed on the right side lift arm.

Use the chain hoist and lower the lift arms so they rest on
the blocking.

Figure 50-50-13

N-20773

Raise the lift arms with the chain hoist so the lift arms are
free from the loader [Figure 50-50-14].
2

N-20772

Remove the upright pivot pin mounting bolt (Item 1)

[Figure 50-50-13] and nut. (Both sides.)

753 Bobcat Loader

50-50-4 Service Manual
354 of 726
LIFT ARM (CONT’D)

Removal And Installation (Cont'd)

Figure 50-50-15

N-20774

Pull the lift arms away from the loader [Figure 50-50-15].

Lower the lift arms slowly and put on the floor.

Dealer Copy -- Not for Resale

Reverse the removal procedure to install the lift arms on
the loader.

753 Bobcat Loader

50-50-5 Service Manual
355 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

50-50-6 Service Manual
356 of 726
REAR GRILL Figure 50-60-3

Gas Cylinder Removal And Installation

1
Figure 50-60-1

N-21155

Remove the rod end (Item 1) [Figure 50-60-3] of th e

N-20595 cylinder off the ball joint mount.

Reverse the removal procedure to install a new gas

Open the rear door and raise the rear grill [Figure 50-60- cylinder.
1].

Dealer Copy -- Not for Resale

Figure 50-60-2

1
N-21154

Remove the base end of the cylinder off the stationary

ball joint mounted on the loader frame (Item 1) [Figure
50-60-2].

753 Bobcat Loader

50-60-1 Service Manual
357 of 726
REAR GRILL (CONT’D) Figure 50-60-6

Removal And Installation

Figure 50-60-4

N-20824

Lower the rear grill [Figure 50-60-6].

N-20727
Figure 50-60-7

Open the rear door and raise the rear grill [Figure 50-60- 1
4].

Dealer Copy -- Not for Resale

Figure 50-60-5 2

N-19218

Remove the retainer pin (Item 1) [Figure 50-60-7] from

the pivot pin (both sides).
N-20730
Remove the pivot pin (Item 2) [Figure 50-60-7] (both
sides).
Remove the gas cylinder rod end (Item 1) [Figure 50-60-
5] from the rear grill. (See Gas Cylinder Removal And Lift the rear grill from the loader.
Installation on Page 50-60-1.)
Reverse the removal procedure to install a new grill.

753 Bobcat Loader

50-60-2 Service Manual
358 of 726
REAR DOOR Figure 50-70-3

Removal And Installation

1
Figure 50-70-1

1
P-43360

Remove the top and bottom door hinge mounting bolts

P-43359 (Item 1) [Figure 50-70-3] and nuts.

NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure retainer (Item 3) [Figure 50-70-3] in the top
50-70-1] from the engine harness. hinge as shown.

Dealer Copy -- Not for Resale

Remove both rear lights (Item 2) [Figure 50-70-1] from
Installation: Tighten the mo unting bolts and nuts to 25-
the door. (See Rear Removal And Installation on Page
28 ft.-lbs. (34-38 Nm) torque.
60-60-2.)

Figure 50-70-2 Lift the door away from the loader frame and put the door
flat on the floor.

Installation: Reverse the removal procedure to install the

rear door.
2

P-34588

Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.

Connect a c hain hoist (Item 2) [Figure 50-70-2] to th e

lifting chain.

753 Bobcat Loader

50-70-1 Service Manual
359 of 726
REAR DOOR (CONT’D) Striker Disassembly and Assembly

Striker Removal and Installation Figure 50-70-6

Figure 50-70-4 LATER STYLE

2 2
EARLY STYLE 3

4
1

P-31320

P-28889
Remove the lock nut (Item 1) [Figure 50-70-6].

Figure 50-70-5 Remove the rollers (Item 2) and the spacer (Item 3) from
the bolt (Item 4) [Figure 50-70-6].

Dealer Copy -- Not for Resale

LATER STYLE
Check the parts for wear and replace as needed.
1
Installation: Reverse the removal procedure to install the
rear door striker.

P-31126

Remove the two striker mount bolts (Item 1) [Figure 50-

70-4] and [Figure 50-70-5].

Remove the striker assembly from the loader.

753 Bobcat Loader

50-70-2 Service Manual
360 of 726
REAR DOOR (CONT’D) Figure 50-70-8

Door Latch and Catch Adjustment EARLY STYLE

WARNING
AVOID INJURY OR DEATH
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497 1

Figure 50-70-7
P-24793

1 On early style loaders, (S/N 515840618 and Below) the

tailgate latch can be adjusted also. Loosen the four
attaching bolts (Item 1) [Figure 50-70-8], adjust the latch
and then retighten to 80-90 in.-lbs. (9-10 Nm) torque.
Later style loaders do not have an adjustment here.

Dealer Copy -- Not for Resale

Close the rear door. (This will align the striker assembly
to the correct position.)
1
Open the door.

P-31126 Tighten both striker mount bolts (Item 1) [Figure 50-70-

7].

Loosen the striker assembly mount bolts (Item 1) [Figure Close the rear door.
50-70-7].

Align the striker assembly in the center of the mounting

holes.

NOTE: Tighten the striker assembly, top mount bolt

only, until it will hold the striker assembly in
the center of the mounting slots.

753 Bobcat Loader

50-70-3 Service Manual
361 of 726
REAR DOOR (CONT’D) Figure 50-70-11

Latch Removal and Installation (S/N 515840618 &

Below)

Figure 50-70-9 3

P-31127

1 Remove the spring (Item 1) [Figure 50-70-11] from the

door handle.
P-24793
Remove the spring (Item 2) [Figure 50-70-11] from the
door latch.
Remove the door latch mounting bolts (Item 1) [Figure
50-70-9] from the door latch mechanism.

Dealer Copy -- Not for Resale

Remove the door latch (Item 3) [Figure 50-70-11] from
the door handle.
Installation: Tighten the mounting bolts to 80-90 in.-lbs.
(9-10 Nm) torque. Figure 50-70-12

Remove the latch and handle mechanisms from the rear

door.

Latch Removal and Installation (S/N 515840619 & 1

Above)

Figure 50-70-10

2 P-31128

Remove the do or handle (Item 1) [Figure 50-70-12]

from the rear door.

1
P-31125

Disconnect the s pring (Item 1) [Figure 50-70-10] from

the rear door.

Remove the bolt and nut (Item 2) [Figure 50-70-10] from

the latch.

753 Bobcat Loader

50-70-4 Service Manual
362 of 726
FUEL TANK Figure 50-80-3

Removal And Installation

Figure 50-80-1

P-4222

Remove the two mounting bolts (Item 1) [Figure 50-80-

P1616 3] from the battery holder.

Installation: Tighten the battery holder mounting bolts to

Remove the cover (Item 1) [Figure 50-80-1] which is 25-28 ft.-lbs. (34-38 Nm) torque.
installed over the fu el drain near the rear of th e
chaincase.

Dealer Copy -- Not for Resale

Remove the b attery holder (Item 2) [Figure 50-80-3]
from the loader.
Installation: Tighten the cover mounting bolts to 25-28
ft.-lbs. (34-38 Nm) torque. Figure 50-80-4

Figure 50-80-2

1
2

P-4225

P1619
Disconnect the fuel fill hose (Item 1) and the vent hose
(Item 2) [Figure 50-80-4] from the fuel tank.
Drain the fuel from the tank through the fuel drain (Item 1)
[Figure 50-80-2].

Open the rear door of the loader.

Remove the engine/hydrostatic pump assembly from the

loader. (See Removal And Installation on Page 70-80-1.)

753 Bobcat Loader

50-80-1 Service Manual
363 of 726
FUEL TANK (CONT’D) Fuel Level Sender

Removal And Installation (Cont'd) Figure 50-80-7

Figure 50-80-5

P-4228

P-4229
Loosen the fuel level sender (Item 1) [Figure 50-80-7]
with a wrench.
Lift the fuel tank up and remove the tank from the loader
[Figure 50-80-5]. Turn the fuel level sender (Item 1) [Figure 50-80-7] out

Dealer Copy -- Not for Resale

and remove it from the fuel tank. Check the fuel level
Figure 50-80-6 sender for damage and replace if necessary.

Installation: Tighten the fuel level sender to 50- 60 in.-

lbs. (5,7-6,8 Nm) torque.

P-4226

Remove the fue l inlet screen (Item 1) [Figure 50-80-6].

Clean and dry the screen. Check the screen for damage
and replace if necessary.

Reverse the removal procedure to install the fuel tank.

753 Bobcat Loader

50-80-2 Service Manual
364 of 726
CONTROL PEDALS Figure 50-90-2

Removal And Installation

WARNING 1

AVOID INJURY OR DEATH

Adjust locking tabs on control linkage so that lift and
tilt control pedals or (Mechanical Hand Controls) are
locked in neutral when the seat bar is up.
W-2104-0199

Figure 50-90-1 P-28909

1
Remove the two mounting bolts (Item 1) [Figure 50-90-2]
from the pedal mounting bracket.

Remove the pedal assembly from the loader.

Pedal Adjustment

Dealer Copy -- Not for Resale

After installing the pedal, adjust the pedal so that there is
clearance under the rear of th e pedal. The valve spool
must travel full stroke without the pedal hitting the floor
panel.

P-28907

Remove the bolt (Item 1) [Figure 50-90-1] and nut from

the pedal linkage.

Installation: Tighten the bolt and nut to 25-28 ft.-lbs. (34-

38 Nm) torque.

Check the rubber bushing in the pedal for wear and

replace as needed.

753 Bobcat Loader

50-90-1 Service Manual
365 of 726
CONTROL PEDALS (CONT’D) Figure 50-90-4

Crossbar Linkage Removal And Installation

WARNING P-28941

Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm Remove the bolt and nut ( Item 1) [Figure 50-90-4] to
support device. Failure to use an approved lift arm disconnect the lift pedal linkage from crossbar.
support device can allow the lift arms or attachment
to fall and cause injury or death. Figure 50-90-5
W-2059-0598

Dealer Copy -- Not for Resale

Figure 50-90-3

1 P-28896

Remove the hairpin clip and cross-pin from the control

P-28943 valve lift spool (Item 1) [Figure 50-90-5].

Disconnect the crossbar from the control valve.

Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

Remove the crossbar pivot bolt (Item 1) [Figure 50-90-

3].

753 Bobcat Loader

50-90-2 Service Manual
366 of 726
CONTROL PEDALS (CONT’D) Figure 50-90-8

Crossbar Linkage Removal And Installation (Cont’d)

Figure 50-90-6
1

P-30150
1

Remove the bolt (Item 1) [Figure 50-90-8] and nut from

P-28944 the pedal linkage.

Installation: Tighten the bolt and nut to 25-28 ft.-lbs. (34-

Remove the crossmember from the pivot [Figure 50-90- 38 Nm) torque.
6].

Dealer Copy -- Not for Resale

Tilt Foot Pedal Linkage Removal And Installation
Installation: Check the nylon bushing (Item 1) [Figure
50-90-6] for wear and replace as needed. Figure 50-90-9

Lift Foot Pedal Linkage Removal And Installation

Figure 50-90-7

1
1

P-28942

Remove the hai rpin clip and cross-pin (Item 1) [Figure

P-28940 50-90-9] to disconnect the tilt foot pedal linkage from the
control valve.

Remove the bolt and nut ( Item 1) [Figure 50-90-7] to

disconnect the lift foot pedal linkage from the crossbar
linkage.

753 Bobcat Loader

50-90-3 Service Manual
367 of 726
CONTROL PEDALS (CONT’D)

Tilt Foot Pedal Linkage Removal And Installation

(Cont’d)

Figure 50-90-10

P-28907

Remove the bolt (Item 1) [Figure 50-90-10] and nut from

the pedal linkage.

Dealer Copy -- Not for Resale

Installation: Tighten the bolt and nut to 25-28 ft.-lbs. (34-
38 Nm) torque.

753 Bobcat Loader

50-90-4 Service Manual
368 of 726
CONTROL PEDALS (ACS) Figure 50-91-3

Foot Sensor Removal And Installation

Figure 50-91-1

1
2
P-21936

1 P-21927

Remove the two bolts (Item 1) [Figure 50-91-3] from the

P-28957 foot sensor shield.

Installation: Tighten the bolts to 80-90 in.-lbs. (9,0-10,2

Pull the p in (Item 1) [Figure 50-91-1] holding the foot Nm) torque.
pedal linkage to the sensor.

Dealer Copy -- Not for Resale

Figure 50-91-4
Disconnect the two connectors (Item 2) [Figure 50-91-1]
from the sensor and lock solenoid.

Figure 50-91-2 1

P-21924

Remove foot lock solenoid (Item 1) [Figure 50-91-4].

P-28958
Installation: Apply a dr op of oil to the solenoid threads
and tighten the so lenoid to 35-40 ft.-lbs. (47-54 Nm)
Tilt the foot pedal up an d remove the two nuts (Item 1) lubed torque.
[Figure 50-91-2].
Remove the two bolts (Item 2) [Figure 50-91-4] from the
Remove the foot pedal and sensor assembly from the bracket and sensor assembly.
loader.
Installation: Tighten the bolts to 25-28 ft.-lbs. (34-38
Nm) torque.

Remove the sensor assembly.

753 Bobcat Loader

50-91-1 Service Manual
369 of 726
CONTROL PEDALS (ACS) (CONT’D) Foot Pedal Linkage Disassembly And Assembly

Foot Pedal Removal And Installation Figure 50-91-7

Figure 50-91-5

1
1 P-21931

P-28957
Remove the bolt (Item 1) holding the linkage (Item 2)
[Figure 50-91-7] to the side of the foot pedal.
Remove the pi n (Item 1) [Figure 50-91-5] holding the
linkage to the sensor. Figure 50-91-8

Dealer Copy -- Not for Resale

Figure 50-91-6

2
3

1
P-21932

P-28958
Remove the spacer (Item 1), linkage (Item 2), and nut
(Item 3) [Figure 50-91-8] from the foot pedal.
Tip the foot pedal up and r emove the two nuts (Item 1)
[Figure 50-91-6].

Remove the foot pedal assembly.

753 Bobcat Loader

50-91-2 Service Manual
370 of 726
CONTROL PANEL Figure 50-100-1

Removal and Installation 2

3
1

WARNING P-28847

Never work on a machine with the lift arms up unless

the lift arms are secured by an approved lift arm Loosen the j am nut (Item 1) from the by -pass control
support device. Failure to use an approved lift arm knob. Remove the control knob (Item 2) jam nut (Item 1)
support device can allow the lift arms or attachment and rubber washer (Item 3) [Figure 50-100-1] from
to fall and cause injury or death. control panel.
W-2059-0598
Disconnect the control harness connectors (Item 4)

Dealer Copy -- Not for Resale

[Figure 50-100-1] from the right side control lever.

NOTE: If the loader is equipped with front auxiliary

WARNING hydraulics, also disconnect the electrical
connectors from the left side control lever.
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

Raise the lift arms and install an approved lift arm

support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

Remove the e ngine speed control. (See Removal And

Installation on Page 70-20-1.)

753 Bobcat Loader

50-100-1 Service Manual
371 of 726
CONTROL PANEL (CONT’D) Figure 50-100-4

Removal and Installation (Cont'd)

2
Figure 50-100-2

2 2
1

P-28846
1
1

Remove the fuse/relay holder bracket (Item 1) [Figure

P-28924 50-100-4].

Remove the fuse/relay block (Item 2) [Figure 50-100-4].

Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-2] which are connected to the
steering shaft on the control panel.

Dealer Copy -- Not for Resale

Remove the four steering linkage mounting bolts (Item 2)
[Figure 50-100-2].

Installation: Align the marks on the steering linkage

bars. Tighten the steering linkage mounting bolts to 2 5-
28 ft.-lbs. (34-38 Nm) torque.

Figure 50-100-3

1
2 2

P-28841

Remove the fuse/relay cover mounting bolts (Item 2)

[Figure 50-100-3].

Remove the fuse/relay cover (Item 1) [Figure 50-100-3].

753 Bobcat Loader

50-100-2 Service Manual
372 of 726
CONTROL PANEL (CONT’D)

Removal and Installation (Cont'd)

Figure 50-100-5

P-28952

Figure 50-100-6

Dealer Copy -- Not for Resale

1

P-28953

Remove the control panel mounting bolts (Item 1)

[Figure 50-100-5] & ( Item 1) [Figure 50-100-6] from
both sides of the control panel.

Installation: Tighten the control panel mounting bolts to

25-28 ft.-lbs. (34-38 Nm) torque.

Remove the control panel from the loader.

Installation: Reverse the removal procedure to install

the control panel.

753 Bobcat Loader

50-100-3 Service Manual
373 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

50-100-4 Service Manual
374 of 726
CONTROL HANDLE Figure 50-110-2

Shock Removal And Installation

Figure 50-110-1
2

1
3

1
P-4146

Remove the steering shaft pivot bolt (Item 1) [Figure 50-

2
P-28954 110-2] from both sides of the control panel.

Installation: Tighten the pivot bolts to 180-200 in.-lbs.

Remove the m ounting nut (Item 1) [Figure 50-110-1] (21-23 Nm) torque.
from the end of the shock connected to the steering
linkage.

Dealer Copy -- Not for Resale

Remove the steering shaft from the control panel.

Remove the m ounting nut (Item 2) [Figure 50-110-1] Shaft Disassembly And Assembly
from the other end of the shock connected to the bracket
on the control panel. Figure 50-110-3

Installation: Tighten the mounting bolts to 2 5-28 ft.-lbs.

(34-38 Nm) torque.

Shaft Removal And Installation

NOTE: The steering shaft can be removed without 1

removing the control panel from the loader. 1
Photo [Figure 50-110-2] shows the control
panel removed for clarity purpose only.

Remove the steering linkage mounting bolts (Item 3) 1

[Figure 50-110-1].

Remove the s teering shock mounting nuts (Item 2) P-4154

[Figure 50-110-1].

Disassemble the right and left steering shafts from the

cross shaft assembly [Figure 50-110-3].

Assembly: Install new nylon bushings (Item 1) [Figure

50-110-3] as needed when assembling the steering
shaft. Be sure to apply grease on the cross shaft before
installing the right and left steering shaft.

753 Bobcat Loader

50-110-1 Service Manual
375 of 726
CONTROL HANDLE (CONT’D) Remove the c ontrol lever (Item 2) [Figure 50-110-5] by
sliding the lever through the rubber boot (Item 1) [Figure
Shaft Disassembly And Assembly (Cont’d) 50-110-6] on the front of the control panel.

Figure 50-110-4 Installation: Tighten the u-bolts so the lever can not be
moved either right or left when seated in the operator
seat. Be sure the control lever does not interfere with the
1 operator cab when lowering or raising the cab.

Rubber Boot Replacement

Figure 50-110-6

P-28845 2

To remove the steering shaft mounting bracket (Item 2)

[Figure 50-110-2], remove the three mounting bolts
(Item 1) [Figure 50-110-4] from the front of th e control

Dealer Copy -- Not for Resale

1
panel.
P-28845
Remove the steering shaft mounting bracket.

Installation: Tighten the mounting bolts to 2 5-28 ft.-lbs. To replace the rubber boot (Item 1) [Figure 50-110-6] on
(34-38 Nm) torque. the control panel, remove the control lever (See Lever
Removal And Installation on Page 50-110-2.)
Lever Removal And Installation
Drill out the four rivets (Item 2) [Figure 50-110-6] located
Figure 50-110-5 on the flange of the rubber boot and remove the old boot.

Install the new boot and reinstall the control lever.

2 P-28843

Disconnect the electrical connectors from the control

lever [Figure 50-110-5].

Remove the nuts from the t wo U-bolts (Item 1) [Figure

50-110-5] used to mount the control lever.

Remove the U-bolts from the control lever mount.

753 Bobcat Loader

50-110-2 Service Manual
376 of 726
CONTROL HANDLE (CONT’D) Figure 50-110-9

Linkage Removal And Installation

Figure 50-110-7
5
6
4
1

2
2 2 3
N-15310
1

The centering plate/centering spring assembly consists

P-3729 of the following parts;

ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering
1 Shoulder Bolt
spring shoulder bolt (Item 2) [Figure 50-110-7].
2 Bushings

Dealer Copy -- Not for Resale

Remove the shoulder bolt/spring assembly. 3 Spring
4 Lock Nut
Installation: Tighten the centering spring shoulder bolt
and a NEW lock nut to 25-28 ft.-lbs. (34-38 Nm) torque. 5 Centering Plate
6 Guide Bushings
Figure 50-110-8

Figure 50-110-10

1 1
2

1 2

2
3 2

P-3736

N-15312
Slide the plate (Item 1) to the right and remove it from the
two guide pins (Item 2) [Figure 50-110-8].
Check the wear on the centering blocks (Item 1) [Figure
NOTE: The two guide bushings (Item 3) will be loose 50-110-10].
and can fall out of the plate (Item 1) as soon as
it is removed from the guide pins (Item 2) If the centering blocks need replacement, remove the
[Figure 50-110-8]. bolts (Item 2) [Figure 50-110-10]. Remove the centering
blocks.

Installation: Tighten the centering block bolts to 25-28

ft.-lbs. (34-38 Nm) torque.

753 Bobcat Loader

50-110-3 Service Manual
377 of 726
CONTROL HANDLE (CONT’D) Figure 50-110-13

Linkage Removal And Installation (Cont'd)

Figure 50-110-11
2

2
1
3

2 P-3734
1

Remove the linkage bar (Item 1) and remove the torsion

P-3733 bushing (Item 2) [Figure 50-110-13].

If the surface of any of the four pintle cams (Item 1) are

worn, loosen the bolt (Item 2) [Figure 50-110-11] and
rotate the cams 1/4 turn.

Dealer Copy -- Not for Resale

Tighten the bolts to 45-50 ft.-lbs. (62-68 Nm) torque.

When replacing the old style pintle levers, wear cams and
cam bolts, install the latest style parts.

Figure 50-110-12

P-3733

Remove the nut (Item 1) [Figure 50-110-12] from the

torsion bushing/linkage bar. The bolts is threaded into the
linkage bar, remove the bolt from underneath the pintle
lever.

Installation: Tighten the bolt to 11-13 ft.-lbs. (21-25 Nm)

torque, then tighten the nut to 21-25 ft.-lbs. (28-33 Nm)
torque.

753 Bobcat Loader

50-110-4 Service Manual
378 of 726
CONTROL HANDLE (CONT’D) Linkage Adjustment

Linkage Removal And Installation (Cont'd)

Figure 50-110-14
WARNING
1
Never work on a machine with the lift arms up 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 lift arms or attachment
to fall and cause injury or death.
W-2059-0598
1
3 2

1
WARNING
P-28954
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
Remove the nuts (Item 1) [Figure 50-110-14] from both fall or move and cause injury or death.
shock absorber ball joint ends. W-2017-0286

Dealer Copy -- Not for Resale

Remove the shock absorbers. Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
Installation: Tighten the nuts to 25-28 ft.-lbs. (34-38 Nm) on Page 10-20-1.)
torque.
Lift and block the loader. (See LIFTING AND BLOCKING
Remove the nuts (Item 2) from the linkage bar mounting THE LOADER on Page 10-10-1.)
bolt. The bolts (Item 3) are threaded into the linkage bars,
remove the bolts (Item 3) [Figure 50-110-14]. Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)
The torsion bushings can now be r emoved from the
steering bell cranks. Connect the remote start tool (MEL1429). (See REMOTE
START on Page 10-60-1.)
Installation: Tighten the bol ts to 11-13 ft.-lbs. (21-25
Nm) torque, then tighten the nuts to 25-28 ft.-lbs. (34-38
Nm) torque.

Installation: Reverse the removal procedure to

assemble the linkage.

The linkage and the centering plate must be r eadjusted

for neutral after the components have been reassembled.
(See Linkage Neutral Adjustment on Page 50-110-8.)

753 Bobcat Loader

50-110-5 Service Manual
379 of 726
CONTROL HANDLE (CONT’D) Figure 50-110-17

Linkage Adjustment (Cont'd)

Figure 50-110-15

2
P-37574

1 3
S/N 515844473 & Above Only
P-28954
Remove access plug from the top of the control panel.

Pre-load tension in the torsion bushings must be Turn the control lever drift adjustment bolts (Item 1)
removed before adjusting the steering linkage. [Figure 50-110-17] (one on each control lever) out until it

Dealer Copy -- Not for Resale

is flush with the bottom of the nut.
Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt
(Item 2). The bolt (Item 2) is threaded into the linkage bar Figure 50-110-18
(Item 3). The bolt (Item 2) [Figure 50-110-15] must be
loosened enough to allow the torsion bushing to turn
freely between the steering bellcrank and the linkage bar.

Figure 50-110-16

3
1 2

P-3724

2
Move the right side steering lever to the rear and install a
3 3/8 inch (10 mm) thick spacer (Item 1) between the pintle
4 P-3726 arm cam (Item 2) and the centering block (Item 3)
[Figure 50-110-18].

Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt

(Item 2). The bolt (Item 2) is threaded into the linkage bar
(Item 3). The bolt (Item 2) [Figure 50-110-16] must be
loosened enough to allow the torsion bushing to turn
freely between the pintle arm and the linkage bar.

753 Bobcat Loader

50-110-6 Service Manual
380 of 726
CONTROL HANDLE (CONT’D) Figure 50-110-21

Linkage Adjustment (Cont'd)

Figure 50-110-19

1
2

P-3727

1
Loosen the two bolts and nuts (Item 1) [Figure 50-110-
3 P-3723 21] on each steering linkage bar.

Figure 50-110-22
Move the right side steering lever forward and install a
15/16 inch (24 mm) thick spacer (Item 1) between the
center plate (Item 2) and the mounting plate (Item 3)

Dealer Copy -- Not for Resale

[Figure 50-110-19].

This will allow the pintle arms to move freely while

adjusting the steering linkage for full forward travel
speed.

Remove the 3/8 inch (10 mm) thick spacer (Item 1)

[Figure 50-110-18].

Figure 50-110-20 P-3728

4 Move the left control lever to the full forward position, then
pull forward on the left rear linkage bar until the pintle arm
is rotated to the front as far as possible [Figure 50-110-
2 22]. Use a locking plier and clamp the two li nkage bars
together.
1
Installation:Tighten the nuts and bolts to 25-28 ft.-lbs.
3 (34-38 Nm) torque.
4
Check the lever movement to make sure that the pintle
arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
P-3730
Repeat the procedure for the right side linkage.

Before adjusting the linkage, check that the p intle arm

mounting bolt (Item 1) is tight, 25-28 ft.-lbs. (34-38 Nm)
torque and that there is no pl ay between the pintle arm
(Item 2) and the square pump shaft (Item 3). Also check
that the cam mounting bolts (Item 4) [Figure 50-110-20]
are tight, 45-50 ft.-lbs. (62-68 Nm) torque.

753 Bobcat Loader

50-110-7 Service Manual
381 of 726
CONTROL PANEL (CONT'D) If the dr ift is excessive to the right, turn the left
adjustment bolt in.
Linkage Adjustment (Cont'd)
NOTE: When using the drift adjustment bolts, only
Figure 50-110-23 adjust one bolt for each test drive.

In addition only move each bolt a maximum of

one turn for each test drive. This will help
prevent over correction and excess reduction
in travel speed.

Drift adjustment is for forward travel only.

Adjust the drift to an acceptable level.

Re-install the plug in the drift bolt access hole after

1 adjustment.
P-3723

Linkage Neutral Adjustment

Remove the spacer (Item 1) [Figure 50-110-23].
The following tool listed will be needed to do the following
procedure:
Disconnect remote start tool. (See REMOTE START on
Page 10-60-1.)
MEL1563 - Remote Start Tool Kit

Dealer Copy -- Not for Resale

Figure 50-110-24
Connect the remote start tool to the engine harness. (See
REMOTE START on Page 10-60-1.)

WARNING
Put jackstands under the front axles and rear corners
1 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

P-37574

S/N 515844473 & Above Only

Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-110-24] in until it
touches the U-bolt holding the control lever.

Repeat steps on the other control lever.

Drive the loader forward and check for drift.

The traditional benchmark for drift is less than 10 f t. of

“drift” in 100 ft. of travel distance.

If the dr ift is excessive to the le ft, turn the r ight

adjustment bolt (Item 1) [Figure 50-110-24] in.

753 Bobcat Loader

50-110-8 Service Manual
382 of 726
CONTROL PANEL (CONT'D) Figure 50-110-27

Linkage Neutral Adjustment (Cont'd)

Figure 50-110-25

P-3725
2 3
4 Adjust the left centering block first [Figure 50-110-27].
P-3726
Start the engine and run at high RPM.

Loosen the nut (Item 1) a couple of turns, then loosen the Figure 50-110-28
bolt (Item 2). The bolt (Item 2) is threaded into the linkage
bars (Items 3 & 4) [Figure 50-110-25].

Dealer Copy -- Not for Resale

1
The bolt (Item 2) [Figure 50-110-25] must be loose
enough to a llow the torsion bushing to turn freely
between the pintle arm and the linkage bar.

Figure 50-110-26

2 1
2
1

P16121

Move the traction lock override switch (Item 1) [Figure

50-110-28] to the OFF position so the traction function is
unlocked. The wheels are now able to turn.

Move the left control lever until the tires do not turn
P-3731 (neutral position).

Move the left centering block to the left until it contacts

Loosen the four bolts (Item 1) [Figure 50-110-26] holding both pintle cams and the control lever is still in the neutral
the two centering blocks. Move the right hand centering position [Figure 50-110-27].
block to the right as far as possible.
Tighten the bolts to 25-28 ft.-lbs. (34-38 Nm) torque.
NOTE: Bolt holes (Item 2) [Figure 50-110-26] are
slotted for pintle arm centering adjustment.

753 Bobcat Loader

50-110-9 Service Manual
383 of 726
CONTROL HANDLE (CONT’D) Figure 50-110-30

Linkage Neutral Adjustment (Cont'd)

NOTE: If the centering blocks are worn, they can be 1

removed and rotated 180 degrees and
reinstalled. If the cams are worn, they can be
loosened and rotated 90 degrees and
reinstalled.

Figure 50-110-29

2
3
4
P-3726

Tighten the two bolts (Item 1) to 11-13 ft.-lbs. (15-17 Nm)

torque, then tighten the two nuts (Item 2) [Figure 50-110-
30] to 25-28 ft.-lbs. (34-38 Nm) torque.

Figure 50-110-31

Dealer Copy -- Not for Resale

P-3732

Adjust the right centering block [Figure 50-110-29].

Move the right control lever until the t ires do not turn
(neutral position).
1
Move the right centering block to the left until it contacts
both pintle cams and the control lever is still in the neutral
2
position [Figure 50-110-29].

Tighten the bolts to 25-28 ft.-lbs. (34-38 Nm) torque. P-28954

Test both levers by moving them backward and forward

and letting them return to neutral by the return spring Tighten the two bolts to 11-13 ft.-lbs. (15-17 Nm) torque,
force. then tighten the two nuts to 25-28 ft.-lbs. (34-38 Nm)
torque at the steering cross shaft (Items 1 & 2 ) [Figure
If the levers do not return to neutral and the tires do not 50-110-31].
come to a c omplete stop, repeat the adjustment
procedure again.

Stop the engine.

753 Bobcat Loader

50-110-10 Service Manual
384 of 726
CONTROL HANDLE (ADVANCED HAND CONTROL) Figure 50-111-2
(AHC)

Components Identification

Figure 50-111-1

Dealer Copy -- Not for Resale

N-17783

Handle Control Unit (Item 1) [Figure 50-111-2].

N-17774

Control Handle (Item 1) [Figure 50-111-1].

753 Bobcat Loader

50-111-1 Service Manual
385 of 726
CONTROL HANDLE (ADVANCED HAND CONTROL) Figure 50-111-4
(AHC) (CONT'D)

Handle Control Unit Removal And Installation

Figure 50-111-3

Dealer Copy -- Not for Resale

2

N-17783

Disconnect the loader control harness (Item 1) [Figure

50-111-4] from the handle control harness.

N-17774

To remove the handle control unit, slide the rubber

handle cover (Item 1) [Figure 50-111-3] up the handle.

Remove the two mounting bolts (Item 2) [Figure 50-111-

3] from the control cover.

Remove the control cover.

753 Bobcat Loader

50-111-2 Service Manual
386 of 726
CONTROL HANDLE (ADVANCED HAND CONTROL) Figure 50-111-6
(AHC) (CONT'D)

Handle Control Unit Removal And Installation

(Cont'd)

Figure 50-111-5

1
P13737 1

Using a small screwdriver remove the ha ndle control

Dealer Copy -- Not for Resale

electrical connector from the clip [Figure 50-111-5].
2

N-17785

Using an allen wrench, remove the two mounting screws

(Item 1) [Figure 50-111-6] from the control unit.

NOTE: A small screwdriver (Item 2) [Figure 50-111-6]

in the control unit may be needed to hold the
center spacer from turning.

Installation: Tighten the control unit mounting screws to

85 in.-lbs. (9,6 Nm) torque.

753 Bobcat Loader

50-111-3 Service Manual
387 of 726
CONTROL HANDLE (ADVANCED HAND CONTROL) Figure 50-111-8
(AHC) (CONT'D)
3
Handle Control Unit Removal And Installation 2
(Cont'd)

Figure 50-111-7

N-17392

NOTE: The control unit (Item 1) [Figure 50-111-8] can

only be replaced as a complete assembly.

Check the spacer (Item 2) and screws (Item 3) [Figure

50-111-8] and replace as needed.

Dealer Copy -- Not for Resale

Figure 50-111-9

1
2

N-17380
N-17470

Remove the mo unting bolt and nut (Item 1) [Figure 50-

111-7] from the control handle and shaft. Installation: When installing the control unit into the
control handle, check the routing of the switch handle
Remove the control unit (Item 2) [Figure 50-111-7] from wire harness (Item 1) [Figure 50-111-9] to assure proper
the control handle. return of the control handle to neutral.

Installation: Tighten the mounting bolt to 35 in.-lbs (3,9

Nm) torque.

753 Bobcat Loader

50-111-4 Service Manual
388 of 726
CONTROL HANDLE (ADVANCED HAND CONTROL) Control Handle Disassembly And Assembly
(AHC) (CONT'D)
Figure 50-111-12
Control Handle Removal And Installation

Figure 50-111-10

2
1
N-17394

N-17384 Remove the handle sleeve (Item 1) and bushings (Item 2)

[Figure 50-111-12] from the handle.
Remove the handle control unit. (See Handle Control Check all parts for wear and replace as needed.
Unit Removal And Installation on Page 50-111-2.)

Dealer Copy -- Not for Resale

Figure 50-111-13
Remove the switch handle. (See Switch Handle Removal
and Installation on Page 60-120-5.)

Remove the rubber handle cover (Item 1) [Figure 50-

111-10] from the handle.

Figure 50-111-11

2 2 N-17393

Check the mounting bolt (Item 1) [Figure 50-111-13] that

connects the handle to the ha ndle control unit for wear,
replace as needed.

N-17385

Using a small screwdriver, hold the handle spacer (Item

1) and remove the allen head screws (Item 2) [Figure 50-
111-11] from the handle assembly.

Installation: Tighten the allen head screws to 35 in.-lbs.

(4 Nm) torque.

753 Bobcat Loader

50-111-5 Service Manual
389 of 726
CONTROL HANDLE (ADVANCED HAND CONTROL) Figure 50-111-16
(AHC) (CONT'D)

Control Lever Removal And Installation

Figure 50-111-14

1
1 1
1

P-32595

Loosen the two u -clamps (Item 1) [Figure 50-111-15]

nuts.
N-17772
Installation: Tighten the u-bolts so the lever can not be
moved either right or left when seated in the operator
Disconnect the electrical connectors (Item 1) [Figure 50- seat. Control lever end (Item 2) [Figure 50-111-15]
111-14] from the control lever switch handle.

Dealer Copy -- Not for Resale

should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
Remove the electrical connectors from the control lever raising the cab. The distance between handles should be
switch handle. (See Switch Handle Removal and 18.25 inches [Figure 50-111-16].
Installation on Page 60-120-5.)
Remove the control lever from the cross shaft and control
Installation: The connectors are color coded and should panel.
be matched upon re-assembly.
Figure 50-111-17
Figure 50-111-15

P13734
N-17773

The control lever (Item 1) [Figure 50-111-17] must be

replaced as a complete unit.

The connector clip (Item 2) [Figure 50-111-17] can be

replaced separately from the control lever.

753 Bobcat Loader

50-111-6 Service Manual
390 of 726
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) (CONT'D)

Control Lever Boot

Figure 50-111-18

N-17775

To replace the rubber boot (Item 1) [Figure 50-111-18]

on the con trol panel, remove the control lever. (See

Dealer Copy -- Not for Resale

Control Lever Removal And Installation on Page 50-111-
6.)

Drill out the four rivets (Item 2) [Figure 50-111-18]

located on the flange of the rubber boot and remove the
old boot.

Install the new boot and reinstall the control lever. (See
Control Lever Removal And Installation on Page 50-111-
6.)

753 Bobcat Loader

50-111-7 Service Manual
391 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

50-111-8 Service Manual
392 of 726
CONTROL HANDLE (ADVANCED HAND CONTROL) Handle Sensor Removal And Installation
(AHC) W/PUSH BUTTON FLOAT
Figure 50-112-3
Components Identification

Figure 50-112-1

1
1

P16581

P-28960 To remove the handle sensor, slide the rubber handle

cover (Item 1) [Figure 50-112-3] up the handle.
Control Handle (Item 1) [Figure 50-112-1]. Figure 50-112-4

Dealer Copy -- Not for Resale

Figure 50-112-2

1
1

N-22797

N-22797
Disconnect the loader control harness (Item 1) [Figure
50-112-4] from the handle control harness.
Handle Sensor (Item 1) [Figure 50-112-2].

753 Bobcat Loader

50-112-1 Service Manual
393 of 726
CONTROL HANDLE(ADVANCED HAND CONTROL) Figure 50-112-7
(AHC) W/PUSH BUTTON FLOAT (CONT'D)

Handle Sensor Removal And Installation (Cont'd)

Figure 50-112-5

2
1
1

N-22793

Figure 50-112-8

N-22803

Using a small screwdriver remove the ha ndle control

electrical connector from the clip (Item 1) by pushing the

Dealer Copy -- Not for Resale

connector down out of the connector clip (Item 2) [Figure
50-112-5].

Figure 50-112-6
1 1

P16580

Remove the spacers (Item 1) [Figure 50-112-7] &

1
[Figure 50-112-8].
1

N-22790

Using an allen wrench, remove one of the two mounting

screws (Item 1) [Figure 50-112-6] from the handle
sensor.

Installation: Tighten the handle sensor mounting screws

to 85 in.-lbs. (9,6 Nm) torque.

753 Bobcat Loader

50-112-2 Service Manual
394 of 726
CONTROL HANDLE(ADVANCED HAND CONTROL) Control Handle Removal And Installation
(AHC) W/PUSH BUTTON FLOAT (CONT'D)
Figure 50-112-11
Handle Sensor Removal And Installation (Cont'd)

Figure 50-112-9

2 N-22792

P16574 Remove the handle sensor (Item 1) [Figure 50-112-11].

(See Handle Sensor Removal And Installation on Page
50-112-1.)
Remove the mo unting bolt and nut (Item 1) [Figure 50-
112-9] from the control handle and shaft.

Dealer Copy -- Not for Resale

Figure 50-112-12
Remove the h andle sensor (Item 2) [Figure 50-112-9]
from the control handle.
1
Installation: Tighten the mounting bolt to 35 in.-lbs (3,9
Nm) torque.

Figure 50-112-10

P16534
1
3
Remove the switch handle (Item 1) [Figure 50-112-12].
(See Switch Handle Removal and Installation on Page
60-120-5.)

3
2 P16576

NOTE: The handle sensor (Item 1) [Figure 50-112-10]

can only be replaced as a complete assembly.

Check the spacer (Item 2) and screws (Item 3) [Figure

50-112-10] and replace as needed.

753 Bobcat Loader

50-112-3 Service Manual
395 of 726
CONTROL HANDLE(ADVANCED HAND CONTROL) Control Handle Disassembly And Assembly
(AHC) W/PUSH BUTTON FLOAT (CONT'D)
Figure 50-112-15
Control Handle Removal And Installation (Cont’d)

Figure 50-112-13

2
1
N-17394

N-17384 Remove the handle sleeve (Item 1) and bushings (Item 2)

[Figure 50-112-15] from the handle.
Remove the rubber handle cover (Item 1) [Figure 50- Check all parts for wear and replace as needed.
112-13] from the handle.

Dealer Copy -- Not for Resale

Figure 50-112-16
Figure 50-112-14

2 2
1

N-22796
N-17385

Check the mounting bolt (Item 1) [Figure 50-112-16] that

Using a small screwdriver, hold the handle spacer (Item connects the handle to the ha ndle sensor unit for wear,
1) and remove the allen head screws (Item 2) [Figure 50- replace as needed.
112-14] from the handle assembly.

Installation: Tighten the allen head screws to 35 in.-lbs.

(4 Nm) torque.

753 Bobcat Loader

50-112-4 Service Manual
396 of 726
CONTROL HANDLE (ADVANCED HAND CONTROL) Figure 50-112-19
(AHC) W/PUSH BUTTON FLOAT (CONT'D)

Control Lever Removal And Installation

Figure 50-112-17

1
1
1

1
P-32595

Loosen the two u-clamps (Item 1) [Figure 50-112-18]

nuts.
N-17772
Installation: Tighten the u-bolts so the lever can not be
moved either right or left when seated in the operator
Disconnect the electrical connectors (Item 1) [Figure 50- seat. Control lever end (Item 2) [Figure 50-112-18]
112-17] from the control lever switch handle.

Dealer Copy -- Not for Resale

should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
Remove the electrical connectors from the control lever raising the cab. The distance between handles should be
switch handle. (See Switch Handle Removal and 18.25 inches [Figure 50-112-19].
Installation on Page 60-120-5.)
Remove the control lever from the cross shaft and control
Installation: The connectors are color coded, match the panel.
colors for re-assembly.
Figure 50-112-20
Figure 50-112-18

P13734
N-17773

The control lever (Item 1) [Figure 50-112-20] must be

replaced as a complete unit.

The connector clip (Item 2) [Figure 50-112-20] can be

replaced separately from the control lever.

753 Bobcat Loader

50-112-5 Service Manual
397 of 726
CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) W/PUSH BUTTON FLOAT (CONT'D)

Control Lever Boot

Figure 50-112-21

2
1

P-28205

To replace the r ubber boot (Item 1) [Figure 50-112-21]

on the control panel, remove the control lever. (See

Dealer Copy -- Not for Resale

Control Lever Removal And Installation on Page 50-112-
5.)

Drill out the fou r rivets (Item 2) [Figure 50-112-21]

located on the flange of the rubber boot and remove the
old boot.

Install the new boot and reinstall the control lever. (See
Control Lever Removal And Installation on Page 50-112-
5.)

753 Bobcat Loader

50-112-6 Service Manual
398 of 726
CONTROL HANDLE (ADVANCED CONTROL Handle Sensor Removal And Installation
SYSTEM) (ACS) ADVANCED HAND CONTROL
Figure 50-113-3
Components Identification

Figure 50-113-1

1 1

P16581

P-28960 To remove the handle sensor, slide the rubber handle

cover (Item 1) [Figure 50-113-3] up the handle.
Control Handle (Item 1) [Figure 50-113-1]. Figure 50-113-4

Dealer Copy -- Not for Resale

Figure 50-113-2

2
1

P-24909

P-24909
Disconnect the loader control harness (Item 1) [Figure
50-113-4] from the handle sensor harness.
Handle Sensor (Item 1) [Figure 50-113-2].
Disconnect the loader control harness (Item 2) [Figure
NOTE: The calibration procedure must be followed 50-113-4] from the handle connector.
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60-
123-14.)

753 Bobcat Loader

50-113-1 Service Manual
399 of 726
CONTROL HANDLE (ADVANCED CONTROL Figure 50-113-7
SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT'D)

Handle Sensor Removal And Installation (Cont'd)

Figure 50-113-5

1
1

2 1

P-24912

Using an allen wrench, remove one of the two mounting

screws (Item 1) [Figure 50-113-7] from the handle
sensor.
P-24910

Installation: Tighten the handle sensor mounting screws

to 85 in.-lbs. (9,6 Nm) torque.
Using a small screwdriver remove the ha ndle sensor

Dealer Copy -- Not for Resale

electrical connector (Item 1) from the clip by pushing the
connector down out of the connector clip (Item 2) [Figure
50-113-5].

Figure 50-113-6

2
1

P-24911

Using a s mall screwdriver, remove the electrical

connector (Item 1) from the clip by pushing the connector
down out of the co nnector clip (Item 2) [Figure 50-113-
6].

753 Bobcat Loader

50-113-2 Service Manual
400 of 726
CONTROL HANDLE (ADVANCED CONTROL EARLIER VERSION HAND CONTROLS ONLY;
SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT'D) Figure 50-113-10
Handle Sensor Removal And Installation (Cont'd)

Figure 50-113-8

2
2

1
P-24914

Remove the m ounting bolt and nut (Item 1) [Figure 50-

P-24915 113-10] from the control handle and shaft.

NOTE: Be careful not to loose the recessed nut on

Figure 50-113-9

Dealer Copy -- Not for Resale

the other side of the handle.

Remove the handle sensor (Item 2) [Figure 50-113-10]

from the control handle.

Installation: Tighten the mounting bolt to 32-38 in.-lbs

(3,6-4,3 Nm) torque.

Figure 50-113-11

1
5

P-24913

1
Remove the s pacers (Item 1) [Figure 50-113-8] &
[Figure 50-113-9] while removing the mounting pin (Item 4
2) [Figure 50-113-8]. 3
3

2 P-24917

NOTE: The handle sensor (Item 1) [Figure 50-113-11]

can only be replaced as a complete assembly.

Check the spacers (Item 2), screws (Item 3), mounting

pin (Item 4), bolt/nut (Item 5) [Figure 50-113-11] and
replace as needed.

753 Bobcat Loader

50-113-3 Service Manual
401 of 726
CONTROL HANDLE (ADVANCED CONTROL Figure 50-113-14
SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT'D)

CURRENT VERSION HAND CONTROLS:

Figure 50-113-12

P-24909

1 Installation: When installing the handle sensor into the

control handle, check the routing of the switch handle
wire harness (Item 1) [Figure 50-113-14] to assure
P-21880 proper return of the c ontrol handle to neu tral and
minimize harness movement.
Remove one of the two mounting screws (Item 1) [Figure

Dealer Copy -- Not for Resale

NOTE: The calibration procedure must be followed
50-113-12] from the handle sensor.
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Installation: Tighten bolt to 3 2-38 in.-lbs. (3,6-4,3 Nm)
Calibration Of The ACS System on Page 60-
torque.
123-14.)
Figure 50-113-13

3
4
3

2
P-24918

Remove the handle sensor (Item 1) [Figure 50-113-13]

from the handle assembly.

NOTE: The handle sensor (Item 1) [Figure 50-113-13]

can only be replaced as a complete assembly.

Check the spacers (Item 2), screws (Item 3), mounting

pins (Item 4) [Figure 50-113-13] and replace as needed.

753 Bobcat Loader

50-113-4 Service Manual
402 of 726
CONTROL HANDLE (ADVANCED CONTROL Figure 50-113-17
SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT'D)

Control Handle Removal and Installation

1
Figure 50-113-15

N-17384

Remove the rubber handle cover (Item 1) [Figure 50-

113-17] from the handle.

P-24909 Figure 50-113-18

Remove the handle sensor (Item 1) [Figure 50-113-15].

Dealer Copy -- Not for Resale

(See Handle Sensor Removal And Installation on Page
50-113-1.)
1
Figure 50-113-16

2 2
1

N-17385

Using a small screwdriver, hold the handle spacer (Item

1) and remove the allen head screws (Item 2) [Figure 50-
113-18] from the handle assembly.

P16534 Installation: Tighten the allen head screws to 35 in.-lbs.

(4 Nm) torque.
Remove the switch handle (Item 1) [Figure 50-113-16].
(See Switch Handle Removal on Page 60-123-6.)

753 Bobcat Loader

50-113-5 Service Manual
403 of 726
CONTROL HANDLE (ADVANCED CONTROL Control Lever Removal and Installation
SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT'D) Figure 50-113-21
Control Handle Disassembly and Assembly

Figure 50-113-19 1
1 1

N-17772

2
1 Disconnect the electrical connectors (Item 1) [Figure 50-
N-17394 113-21] from the control lever switch handle.

Remove the electrical connectors from the control lever

Remove the handle sleeve (Item 1) and bushings (Item 2)

Dealer Copy -- Not for Resale

switch handle. (See ADVANCED CONTROL SYSTEM
[Figure 50-113-19] from the handle.
(ACS) SELECTABLE HAND/FOOT CONTROL on Page
60-123-1.)
Check all parts for wear and replace as needed.
Installation: The connectors are color coded, match the
Figure 50-113-20
colored connectors when assembling.

N-22796

Check the mounting bolt (Item 1) [Figure 50-113-20] that

connects the handle to the handle sensor unit for wear,
replace as needed.

753 Bobcat Loader

50-113-6 Service Manual
404 of 726
CONTROL HANDLE (ADVANCED CONTROL Figure 50-113-24
SYSTEM) (ACS) ADVANCED HAND CONTROL
(CONT'D)

Control Lever Removal and Installation (Cont’d)

Figure 50-113-22

1
1

P13734

2
The control lever (Item 1) [Figure 50-113-24] must be
replaced as a complete unit.

N-17773 The connector clip (Item 2) [Figure 50-113-24] can be

replaced separately from the control lever.
Figure 50-113-23

Dealer Copy -- Not for Resale

Control Lever Boot

Figure 50-113-25

1
P-32595

Loosen the two u-clamps (Item 1) [Figure 50-113-22] N-17775

nuts.
To replace the rubber boot (Item 1) [Figure 50-113-25]
Installation: Tighten the u-bolts so the lever can not be
on the control panel, remove the control lever. (See
moved either right or left when seated in the operator
Control Lever Removal and Installation on Page 50-113-
seat. Control lever end (Item 2) [Figure 50-113-22]
6.)
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
Drill out the four rivets (Item 2) [Figure 50-113-25]
raising the cab. The distance between handles should be
located on the flange of the rubber boot and remove the
18.25 inches [Figure 50-113-23].
old boot.
Remove the control lever from the cross shaft and control
Install the new boot and reinstall the control lever. (See
panel.
Control Lever Removal and Installation on Page 50-113-
6.)

753 Bobcat Loader

50-113-7 Service Manual
405 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

50-113-8 Service Manual
406 of 726
CONTROL HANDLE (ADVANCED CONTROL Handle Sensor Removal And Installation
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL Figure 50-114-3
Components Identification

Figure 50-114-1

1
1

N-17773

Loosen the nuts (Item 1) [Figure 50-114-3].

P-28960

Installation: Tighten the u-bolts so the lever can not be

moved either right or left when seated in the operator
Control Handle (Item 1) [Figure 50-114-1].

Dealer Copy -- Not for Resale

seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.
Figure 50-114-2
Figure 50-114-4

2
P-21879

P-28963

Handle Sensor (Item 1) [Figure 50-114-2].

Tilt the control handle (Item 1) [Figure 50-114-4] to th e
NOTE: The calibration procedure must be followed
center of the loader.
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Lift the boot cover (Item 2) [Figure 50-114-4].
Calibration Of The ACS System on Page 60-
123-14.)

753 Bobcat Loader

50-114-1 Service Manual
407 of 726
CONTROL HANDLE (ADVANCED CONTROL Figure 50-114-7
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL (CONT'D)

Handle Sensor Removal And Installation (Cont'd)

Figure 50-114-5

1
P-21860

Remove the handle lock solenoid connector (Item 1)

[Figure 50-114-7] from the clip.
2
P-21836 NOTE: Pry out with a small screw driver and push the
connector down.
Disconnect the ha rness connector (Item 1) [Figure 50-

Dealer Copy -- Not for Resale

Figure 50-114-8
114-5] from the handle sensor connector.
1
Disconnect the ha rness connector (Item 2) [Figure 50-
114-5] from the handle lock solenoid connector.

Figure 50-114-6 5
2

1 4

1 P-21862

Remove one of the two mounting screws (Item 1) [Figure

50-114-8] from the handle sensor.

P-21861 Installation: Tighten screws to 32-38 in.-lbs. (3,6-4,3

Nm) torque.
Remove the handle sensor connector (Item 1) [Figure
While removing the mounting pin (Item 2) from the
50-114-6] from the clip.
handle sensor, remove the one pl astic spacer (Item 3),
the spring (Item 4) and washer (Item 5) [Figure 50-114-
NOTE: Pry out with a small screw driver and push the
8].
connector down.

753 Bobcat Loader

50-114-2 Service Manual
408 of 726
CONTROL HANDLE (ADVANCED CONTROL Check the spacer (Item 2) and screws (Item 3), mounting
SYSTEM) (ACS) SELECTABLE HAND/FOOT pin (Item 4), spring (Item 5), washer (Item 6), bolt/nut
CONTROL (CONT'D) (Item 7), stop strap (Item 8) [Figure 50-114-10] and
replace as needed.
Handle Sensor Removal And Installation (Cont’d)
CURRENT VERSION HAND CONTROLS:
EARLIER VERSION HAND CONTROLS ONLY:
Figure 50-114-11
Figure 50-114-9

1
1

P-21880
P-21863

Dealer Copy -- Not for Resale

Remove one of the two mounting screws (Item 1) [Figure
Remove the top mounting bolt (Item 1) [Figure 50-114-9]
50-114-11] from the handle sensor.
from the handle sensor.
Installation: Tighten bolt to 32-38 in.-lbs. (3,6-4,3 Nm)
NOTE: Be careful not to lose the recessed nut on the
torque.
other side of the handle.

Installation: Tighten bolt to 3 2-38 in.-lbs. (3,6-4,3 Nm)

torque.

Figure 50-114-10

7
3

4
3
6
5
2
P-21791

Remove the handle sensor (Item 1) [Figure 50-114-10]

from the handle assembly.

NOTE: The handle sensor (Item 1) [Figure 50-114-10]

can only be replaced as a complete assembly.

753 Bobcat Loader

50-114-3 Service Manual
409 of 726
CONTROL HANDLE (ADVANCED CONTROL Figure 50-114-14
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL (CONT'D)
2 3
Handle Sensor Removal And Installation (Cont’d)

CURRENT VERSION HAND CONTROLS: (Cont’d)

Figure 50-114-12

4
3 8
1
1
P-21799

4 Installation: When installing the handle sensor into the

3 control handle, check the routing of the switch handle
wire harness (Item 1) [Figure 50-114-13] & [Figure 50-
5 6 114-14] to as sure proper return of the c ontrol handle to
2 neutral and minimize harness movement.
P-21882

Dealer Copy -- Not for Resale

NOTE: Route wires (Item 2) [Figure 50-114-13] &
[Figure 50-114-14] as shown away from stop
Remove the handle sensor (Item 1) [Figure 50-114-12]
strap (Item 3) [Figure 50-114-13] & [Figure 50-
from the handle assembly.
114-14] to avoid wire damage.
NOTE: The handle sensor (Item 1) [Figure 50-114-12]
NOTE: The calibration procedure must be followed
can only be replaced as a complete assembly.
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Check the spacer (Item 2) and screws (Item 3), mounting
Calibration Of The ACS System on Page 60-
pin (Item 4), spring (Item 5), washer (Item 6), bolt/nut
123-14.)
(Item 7), stop strap (Item 8) [Figure 50-114-12] and
replace as needed.

Figure 50-114-13

P-21878

753 Bobcat Loader

50-114-4 Service Manual
410 of 726
CONTROL HANDLE (ADVANCED CONTROL Figure 50-114-17
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL (CONT'D)

Control Handle Removal and Installation

1
Figure 50-114-15

N-17384

1
Remove the rubber handle cover (Item 1) [Figure 50-
114-17] from the handle.

P-21879 Figure 50-114-18

Remove the handle sensor (Item 1) [Figure 50-114-15].

Dealer Copy -- Not for Resale

(See Handle Sensor Connector on Page 60-123-5.)

Figure 50-114-16 1

2 2
1

N-17385

Using a small screwdriver, hold the handle spacer (Item

1) and remove the allen head screws (Item 2) [Figure 50-
114-18] from the handle assembly.
P16534

Installation: Tighten the allen head screws to 35 in.-lbs.

(4 Nm) torque.
Remove the switch handle (Item 1) [Figure 50-114-16].
(See Switch Handle Removal on Page 60-123-6.)

753 Bobcat Loader

50-114-5 Service Manual
411 of 726
CONTROL HANDLE (ADVANCED CONTROL Control Lever Removal and Installation
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL (CONT'D) Figure 50-114-21
Control Handle Disassembly and Assembly

Figure 50-114-19
1
1 1

N-17772

2
1 Disconnect the electrical connectors (Item 1) [Figure 50-
N-17394 114-21] from the control lever switch handle.

Remove the electrical connectors from the control lever

Remove the handle sleeve (Item 1) and bushings (Item 2)

Dealer Copy -- Not for Resale

switch handle. (See ADVANCED CONTROL SYSTEM
[Figure 50-114-19] from the handle.
(ACS) SELECTABLE HAND/FOOT CONTROL on Page
60-123-1.)
Check all parts for wear and replace as needed.
Installation: The connectors are color coded, match the
Figure 50-114-20
colors on the connectors when assembling.

N-22796

Check the mounting bolt (Item 1) [Figure 50-114-20] that

connects the handle to the han dle sensor for wear,
replace as needed.

753 Bobcat Loader

50-114-6 Service Manual
412 of 726
CONTROL HANDLE (ADVANCED CONTROL Figure 50-114-24
SYSTEM) (ACS) SELECTABLE HAND/FOOT
CONTROL (CONT'D)

Control Lever Removal and Installation (Cont’d)

Figure 50-114-22
2

1
1

P13734

2 The control lever (Item 1) [Figure 50-114-24] must be

replaced as a complete unit.

N-17773 The connector clip (Item 2) [Figure 50-114-24] can be

replaced separately from the control lever.
Figure 50-114-23

Dealer Copy -- Not for Resale

Control Lever Boot

Figure 50-114-25

P-32595 1

Loosen the two u-clamps (Item 1) [Figure 50-114-22] N-17775

nuts.
To replace the rubber boot (Item 1) [Figure 50-114-25]
Installation: Tighten the u-bolts so the lever can not be
on the control panel, remove the control lever. (See
moved either right or left when seated in the operator
Control Lever Removal and Installation on Page 50-113-
seat. Control lever end (Item 2) [Figure 50-114-22]
6.)
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
Drill out the four rivets (Item 2) [Figure 50-114-25]
raising the cab. The distance between handles should be
located on the flange of the rubber boot and remove the
18.25 inches [Figure 50-114-23].
old boot.
Remove the control lever from the cross shaft and control
Install the new boot and reinstall the control lever. (See
panel.
Control Lever Removal and Installation on Page 50-113-
6.)

753 Bobcat Loader

50-114-7 Service Manual
413 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

50-114-8 Service Manual
414 of 726
 ELECTRICAL SYSTEM & ANALYSIS

ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/

FOOT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-1 ELECTRICAL
Actuators Disassembly And Assembly . . . . . . . . . . . . . 60-123-11 SYSTEM &
ACS Controller Removal And Installation . . . . . . . . . . . . 60-123-5 ANALYSIS
Calibration Of The ACS System . . . . . . . . . . . . . . . . . . 60-123-14
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-122-1
Controller, Connector And Wire Identification . . . . . . . . . 60-123-4
Foot Lock Solenoid Connector. . . . . . . . . . . . . . . . . . . . 60-123-18
Foot Lock Solenoid Removal And Installation . . . . . . . . 60-123-18
Foot Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-17
Foot Sensor Disassembly And Assembly . . . . . . . . . . . 60-123-17 DRIVE
Hand Controls Only Calibration Procedure . . . . . . . . . . 60-123-15 SYSTEM
Handle Lock Solenoid Connector . . . . . . . . . . . . . . . . . 60-123-13
Handle Lock Solenoid Disassembly And Assembly. . . . 60-123-12
Handle Lock Solenoid Removal And Installation . . . . . . 60-123-12
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . 60-123-5
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-123-8
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-6
Switchable Hand/Foot Controls Calibration Procedure . 60-123-14

Dealer Copy -- Not for Resale

ELECTRICAL
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-3 SYSTEM &
ANALYSIS
ADVANCED HAND CONTROL (AHC) SYSTEM . . . . . . . . . 60-120-1
Actuators Disassembly And Assembly . . . . . . . . . . . . . . 60-120-8
AHC Controller Removal And Installation . . . . . . . . . . . . 60-120-4 ENGINE
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1 SERVICE
Control Handle Unit Connector . . . . . . . . . . . . . . . . . . . . 60-120-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
Switch Handle Removal and Installation . . . . . . . . . . . . . 60-120-5
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-2 SPECIFICATIONS

ADVANCED HAND CONTROL (AHC) SYSTEM (W/PUSH BUTTON

FLOAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-121-1
Actuators Disassembly And Assembly . . . . . . . . . . . . . . 60-121-9
AHC Controller Removal And Installation . . . . . . . . . . . . 60-121-4
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-121-1
Controller Connector And Wire Identification. . . . . . . . . . 60-121-3
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . 60-121-6
Handle Sensor Removal And Installation . . . . . . . . . . . . 60-121-4
Switch Handle Removal And Installation . . . . . . . . . . . . . 60-121-7
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-121-2

Continued On Next Page

753 Bobcat Loader

60-01 Service Manual
415 of 726
 ELECTRICAL SYSTEM & ANALYSIS (CONT’D)

ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND

CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-122-1
Actuators Disassembly And Assembly . . . . . . . . . . . . . 60-122-10
ACS Controller Removal And Installation . . . . . . . . . . . . 60-122-4
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . 60-122-1
Controller, Connector And Wire Identification . . . . . . . . . 60-122-3
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . 60-122-4
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-122-7
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 60-122-5
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-122-2

ALTERNATOR (55 AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . 60-30-6
Rectifier (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2

Dealer Copy -- Not for Resale

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5

ALTERNATOR (90 AMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-1

Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . 60-31-1
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-1
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-7
Alternator Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-9
Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-2
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-7
High Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-4
Low Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-3
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . 60-31-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-5
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-8
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-8
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-8
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-31-8

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . 60-20-3

Continued On Next Page

753 Bobcat Loader

60-02 Service Manual
416 of 726
 ELECTRICAL SYSTEM & ANALYSIS (CONT’D)

BICS™ SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Additional Inspection For Loaders With Advanced Hand Controls (AHC) 60-
90-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine
STOPPED - Key ON). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting The BICS™ Controller (Engine STOPPED - Key ON) . . . 60-90-1
Inspecting The Lift Arm By-Pass Control . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . 60-90-1
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . 60-90-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-4

BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Identification Chart (S/N 515843087 & Above) . . . . . . . . . . . . . . . . . 60-70-2
Identification Chart (S/N 515843086 & Below) . . . . . . . . . . . . . . . . . 60-70-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-4

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Dealer Copy -- Not for Resale

ELECTRICAL/HYDRAULIC CONTROLS REFERENCE . . . . . . . . . . . 60-130-1
Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-123-1

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Relay Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-3

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Front Accessory Panel Removal And Installation . . . . . . . . . . . . . . 60-50-10
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Option and Field Accessory Panels . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Right Panel - (Deluxe) (With Keyless Start) . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel - (Standard) (With Key Switch) . . . . . . . . . . . . . . . . . . . . 60-50-2
Right Panel Setup Display Options (Deluxe) . . . . . . . . . . . . . . . . . . . 60-50-5

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2

753 Bobcat Loader

60-03 Service Manual
417 of 726
 ELECTRICAL SYSTEM & ANALYSIS (CONT’D)

SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

BICS™ Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

STARTER (NIPPONDENSO) . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-12
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-9
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-12
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

STARTER (VALEO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . 60-41-4
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-7

Dealer Copy -- Not for Resale

No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-2

TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-6
Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-4
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . 60-110-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

753 Bobcat Loader

60-04 Service Manual
418 of 726
 BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
RED = RED CAB FRONT LIGHT
ACCESSORY
2750

753 WIRING SCHEMATIC RNG = ORANGE 2740

MONITORING 3000-3999 LBL CONNECTORS 2760
BLK = BLACK HARNESS 6718870
HYDRAULIC 4000-4999 LGN LBL = LIGHT BLUE FRONT WORKLIGHTS
WIRES CONNECT BY LETTER
DBL = DARK BLUE B B

C435
ACROSS CONNECTORS ATTACHMENT CONTROLS 5000-5999 YEL 2750 2750
S/N 515830001-34999 A B LIGHTS 6000-6999 PNK
LGN = LIGHT
6110 A A 6110
GREEN
S/N 516220001-21999 B A ACCESSORIES 7000-7999 WHT DGN = DARK
ENGINE 8000-8999 TAN GREEN A A

C434
6120 6120
(PRINTED APRIL 2003) SOME CONNECTOR
BODIES NOT SHOWN
COMMUNICATION 9000-9999 PUR YEL = YELLOW
2760 B B 2760
PNK = PINK
V-0009 FOR DRAWING CLARITY WHT = WHITE LEFT PANEL
BRN = BROWN
TAN = TAN
Printable Version Click Here PUR = PURPLE
GRY = GRAY
9340
2910
D
G
HEADLIGHTS
GROUND
1210 E PROTECTED POWER
FUSE 5 FUSE 1 FUSE 9
1910 F COMPUTER POWER
TRACTION HEATER UNSWITCHED CONNECTS TO
FRONT &
TAILGATE/ 2650
2640
30A
FUSE 6 FUSE 2
25A
MARKER
LIGHT
REAR LIGHT
SWITCH
POWER FUSE 10
25A C407
ON THIS PAGE
9210
9110
K
H
SYSTEM Rx
SYSTEM Tx

2630 2600
FUEL PULL FR & MK LT ATTCHMNT
C407 9300 A CLOCK/LATCH

WORK LIGHTS 2620

2610
30A
FUSE 7
15A
FUSE 3
REAR LT
FUSE 11
25A

ALT & KITS A

9310
9330
B
J
DATA
START
HARNESS 6716419 15A FUEL TRACTION 25A 9320 C BUZZER
GLOW PLUG STARTER FUSE 12
FUSE 8 FUSE 4 PULL PULL
RIGHT
TAILLIGHT 2610 6320 COMPUTER ACC PLUGS

6100
25A 25A
9320
BUZZER
2930
LEFT
2640 6330 RIGHT PANEL
TAILLIGHT 6100 8 8 6100
9340 11 11 9340
RIGHT 9200 10 10 9200 9330 J START
WORK 2620 6200
LIGHT 6210 9100 9 9 9100 9310 B DATA

C408
2900 4 4 2900 9300 A CLOCK/LATCH

LEFT WORK 1900 2 2 1900 9120 H SYSTEM Tx

2630 6210
LIGHT 1200 1 1 1200 9220 K SYSTEM Rx

AIR FILTER SWITCH FUEL SENDER 20- 9350 12 12 9350 1920 F COMPUTER POWER
270 ohm 3900 5 5 3900 1220 E PROTECTED POWER
7100
3920 7 7 3920 2920 G GROUND
BACKUP
ALARM 2650 3910 6 6 3910 9350 D KEY/ENTER SWITCH
2740 3 3 2740 C OPEN

2600

7100
6200
6310
TO OPTIONS
2910

B F G D E C H A
(BACKUP
ALARM SWITCH)
C404
A B

C405
A B

C406
MAIN FRAME 2900 2920
2930
HARNESS 6719802 C
3900
C103 A B A B A B
3920 B
SEAT
BAR
3910 A
B F G D E C H A
MAIN

7100

3700
3710

3100
3110
2000 CAB

9340

2900

3900
9200
9100

1900
1200
9350

3920
3910
FRAME

ENGINE
2600

6600
6500
6400
7100
6200
6310
HARNESS 6718871 RIGHT HANDLE

D2
D1

A1
A2
A3

D3
C3
C2
C1
B3
B2
B1
E3

E2
J2

E1

F2
F3

F1
3110
J4
3010
6310 N 3710 J1 J2 E1 4300 4300 B B WHT

SEATBAR SENSOR

SEATBAR SENSOR
+ 6200 S

SENSOR SIGNAL
FUEL SENDER SPARE ANALOG

ENG COOLANT SPARE ANALOG

E3

SPARE DIGITIAL
A 4320 4320 D D WHT/RED
PWM

SEATBAR
3500

GROUND
SUPPLY

3900

3910

3920
IN 1

IN 2

IN 1

A1

A2

A3
A1

A2

A3
C 7100 R R 7100 E2 4310 4310 C C WHT/BLK
ENG OIL PRESSURE 3520
SENDER 0.5-7.5 V - B
6400 W
K3

TEMP SENDER
3510 RIGHT

HYD TEMP
SENDER
P

SIGNAL
6500
J1

OPEN

OPEN
OPEN
3100

3200

3300
ROCKER

B1

B2

B3
B1

B2

B3

C409
6600 V A1 4910 4910 F F LGN/WHT UP
ENGINE COOLANT t J4

HYD CHARGE

HYD CHARGE
PRESSURE +

DIGITAL IN 2
PRESSURE
3010 F2 G G

SIGNAL

SPARE

OPEN

OPEN

OPEN
SENDER

3400

3420
3200

C1

C2

C3
C1

C2

C3
DETENT
J3

RH TWO SPEED
500-3000 ± 30 ohm

LH AUX RIGHT
3100 B1 B1 4920 4920 E E DGN

BRAKE SW
3210

4910

4810

4500
A1

A2

A3
IN
3700 E2 K2 K K

BATTERY IN (1)

BATTERY IN (2)

BATTERY IN (3)
UNSWITCHED

UNSWITCHED

UNSWITCHED
J1 J2

1110

1120

1130
BLACK WHITE
K D1 C1 J

A1

A2

A3
3500 K 3500 4930 4930 J YEL

LH AUX LEFT
3600

RH FRONT
SKI

BRAKE SW
DETENT
L L D2 H

4920

4820

1400
SPEED SENSOR (VR) 3520 3520 D1

OUT
4940 4940 H

B1

B2

B3
LGN CONTROL

ENG SPEED +
PRESSURE +

SYSTEM Rx
SYSTEM Tx
PRESSURE
3610

ENG OIL

ENG OIL

SIGNAL

OPEN
9100

9200
(hall)
3500

3520

GROUND

GROUND

D1

D2

D3
C C B2

D1

D2

D3
3200 3200 A

OPEN
RNG

2100
B3 A

2110
1400 1490

B1

B2

B3

RH SKI DOWN

LH SKI DOWN

EHC INPUT
3600 M M 3600 E1
HYD FILTER

4930

4830

9400
FILTER SIGNAL

C1

C2

C3
HYD CHARGE

HEADLIGHT
COMPUTER

KEY/ENTER
ENG SPEED
BRAKE SWITCH

FUEL PULL RELAY

SIGNAL (vr)

AIR FILTER

SWITCH

SWITCH
POWER
SIGNAL
F3
Dealer Copy -- Not for Resale

1900

9350

9340
FUEL HOLD

FEEDBACK
FUEL PULL
3600

3700

3430

E1

E2

E3
E1

E2

E3
HARNESS 6715975 A3 4500 1450

8800

8110

8150
C1

C2

C3
C3
C403

EHC OUTPUT
LH SKI UP
RH SKI UP
K1

4940

4840

9410
t

PROTECTED

D1

D2

D3
SIGNAL (hall)
ENG SPEED

GROUNDS

GROUND
STARTER RELAY

POWER
SENSOR

OPEN
OPEN

1200

2900
BRAKE PULL

GLOW PLUG
3010

F1

F2

F3
F F F F B3 H

F1

F2

F3
3300 3300 3300 3300 H

RELAY

RELAY
8210

4110

8510
HYD TEMP SENDER LEFT HANDLE

D1

D2

D3

PWM SIGNAL
538-1824 ±30 ohm 3310 E E 3310 3400 H H 3400 C1 C3 9400 J J

PWM +

PWM -

4310

4320
4300
E1

E2

E3
G G 3420 X X 3420 C2 D3 9400 1480 A A RNG

BRAKE PULL
C102

GLOW PLUG
FEEDBACK

FEEDBACK

FEEDBACK
STARTER
+ A

8250

4150

8550
E1

E2

E3
HYD CHARGE PRESS 3400 A A 3400 2300 B B 2300 A1 D2 4840 4840 C C WHT SKI

C410
SENDER 0.5-7.5 V C C C J J E3
J4
4830 B B CONTROL
3420 3420 3430 3430 WHITE C2 4830 BLU
-B 3410 B B 3410 W 6400 A3 J3
BLACK
B2 4820 4820 G G YEL/LGN
PADDLE

SPOOL LOCK
FRONT BASE

FRONT ROD
H H P 6500 F1 A2 4810 4810 F F YEL/RED MOMENTARY

4340

4330

4360
F1

F2

F3
HYD OIL FILTER
700 SERIES

REAR WKLT

MARKER LT
PRESSURE SWITCH
3430 D D 3430 V 6600 D3 G2 4430 K K

RELAY

RELAY
OPEN

6210

6320
F1

F2

F3

TRACTION HOLD
T 8800 A2 G1 4440 E

REAR BASE
E

REAR ROD
4440

4430

4200
G1

G2

G3
U 8250 J1 4460 D D

RESERVED

RESERVED

RESERVED
GLOW PLUGS

(R TURN)
(L TURN)
(HORN)

G1

G2

G3
0.4 ohm 8500 G G 8500 J2 4450

TWO SPEED
BICS LOCK
B

POSITION
BRN

BUCKET
HR

4410

4420

4350
T D J3

H1

H2

H3
8500 8800 8200 4470

C412 C411
TURN

RELAY OUTPUT
D

ATTACHMENT
ACCESSORY
YEL

KEY INPUT

CONTROL
TO OPTIONS SIGNAL

TRAVEL
8100 E S 6200 F2 4330

8000

9800

4730
H1

H2

H3
(ACCESSORY A DGN

REAR BLEED
HIGH FLOW

DIVERTER
1800 A N 6310 F1 4340 CONNECTOR)

4460

4450

4470
J1

J2

J3
C101

SPARE OUTPUT 1

SPARE OUTPUT 2
A A 8800 D E H1

RESERVED
HOLD 8200 8100 4410

(ATT ACC)
WHT TO BLK = 0.26 ohm
E

J1

J2

J3

(SERIAL RIGHT)
RED TO BLK= 10.9 ohm

(SERIAL LEFT)
C C 2800 8250 U A 1800 F3 4360

FUTURE

FUTURE

OPEN
FUEL SHUT OFF

K1

K2

K3
PULL B B 8100 H2 4420 TO OPTIONS A RNG/DBL

CAN SHIELD
CAN HIGH

CAN LOW
(ACCESSORY

9500

9600

9700
K1

K2

K3
H3 CONNECTOR) B RNG/WHT HORN

ALTERNATOR G3 4200

S REAR ROD

G1

G2
G3
J3

H3
C1
E1
H1
C3
C2

D1

B3

E3
D3
B1
B2

D2
E2

A1
A2
A3
K1
K2
K3
H2
F3
F2

F1
J3

J1
J2
EXC CONNECTS TO

C413
1020 TO OPTIONS 4430 A A 7.5 ohm nominal
1010 1800 C407
ON THIS PAGE (ACCESSORY at 12 VDC
BAT 2010 CONNECTOR)
BROWN TIE STRAP 2430 B B
REAR BASE
C407 C427 120 ohm

4110
4730
8800
8250
8000
8150
8110
6320
6210
8210

2100

8550
8510

2110

4150

1110
1120
1130
9500
9600
9700
9800
STARTER ALTERNATOR ENGINE

C414
4440 A A 7.5 ohm nominal
B M S 2010 A E F H G C B A D at 12 VDC
1010 8200 ACD & REMOTE START
WHITE TIE STRAP 2440 B B

2090
2090
R CONNECTOR HIGH FLOW
8250 LOCATED AT REAR OF

C415
4460 A A
6400
6500
6600
6300

4730

MACHINE 7.5 ohm nominal

6000

BLUE TIE STRAP 2460 B B at 12 VDC

GROUNDS
2480 D C B A G F E DIVERTER
TO OPTIONS TO OPTIONS 4450 A A
C426

C416
2460 7.5 ohm nominal
(ACCESSORY (ACCESSORY at 12 VDC
2450 CONNECTOR) CONNECTOR)
YELLOW TIE STRAP 2450 B B
D C B A G F E
REAR AUX RELIEF
2440 2400
C401 C402

C417
2430 4480 A A 9.8 ohm nominal
B A D C B A at 12 VDC
2480 B B

9800
9700
9600
9500
2710
1160
1710
2340 GREEN TIE STRAP

2330 FRONT AUX RELIEF

C424
4490 A A 11 ohm nominal
2730
1140
1700

1150

2100
2720
1720

at 14 VDC
2490 2490 B B
2420 FRONT ROD

C418
2410 4330 A A 3.3 ohm nominal
at 10 VDC
2390 2390 2330 B B
2380 FRONT BASE

C419
2370 4340 A A 3.3 ohm nominal
at 10 VDC
2200 2340 B B
2000 HYD LOCK VALVE

C420
2300 1800 4410 A A
2740 FUSE 11 9.8 ohm nominal
1720 25A at 12 VDC
2410 B B
2730 1700 1055
8000

8500
8550
8510

4110
4150
4100
2120 TILT SPOOL LOCK
2720 FUSE 12

C421
6310
6000
6300

A A
8100
8150
8110

6320

6200
6210

8200
8210

USED IN AHC 25A 4370

AHC POWER
1140

2710 EQUIPPED LOADERS 7.7 ohm nominal

2110 2370 B B

1150
1160
ONLY SWITCHED REAR GLOW
FUSE 10 MARKE TRACTION
POWER FUEL PULL LIGHT STARTER PLUG LOCK LIFT SPOOL LOCK
ATTACHMENT 25A R LIGHT
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A

C422
1710 A A

1130
4380
1110
1120
HEATER 7.7 ohm nominal
25A 2380 B B
30 85 30 85 30 85 30 85 30 85 30 85 85 30 UNSW
FUSE 1 POWER
BUCKET POSITION
2020
2030
1330

RELAY GROUNDS 2000-2060

1050
2000
2010

1350
2040
2050

1320
2010
2020

1030
2060

1060
2030
2040

2050
2060
1360

25A

C423
ARE CONNECTED IN SERIES FUSE 9 4420 A A 6.7 ohm nominal
at 12 VDC
2420 B B
30A 15A 15A 25A

1070
BATTERY FUSE 6 FUSE 2 FUSE 3 30A FUSE 4 TRACTION LOCK
1050 FUSE 5
1300
- +
100A 1030
4200 A A HOLD WHT TO BLK =

C425
1010 1060 0.26 ohm
2200 C C RED TO BLK=
1310 10.9 ohm
4100 B B PULL
1040

Printed in U.S.A. V-0009 (4-7-03)

419 of 726
 753 WIRING SCHEMATIC
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK
RED = RED
RNG = ORANGE
BLK = BLACK
CAB FRONT LIGHT
ACCESSORY 2740
2750

NOTE: THESE ARE NOT FOUND CONNECTORS 2760

MONITORING 3000-3999 LBL LBL = LIGHT BLUE
DBL = DARK BLUE * ON ALL MACHINES.
HARNESS 6718870 M M

WITH ADVANCED HAND CONTROL OPTION WIRES CONNECT BY

LETTER ACROSS
HYDRAULIC 4000-4999 LGN
LGN = LIGHT GREEN
B B
FRONT WORKLIGHTS

C435
ATTACHMENT CONTROLS 5000-5999 YEL DGN = DARK GREEN 2750 2750
CONNECTORS YEL = YELLOW
S/N 515830001-34999 A B
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
PNK = PINK
WHT = WHITE
6110 A A 6110

B A
S/N 516220001-21999

DGN

DGN
BRN = BROWN

RED

RED

RED

RED
BLK

BLK
BLK

BLK
ENGINE 8000-8999 TAN A A

C434
TAN = TAN 6120 6120
SOME CONNECTOR COMMUNICATION 9000-9999 PUR PUR = PURPLE
(PRINTED APRIL 2003) BODIES NOT SHOWN GRY = GRAY
2760 B B 2760

FOR DRAWING CLARITY LEFT PANEL 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

V-0010 TILT ACTUATOR LIFT ACTUATOR

9340 D HEADLIGHTS C428 C429

Printable Version Click Here 2910 G GROUND
TILT ACTUATOR LIFT ACTUATOR

1210 E PROTECTED POWER 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

FUSE 5 FUSE 1 FUSE 9
1910 F COMPUTER POWER
TRACTION HEATER UNSWITCHED CONNECTS TO
FRONT & C407 K
TAILGATE/ 30A 25A REAR SWITCH 25A 9210 SYSTEM Rx
2650
MARKER ON THIS PAGE
FUSE 6 FUSE 2 LIGHT POWER FUSE 10 9110 H SYSTEM Tx
2640 LIGHT
2630 2600
FUEL PULL FR & MK LT ATTCHMNT
C407 9300 A CLOCK/LATCH

WORK LIGHTS 2620

2610
30A
FUSE
7
15A
FUSE 3
REAR LT
FUSE 11
25A

ALT & KITS A

9310
9330
B
J
DATA
START
ADVANCED HAND CONTROL MODULE
HARNESS 6716419 15A GLOW FUEL TRACTION 25A 9320 C BUZZER
FUSE STARTER FUSE 12
FUSE 4 PLUG PULL PULL
RIGHT 8
COMPUTER ACC PLUGS
TAILLIGHT 2610 6320

6100
25A 25A
9320
BUZZER A B K H J B C D E A G F
2930
LEFT C430
TAILLIGHT
2640 6330
6100 8 8 6100
RIGHT PANEL C431
A B K H J B C D E A G F
9340 11 11 9340
RIGHT 9200 10 10 9200 9330 J START
6200

4580
9410
9400
4640
4720
4700
4710
4620
4600
4610
WORK 2620 9

1740
2240
6210 9100 9 9100 9310 B DATA

C408
LIGHT
4 4 9300 A CLOCK/LATCH

*
2900 2900
1900 2 2 1900 9120 H SYSTEM Tx
LEFT WORK
2630 6210 1
LIGHT 1200 1 1200 9220 K SYSTEM Rx
AIR FILTER FUEL SENDER 9350 12 12 9350 1920 F COMPUTER POWER
SWITCH 20-270 ohm 5
3900 5 3900 1220 E PROTECTED POWER
7100 7 7
3920 3920 2920 G GROUND
BACKUP 6

1730
2650 3910 6 3910 9350 D KEY/ENTER SWITCH
ALARM

4720
4700
4710

4620
4600
4610
TO OPTIONS 2740 3 3 2740 C OPEN

2600

7100
6200
6310
(BACKUP
2910 POWER FROM
ALARM

B F G D E C H A
SWITCH)

C404 C405
A B A B

C406
MAIN FRAME 2900 2920
2930
FUSE 12
ON THIS PAGE C A B C A B
HARNESS 6719803 or 6727129 C
R HANDLE L HANDLE
3900
C103 A B A B A B
3920 B
SEAT
BAR
C432 C433
CONNECTS TO CONNECTS TO
3910 A C432 C433
B F G D E C H A ON THIS PAGE ON THIS PAGE
MAIN

7100

3700
3710

3100
3110
2000 CAB

9340

2900

3900
9200
9100

1900
1200
9350

3920
3910
FRAME
RIGHT HANDLE
ENGINE
2600

6600
6500
6400
7100
6200
6310
AHC
HARNESS 6718871 A PNK/RED

D2
D1

A1
A2
A3

D3
C3
C2
C1
B3
B2
B1

C432
E3

E2
E1

F2
F3

F1
J2 J4 CONNECTOR
TILT
3110 CONNECTS TO C PNK/DGN
CONTROL
3010
6310 N 3710 J1 J2 D3 9410
C432 B PNK/BLK
ON THIS PAGE

SEATBAR SENSOR

SEATBAR SENSOR

SENSOR SIGNAL
+ S

FUEL SENDER SPARE ANALOG

ENG COOLANT SPARE ANALOG

SPARE DIGITIAL
6200 C3 9400
A

SEATBAR
SUPPLY

GROUND
3500

3920
3900

3910
IN 1

IN 2

IN 1

A1

A2

A3
A1

A2

A3
C 7100 R R 7100 E1 4300 4300 B B WHT
ENG OIL PRESSURE 3520
SENDER 0.5-7.5 V - B
6400 W E3 4320 4320 D D WHT/RED

TEMP SENDER
3510 PWM

HYD TEMP
SENDER
SIGNAL

OPEN

OPEN
6500 P C

OPEN
J1 E2 C

3100

3200

3300
4310 4310

B1

B2

B3
WHT/BLK

B1

B2

B3
6600 V K3
ENGINE COOLANT RIGHT
J4

HYD CHARGE

HYD CHARGE
t

PRESSURE +

DIGITAL IN 2
PRESSURE
3010 F2

SIGNAL
ROCKER

SPARE

OPEN

OPEN

OPEN
SENDER

3400

3420

C1

C2

C3
C1

C2

C3
3200

C409
A1 4910 4910 F F LGN/WHT UP

RH TWO SPEED

LH AUX RIGHT
500-3000 ± 30 ohm 3100 B1 J3

BRAKE SW
4910

4810

4500
3210

A1

A2

A3
IN
3700 E2 G G

BATTERY IN (1)

BATTERY IN (2)

BATTERY IN (3)
UNSWITCHED

UNSWITCHED

UNSWITCHED
J1 J2
DETENT

1110

1120

1130
BLACK WHITE
D1 B1 E E

A1

A2

A3
3500 K K 3500 3500 4920 4920 DGN

LH AUX LEFT
RH FRONT

BRAKE SW
3600

DETENT
L D2 K2 K K

4920

4820

1400
3520 3520

OUT
L

B1

B2

B3
SPEED SENSOR (VR) 3520

ENG SPEED +
PRESSURE +

SYSTEM Rx
SYSTEM Tx
PRESSURE
ENG OIL

ENG OIL

SIGNAL
3610

OPEN
9100

9200
(hall)
3500

3520

GROUND

GROUND

D1

D2

D3
C B2 C1 J

D1

D2

D3
3200 C 3200 3200 4930 4930 J

OPEN
YEL

2100
2110
B1

B2

B3
SKI

RH SKI DOWN

LH SKI DOWN

EHC INPUT
3600 M M 3600 3600 E1 D1 4940 4940 H H LGN CONTROL

4930
HYD FILTER

4830

9400
FILTER SIGNAL

C1

C2

C3
HYD CHARGE

HEADLIGHT
COMPUTER

KEY/ENTER
ENG SPEED
SIGNAL (vr)

AIR FILTER

SWITCH

SWITCH
POWER
SIGNAL
F3
Dealer Copy -- Not for Resale
C403

1900

9350

9340
FUEL HOLD
A

FEEDBACK
FUEL PULL

FUEL PULL
3600

3700

3430

E1

E2

E3
B3 A RNG

E1

E2

E3
1400 1490

RELAY
HARNESS 6715975

8800

8110

8150
C1

C2

C3
C3

EHC OUTPUT
LH SKI UP
RH SKI UP

4940

4840

9410
PROTECTED
SIGNAL (hall)

D1

D2

D3
t

ENG SPEED

GROUNDS

GROUND
STARTER RELAY

POWER
SENSOR

OPEN
OPEN

1200

2900
BRAKE PULL

GLOW PLUG
3010

F1

F2

F3
F B3 A3 H

F1

F2

F3
3300 F F 3300 3300 F 3300 3300 4500 1450 H

RELAY

RELAY
8210

4110

8510
LEFT HANDLE

D1

D2

D3
HYD TEMP SENDER

PWM SIGNAL
538-1824 ±30 ohm 3310 E E 3310 3400 H H 3400 3400 C1 K1 BRAKE SWITCH J J

PWM +

PWM -

4310

4320
4300
E1

E2

E3
G G 3420 X X 3420 3420 C2 1480 A A RNG

BRAKE PULL

GLOW PLUG
FEEDBACK

FEEDBACK

FEEDBACK
C102

STARTER
+ A

8250

4150

8550
E1

E2

E3
HYD CHARGE PRESS 3400 A A 3400 2300 B B 2300 A1 D2 4840 4840 C C WHT SKI

C410
SENDER 0.5-7.5 V C 3420 C C 3420 3430 J J 3430 3430 E3
J4
WHITE C2 4830 4830 B B DBL CONTROL

-B 3410 B B 3410 W 6400 A3 J3

BLACK
B2 4820 4820 G G YEL/DGN
PADDLE

TRACTION HOLD SPOOL LOCK

FRONT BASE

FRONT ROD
H H P 6500 F1 A2 4810 4810 F F YEL/RED MOMENTARY

4340

4330

4360
F1

F2

F3
REAR WKLT
HYD OIL FILTER

MARKER LT
V 6600 D3 700 SERIES G2 4430 K K

RELAY

RELAY
3430 D D 3430

OPEN

6210

6320
PRESSURE SWITCH

F1

F2

F3
T 8800 A2 G1 4440 E

REAR BASE

REAR ROD
E

4440

4430

4200
G1

G2

G3

*
U 8250 J1 4460 4640 D D

RESERVED

RESERVED

RESERVED
(R TURN)
(L TURN)
(HORN)
GLOW PLUGS

G1

G2

G3
0.4 ohm 8500 G G 8500 J2 4450

TWO SPEED
BICS LOCK
A

POSITION
BRN

BUCKET
4410

4420

4350
D J3

H1

H2

H3
HR 8500 8800 T 8200 4470

RELAY OUTPUT
TURN

ATTACHMENT
TO OPTIONS

ACCESSORY

C411
E

KEY INPUT
YEL

CONTROL
SIGNAL

TRAVEL
S F2

8000

9800
6200 4330 (ACCESSORY

H1

H2
8100 E

4730
H3
C DGN

REAR BLEED
CONNECTOR)

HIGH FLOW

DIVERTER
1800 A N 6310 F1 4340

4460

4450

4470
J1

J2

J3
D
C101

SPARE OUTPUT 1

SPARE OUTPUT 2
E H1

RESERVED
A 8100 4410

(ATT ACC)
WHT TO BLK = 0.26 ohm HOLD A 8800 8200 D
B

J1

J2

J3

(SERIAL RIGHT)
(SERIAL LEFT)

C412
RED TO BLK= 10.9 ohm C C 2800 8250 U A 1800 F3 4360 TO OPTIONS

FUTURE

FUTURE

OPEN
FUEL SHUT OFF

K1

K2

K3
(ACCESSORY
PULL B B 8100 H2 4420 A RNG/DBL

CAN SHIELD
CAN HIGH
CONNECTOR)

CAN LOW
9500

9600

9700
K1

K2

K3
H3 B RNG/WHT HORN

ALTERNATOR
G3 4200
AHC
A BRN/RED

C433
CONNECTOR
S CONNECTS TO LIFT

G1

G2
G3
H3
C1
E1
H1
C3
C2

D1

B3

E3
D3
B1
B2

D2
E2

A1
A2
A3
K1
K2
K3
H2
F3
F2

F1
J3

J1
J2
EXC CONNECTS TO TO OPTIONS J3 C433
C BRN/DGN
CONTROL
1020
1010 1800 C407 (ACCESSORY ON THIS PAGE B BRN/BLK
2010 ON THIS PAGE CONNECTOR)
BAT
C407 C427 120 ohm

4110
4730
8800
8250
8000
8150
8110
6320
6210
8210

2100

8550
8510

2110

4150

1110
1120
1130
9500
9600
9700
9800
STARTER ALTERNATOR ENGINE

B M S 2010 A E F H G C B A D
1010 8200 ACD & REMOTE START

2090
2090
R CONNECTOR
8250 LOCATED AT REAR OF REAR ROD
6400
6500
6600
6300

4730

MACHINE

C413
4430 A A
6000

GROUNDS 7.5 ohm nominal

2480 BROWN TIE STRAP 2430 B B at 12 VDC
2460
D C B A G F E REAR BASE
TO OPTIONS TO OPTIONS
C426

C414
2450 (ACCESSORY (ACCESSORY 4440 A A
CONNECTOR) CONNECTOR) 7.5 ohm nominal
2440 2400 D C B A G F E
WHITE TIE STRAP 2440 B B at 12 VDC
2430 C401 C402 HIGH FLOW

C415
2340 B A D C B A 4460 A A
7.5 ohm nominal

9800
9700
9600
9500
2710
1160
1710
2330 BLUE TIE STRAP 2460 B B at 12 VDC
2100 DIVERTER
2730
1140
1700

1150

C416
2720
1720

2490 4450 A A
7.5 ohm nominal
2420 YELLOW TIE STRAP 2450 B B at 12 VDC
2410 REAR AUX RELIEF

C417
2390 2390 4480 A A
9.8 ohm nominal
2240
GREEN TIE STRAP 2480 B B at 12 VDC
2200 FRONT AUX RELIEF

C424
2000 4490 A A
11 ohm nominal
2490 B B at 14 VDC
2300 FRONT ROD
2740 1800

C418
1720 FUSE 11 4330 A A
2730 25A
2120 3.3 ohm nominal
2330 B B
6310
6000
6300

2720 1700 1055 at 10 VDC

8000

8500
8550
8510

4110
4150
4100
8100
8150
8110

GOES TO FUSE 12 FRONT BASE

2710
6320

6200
6210

8200
8210

2110 ADVANCED HAND AHC POWER 25A

1140

C419
1730 4340 A A
CONTROL MODULE 3.3 ohm nominal

1150

1160
ON THIS PAGE SWITCHED REAR GLOW TRACTION 2340 B B
FUSE 10 FUEL PULL MARKE LIGHT STARTER LOCK at 10 VDC
25A POWER PLUG
ATTACHMENT R LIGHT HYD LOCK VALVE
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A

1130
1710
1110
1120

C420
4410 A A
HEATER 9.8 ohm nominal
30 85 30 85 30 85 30 85 30 85 30 85 85 30 UNSW 2410 B B at 12 VDC
25A POWER
BUCKET POSITION
2020
2030

FUSE 1
1330
1050
2000
2010

1350
2040
2050

1320
2010
2020

1030
2060

1060
2030
2040

2050
2060
1360

25A

C423
FUSE 9 4420 A A 6.7 ohm nominal
RELAY GROUNDS 2000-2060 at 12 VDC
ARE CONNECTED IN SERIES 2420 B B
30A 15A 15A 30A 25A

1070
BATTERY FUSE 6 FUSE 2 FUSE 3 FUSE 5 FUSE 4 TRACTION LOCK
1050
- + 1300
100A 1030
4200 A A HOLD WHT TO BLK =

C425
1010 1060 0.26 ohm
2200 C C RED TO BLK=
1310 10.9 ohm
4100 B B PULL
1040

Printed in U.S.A. V-0010 (4-8-03)

420 of 726
 LEFT RIGHT LEFT PANEL

753 WIRING SCHEMATIC * NOTE: THESE ARE NOT

FOUND ON ALL
FRONT
WORKLIGHTS 2910 G GROUND
MACHINES. 9340 D HEADLIGHTS
B A A B

(Without ACS Option) E

1210 PROTECTED POWER
C434 C435 F
* LIFT ARM
RELEASE
SWITCH
B A A B
1910
9110 H
COMPUTER POWER
SYSTEM Tx

S/N 515835000 - 515834999 RED = RED

2750
6110

6120
2760
WIRES CONNECT BY 9210 K SYSTEM Rx TILT SPOOL LOCK
RNG = ORANGE
BLK = BLACK LETTER ACROSS H H * 4030
9300 A CLOCK/LATCH
(NOT Used With AHC or ACS)
SEE FUSE/RELAY
*

C421
C407
S/N 516222000 - 516221999 LBL = LIGHT BLUE CONNECTORS CENTER
J J 1340
9310 B DATA
A A 4370 DIVERTER

C416
A B 7.7 ohm
DBL = DARK BLUE (EUROPEAN A 6100 A A 6100 PWM B B 2370 4450 A A 7.5 ohm
J
(PRINTED APRIL 2003) LGN = LIGHT GREEN
DGN = DARK GREEN
B A LIGHTING)
THIS PAGE
2900 M M 2900
9330
9320 C
START
BUZZER LIFT SPOOL LOCK
YELLOW TIE STRAP 2450 B B 12V

YEL = YELLOW 9340 C C 9340

V-0128 PNK = PINK
SOME CONNECTOR (NOT Used With AHC or ACS)

C422
WHT = WHITE BODIES NOT SHOWN 9200 D D 9200 7.7 ohm A A 4380
9320 +
BRN = BROWN FOR DRAWING CLARITY 9100 E E 9100 BUZZER PWM B B 2380
-

C408
SEE CONTROL 2930
Printable Version Click Here TAN = TAN
PUR = PURPLE
GRY = GRAY
MODULE J4
B 4500
2740
F
S
F
S
4500
2740 2770
1930
BRAKE
RIGHT PANEL
FRONT AUX RELIEF
THIS PAGE SWITCH BICS HYDRAULIC
9330 J START

C424
1900 P P 1900 LOCK 4490 A A 11 ohm
BATTERY FEED 1000-1999 RED, RED/WHT, RNG 9310 B DATA

C420
B B 12V
GROUND 2000-2999 BLK 1200 R R 1200 9.7 ohm A A 4410 2490
9300 A CLOCK/LATCH
MONITORING 3000-3999 LBL 9350 B B 9350 12V B B 2410
HYDRAULIC 4000-4999 LGN C
9220 K SYSTEM Rx
ATTACHMENT CONTROLS 5000-5999 YEL 3900 L L 3900 REAR AUX RELIEF
9120 H SYSTEM Tx

C417
LIGHTS 6000-6999 PNK 3920 B SEAT BAR FRONT ROD 4480 A A
2530 GROUNDS ACCESSORIES 7000-7999 WHT G G 3920
SENSOR 9.8 ohm
1920 F COMPUTER POWER GREEN TIE STRAP

C418
ENGINE 8000-8999 TAN 3910 K K A A A 4330 2480 B B 12V
2480 3910 3.3 ohm
COMMUNICATION 9000-9999 PUR 1220 E PROTECTED POWER PWM
2460 N N B B 2330
2910 9350 D RUN/ENTER SWITCH

2900
9340
9200
9100
1900
1200
9350
3900
3920
3910
2900 2920 FOUND ONLY IN MAINFRAME HARNESS 6729055
2450 2930
MAIN 2920 G GROUND
2440 2400 2770 CAB 2000 FRONT BASE
FRAME C OPEN
2750 2740

C419
2430 2760 3.3 ohm A A 4340

2340 CAB 6727178 PWM

B B 2340

B3
D3

D2
D1

A1
A2
A3
C3
C2
C1

B2
B1
E3

E1

E2
F2

F3

F1
FRONT/REAR AUX
2330 RELIEF

C447
2520 4490 A A
J2 WHITE 9.8 ohm

C406
GREEN TIE STRAP
2100 FUEL SENDER A A 3100 3100 B1 PROTECTED COMPUTER
SYSTEM Tx OPEN OPEN
SEATBAR SENSOR F1 4340 2490 B B 12V
POWER POWER SUPPLY
30-270 ohm
2490 B B 3110 F1 F1 E1
D C
B1 A1 F2 4330
1 1
F3 1200 1900 9100 3900 H1 4410

K3

K2

K1
2420 OPEN
KEY/ENTER
SWITCH
SYSTEM Rx OPEN OPEN
SEATBAR
SENSOR SIGNAL
FOUND ONLY IN MAINFRAME HARNESS 6729962
2410 D J2 C K3
F2 E2 B2 A2

900 LOAD SENSE

C405
WHITE
2 2

HIGH FLOW /
A A 3700 3700 E2 K2

REAR AUX

DIVERTER
RELIEF

4460
2380 2390

4470
AIR FILTER 9350 9200 3910

4450
J3

J2

J1
HEADLIGHT SEATBAR SENSOR
OPEN
SWITCH B B 3710 3010 F2 GROUND
SWITCH
OPEN OPEN
GROUND
F3 4360
2370 D C
F3 E3 B3 A3
3 3 G2

TWO SPEED
+

SOLENOID
HYD LOCK
POSITION
2200

BUCKET
A 2900 9340 3920

4350

4420

4410
H3

H2

H1
A A 3400 3400 C1 G1

C105
2000 HYDRAULIC CHARGE
C
PRESSURE SENDER C C 3420 3420 C2 J2 4450

TRACTION HOLD SPOOL LOCK

2240
-

REAR BASE
REAR ROD
0.5 - 7.5 V B

4200

4430

4440
B B 3410 D3 J3

RESERVED

G3

G2

G1
4470

GROUNDS
DIGITAL 2

SENSOR
3010
SPARE
BUCKET POSITIONING

(hall)
F3

F2

F1
CONTROL MODULE

C423
HYDRAULIC J1
2800 4420 A A 9.8 ohm

C112 C108
TEMPERATURE

FRONT BASE
FRONT ROD
A A 3300 3300 B3 H3 12V

FILTER SIGNAL
HYD CHARGE

J4 WHITE
4360
ENG SPEED

4330

4340
B B

AIR FILTER
SENDER 2420

F3

F2

F1
3610

3700

SIGNAL

3600

SIGNAL
3430
E3

E2

E1
2300 500-3000 ohm B B 3310 H2 4420
3510
D2 4840

PRESS SIGNAL

PRESSURE +
2600

WHITE
ENG OIL
ENG OIL
A

J4
A E3

3520
3430 3430 3430

OPEN

3500
C2 4830

D3

D2

D1
HYDRAULIC OIL FILTER

J1 BLACK
2110 (DIFFERENTIAL) SWITCH B B SEE LEFT B2 4820

PWM SIGNAL
HANDLE

PWM +
4300
DIFFERENTIAL SWITCH HARNESS 6728626

PWM -
C A3

4310
4640

4320
A2 4810

E3

E2

E1
BLACK
CONNECTOR

J1
2740
+ THIS PAGE B3 1400
2730 A SEE CAB CONNECTOR

EHC OUTPUT
PRESS SIGNAL
D1

RH SKI UP
ENGINE OIL 3500 3500

HYD CHARGE ENG COOLANT

HYD CHARGE
PRESSURE +

LH SKI UP
2120 A A A3 4500 B

C107

RESERVED
(AC INPUT)

9410

4840

4940
3420

3400

D3

D2

D1
2720 PRESSURE THIS PAGE

C3

C2

C1
C 3520 3520 D2 SEE
SENDER - C C D1 4940
2710 B CONTROL
0.5-7.5 V B 3510 C1

RH SKI DOWN
4930

LH SKI DOWN
B

FUEL SENDER

EHC INPUT
HYDRAULIC
2350 SPARE ACCESSORY UNSWITCHED
MODULE

9400
3300

3100

SIGNAL

4830

4930
3200

C3

C2

C1
CAN HIGH OPEN OPEN STARTER FEEDBACK
STARTER RELAY FUEL HOLD

TEMP
TEMP
B3

B2

B1
OUTPUT 2 RELAY OUTPUT OPEN BATTERY IN (1)
B1 4920
J1 THIS

C106
K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
SPEED A A 3600 3600 E1 A1 4910 PAGE
8800 1110

LH AUX LEFT
9500 8000 8250 8210

BRAKE SW

RH FRONT
ANALOG 2

ANALOG 1

DETENT
SENSOR

HANDLE
B B

4640
ATTACHMENT BRAKE PULL

SPARE

SPARE
REAR WKLT BRAKE PULL UNSWITCHED
3610

FLOAT

4820

4920
1400

OUT
E2

B3

B2

B1
CAN LOW OPEN FUEL PULL RELAY GROUND
4310

A3

A2

A1
KEY INPUT RELAY FEEDBACK RELAY BATTERY IN (2)
C
J3
C3 K2 J2 H2 G2 F2 BLACK E2 D2 C2 B2 A2 E3 4320

RH TWO SPEED
LH AUX RIGHT
9600 9800 6210 4150 4110 8110 2110 1120

BRAKE SW
E1 4300

4500

4810

4910
ENGINE HARNESS 6726601
TWO SPEED TRAVEL MARKER LT GLOW PLUG GLOW PLUG FUEL PULL UNSWITCHED

A3

A2

A1
IN
CAN SELECT OPEN GROUND
MAKE-UP CONTROL RELAY FEEDBACK RELAY FEEDBACK BATTERY IN (3)

K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
K1
ENGINE t 9700 4730 6320 8550 8510 8150 2100 1130 C3 9400
J3
C104

C113

4220
COOLANT A A 3200 B B 3200 3200 B2 D3 9410
180
SENDER BLAC

2520
4240

4810
4820
4830
4840

4640
1480
4940
4300
4320
4310
4230
4910
4920
2530

1490
A A

4930
B B 3210 1800 G3 4200
500-3000 ohm 0
K

H3
H1

D3

D1

C1
C3
C2

B2
B3

D2

A3
A2
A1

H2
K1
K2
K3

G1
G2
G3

B1
E3

E1

E2
F3

F2

F1
J1
J2

J3
B D C G F E K J H A E H J A F G B C K D
ALTERNATOR SUPPLY
1020 C409 C410
C110

B B E H J A F G B C K D

4730

4110
FUEL B D C G F E K J H A

8000

6320

6210

8550
8510

8250
8210

8800
8150
8110

2110
2100

4150

1130
1120
1110

9800
9500
9600
9700
A A 1800 SHUTOFF
B
EXCITATION

WHT/LGN

YEL/RED
YEL/LGN
WHT/RED
HOLD

WHT/BLK
A A 8800

DBL
2010 10.9 ohm

C101

DGN

WHT
RNG
Dealer Copy -- Not for Resale

YEL

RNG
LGN
WHT
1010 C C 2800
STARTER
PULL

0.3 ohm B B 8100

M R
C109

BATTERY CABLE 8250 B B 8250

B S PWM
8200 A A 8200 RIGHT SKI SIDE SKI
ROCKER CTRL SHIFT CTRL
UP DETENT
TAILGATE / WORKLIGHTS 6716419 FLOW
LEFT HANDLE
F F RIGHT HANDLE
2600 B B 2600
RIGHT HORN
2620 6200 6200 H H 6200 TURN SIGNAL
WORKLIGHT
C103

6210 6310 A A 6310 TRACTION LOCK

9410
9400
LEFT
2630 6210 E E 6400
WORKLIGHT HOLD 10.9 ohm
A

C425
6500 4200 A
D D
RIGHT SEE CAB 2200 C C
2610 6320 G 6600 GLOW PLUGS

RNG/WHT
G B A

RNG/DBL
TAILLIGHT CONNECTOR
C404

0.4 ohm B

BRN
DGN
4100

YEL
BACKUP 7100 C C 7100 A TO OPTIONS THIS PAGE
B PULL 0.3 ohm
LEFT
2640 6330 ALARM B (BACKUP C473
TAILLIGHT
2650 ALARM SWITCH) C407 B A
HR
A
J 2730 ACS E B A D D B A

9420
2650

9420
P JUMPER

8500
6600
2640
C411 C412

6000
2630 2600 M 6500
TO OPTIONS TO OPTIONS
2620 L 6400 (ACCESSORY (ACCESSORY
F 4730 CONNECTOR) CONNECTOR)
2610
D 4235
N 6300
C488

C 4275
E 4550
S 1700
A 1140

H 1150
R
B
G
K (ALTERNATOR
& KITS) TO OPTIONS
TO OPTIONS 1800 (ACS
(ACCESSORY CONNECTOR) FUSE 11 CONNECTOR)
25A
8000

6300
6000

6320

6200
6210

8500
8550
8510

8200
8210

8100
8150
8110

4110
4150
4100

1130
1120
1110
6310

1700 1055 4220 M

L
C489

4275
B 2720 SWITCHED MARKER REAR GLOW FUEL TRACTION
LIGHT LIGHT PLUG STARTER PULL P

(COMPUTER)
A 1720 1720 POWER LOCK

FUSE 4
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A N

25A
TO OPTIONS (ATTACHMENT)
FUSE 10 4550 K
(ACCESSORY 30 85 30 85 30 85 30 85 30 85 30 85 85 30
CONNECTOR) 25A 9720 E
1710
1050
2000
2010

1330
2020
2030

1320
2010
2020

1060
2030
2040

2060

1350
2040
2050

2050
2060
1360
1030
9620 D

C492
(HEATER R
) 1 FUSE 2 120
FUSE FUSE 3 FUSE 6 FUSE 5 S
15A 15A 30A 30A OHM
25A
RESISTOR
J
MAINFRAME HARNESS 6729055 or 6729962 1140
9520 C
1150 1160 G
1070 2240 H
RELAY GROUNDS 2000-2060 FUSE 9 FUSE 12 1740 B
ARE CONNECTED IN SERIES 25A 25A

FUSE / RELAY CENTER (UNSWITCHED

POWER) (ACS)
1170 A
F
FUSE 5 FUSE 1 FUSE 9
TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
FUSE 6 FUSE 2 LIGHT POWER FUSE 10

1080
LIGHT
FUEL PULL FR & MK LT ATTCHMNT
1040
30A 15A 25A
FUSE 7 FUSE 3 FUSE 11
REAR LT ALT & KITS

1160
1730
9800
9510
9610
9710
2710
15A GLOW FUEL TRACTION 25A
STARTER
FUSE 8 FUSE 4 PLUG PULL PULL FUSE 12
COMPUTER ACS 1050
25A 25A - + 1300
1060
F E D A B C G
TO OPTIONS
100A
1010 1030
C426 (ATTACHMENT
ACD & REMOTE CONTROL)
1310 START CONNECTOR

Printed in U.S.A.
1040 V-0128 (4-9-03)
BATTERY 1080

421 of 726
 LEFT RIGHT LEFT PANEL
* NOTE: THESE ARE NOT FRONT

753 WIRING SCHEMATIC FOUND ON ALL

MACHINES.
B A A B
WORKLIGHTS 2910
9340
1210
G
D
E
GROUND
HEADLIGHTS
PROTECTED POWER
C434 C435
(With ACS Option) * LIFT ARM
RELEASE
SWITCH
B A A B
1910
9110
F
H
COMPUTER POWER
SYSTEM Tx

2750
6110

6120
2760
WIRES CONNECT BY 9210 K SYSTEM Rx TILT SPOOL LOCK
S/N 515835000 - 515843086 LETTER ACROSS H H * 4030
9300 A CLOCK/LATCH
(NOT Used With AHC or ACS)
SEE FUSE/RELAY
*

C421
C407
RED = RED CONNECTORS CENTER
J J 1340 A A 4370 DIVERTER
9310 B DATA
S/N 516222000 - 516225447

C416
A B 7.7 ohm
RNG = ORANGE (EUROPEAN A 6100 A A 6100 PWM B B 2370 4450 A A 7.5 ohm
BLK = BLACK B A LIGHTING) 9330 J START
12V
2900 M M 2900 YELLOW TIE STRAP 2450 B B
(PRINTED APRIL 2003) LBL = LIGHT BLUE
DBL = DARK BLUE
SOME CONNECTOR
THIS PAGE
9340 C C 9340
9320 C BUZZER LIFT SPOOL LOCK
(NOT Used With AHC or ACS)
LGN = LIGHT GREEN
V-0261

C422
DGN = DARK GREEN BODIES NOT SHOWN 9200 D D 9200 7.7 ohm A A 4380
9320 +
YEL = YELLOW FOR DRAWING CLARITY 9100 E E 9100 BUZZER PWM B B 2380
-

C408
PNK = PINK SEE CONTROL 2930
WHT = WHITE MODULE J4
B 4500 F F 4500 1930 RIGHT PANEL

Printable Version Click Here BRN = BROWN

TAN = TAN
THIS PAGE 2740 S S 2740 2770
BRAKE
SWITCH 9330 J START BICS HYDRAULIC
FRONT AUX RELIEF

C424
PUR = PURPLE 1900 P P 1900 LOCK 4490 A A 11 ohm
BATTERY FEED 1000-1999 RED, RED/WHT, RNG 9310 B DATA

C420
GRY = GRAY B B 12V
GROUND 2000-2999 BLK 1200 R R 1200 9.7 ohm A A 4410 2490
9300 A CLOCK/LATCH
MONITORING 3000-3999 LBL 9350 B B 9350 12V B B 2410
HYDRAULIC 4000-4999 LGN C
9220 K SYSTEM Rx
ATTACHMENT CONTROLS 5000-5999 YEL 3900 L L 3900 REAR AUX RELIEF
9120 H SYSTEM Tx

C417
LIGHTS 6000-6999 PNK 3920 B SEAT BAR FRONT ROD 4480 A A
2530 GROUNDS ACCESSORIES 7000-7999 WHT G G 3920
SENSOR 9.8 ohm
1920 F COMPUTER POWER GREEN TIE STRAP

C418
ENGINE 8000-8999 TAN 3910 K K A A A 4330 2480 B B 12V
2480 3910 3.3 ohm
COMMUNICATION 9000-9999 PUR 1220 E PROTECTED POWER PWM
2460 N N B B 2330
2910 9350 D RUN/ENTER SWITCH

2900
9340
9200
9100
1900
1200
9350
3900
3920
3910
2900 2920 FOUND ONLY IN MAINFRAME HARNESS 6729055
2450 2930
MAIN 2920 G GROUND
2440 2400 2770 CAB 2000 FRONT BASE
FRAME C OPEN
2750 2740

C419
2430 2760 3.3 ohm A A 4340

2340 CAB 6727178 PWM

B B 2340

B3
D3

D2
D1

A1
A2
A3
C3
C2
C1

B2
B1
E3

E1

E2
F2

F3

F1
FRONT/REAR AUX
2330 RELIEF

C447
2520 4490 A A
J2 WHITE 9.8 ohm

C406
GREEN TIE STRAP
2100 FUEL SENDER A A 3100 3100 B1 PROTECTED COMPUTER
SYSTEM Tx OPEN OPEN
SEATBAR SENSOR F1 4340 2490 B B 12V
POWER POWER SUPPLY
30-270 ohm
2490 B B 3110 F1 F1 E1
D C
B1 A1 F2 4330
1 1
F3 1200 1900 9100 3900 H1 4410

K3

K2

K1
2420 OPEN
KEY/ENTER
SWITCH
SYSTEM Rx OPEN OPEN
SEATBAR
SENSOR SIGNAL
FOUND ONLY IN MAINFRAME HARNESS 6729962
2410 D J2 C K3
F2 E2 B2 A2

900 LOAD SENSE

C405
WHITE
2 2

HIGH FLOW /
A A 3700 3700 E2 K2

REAR AUX

DIVERTER
RELIEF

4460
2380 2390

4470
AIR FILTER 9350 9200 3910

4450
J3

J2

J1
HEADLIGHT SEATBAR SENSOR
OPEN
SWITCH B B 3710 3010 F2 GROUND
SWITCH
OPEN OPEN
GROUND
F3 4360
2370 D C
F3 E3 B3 A3
3 3 G2

TWO SPEED
+

SOLENOID
HYD LOCK
POSITION
2200

BUCKET
A 2900 9340 3920

4350

4420

4410
H3

H2

H1
A A 3400 3400 C1 G1

C105
2000 HYDRAULIC CHARGE
C
PRESSURE SENDER C C 3420 3420 C2 J2 4450

TRACTION HOLD SPOOL LOCK

2240
-

REAR BASE
REAR ROD
0.5 - 7.5 V B

4200

4430

4440
B B 3410 D3 J3

RESERVED

G3

G2

G1
4470

GROUNDS
DIGITAL 2

SENSOR
3010
SPARE
BUCKET POSITIONING

(hall)
F3

F2

F1
CONTROL MODULE

C423
HYDRAULIC J1
2800 4420 A A 9.8 ohm

C112 C108
TEMPERATURE

FRONT BASE
FRONT ROD
A A 3300 3300 B3 H3 12V

FILTER SIGNAL
HYD CHARGE

J4 WHITE
4360
ENG SPEED

4330

4340
B B

AIR FILTER
SENDER 2420

F3

F2

F1
3610

3700

SIGNAL

3600

SIGNAL
3430
E3

E2

E1
2300 500-3000 ohm B B 3310 H2 4420
3510
D2 4840

PRESS SIGNAL

PRESSURE +
2600

WHITE
ENG OIL
ENG OIL
A

J4
A E3

3520
3430 3430 3430

OPEN

3500
C2 4830

D3

D2

D1
HYDRAULIC OIL FILTER

J1 BLACK
2110 (DIFFERENTIAL) SWITCH B B SEE LEFT B2 4820

PWM SIGNAL
HANDLE

PWM +
4300
DIFFERENTIAL SWITCH HARNESS 6728626

PWM -
C A3

4310
4640

4320
A2 4810

E3

E2

E1
BLACK
CONNECTOR

J1
2740
+ THIS PAGE B3 1400
2730 A SEE CAB CONNECTOR

EHC OUTPUT
PRESS SIGNAL
D1

RH SKI UP
ENGINE OIL 3500 3500

HYD CHARGE ENG COOLANT

HYD CHARGE
PRESSURE +

LH SKI UP
2120 A A A3 4500 B

C107

RESERVED
(AC INPUT)

9410

4840

4940
3420

3400

D3

D2

D1
2720 PRESSURE THIS PAGE

C3

C2

C1
C 3520 3520 D2 SEE
SENDER - C C D1 4940
2710 B CONTROL
0.5-7.5 V B 3510 C1

RH SKI DOWN
4930

LH SKI DOWN
B

FUEL SENDER

EHC INPUT
HYDRAULIC
2350 SPARE ACCESSORY UNSWITCHED
MODULE

9400
3300

3100

SIGNAL

4830

4930
3200

C3

C2

C1
CAN HIGH OPEN OPEN STARTER FEEDBACK
STARTER RELAY FUEL HOLD

TEMP
TEMP
B3

B2

B1
OUTPUT 2 RELAY OUTPUT OPEN BATTERY IN (1)
B1 4920
J1 THIS

C106
K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
SPEED A A 3600 3600 E1 A1 4910 PAGE
8800 1110

LH AUX LEFT
9500 8000 8250 8210

BRAKE SW

RH FRONT
ANALOG 2

ANALOG 1

DETENT
SENSOR

HANDLE
B B

4640
ATTACHMENT BRAKE PULL

SPARE

SPARE
REAR WKLT BRAKE PULL UNSWITCHED
3610

FLOAT

4820

4920
1400

OUT
E2

B3

B2

B1
CAN LOW OPEN FUEL PULL RELAY GROUND
4310

A3

A2

A1
KEY INPUT RELAY FEEDBACK RELAY BATTERY IN (2)
C
J3
C3 K2 J2 H2 G2 F2 BLACK E2 D2 C2 B2 A2 E3 4320

RH TWO SPEED
LH AUX RIGHT
9600 9800 6210 4150 4110 8110 2110 1120

BRAKE SW
E1 4300

4500

4810

4910
ENGINE HARNESS 6726601
TWO SPEED TRAVEL MARKER LT GLOW PLUG GLOW PLUG FUEL PULL UNSWITCHED

A3

A2

A1
IN
CAN SELECT OPEN GROUND
MAKE-UP CONTROL RELAY FEEDBACK RELAY FEEDBACK BATTERY IN (3)

K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
K1
ENGINE t 9700 4730 6320 8550 8510 8150 2100 1130 C3 9400
J3
C104

C113

4220
COOLANT A A 3200 B B 3200 3200 B2 D3 9410
180
SENDER BLAC

2520
4240

4810
4820
4830
4840

4640
1480
4940
4300
4320
4310
4230
4910
4920
2530

1490
A A

4930
B B 3210 1800 G3 4200
500-3000 ohm 0
K

H3
H1

D3

D1

C1
C3
C2

B2
B3

D2

A3
A2
A1

H2
K1
K2
K3

G1
G2
G3

B1
E3

E1

E2
F3

F2

F1
J1
J2

J3
B D C G F E K J H A E H J A F G B C K D
ALTERNATOR SUPPLY
1020 C409 C410
C110

B B E H J A F G B C K D

4730

4110
FUEL B D C F E J H A G K

8000

6320

6210

8550
8510

8250
8210

8800
8150
8110

2110
2100

4150

1130
1120
1110

9800
9500
9600
9700
A A 1800 SHUTOFF
B
EXCITATION

WHT/LGN

RNG/BLK
RNG/BLK

YEL/RED
WHT/RED
HOLD

WHT/BLK

YEL/RED

PNK
TAN
A A

DBL
2010 10.9 ohm 8800

C101

DGN

WHT
RNG

PUR
RNG
Dealer Copy -- Not for Resale

LGN
YEL
WHT
1010 C C 2800
STARTER
PULL

0.3 ohm B B 8100

M R 1 3 2 2 1 3
C109

BATTERY CABLE 8250 B B 8250 C465

B S PWM C466
8200 A A 8200 RIGHT 1 3 2 2 1 3
SKI SIDE
ROCKER SKI FLOAT
CTRL SHIFT
UP DETENT CTRL

TAILGATE / WORKLIGHTS 6716419 FLOW

HANDLE HANDLE
F F RIGHT HANDLE LOCK LOCK LEFT HANDLE
2600 B B 2600 AHC LIFT TURN
AHC TILT HORN

9410
9400
RIGHT HALL
2620 6200 6200 H H 6200 HALL SIGNAL
WORKLIGHT
C103

SENSOR SENSOR
6210 6310 A A 6310 TRACTION LOCK
LEFT
2630 6210 E E 6400
WORKLIGHT B A

PUR/WHT

PUR/WHT
RED/WHT

RED/WHT
HOLD 10.9 ohm

BLK/WHT

BLK/WHT
A

C425
6500 4200 A
D D
RIGHT
2610 6320 2650 G G 6600 SEE CAB GLOW PLUGS 2200 C C C473
TAILLIGHT CONNECTOR

BRN
DGN
C404

YEL
0.4 ohm 4100 B B A
7100 C C 7100 A TO OPTIONS THIS PAGE
B PULL 0.3 ohm

RED
BLK
LEFT B (BACKUP
2640 6330
TAILLIGHT BACKUP ALARM ALARM SWITCH) C407 1 3 2 1 3 2

9420
9420
HR C450 C449
A ACS
E B A D D B A
2730 J J 2730 JUMPER 1 3 2 1 3 2
P

8500
6600 P 6600
C411 C412

6000
6500 M M 6500 A C B A C B
TO OPTIONS TO OPTIONS
6400 L L 6400 C469 C472 (ACCESSORY (ACCESSORY
F 4730 A C B A C B CONNECTOR) CONNECTOR)
4730 F
hand 4 D
4235 4235 D 4235

1510
4650
2650
1610
4750
2750
13 ohm 13 ohm
6300 N N 6300
at 12V
at 12V
C488

5 4275 4275 C C 4275 FOOT PEDAL FOOT PEDAL

foot 6 E 4550 LOCK - LIFT LOCK - TILT
4550 E
1700 S S 1700
h TILT ACTUATOR LIFT ACTUATOR
1140 A A 1140
1700 1150 H H 1150
f M M
2 4550 R R C467 C468
1 B B 1 3 2 1 3 2
G G

4270
2500
4280
2510
K K (ALTERNATOR
TO OPTIONS

DGN

DGN
RED

RED

RED

RED
BLK

BLK
BLK

BLK
1800 & KITS)
TO OPTIONS (ACS
(ACCESSORY CONNECTOR) FUSE 11 CONNECTOR)
25A
8000

6300
6000

6320

6200
6210

8500
8550
8510

8200
8210

8100
8150
8110

4110
4150
4100

1130
1120
1110
6310

1700 1055 4220 M M 4220

8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
L L
C489

4275 4275
B 2720 MARKER REAR GLOW C428
SWITCHED FUEL TRACTION C429
LIGHT LIGHT PLUG STARTER PULL P A 1170

(COMPUTER)
A 1720 1720 POWER LOCK 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

FUSE 4
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A N N

25A
TO OPTIONS (ATTACHMENT)
FUSE 10 4550 K K
(ACCESSORY 30 85 30 85 30 85 30 85 30 85 30 85 85 30

4790

4780

1630
4770
2770

4690

4680

1530
4670
2670
CONNECTOR) 25A 9720 E E
1710
1050
2000
2010

1330
2020
2030

1320
2010
2020

1060
2030
2040

2060

1350
2040
2050

2050
2060
1360
1030
9620 D D

C492
(HEATER R R
) 1 FUSE 2 120
FUSE FUSE 3 FUSE 6 FUSE 5 S S
15A 15A 30A 30A OHM
25A
RESISTOR J
J
MAINFRAME HARNESS 6729055 or 6729962 1140
9520 C C

2260

2270
4260
4220

4780

4690
4680
4790
1190
1180
1150 1160 G G
1070 2240 H H
RELAY GROUNDS 2000-2060 FUSE 9 C B G E J K A H D F
FUSE 12 1740 B B
ARE CONNECTED IN SERIES 25A 25A

FUSE / RELAY CENTER (UNSWITCHED

POWER) (ACS)
1170 A
F
F
P
4550
9720
C
F
GRAY
J3
FUSE 5 FUSE 1 FUSE 9 9620 E
TRACTION HEATER UNSWITCHED
FRONT & 9520 D
30A 25A REAR SWITCH 25A
MARKER 2250 J1 ADVANCED HYDRAULIC CONTROL MODULE
FUSE 6 FUSE 2 LIGHT POWER FUSE 10 G

1080
LIGHT
1040
FUEL PULL FR & MK LT ATTCHMNT 2240 2280 H
30A 15A 25A 1740 B
J2
FUSE 7 FUSE 3
REAR LT
FUSE 11
ALT & KITS
ACS HARNESS - 1500 A
BLACK

1160
1730
9800
9510
9610
9710
2710
15A GLOW FUEL TRACTION
STARTER
25A 6729023, 6733430 A G B K C J D F H E
FUSE 8 FUSE 4 PLUG PULL PULL FUSE 12
COMPUTER ACS 1050 OR 6729054 (6729023
25A 25A - + 1300
1060
F E D A B C G Shown, See 763 Schematic -
TO OPTIONS S/N & Above for 6733430, or
100A
1010 1030
C426 (ATTACHMENT See Options for 6729054)
ACD & REMOTE CONTROL)

2760

2660
4760
1620

4660
1520
1310 TILT LIFT
START CONNECTOR
PEDAL PEDAL
1040 2
Printed in U.S.A. 2 1 1

C470

C471
BATTERY 1080 3 3 3 3
1 1 2 2
V-0261 (4-9-03)
422 of 726
 PROTECTED POWER

PROTECTED POWER
RUN/ENTER SWITCH

COMPUTER POWER F

COMPUTER POWER
TILT SPOOL LOCK

RIGHT PANEL

LEFT PANEL
(NOT Used With AHC or ACS)

753

CLOCK/LATCH A

CLOCK/LATCH
C421

HEADLIGHTS
4370 1 1

SYSTEM Rx K

SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK

SYSTEM Tx H
7.7 ohm

GROUND
2370 2 2

GROUND
(NOT Used With AHC or ACS) PWM

BUZZER

BUZZER
C422

START J

START
OPEN
1

DATA B
4380 1

DATA
7.7 ohm

WIRING SCHEMATIC
PWM
2380 2 2
BICS HYDRAULIC LOCK

G
C

D
E

B
A
K

E
F
J
C420
4410 A A 9.8 ohm

(Without ACS Option) 2410 B B 12V

2920
9350
1220
1920
9120
9220
9300
9310
9330

2930
9320

9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD

C423

C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
WIRES CONNECT BY LETTER 12V
753 (S/N 515843087 AND ABOVE) ACROSS CONNECTORS
B B 2420 2330 2 2 PWM FRONT BASE

C419 C106
4340 1 1 3.3 ohm
(S/N 516225448 AND ABOVE)

CAB 6727178
A B PWM
2340 2 2
B A
(PRINTED APRIL 2003) DIVERTER
3600 A A

C416
SPEED
SOME CONNECTOR 4450 A A
V-0262 7.5 ohm 3610 B B SENSOR MAIN

WORKLIGHTS
BODIES NOT SHOWN YELLOW TIE STRAP 2450 B B 12V FRAME

FRONT
FOR DRAWING CLARITY HYDRAULIC
3300 A A TEMPERATURE
Printable Version Click Here

SWITCH
SENDER

BRAKE
FRONT AUX RELIEF 3310 B B

1930
RED = RED 500-3000 ohm

2000
C424
RNG = ORANGE 4470 A A 11 ohm
BLK = BLACK GREEN TIE 12V

C435
2470 B B

RIGHT
LBL = LIGHT BLUE STRAP 2760 B B
UNSWITCHED POWER 1000-1999 RED
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE A SEE C113 6120 A A
SWITCHED POWER 1000-1999 RNG LGN = LIGHT GREEN
GROUNDS

C405 C406
GROUND 2000-2999 BLK DGN = DARK GREEN SEAT

CAB
YEL = YELLOW 3700 A A

C434
MONITORING 3000-3999 LBL AIR FILTER BAR 6110 A A

LEFT
4330
PNK = PINK

4360

4340
4410
4420
2530 HYDRAULIC 4000-4999 LGN B B SWITCH

2770
SEE J1 B 3710

3300
2110

3700
3200
B B

3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE 2750

4470
4450
2470 LIGHTS 6000-6999 PNK BRN = BROWN 3110 B B FUEL
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER - +8
2450 2400 3100 A A 2910
ENGINE 8000-8999 TAN PUR = PURPLE 30-270 ohm
2340 COMMUNICATION 9000-9999 PUR GRY = GRAY
J1 J2 2920 2900

C
2930

A
2330 29 26 J1 J2 32 1 41 3 21 10 38 48 8 18 2770
2740 2750

3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2520 3100 2760
SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX
COOLANT
PWM +8V ENG SPEED 28
LOCK ANALOG 1 OPEN TEMP SIGNAL SIGNAL
ROD GROUND Tx RIGHT SUPPLY
+
A 1 2 3 4 5 6 7 8 9 10
2100 A A 3400 3400 15
HYDRAULIC CHARGE C 4360 4330 2900 9100 4810 3200 4300 3600 N K G L B R P S F E D C M A J H
PRESSURE SENDER C C 3420 3420 47
C408
- PROTECTED
0.5 - 7.5 V B OPEN
SPARE
ANALOG 2 POWER
SYSTEM
Rx
LH AUX SPARE
DIGITAL 1
AIR FILTER
PWM -
RH FRONT
OPEN LEFT SIGNAL DETENT
2420 B B 3410 3010 23 23 9400 F
11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2410
3700 42 9410 G
B 9110 1200 9200 4820 4310 4920
2380 2390 PWM RH SKI
STATUS LH SKI FUEL
SEE J2 FRONT COMPUTER SEAT BAR

3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN OPEN SIGNAL
BASE IN DOWN SENDER DOWN
2370
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
2200 9400 1900 3900
P05 4830 3100 4320 4930
4340
2000 BUCKET 35 3910 SEE FUSE/RELAY
OPEN POSITION OPEN
KEY/ENTER SEATBAR
GROUND
LH SKI
UP OPEN GROUND OPEN
RH SKI
UP
A CENTER
SWITCH
2240 3 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38 39 40
4420 9350 3910 4840
8
2110 4940 25 3900 C407 LIGHTING)

C112
HYDRAULIC OIL A A 3430 3430 3 34 9350
2800 HYD LOCK STATUS
HEADLIGHT SEATBAR BRAKE SW HYDRAULIC
FILTER (DIFFERENTIAL) SOLENOID OUT FLOAT
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
3610 SWITCH B B 14 1200
2300 41 42 43 44 45 46 47 48 49 50
3510 4410 9410 4640 9340 3920 4500 3300 24 1900
2600
DIFFERENTIAL SWITCH RESERVED HYD FILTER RESERVED TWO SPEED LEFT GLOW PLUG TRACTION LOCK 46 4500
OPEN SPARE RELAY
(AC INPUT) OPEN SIGNAL (BOOTSTRAP) MAKE-UP OPEN
BLINKER PULL / 963
OUTPUT 1

2110
HARNESS 6728628 1 2 3 5 66 7
8
8 9 10
5 9100

3430 4390 6410 8510 4110

15 9200

2740 RESERVED STARTER UNSWITCHED CAN HYD CHARGE RIGHT TRACTION HIGH FLOW / REAR WKLT FUEL RELAY
44 9340
(hall) FEEDBACK BATTERY (1) HIGH PRESS +8V OPEN
BLINKER LOCK HOLD OPEN
900 LOAD HOLD
RELAY
2730 ENGINE OIL A A 3500 3500 37 4 2900

C107
2120 11 12 13 14 15 16
16 17 18
18 19 20
PRESSURE C 4940
2720 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER -
B 4930
2710 0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
ENGINE HARNESS 6729973 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4640
ENGINE t 4350 8150 1130 9700 8550 3500 2100 6320 8110
C104

COOLANT A A B A 36 4840
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V
SPARE HYD CHARGE ENG OIL RESERVED
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY
OUTPUT 2 PRESS SIGNAL OPEN PRESS SIGNAL (FAN OUTPUT)
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48
48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110

G A A J2

D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 17 41 4
B
B B 1800
FUEL
EXCITATION J1
SHUTOFF
ALTERNATOR 2010

4910
HOLD PULL

4730

4110

4200

1400
8000

6320

6210

8550
8510

8250
8210

8800
8150
8110

2100

4150

1130
1120
1110

9800
9500
9600
9700
10.9 ohm A A 8800

1480
4810
4820
4830
4840
4640

4300
4320
4310
4910
4920
4930
4940

4230
2530
1490
2520
4240
1010
STARTER 0.3 ohm
C
B
C
B
2800
8100
Dealer Copy -- Not for Resale

G
H

C
D
E

G
F

B
D
C

H
A

K
F
J

J
BATTERY CABLE M R
C109

B 8250 B B 8250 Traction Lock C410 C409

S
8200 A A

G
H

C
D

G
E

D
C

H
F

K
8200

J
4200 A 10.9 ohm
A HOLD

C425

YEL/LGN
YEL/RED

WHT/RED
WHT/BLK
WHT/LGN
C

WHT
2200

WHT
PUR

DGN
C

YEL
RGN

DBL

LGN
RGN
TO OPTIONS 4100 B B PULL 0.3 ohm
(ACCESSORY
TAILGATE / WORKLIGHTS 6716419 CONNECTOR)
F F
+ -
2600 B B 2600

FLOAT
SHIFT

SKI CTRL
SIDE
RIGHT
2620 6200 6200 H H 6200 PWM
WORKLIGHT LEFT HANDLE
C103

TWO SPD

SKI CTRL
DETENT
6210 6310 A A

FLOW
6310
HORN
LEFT
2630 6210 E E 6400 GLOW PLUGS TURN SIGNAL
RIGHT
WORKLIGHT
D 6500
0.4 ohm HANDLE
D
RIGHT
2610 6320 2650 G G 6600

RNG/WHT
RNG/DBL
TAILLIGHT
C404

SEE CAB
7100 C C 7100 A TO OPTIONS HR

DGN
BRN

YEL
CONNECTOR
LEFT B (BACKUP ALARM
2640 6330
TAILLIGHT BACKUP ALARM SWITCH) C407

8500

D
E

B
A
A
J 2730
P 6600 C411 C412
6000
M 6500
TO OPTIONS TO OPTIONS
L 6400
(ACCESSORY (ACCESSORY
F 4730 CONNECTOR) CONNECTOR)
D 4235
C488

TO OPTIONS N 6300
(ACCESSORY
CONNECTOR) C 4275
E 4550
S 1700
A 1140 1740

H 1150
R
B
G
K (ALTERNATOR
1800 & KITS)
FUSE 11
25A
8010

6300
6000

6320

6200
6210

8500
8550
8510

8200
8210

8100
8150
8110

4110
4150
4100

1130
1120
1110
MAINFRAME HARNESS
6310

1700 1055 4220 M M

J J
C489

TO OPTIONS B 2720 SWITCHED MARKER REAR GLOW FUEL

(ACCESSORY LIGHT PLUG STARTER PULL TRACTION
6732801
POWER LIGHT 4275 L L
CONNECTOR) A 1720 1720
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK

25A
P P
(ATTACHMENT)

(COMPUTER)
N N

FUSE 4
FUSE 10 30 85 30 85 30 85 30 85 30 85 30 85 85 30
25A 4550 K K
1730
1050
2010
2000

1330
2030
2020

1320
2020
2010

1060
2040
2030

1030
2060

1350
2050
2040

2060
2050
1360
9720 E E

C492
(HEATER
) 9620 D D
FUSE 1 FUSE 2 FUSE 3 FUSE 6 FUSE 5
15A 9410 S S 9420
25A 15A 30A 30A

120
1140 9400 R R
G G
1150 1160 9520 C C
1070 2240 H H
RELAY GROUNDS 2000-2060
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A

(ACS)
1170 A
F
A
F

1080
1040

FUSE 5 FUSE 1 FUSE 9

TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER 1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT

30A 15A 25A 1050

FUSE 7 FUSE 3 FUSE 11

G
-
D

C
E

A
B
1300
F

REAR LT ALT & KITS

+ TO OPTIONS
1060

FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
COMPUTER ACS
ACD & REMOTE V-0262 (4-9-03)
1310 START CONNECTOR
25A 25A
1040
Printed in U.S.A. 1080
BATTERY
423 of 726
 PROTECTED POWER

PROTECTED POWER
RUN/ENTER SWITCH D

COMPUTER POWER F

COMPUTER POWER
TILT SPOOL LOCK

RIGHT PANEL

LEFT PANEL
(NOT Used With AHC or ACS)

CLOCK/LATCH A

CLOCK/LATCH
C421

HEADLIGHTS
4370 1

753

SYSTEM Rx K

SYSTEM Rx
SYSTEM Tx
LIFT SPOOL LOCK

SYSTEM Tx H

GROUND
2370 2

GROUND G
(NOT Used With AHC or ACS)

BUZZER

BUZZER
C422

START J

START J
OPEN
1

DATA B
4380

DATA B
2380 2

WIRING SCHEMATIC BICS HYDRAULIC LOCK

G
C

D
E

A
K

E
F
C420
4410 A A 9.8 ohm
2410 B B 12V

(With ACS Option)

2920
9350
1220
1920
9120
9220
9300
9310
9330

2930
9320

9320
9330
9310
9300
9210
9110
1910
1210
9340
2910
BUCKET POSITIONING FRONT ROD

C423

C418
9.8 ohm A A 4420 4330 1 1 3.3 ohm
WIRES CONNECT BY LETTER 12V
PWM
B B 2420 2330 2 2 FRONT BASE
ACROSS CONNECTORS
753 (S/N 515843087 AND ABOVE)

C419 C106
4340 1 1 3.3 ohm

CAB 6727178
A B PWM
2340 2 2
(S/N 516225448 AND ABOVE) B A
DIVERTER
(PRINTED APRIL 2003) 3600 A A

C416
SPEED
SOME CONNECTOR 4450 A A 7.5 ohm SENSOR MAIN
3610 B B

WORKLIGHTS
BODIES NOT SHOWN 12V FRAME
V-0263 YELLOW TIE STRAP 2450 B B

FRONT
FOR DRAWING CLARITY HYDRAULIC
3300 A A TEMPERATURE

SWITCH
SENDER

BRAKE
Printable Version Click Here FRONT AUX RELIEF 3310 B B

1930
RED = RED 500-3000 ohm

2000
C424
RNG = ORANGE 4470 A A 11 ohm
BLK = BLACK GREEN TIE 12V

C435
2470 B B

RIGHT
LBL = LIGHT BLUE STRAP 2760 B B
UNSWITCHED POWER 1000-1999 RED
FUSED, UNSWITCHED POWER 1000-1999 RED/WHT DBL = DARK BLUE A SEE C113 6120 A A
SWITCHED POWER 1000-1999 RNG LGN = LIGHT GREEN
GROUNDS

C405 C406
GROUND 2000-2999 BLK DGN = DARK GREEN SEAT

CAB
YEL = YELLOW 3700 A A

C434
MONITORING 3000-3999 LBL AIR FILTER BAR 6110 A A

LEFT
4330
PNK = PINK

4360

4340
4410
4420
2530 HYDRAULIC 4000-4999 LGN B B SWITCH

2770
SEE J1 B 3710

3300
2110

3700
3200
B B

3600
ATTACHMENT CONTROLS 5000-5999 YEL WHT = WHITE 2750

4470
4450
2470 LIGHTS 6000-6999 PNK BRN = BROWN 3110 B B FUEL
ACCESSORIES 7000-7999 WHT TAN = TAN SENDER - +8
2450 2400 3100 A A 2910
ENGINE 8000-8999 TAN PUR = PURPLE 30-270 ohm
2340 COMMUNICATION 9000-9999 PUR GRY = GRAY
J1 J2 2920 2900

C
2930

A
2330 29 26 J1 J2 32 1 41 3 21 10 38 48 8 18 2770
2740 2750

3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
2520 3100 2760
SPOOL SPARE FRONT COMPUTER SYSTEM LH AUX
COOLANT
PWM +8V ENG SPEED 28
LOCK ANALOG 1 OPEN TEMP SIGNAL SIGNAL
ROD GROUND Tx RIGHT SUPPLY
+
A 1 2 3 4 5 6 7 8 9 10
2100 A A 3400 3400 15
HYDRAULIC CHARGE C 4360 4330 2900 9100 4810 3200 4300 3600 N K G L B R P S F E D C M A J H
PRESSURE SENDER C C 3420 3420 47
C408
- PROTECTED
0.5 - 7.5 V B OPEN
SPARE
ANALOG 2 POWER
SYSTEM
Rx
LH AUX SPARE
DIGITAL 1
AIR FILTER
PWM -
RH FRONT
OPEN LEFT SIGNAL DETENT
2420 B B 3410 3010 23 23 9400 F
11 12 13 14 15 16 17 18 19 20 N K G L B R P S F E D C M A J H
2410
3700 42 9410 G
B 9110 1200 9200 4820 4310 4920
2380 2390 PWM RH SKI
STATUS LH SKI FUEL
SEE J2 FRONT COMPUTER SEAT BAR

3910
3920
3900
9350
1200
1900
2740
4500
9100
9200
9340
2900
6100
OPEN OPEN SIGNAL
BASE IN DOWN SENDER DOWN
2370
POWER +8v
J2
21 22 23 24 25 26 27 28 29 30
2200 9400 1900 3900
P05 4830 3100 4320 4930
4340
2000 BUCKET 35 3910 SEE FUSE/RELAY
OPEN POSITION OPEN
KEY/ENTER SEATBAR
GROUND
LH SKI
UP OPEN GROUND OPEN
RH SKI
UP
A CENTER
SWITCH
2240 3 45 3920 (EUROPEAN
31 32 33 34 35 36 37 38 39 40
4420 9350 3910 4840
8
2110 4940 25 3900 C407 LIGHTING)

C112
HYDRAULIC OIL A A 3430 3430 3 34 9350
2800 HYD LOCK STATUS
HEADLIGHT SEATBAR BRAKE SW HYDRAULIC
FILTER (DIFFERENTIAL) SOLENOID OUT FLOAT
SWITCH SIGNAL IN
OPEN TEMP OPEN OPEN
3610 SWITCH B B 14 1200
2300 41 42 43 44 45 46 47 48 49 50
3510 4410 9410 4640 9340 3920 4500 3300 24 1900
2600
DIFFERENTIAL SWITCH RESERVED HYD FILTER RESERVED TWO SPEED LEFT GLOW PLUG TRACTION LOCK 46 4500
OPEN SPARE RELAY
(AC INPUT) OPEN SIGNAL (BOOTSTRAP) MAKE-UP OPEN
BLINKER PULL / 963
OUTPUT 1

2110
HARNESS 6728628 1 2 3 5 66 7
8
8 9 10
5 9100

3430 4390 6410 8510 4110

15 9200

2740 RESERVED STARTER UNSWITCHED CAN HYD CHARGE RIGHT TRACTION HIGH FLOW / REAR WKLT FUEL RELAY
44 9340
(hall) FEEDBACK BATTERY (1) HIGH PRESS +8V OPEN
BLINKER LOCK HOLD OPEN
900 LOAD HOLD
RELAY
2730 ENGINE OIL A A 3500 3500 37 4 2900

C107
2120 11 12 13 14 15 16
16 17 18
18 19 20
PRESSURE C 4940
2720 C C 3520 3520 49 8250 1110 9500 3400 6510 4200 4460 6210 8800
40
SENDER -
B 4930
2710 0.5-7.5 V B B 3510 TRACTION LOCK SENSOR TRAVEL F&R AUX RESERVED UNSWITCHED
30
SPARE
DIGITAL 2 PULL FEEDBACK GROUNDS
CAN
LOW CONTROL J1 RELIEF (SENSOR GRND) BATTERY (2)
DIVERTER STARTER
RELAY
20 4920
21 22 23 24 25 26 27 28 29 30
4150 3010 9600 4730
P01 4470 1120 4450 8210 19 4310
29 4320
ENGINE HARNESS 6729973 TWO SPEED
SOLENOID
OPEN
FUEL PULL
FEEDBACK
UNSWITCHED
BATTERY (3)
CAN
SELECT OPEN
GLOW PLUG
FEEDBACK
ENG OIL
PRESS +8v GROUND
MARKER
LT RELAY
FUEL PULL
RELAY
9 4300
31 32 33 34 35 36 37 38 39 40
4640
ENGINE t 4350 8150 1130 9700 8550 3500 2100 6320 8110
C104

COOLANT A A B A 36 4840
C113
3200 B 3200 SEE J2-8 HANDLE SWITCH PWR / RESERVED ATTACHMENT +5V
SPARE HYD CHARGE ENG OIL RESERVED
SENDER POWER ACC RELAY (CAN SHIELD) KEY INPUT SUPPLY
OUTPUT 2 PRESS SIGNAL OPEN PRESS SIGNAL (FAN OUTPUT)
4830
500-3000 ohm B B 3210 26
41 42 43 44 45 46 47 48
48 49 50
180 16 4820
A A 1800
8000 9800 3420 7200 3520
SUPPLY 0 1400
1020
J1 6 4810
C110

G A A J2

D3
E3
25 42 39 19 36 9 12 30 20 32 40 38 10 22 33 28 13 44 14 24 34 17 41 4
B
B B 1800
FUEL
EXCITATION J1
SHUTOFF
ALTERNATOR 2010

4910
HOLD PULL

4730

4110

4200

1400
8000

6320

6210

8550
8510

8250
8210

8800
8150
8110

2100

4150

1130
1120
1110

9800
9500
9600
9700
10.9 ohm A A 8800

1480
4810
4820
4830
4840
4640

4300
4320
4310
4910
4920
4930
4940

4230
2530
1490
2520
4240
1010
STARTER 0.3 ohm
C
B
C
B
2800
8100
Dealer Copy -- Not for Resale

G
H

C
D
E

G
F

B
D
C

H
A

K
F
J

J
BATTERY CABLE M R
C109

B 8250 B B 8250 Traction Lock C410 C409

S
8200 A A

G
H

C
D

G
E

D
C

H
F

K
8200

J
4200 A 10.9 ohm
A HOLD

C425

YEL/LGN
YEL/RED

WHT/RED
WHT/BLK
WHT/LGN

A
A

B
B
C

WHT
2200

WHT
PUR

DGN
C

YEL
RGN

DBL

LGN
RGN
TO OPTIONS C465 C466
4100 B B

A
PULL 0.3 ohm

B
B
(ACCESSORY
TAILGATE / WORKLIGHTS 6716419 CONNECTOR)
F F
+ - HANDLE
2600 B B 2600 HANDLE LOCK

FLOAT
SHIFT

SKI CTRL
SIDE
RIGHT LOCK
2620 6200 6200 H H 6200 PWM
WORKLIGHT LEFT HANDLE
C103

TWO SPD

SKI CTRL
DETENT
6210 6310 A A

FLOW
6310
HORN
LEFT
2630 6210 E E 6400 GLOW PLUGS
AHC LIFT
TURN SIGNAL
RIGHT
WORKLIGHT HALL SENSOR
D 6500
0.4 ohm HANDLE
D AHC TILT
RIGHT

B
C
A
2610 6320 2650 G G 6600 HALL SENSOR

RNG/WHT
RNG/DBL
TAILLIGHT
C404

SEE CAB
7100 C C 7100 A TO OPTIONS HR C450

DGN
BRN

YEL
CONNECTOR

B
C
A
LEFT B (BACKUP ALARM
2640 6330

A
C
B
TAILLIGHT BACKUP ALARM SWITCH) C407 C449

8500

C
B

D
E

B
A
A

B
C
A
2730 J J 2730
C411

B
C
C412

A
6600 P P 6600 C469
6000
6500 M M 6500 C472

A
C
B
TO OPTIONS TO OPTIONS

C
B

A
6400 L L 6400
(ACCESSORY (ACCESSORY

4750
1610

2750
4730 F F 4730 CONNECTOR) CONNECTOR)

1510
4650
hand 4

2650
4235 4235 D D 4235
C488

6300 N N 6300 13 ohm

5 C 4275 12V
4275 4275 C
FOOT PEDAL LOCK TILT ACTUATOR LIFT ACTUATOR
foot 6 4550 E E 4550
1700 S S 1700 M M
h
1140 A A 1140 1740

BLK
1150

DGN
1700 1150 H H

RED
f A B A B

RED
BLK

DGN
RED

RED
BLK

BLK
2 4550 R R
C467 C468
1 B B
A B

8
7
6
5
4
3
2
1
A B

8
7
6
5
4
3
2
1
G G C428
C429

4270
2500
4280
2510
K

8
7

5
4
3
2
1
K (ALTERNATOR

6
1800 & KITS)

8
7
6
5
4
3
2
1
FUSE 11

1630
4770
2770
4790

4780
25A
8010

6300
6000

6320

6200
6210

8500
8550
8510

8200
8210

8100
8150
8110

4110
4150
4100

1130
1120
1110
MAINFRAME HARNESS
6310

1530
4670
2670
4690

4680
1700 1055 4220 M M 4220
J J
C489

TO OPTIONS B 2720 SWITCHED MARKER REAR GLOW FUEL

(ACCESSORY LIGHT PLUG STARTER PULL TRACTION L 4275
6732801
POWER LIGHT 4275 L
CONNECTOR) A 1720 1720
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86 86 87 87A LOCK

25A
P A 1170
(ATTACHMENT)

(COMPUTER)
N N

FUSE 4
FUSE 10

4680
4260
4220

4780
2270
2260

4790

4690
30 85 30 85 30 85 30 85 30 85 30 85 85 30

1180
1190
25A 4550 K K 4550
1730
1050
2010
2000

1330
2030
2020

1320
2020
2010

1060
2040
2030

1030
2060

1350
2050
2040

2060
2050
1360
9720 E E 9720
(HEATER C B G E J H K A D F
9620 D D 9620

C492
) FUSE 2 FUSE 5
FUSE 1 FUSE 3 FUSE 6
25A 15A 30A 30A
9410 S S 9420 4550 C GREY
15A

120
1140 9400 R R 9720 F J3
G G 9620 E
1150 1160 9520 C C 9520 9520 D
1070 2240 H H 2240 2250 J1 ACS Controller
RELAY GROUNDS 2000-2060 G Advanced Control System
ARE CONNECTED IN SERIES FUSE 9 FUSE 12 1740 B B 1740 2280 H
FUSE / RELAY CENTER 25A
(UNSWITCHED
POWER)
25A

(ACS)
1170 A
F
F
P
1740
1500
B
A
J2
BLACK
A B C D K G F H
1080
J E
1040

4750

4650

4670

4770
FUSE 5 FUSE 1 FUSE 9
TRACTION HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER 1160
1730
9800
9510
9610
9710
2710
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHMNT A A 1620

C470
30A 15A 25A 1050 TILT C C 4760
FUSE 3 PEDAL
FUSE 7 FUSE 11 B

G
-
D

C
E

A
B
1300
F

+ B 2760
REAR LT ALT & KITS
1060 TO OPTIONS

FUSE 8
15A
FUSE 4
GLOW
PLUG
FUEL
PULL
TRACTION
PULL
STARTER
25A
FUSE 12
100A
1010 1030
C426 (ATTACHMENT
CONTROL) A A 1520

C471
ACD & REMOTE
COMPUTER

25A
ACS

25A
1310 START CONNECTOR LIFT
PEDAL
C C 4660 ACS HARNESS 6733430
1040 B B 2660
Printed in U.S.A. 1080 V-0263 (4-9-03)
BATTERY
424 of 726
 753 WIRING SCHEMATIC
OPTIONS TO ENGINE OR MAINFRAME
S/N 515830001 AND ABOVE EUROPEAN ONLY TO ENGINE OR MAINFRAME
7100 C
S/N 516220001 AND ABOVE RNG C
2650 F
RNG/DGN F
(PRINTED NOVEMBER 2001)

C103
6600 G
DGN/YEL G

C103
V-0129 6400 E
YEL E BACK-UP
BACK-UP
ALARM 6310 A
ALARM PNK A
6500 D
DGN D
Printable Version Click Here BLK/WHT
BLK
H
B
6200
2600
H
B AIR CONDITIONER SWITCH
THERMOSTAT
3100 A A

DGN/YEL

C630
DGN/YEL

6340

C612
2620
OFF A 7010 B B

PNK

BLK

2610
6610
6320
BLK

6620

6330
2640
PNK
BLK
PNK
BLK
LOW B 2310 2205 C C
2100
MEDIUM TO OPTIONS (AC)
2630 6210 HIGH
DBL/WHT E F C A B D F E D C B A
E F C A B D F E D C B A
C604 C605 REGISTRATION
C602 C603 REGISTRATION LEFT WORK RIGHT WORK
LEFT WORK RIGHT WORK HERE OR TO OPTIONS
E F C A B D F E D C B A LAMP (HVAC JUMPER) HEATER VALVE
E F C A B D F E D C B A LAMP
DBL A A 3200 1300 A A RED 10

C613
WHT B B 7200 D D WHT 8 M

C614
7000
DELUXE EUROPEAN C
1110
POTENTIOMETER
BLK C C 2110 2130 C C BLK 7
B B
REAR TAILLIGHT HARNESS - 6714546 TAILLIGHT HARNESS - 6718198 E E
LEFT TAILLIGHT RIGHT TAILLIGHT 1000 B
LEFT TAILLIGHT RIGHT TAILLIGHT F F

L 5000 3 3 YEL BLOWER MOTOR

TO OPTIONS
TO MAINFRAME M

C617 OR C642
(HVAC OR HVAC/ACCESSORY) 1200 2 2 RED

C611
A 1140 1140 B H 1010 1 1 RNG M
C401

D 1700 1740 A 2200 4 4 BLK

BLOWER SWITCH POWER RELAY
B 2730 2740 C 5 5 TO OPTIONS
(DELUXE ACCESSORY)
C 1120 FLASHER TO OPTIONS REAR WIPER 6 6 85 86
1740 2210
(POWER BOB-TACH) MOTOR 87 A

1150

C617
LIGHT SWITCH 30
POWER BOB-TACH E B
BEACON SWITCH
SWITCH
2770 V 87A 1190

2745 1
6420 2760 D M HVAC HARNESS - 6725933 2740 C

C601
6 5 2 1 REAR WIPER 1700
4 7000 A SWITCH
2
1130 6010 HAZARD SWITCH C
X L 6520 TRAVEL CONTROL
3 1 3 1720 LOCKOUT SWITCH
1180 6430 7010 B 1
1 2 2 FRONT WIPER
2 3 4 3 7220
5 SWITCH 1
4 TO OPTIONS (HVAC)
4 5 2
6530 3 1730 TO OPTIONS (HVAC) HEATER VALVE
TO OPTIONS 6 6

C631

C612
5 2750 2 1 B B 2310 2300 B
(EXTERIOR CAB) 6 TO MAINFRAME 4 1750 A 1300 A A RED 10
5 4700

C633
2725 3 A A 7030 A
E 6700 A 3 2715 D 7200 B B WHT 8 M
4

C614
D 2780 B 6 5
4 C 2130 C C BLK 7
C670

7310 DIODE
C 6300 6300 G 5 B AIR CONDITIONER
TO OPTIONS 6

C427
CLUTCH SOLENOID
F 6440 6400 E (DOME LIGHT) 6 E
HVAC JUMPER HARNESS -

C608
A C 2710 B F
B 6540 6500 F 1110 A
TO LEFT HANDLE CONNECTOR 6600 H 2 1190
6725934 OR 6725936

7020
7010
6410 D TO EUR0. LIGHTS 4700 D 1 2700
CONNECTOR
6510 A POWER 2790

C411
TO OPTIONS (FRONT WIPER)
PLUG
6000 B C DOME LIGHT
C TO OPTIONS SWITCH B A
F

C608
E A RED

C667
7210 A C632
4710 D B BLK
B A
1160 E
2735 B
DOME LIGHT AIR CONDITIONER
DELUXE ACCESSORY HARNESS - 6715366 HARNESS -
6726888 EVAPORATOR (AC)
PRESSURE SWITCH
TO OPTIONS
TO MAINFRAME

C617 OR C642
(HVAC OR HVAC/ACCESSORY)
A 1140 1140 B
C401

D 1700 1740 A
B 2730 2740 C
C 1150 FLASHER TO OPTIONS REAR WIPER
(POWER BOB-TACH) MOTOR
LIGHT SWITCH POWER BOB-TACH TO ENGINE OR MAINFRAME
BEACON SWITCH 2770 E V
SWITCH
1 2760 D M RNG C
2745 6420 BACK-UP

C601
6 5 2 1 REAR WIPER 1710
4 7000 A ALARM RNG/DGN F
2 SWITCH

Dealer Copy -- Not for Resale

C103
1130 6010 HAZARD SWITCH C G
L 6520 TRAVEL CONTROL TO ENGINE OR MAINFRAME
3 X 1 3 1720
1180 6430 7010 B LOCKOUT SWITCH E
1 2 3 2 1 FRONT WIPER
2 3 4 7220 RNG C
5 SWITCH PNK A
4 1
4 5 2 RNG/DGN F
6530 3
1730 D
TO OPTIONS 5 6 G

C103
6 2750 2 1
(EXTERIOR CAB) 6 TO MAINFRAME 4 1750 DBL/WHT H
5 4700 E
E 6700 2725 A 3 2715 BLK B BACK-UP
3 4
6 ALARM A
D 2780 B 4 5
C670

C 6300 6300 G 5 7310

BACK-UP ALARM D

DBL/WHT
TO OPTIONS 6 H

C427
F 6440 6400 E

PNK
BLK

PNK
BLK
6
HARNESS - 6715659

BLK
(DOME LIGHT)

BLK
B

C608
A C 2710 B
B 6540 6500 F 1110 A
TO LEFT HANDLE CONNECTOR 6600 H 2 1190
6410 D TO EUR0. LIGHTS 4700 D 1 2700
CONNECTOR LEFT RIGHT
6510 A POWER 2790
C411

TO OPTIONS (FRONT WIPER) LEFT RIGHT

PLUG WORK WORK
6000 B TAILLIGHT TAILLIGHT
C LIGHT LIGHT
C TO ATTACHMENT
F
E REAR LIGHT HARNESS - 6714350

C667
7210 A B
4710 D J
1760 E TO
N

DELUXE ACCESSORY HARNESS - 6725273 2735 B MAINFRAME P

C404
B
M TO OLDER
7100 A A MODEL ATTACHMENTS

C506
D WHT S
BACK-UP ALARM
TO MAINFRAME C BRN LT

C623
TO OPTIONS SWITCHES
B 2730 (POWER BOB-TACH) 7110 E BLK TM
STROBE OR TO
C401

BEACON A POWER BOB-TACH 2770 E MAINFRAME F DBL CENTER

C402
FLASHER SWITCH 1720 1730 A
C 2760 D G RED GD

C601
1 2720 B H YEL RT
D 1700 7000 A
2 1
BEACON SWITCH
6
2
C BACK-UP ALARM L RNG
2745 ADDITIONAL POWER K
LEFT
FLASHER
RIGHT
FLASHER
C609 4
5 HAZARD SWITCH 3
7010 B
SWITCHES HARNESS - CONNECTOR
RNG

C491
LIGHT LIGHT 2 1 TO
STROBE/BEACON 3
1130
X L
6010
2 1
6430 5 4
6718820
B GRADER HARNESS -
1180 3 1740 A
TO OPTIONS TO OPTIONS
(EXTERIOR CAB)
1 2
4
6530
6 6707303
6700 E 5 2750
C668 OR C670

6
E 6700
2775

TO OPTIONS A
TO OPTIONS TO MAINFRAME
A
2790

2795

(EXTERIOR CAB)
C668

(4 WAY FLASHER) C
C G ADDITIONAL POWER CONNECTOR
6440 1 2 2785 2780 D
C669

C490
C669

F 6440 6400 E 1740 A

2785 2 1 6440 F
D 2780 D 2740 B
6540 3 3 6540 B

C427
FRONT WIPER
B 6540 6500 F M BOTTLE AND TANK
4 WAY FLASHER EXTERIOR CAB HARNESS - A
FRONT WIPER
TO MAINFRAME
B (ACCESSORY CONNECTOR)
HARNESS - 6718873 6718872 C
MOTOR
1730 1720 A

C402
STANDARD ACCESSORY HARNESS - 6715365 H
V 2720 B
M

C622 ALARM

7200 or YEL
7150 or DGN
TO HANDLE CONNECT0R

2765 or BRN
HORN

C412
L X 2730 B
AIR CONDITIONER SWITCH
7200 A
OFF
7000
3100
TO OPTIONS
FRONT HORN HARNESS -

2745
LOW TO OPTIONS TO OPTIONS
MEDIUM
(HVAC) (DELUXE ACCESSORY)
(DELUXE ACCESSORY)
C 7310
6719151
2100 C 2740 C
HIGH
C636

C642
B 2735 2755 B B

C610
C667
B 1140 B
E 7160 C C
A 1740 A
HEATER VALVE A 7210 A A
DBL A A 3200 1300 A A RED 10
HVAC/ACCESSORY D
C637

C635

WHT B B 7200 B B WHT 8 M F WIPER HARNESS - 6718295

C
7000
1110
BLK
POTENTIOMETER
C C 2110 2130 C C BLK 7 HARNESS - or 6729739
6807266
1000 B RED = RED
TO ATTACHMENT
WIRES CONNECT BY
TO OPTIONS TO RNG = ORANGE
(HVAC ADAPTER) (BOOM BLK = BLACK LETTER ACROSS
MAINFRAME
L CONNECTOR) LBL = LIGHT BLUE CONNECTORS
5000 3 A B
A 9500 A DBL = DARK BLUE
M
1200 2 LGN = LIGHT GREEN B A BATTERY FEED 1000-1999 RED, RED/WHT, RNG
B B
C634

9600 DGN = DARK GREEN GROUND 2000-2999 BLK

H 1010 1 MONITORING 3000-3999 LBL
C 9700 C YEL = YELLOW
SOME CONNECTOR
C666

C426
2200 4 PNK = PINK HYDRAULIC 4000-4999 LGN
C640

BLOWER SWITCH POWER RELAY D 9800 D BODIES NOT SHOWN ATTACHMENT CONTROLS 5000-5999 YEL
TO OPTIONS WHT = WHITE
A 7010 6 LIGHTS 6000-6999 PNK
(HVAC/ACCESSORY) 1 1710 E BRN = BROWN FOR DRAWING CLARITY
TO OPTIONS 5 85 86 TAN = TAN ACCESSORIES 7000-7999 WHT
1740 2210 2 1160 F ENGINE 8000-8999 TAN
(HVAC ADAPTER) 87 A PUR = PURPLE
COMMUNICATION 9000-9999 PUR
C636

30 3 2710 G GRY = GRAY

87A 1190 B
HVAC HARNESSES - 6717877 OR 6725275 2740 C
BOOM HARNESS - 6718426 V-0129 (10-30-01)
Printed in U.S.A.

425 of 726
 753 WIRING SCHEMATIC
OPTIONS
S/N 515830001 AND ABOVE TO OPTIONS
S/N 516220001 AND ABOVE (POWER BOB-TACH)
POWER BOB-TACH 2770 E
(PRINTED NOVEMBER 2001) SWITCH
FLASHER
V-0130 2760 D

C601
1
7000 A TO
BEACON SWITCH 2 MAINFRAME
Printable Version Click Here 6
C BROWN TIE STRAPS BROWN TIE STRAP

C413

C413
5 7010 B A 4430 A A REAR ROD
HAZARD SWITCH 3
4 7.5 ohm nominal
2 1 B 2430 B B at 12 VDC
1130 6010 6430 4
L 5
3 X 3
1180 WHITE TIE STRAP
RED = RED TO OPTIONS 1 2 WHITE TIE STRAPS
WIRES CONNECT BY 4 6 REAR BASE

C414

C414
RNG = ORANGE (EXTERIOR CAB) 6530 A 4440 A A
LETTER ACROSS 5 2750 7.5 ohm nominal
BLK = BLACK 6 TO MAINFRAME
CONNECTORS E 6700 B 2440 B B at 12 VDC
LBL = LIGHT BLUE ACS SWITCH
2755
DBL = DARK BLUE A B D 2780 1 BLUE TIE STRAP

C670
LGN = LIGHT GREEN 4550 E BLUE TIE STRAPS
B A B 6540 2 HIGH FLOW

C415

C415
DGN = DARK GREEN 3 R A 4460 A A
YEL = YELLOW F 6440 2745 7.5 ohm nominal
SOME CONNECTOR 4 B 2460 B B
PNK = PINK A 2755 4235 D at 12 VDC
BODIES NOT SHOWN 5
WHT = WHITE 4275 C
C 6
BRN = BROWN FOR DRAWING CLARITY K YELLOW TIE STRAPS YELLOW TIE STRAP

C488
TAN = TAN

C416
DIVERTER

C416
PUR = PURPLE G A 4450 A A
7.5 ohm nominal
GRY = GRAY B B 2450 B B at 12 VDC
2730 J
GREEN TIE STRAP
GREEN TIE STRAPS REAR AUXILIARY
1700 S

C417
C417
A 4480 A A RELIEF
6400 L 9.8 ohm nominal
B 2480 B B at 12 VDC
6500 M
BATTERY FEED 1000-1999 RED, RED/WHT, RNG 1150 H
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL N HIGH FLOW
HYDRAULIC 4000-4999 LGN
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
P
F
EXTENSION
ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
A HARNESS -
COMMUNICATION 9000-9999 PUR STANDARD ACCESSORY HARNESS - 6727468 6718645

TO OPTIONS

C617 OR C642
(HVAC OR HVAC/ACCESSORY)
1140 B
1740 A
2740 C
FLASHER TO OPTIONS REAR WIPER
(POWER BOB-TACH) MOTOR
LIGHT SWITCH POWER BOB-TACH 2770 E
BEACON SWITCH V
2745
1
6420
SWITCH Dealer CopyD -- Not for
2760 M Resale

C601
6 5 2 1 REAR WIPER 1710
4 7000 A SWITCH
2
1130 6010 HAZARD SWITCH C
L 6520 TRAVEL CONTROL
3 X 1 3 1720
1180 6430 7010 B LOCKOUT SWITCH
1 2 3 2 1 FRONT WIPER
2 4 7220
3 5 SWITCH
4 1
4 5 2
6530 3
TO OPTIONS 5 6 1730
6 2750 2 1
(EXTERIOR CAB) 6 4 1750
5 4730
E 6700 2725 3 2715
3 4
D 2780 6 5
4
C670

7310
B 6540 5
TO OPTIONS 6
F 6440 (DOME LIGHT) 6
A

C608
2710 B
C 6300 1110 A
TO LEFT HANDLE
CONNECTOR 2 1190
6410 D 1 2700
TO OPTIONS
6510 A POWER 2790
C411

(FRONT WIPER)
PLUG
6000 B C
C F
E

C667
7210 A
ACS SWITCH TO MAINFRAME 4710 D
1
1770 4550 E 1760 E
2
3 R 2735 B
4
2755 4235 D
5 4275
6 C
K
G
B

C488
2730 J
6400 L
6500 M
1150 H
6300 N
6600 P
TO EUR0. LIGHTS 4730 F
CONNECTOR 1140 A
1700 S

DELUXE ACCESSORY HARNESS - 6727190

V-0130 (10-30-01)
Printed in U.S.A.
426 of 726
 753 WIRING SCHEMATIC
OPTIONS SSL 7-PIN
C426 To Mainframe
Harness
CAN CONNECTOR D F C E A B G
S/N 515830001 AND ABOVE
S/N 516220001 AND ABOVE

9800
1160
9700
1710
9500
9600
2710
(PRINTED NOVEMBER 2001)
V-0131
KEY "RUN" D 9800 C705 J1 - 8-PIN
Printable Version Click Here UNSW POWER 2 1160 2720 H GROUND
CAN SHIELD C 9720 9710 F CAN SHIELD
RIGHT HANDLE SW POWER 1 1740 1730 B SW POWER
PNK/ CAN HIGH A 9503 9604 E CAN LOW

C432

C450
A 1 1 RED
C 3 3 PNK/DGN
TILT CAN LOW B 9606 9501 D CAN HIGH
CONTROL
B 2 2 PNK/BLK
GROUND 3 2730 7-PIN / 14-PIN C OPEN
7-PIN SELECTOR SWITCH A OPEN
C666 ATTACHMENT
CONNECTOR 9501 1
2 G OPEN
3 9500
J 9503
B WHT
4 BOOM-MOUNTED
N 9604 5
D WHT/RED PWM 6 9600 ACD CONNECTORS
SW POWER K 1750 9606
C WHT/BLK

RIGHT
GROUND B 2740 C703 J2 - 10-PIN BLACK
E OUTPUT E 5100 5100 C E OUTPUT

C409
ROCKER
F WHT/LGN UP F OUTPUT F 5350 5350 H F OUTPUT
G G OUTPUT G 5400 5400 J G OUTPUT
DETENT H OUTPUT H 5050
E DGN 5050 B H OUTPUT
K C OUTPUT C 5300 5300 G C OUTPUT
D OUTPUT D 5150 5150 D D OUTPUT
J YEL
SKI A OUTPUT A 5250 5250 F A OUTPUT
H LGN CONTROL
M OUTPUT M 5200 5200 E B OUTPUT
A RNG
ID (K TO L) L 5910 5000 A J OUTPUT
ID (K TO P) P 5510 5450 K K OUTPUT
D PUR FLOAT
J SIGNAL C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
A RNG CONNECTOR
5900 J ID #1
C WHT SKI 5500 A ID #2
C410

B DBL CONTROL
B ID #3
G PNK PADDLE C ID #4
F TAN MOMENTARY
D ID #0
K E OPEN
E F OPEN
H G OPEN
H OPEN
B BRN DELUXE ATTACHMENT CONTROL HARNESS - 6719434
Dealer Copy -- Not for Resale K OPEN
C449 C412 C411

TURN
D YEL
SIGNAL
A DGN
C
E SSL 7-PIN
C426 To Mainframe
Harness
CAN CONNECTOR D F C E A B G
A BLK
B RED HORN

9800
1160
9700
1710
9500
9600
2710
C433

A 1 1 RED/WHT
C 3 3 PUR/WHT
LIFT
CONTROL
KEY "RUN" D 9800 C705 J1 - 8-PIN

2 BLK/WHT
UNSW POWER 2 1160 2720 H GROUND
B 2
CAN SHIELD C 9710 9710 F CAN SHIELD
LEFT HANDLE
SW POWER 1 1730 1720 B SW POWER
CAN LOW B 9620 9610 E CAN LOW

ADVANCED HAND CONTROL CAN HIGH

GROUND
A
3
9520
2730
9510 D CAN HIGH
C OPEN
(WITH PUSH BUTTON FLOAT) - 7-PIN A OPEN
C666 ATTACHMENT
G OPEN
RIGHT STEERING LEVER - 6675742 and J
CONNECTOR

LEFT STEERING LEVER 6675750 N

BOOM-MOUNTED
ACD CONNECTORS
SW POWER K 1740
GROUND B 2740 C703 J2 - 10-PIN BLACK
C433

C433

(TO "D" PIN)

(TO "B" PIN)

A RNG A E OUTPUT E 5100 5100 C E OUTPUT

C410

C431

C LGN C 4640
F OUTPUT F 5350 5350 H F OUTPUT
B BLK B G OUTPUT G 5400 5400 J G OUTPUT
- + H OUTPUT H 5050 5050 B H OUTPUT
C OUTPUT C 5300 5300 G C OUTPUT
D OUTPUT D 5150 5150 D D OUTPUT

ADVANCED HAND CONTROL ADVANCED HAND CONTROL A OUTPUT

M OUTPUT
A
M
5250
5200
5250
5200
F A OUTPUT
E B OUTPUT
G SERIES JUMPER G SERIES FLOAT ID (K TO L) L 5910 5000 A J OUTPUT
ID (K TO P) P 5510 5450 K K OUTPUT
HARNESS - 6728742 HARNESS - 6727328
C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
CONNECTOR
RED = RED 5900 J ID #1
WIRES CONNECT BY
RNG = ORANGE 5500 A ID #2
BLK = BLACK LETTER ACROSS BATTERY FEED 1000-1999 RED, RED/WHT, RNG
LBL = LIGHT BLUE CONNECTORS GROUND 2000-2999 BLK B ID #3
DBL = DARK BLUE A B MONITORING 3000-3999 LBL C ID #4
LGN = LIGHT GREEN HYDRAULIC 4000-4999 LGN
B A
DGN = DARK GREEN ATTACHMENT CONTROLS 5000-5999 YEL D ID #0
YEL = YELLOW LIGHTS 6000-6999 PNK
SOME CONNECTOR ACCESSORIES 7000-7999 WHT E OPEN
PNK = PINK
BODIES NOT SHOWN ENGINE 8000-8999 TAN F OPEN
WHT = WHITE
COMMUNICATION 9000-9999 PUR
BRN = BROWN FOR DRAWING CLARITY G OPEN
TAN = TAN
PUR = PURPLE H OPEN
GRY = GRAY DELUXE ATTACHMENT CONTROL HARNESS - 6727177 or 6729380 K OPEN

Printed in U.S.A. V-0131 (10-30-01)

427 of 726
428 of 726
Dealer Copy -- Not for Resale
 To
Mainframe C410
E H J A F G B C K D
753 WIRING SCHEMATIC

1480

4820

4840

4640
4810

4830
OPTIONS
S/N 515835000-36424
S/N 516222000-22355

4650
(PRINTED NOVEMBER 2001)
V-0132
E H J A F G B C K D
To
Mainframe C409 C410
B D C G F E K J H A E H J A F G B C K D
WIRES CONNECT BY
LETTER ACROSS

WHT/LGN
WHT/RED
WHT/BLK
CONNECTORS

TAN

DBL
PNK
DGN
A B

WHT
RNG

PUR
RNG
YEL
LGN
WHT
B A

SOME CONNECTOR
BODIES NOT SHOWN PWM
FOR DRAWING CLARITY RIGHT
SKI SIDE SKI
ROCKER FLOAT
UP DETENT CTRL SHIFT CTRL
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
GROUND 2000-2999 BLK FLOW
AHC LIFT
MONITORING 3000-3999 LBL HALL
HYDRAULIC 4000-4999 LGN RIGHT HANDLE LEFT HANDLE
SENSOR
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK AHC TILT HORN
TURN SIGNAL
ACCESSORIES 7000-7999 WHT HALL
ENGINE 8000-8999 TAN SENSOR
COMMUNICATION 9000-9999 PUR

Dealer Copy -- Not for Resale

RED = RED

PUR/WHT
RED/WHT
PNK/DGN
PNK/RED

BLK/WHT
PNK/BLK
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE

BRN
DGN
YEL
DBL = DARK BLUE

RED
BLK
LGN = LIGHT GREEN
DGN = DARK GREEN 1 3 2 1 3 2
YEL = YELLOW C450 C449
PNK = PINK 1 3 2 1 3 2 E B A D D B A
WHT = WHITE
BRN = BROWN C411 C412
TAN = TAN C473 A C B A C B TO OPTIONS TO OPTIONS
PUR = PURPLE To
B A C494 C495 (ACCESSORY (ACCESSORY
GRY = GRAY Mainframe
A C B A C B CONNECTOR) CONNECTOR)
9410
9400

Extra Power
Connector
4600
4620
4610
4700
4720
4710
C496

A 1750

B 2750

To
Mainframe
C489

A 1740

B 2740
2720
1720

TILT ACTUATOR LIFT ACTUATOR

4620
4580

4720

4600

4610
4645
4700

4710

M M
B A K H J D C E G A F B

C474 C493
B A K H J D C E G A F B
DGN

DGN
RED

RED

RED

RED
BLK

BLK
BLK

BLK

ADVANCED
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
HAND C428 C429
CONTROL 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
HIBBING
HARNESS -
6729054

HIBBING AHC CONTROLLER

Printed in U.S.A. V-0132 (10-30-01)

429 of 726
 TO TO
MAINFRAME C409 MAINFRAME C410
B D C F E J H A G K E H J A F G B C K D
753 WIRING SCHEMATIC

WHT/LGN

RNG/BLK
RNG/BLK
OPTIONS

YEL/RED
WHT/RED
WHT/BLK

YEL/RED

PNK
TAN

DBL
DGN

WHT
RNG
S/N 515836425 AND ABOVE

PUR
RNG
LGN
YEL
WHT
S/N 516222356 AND ABOVE
1 3 2 2 1 3
(PRINTED NOVEMBER 2001) C465
PWM C466
V-0133 RIGHT 1 3 2 2 1 3
SKI SIDE SKI
ROCKER FLOAT
CTRL SHIFT CTRL
UP DETENT
FLOW
HANDLE HANDLE
RIGHT HANDLE LOCK LOCK LEFT HANDLE
WIRES CONNECT BY AHC LIFT
AHC TILT TURN HORN
LETTER ACROSS HALL SIGNAL
HALL
CONNECTORS SENSOR SENSOR
A B
B A

PUR/WHT

PUR/WHT
RED/WHT

RED/WHT
BLK/WHT

BLK/WHT
SOME CONNECTOR
BODIES NOT SHOWN

BRN
DGN
YEL
FOR DRAWING CLARITY

RED
BLK
1 3 2 1 3 2
C450 C449
BATTERY FEED 1000-1999 RED, RED/WHT, RNG 1 3 2 1 3 2 E B A D D B A
GROUND 2000-2999 BLK
MONITORING 3000-3999 LBL C411 C412
HYDRAULIC 4000-4999 LGN A C B A C B TO OPTIONS TO OPTIONS
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK C469 C472 (ACCESSORY (ACCESSORY
A C B CONNECTOR) CONNECTOR)
ACCESSORIES 7000-7999 WHT A C B
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR

1510
4650
2650
1610
4750
2750
RED = RED
RNG = ORANGE
BLK = BLACK

Dealer Copy -- Not for Resale

LBL = LIGHT BLUE TILT ACTUATOR LIFT ACTUATOR
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
M M
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE 13 ohm 13 ohm

DGN

DGN
RED

RED

RED

RED
BLK

BLK
BLK

BLK
GRY = GRAY at 12V at 12V
FOOT PEDAL FOOT PEDAL
LOCK - LIFT LOCK - TILT
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
C428 C429
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

C467 C468
4790

4780

1630
4770
2770

4690

4680

1530
4670
2670
1 3 2 1 3 2
4270
2500
4280
2510

M 4220
L 4275
A 1170
N
2260

2270
4260
4220

4780

4690
4680
1190

4790
1180

K
E
A
C492

C B G E J K H D F
TO D
MAINFRAME R 4550 C GRAY
S 9720 F J3
J 9620 E
C 9520 D
G 2250 J1 ADVANCED HYDRAULIC CONTROL MODULE
G
H 2240 2280 H
B 1740 B
J2
F 1500 A
P
BLACK
A G B K C J D F H E
2760

2660
4760
1620

4660
1520

2 3 1 2 3 1
C470 C471
2 3 1 2 3 1
ADVANCED CONTROL
SYSTEM HARNESS -
6726925 or 6729023 TILT LIFT
Printed in U.S.A. PEDAL PEDAL V-0133 (11-2-01)

430 of 726
ELECTRICAL SYSTEM INFORMATION

753 WIRING SCHEMATIC

(S/N 515830001-515834999)
(S/N 516220001-516221999)
(PRINTED APRIL 2003)
V-0009

753 WIRING SCHEMATIC

WITH ADVANCED HAND CONTROL OPTION
(S/N 515830001-515834999)
(S/N 516220001-516221999)
(PRINTED APRIL 2003)
V-0010

753 WIRING SCHEMATIC

WITHOUT ADVANCED HAND CONTROL OPTION
(S/N 515835000-515834999)
(S/N 516222000-516221999)
(PRINTED APRIL 2003)
V-0128

753 WIRING SCHEMATIC

WITH ACS OPTION

Dealer Copy -- Not for Resale

(S/N 515835000-515843086)
(S/N 516222000-516225447)
(PRINTED APRIL 2003)
V-0261

753 WIRING SCHEMATIC

WITHOUT ACS OPTION
(S/N 515843087 & Above)
(S/N 516225448 & Above)
(PRINTED APRIL 2003)
V-0262

753 WIRING SCHEMATIC

WITH ACS OPTION
(S/N 515843087 & Above)
(S/N 516225448 & Above)
(PRINTED APRIL 2003)
V-0263

753 Bobcat Loader

60-10-1 Service Manual
431 of 726
ELECTRICAL SYSTEM INFORMATION (CONT’D)

OPTIONS

753 WIRING SCHEMATIC

OPTIONS
(S/N 515820001 & Above)
(S/N 516220001 & Above)
(PRINTED APRIL 2003)
V-0129

753 WIRING SCHEMATIC

OPTIONS
(S/N 515830001 & Above)
(S/N 516220001 & Above)
(PRINTED APRIL 2003)
V-0130

753 WIRING SCHEMATIC

OPTIONS
(S/N 515830001 & Above)
(S/N 516220001 & Above)
(PRINTED APRIL 2003)
V-0131

Dealer Copy -- Not for Resale

753 WIRING SCHEMATIC
OPTIONS
(S/N 515835000-515836424)
(S/N 516220000-516222355)
(PRINTED APRIL 2003)
V-0132

753 WIRING SCHEMATIC

OPTIONS
(S/N 515836425 & Above)
(S/N 516222356 & Above)
(PRINTED APRIL 2003)
V-0133

753 Bobcat Loader

60-10-2 Service Manual
432 of 726
ELECTRICAL SYSTEM INFORMATION (CONT’D)

Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Instructions are necessary before operating or
most common. Many of the recommended procedures servicing a machine. Read and understand the
must be done by authorized Bobcat Service Personnel Operation & Maintenance Manual, Handbook and
only. 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

PROBLEM CAUSE
Battery will not take a 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

Dealer Copy -- Not for Resale

KEY TO CORRECT THE CAUSE
1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or solenoid is damaged.
9. Check the fuses.

753 Bobcat Loader

60-10-3 Service Manual
433 of 726
ELECTRICAL SYSTEM INFORMATION (CONT’D)

Description
IMPORTANT
Figure 60-10-1
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397

Figure 60-10-3

P-28902

Figure 60-10-2 1

Dealer Copy -- Not for Resale

P-28840

The electrical system is also protected by fuses and

relays under the fuse panel cover (Item 1) [Figure 60-10-
3] located in the cab on the steering control panel.

P-13848A

The Loader has a 12 volt, negative ground alternator

charging system. The electrical system is protected by a
100 amp master fuse (Item 1) [Figure 60-10-1] &[Figure
60-10-2] to protect against serious system overloads that
could lead to burned up harness or loader damage. This
fuse is located in the left-hand side engine compartment.
just forward of the engine harness connector.

753 Bobcat Loader

60-10-4 Service Manual
434 of 726
ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuse Location

Description (Cont’d) Figure 60-10-5

IMPORTANT
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397

Figure 60-10-4

P-28846

F5 F1 E D C B F9

Dealer Copy -- Not for Resale

F6 F2 F10
1
F7 F3 F G H J F11

P-28840
F8 F4 F12

The fuse panel cover (Item 1) [Figure 60-10-4] & [Figure Fuses Relays Fuses
60-10-6] has a decal inside to show the location and amp N-18465A

ratings.
Remove the cover to check or replace the fuses.

The location and sizes are shown in [Figure 60-10-5] &

[Figure 60-10-6 on Page 6].

Ref Description Amp.

F1 Heater 25
F2 Front & Marker Lights 15
F3 Rear Lights 15
F4 Bobcat Controller 25
F5 Traction 30
F6 Fuel Shutoff 30
F7 Not Used --
F8 Not Used --
F9 Unswitched Attach. 25
F10 Switched Attach. 25
F11 Alternator & Kits 25
F12 AHC Power 25

753 Bobcat Loader

60-10-5 Service Manual
435 of 726
ELECTRICAL SYSTEM INFORMATION (CONT’D) Solenoid Test

Relay Switch Location Figure 60-10-7

Figure 60-10-6

P9175

P-28903
Use an Ohm meter to measure coil resistance [Figure
60-10-7].
Remove the cover to check or replace the relays.
Coil wires do not have polarity.
The location is shown in [Figure 60-10-5 on Page 5] &

Dealer Copy -- Not for Resale

[Figure 60-10-6]. Correct resistance for the au xiliary, lift and tilt lock coils
are 7-10 ohms.
Ref Description
B Switch Power The other coils (BICS, diverter, select valve) are 5-8
ohms.
C Rear Lights
D Front & Marker Lights
E Not Used
F Glow Plugs
G Fuel Shutoff
H Traction
J Starter

753 Bobcat Loader

60-10-6 Service Manual
436 of 726
BATTERY Figure 60-20-2

Removal And Installation

WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body. 1

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
N-20604
minutes.

If electrolyte is taken internally drink large quantities Disconnect the positive (+) battery cable (Item 1) [Figure
of water or milk! DO NOT induce vomiting. Get 60-20-2].
prompt medical attention.
W-2065-1296
Remove the battery from the loader.

Figure 60-20-1

Dealer Copy -- Not for Resale

2
1

N-20601

Open the rear door.

Disconnect the negative (-) battery cable (Item 1) [Figure

60-20-1].

Remove the b attery hold down clamp (Item 2) [Figure

60-20-1].

753 Bobcat Loader

60-20-1 Service Manual
437 of 726
BATTERY (CONT’D) Servicing

Removal And Installation (Cont'd)

Figure 60-20-3
WARNING
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 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 quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-1296
P9589

Figure 60-20-5
Figure 60-20-4

Dealer Copy -- Not for Resale

P9588
P9590

The battery cables must be clean and the connections

Always clean the terminals and cable ends when tight. Remove acid or corrosion from the bat tery and
installing a new battery [Figure 60-20-3] & [Figure 60- cables with a s odium bicarbonate (baking soda) and
20-4]. water solution [Figure 60-20-5].

When installing the battery in the loader, do not touch any Clean the ter minals and cable ends as shown in fig ure
metal parts with the battery terminal posts. [Figure 60-20-3] and [Figure 60-20-4].

Connect and tighten the battery cables. Connect the Check the electrolyte level in the battery. Add distilled
negative (-) cable last to prevent sparks. water as needed.

Install the battery holddown clamp. Put battery saver P/N (6664458) or grease on the battery
terminals and cable ends to prevent corrosion.

753 Bobcat Loader

60-20-2 Service Manual
438 of 726
BATTERY (CONT’D) If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the
Using A Booster Battery (Jump Starting) operator's seat and one person to co nnect and
disconnect the battery cables.

The key switch must be OFF (Standard Panel) OR the

WARNING STOP Button must be pressed (Deluxe Panel). The
booster battery must be 12 volt.
Batteries contain acid which burns eyes and skin on
Figure 60-20-6
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
2
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get 41
prompt medical attention.
W-2065-1296

N-18532

Dealer Copy -- Not for Resale

WARNING
Keep arcs, sparks flames and lighted tobacco away 3
from batteries. When jumping from booster battery
1
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 N-18531
lean over battery while boosting, testing or charging.

Battery gas can explode and cause serious injury. Connect the end of the first cable (Item 1) to the positive
W-2066-1296 (+) terminal of the booster battery. Connect the other end
of the same cable (Item 2) [Figure 60-20-6] to th e
positive terminal on the loader starter.

Connect the end of the second cable (Item 3) to the

IMPORTANT negative (-) terminal of the booster battery. Connect the
other end of the same cable (Item 4) [Figure 60-20-6] to
Damage to the alternator can occur if: the engine.
• Engine is operated with battery cables
disconnected. Keep cables away from moving parts. Start the engine.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove After the engine has started, remove the ground (-) cable
both cables from the battery.) (Item 4) [Figure 60-20-6] first.
• Extra battery cables (booster cables) are
connected wrong. Remove the cable from the p ositive terminal (Item 2)
I-2023-1285 [Figure 60-20-6].

753 Bobcat Loader

60-20-3 Service Manual
439 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

60-20-4 Service Manual
440 of 726
ALTERNATOR (55 AMP) Alternator Output Test

Adjusting The Alternator Belt

Figure 60-30-1
WARNING
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
2
fall or move and cause injury or death.
W-2017-0286

Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-10-1.)

Disconnect the negative (-) cable from the battery.

NOTE: The photo's may be different but the

1 P-3877 procedure is the same for all models.

Figure 60-30-2
Stop the engine.
2
Raise the operator cab. (See Raising The Operator Cab

Dealer Copy -- Not for Resale

on Page 10-30-1.)

Loosen the alternator mounting bolt (Item 1) [Figure 60-

30-1].

Loosen the adjustment bolt (Item 2) [Figure 60-30-1]. 1

Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span with 15 lbs. (66
N) of force.
P2284

Tighten the adjustment bolt and mounting bolt.

Disconnect the red wire (Item 1) [Figure 60-30-2] from
Lower the operator cab. the alternator. Connect that wire to the negative (-) side
of the ammeter.
Test the alternator as follows:
a. Alternator Output Test Connect the positive (+) side of the ammeter to the
b. Rectifier (Diode) Test output terminal on the alternator (Item 2) [Figure 60-30-
c. Alternator Regulator Test 2].

Disconnect the fuel stop solenoid connector.

Connect the negative (-) cable to the battery.

Turn on the lights and crank the engine for 30 seconds to

discharge the battery.

Connect the fuel stop solenoid, start the engine and run
at 2600 RPM.

The ammeter reading should be between 45-55 amps. at

2600 RPM.

If the reading is low, remove the bolts and pull the

regulator cover away from the alternator.

753 Bobcat Loader

60-30-1 Service Manual
441 of 726
ALTERNATOR (55 AMP) (CONT’D) Alternator Regulator Test

Rectifier (Diode) Test

Figure 60-30-3
WARNING
Output When an engine is running in an enclosed area, fresh
Terminal 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

1 Figure 60-30-4

Regulator
Terminal
Positive
P1304

Negative
The alternator is removed from the loader for clarity
purposes [Figure 60-30-3].

Dealer Copy -- Not for Resale

Disconnect the negative (-) cable from the battery.

Install the wires in th eir original location on th e back of

the alternator.
P2282
Connect a jumper wire (Item 1) [Figure 60-30-3] to the
alternator output terminal and the regulator terminal.
Connect the positive (+) voltmeter lead to the positive (+)
Connect the battery negative (-) cable. battery terminal [Figure 60-30-4].

Start the engine and run at 2600 RPM. Connect the neg ative (-) voltmeter lead to the negative
(-) battery terminal [Figure 60-30-4].
If the reading is within 45-55 amps. at 2600 RPM replace
the rectifier (diode) assembly or replace the alternator. Start the engine and run at 1500-2000 RPM.

If the reading is low, do the Alternator Regulator Test. The voltmeter should read between 13.9-14.7 volts.

If the reading is low stop the engine and disconnect the

battery negative (-) cable.

753 Bobcat Loader

60-30-2 Service Manual
442 of 726
ALTERNATOR (55 AMP) (CONT’D)

Rectifier (Diode) Test (Cont’d)

Figure 60-30-5

Ground
Stud

Brush
Terminal

1 P1364

The alternator is removed from the loader for clarity

purposes [Figure 60-30-5].

Dealer Copy -- Not for Resale

Remove the wires from the back of the alternator.

Remove the regulator cover from the back of the

alternator.

Install the wires on the back of the alternator.

Connect a jumper wire (Item 1) [Figure 60-30-5] from the

brush terminal to the ground stud.

Connect the negative (-) battery cable and start the

engine. Run at 1500 RPM.

If the voltmeter reading is 14.5 or above replace the

regulator.

If the voltmeter reading is below 14.5, repair or replace

the alternator.

753 Bobcat Loader

60-30-3 Service Manual
443 of 726
ALTERNATOR (55 AMP) (CONT’D) Figure 60-30-6

Removal And Installation

1
3

WARNING 4
P-3877

Never work on a machine with the lift arms up unless Disconnect the red wire (Item 1) [Figure 60-30-6] from
the lift arms are secured by an approved lift arm the alternator which comes from the battery.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Disconnect the wiring harness connector (Item 2)
to fall and cause injury or death. [Figure 60-30-6]from the alternator.
W-2059-0598

Dealer Copy -- Not for Resale

Remove the adjustment bolt (Item 3) [Figure 60-30-6]
from the mounting bracket.

IMPORTANT Remove the alternator belt from the alternator pulley.

Remove the mounting bolt (Item 4) [Figure 60-30-6] and

Damage to the alternator can occur if: spacer.
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

Place jackstands under the rear corners of the loader.

Raise the lift arms and install an approved lift arm

support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

Disconnect the negative (-) cable from the battery.

753 Bobcat Loader

60-30-4 Service Manual
444 of 726
ALTERNATOR (55 AMP) (CONT’D) Stator Continuity Test

Disassembly Figure 60-30-8

Figure 60-30-7

1. Nut 9. Rectifier (Diode)

2. Pulley 10. Case Half (Rear)
3. Fan 11. Condenser Assy.
4. Bolt 12. Strap
5. Case Half (Front) 13. Regulator
6. Bearing 14. Brush
7. Rotor 15. Cover
8. Stator

2 3
1 P1369

8 Use an ohmmeter to test the stator.

4 5

Touch the probes to two of the bare stator wires [Figure

60-30-8].
7

Dealer Copy -- Not for Resale

6 12 Move one of the probes to the third wire.

13 The readings should be the same.

If there is no continuity, replace the stator.

11 14
Stator Ground Test
10
9
Figure 60-30-9

15 C-3312

Disassemble the alternator. [Figure 60-30-7].

Remove the regulator cover and regulator.

Remove the four bolts holding halves together.

Pry the halves apart (use a press if needed).

Use a s oft jaw vise to hold rotor while removing pulley

nut.
P1386
Remove front case half from the rotor using a plastic
hammer or press.
Touch one pr obe to a bare stator lead and the other
Unsolder the s tator leads from the r ectifier. Remove the probe to the bare metal surface of the stator [Figure 60-
stator. 30-9].

There should be no continuity.

Replace the stator if there is continuity.

753 Bobcat Loader

60-30-5 Service Manual
445 of 726
ALTERNATOR (55 AMP) (CONT’D) Rectifier Continuity (Diode) Test

Rotor Continuity Test Figure 60-30-12

Figure 60-30-10 1
1
1

P1373

P1365
NOTE: In the diode tests there should be continuity
in one direction only. If the diode being tested
Touch the probes to the slip rings [Figure 60-30-10]. shows no continuity or continuity in both
directions, replace the rectifier assembly.
The ohmmeter should read between 3.065-33.85 ohms.

Dealer Copy -- Not for Resale

Touch the probes to the terminals (Item 1) [Figure 60-30-
If there is no continuity replace the rotor. 12] of each diode and read the meter.

Rotor Ground Test Reverse the probes to check the diode in the other
direction.
Figure 60-30-11
There should be continuity in one direction only.

Figure 60-30-13

1
1

P1378

Touch one probe to one of the slip rings and the other
P1370
probe to the rotor shaft [Figure 60-30-11].

There should be no continuity. Touch one probe to the diode (Item 1) [Figure 60-30-13]
and the other probe to the connected heatsink and read
Replace the rotor if there is continuity. the meter.

Reverse the probes to check the diode in the other

direction.

There should be continuity in one direction only.

753 Bobcat Loader
60-30-6 Service Manual
446 of 726
ALTERNATOR (55 AMP) (CONT’D) Assembly

Rectifier Continuity (Diode) Test (Cont'd) Figure 60-30-15

Figure 60-30-14

1
1

P1808

P1390
Reverse the order of disassembly.

Touch one probe to the diode (Item 1) [Figure 60-30-14] Do not assemble the rear case half.
and the other probe to the connected heatsink and read
the meter.

Dealer Copy -- Not for Resale

Place the rotor in soft jaws when tightening the shaft nut.
Tighten to 50 ft.-lbs. (68 Nm) torque [Figure 60-30-15].
Reverse the probes to c heck the diode in the other
direction. Install the rear case half and the remaining parts.

There should be continuity in one direction only.

753 Bobcat Loader

60-30-7 Service Manual
447 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

60-30-8 Service Manual
448 of 726
ALTERNATOR (90 AMP) Alternator Identification

Adjusting The Alternator Belt Figure 60-31-2

Figure 60-31-1

2
1 2
P-24416

4
1
3 P-24417
1
P-24543
The black cover has been removed to show alternator
rectifier/regulator assembly. The alternator contains field
Stop the engine. coil diodes (low current) (Item 1) [Figure 60-31-2],
grounded heat sink (Item 2) [Figure 60-31-2] & [Figure
Raise the operator cab. (See Raising The Operator Cab

Dealer Copy -- Not for Resale

60-31-3], B+ power heat sink (Item 3) [Figure 60-31-2] &
on Page 10-30-1.) [Figure 60-31-3], regulator (Item 4) [Figure 60-31-2] &
[Figure 60-31-3], and four pair of large power diodes
Loosen the alternator mounting bolt (Item 1) [Figure 60- (Item 1) [Figure 60-31-3] on th e underside of th e
31-1]. rectifier.

Loosen the adjustment bolt (Item 2) [Figure 60-31-1]. Figure 60-31-3

Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span with 15 lbs. (66 4
N) of force.

Tighten the adjustment bolt and mounting bolt.

3
Lower the operator cab. (See Lowering The Operator
Cab on Page 10-30-2.)

1 1
1
2 P-24542

NOTE: The rectifier/regulator assembly has been

removed from the alternator and flipped over
for component identification [Figure 60-31-3].

753 Bobcat Loader

60-31-1 Service Manual
449 of 726
ALTERNATOR (90 AMP) (CONT’D)

Charging System Check

IMPORTANT
If the charging system malfunctions check the following:
Damage to the alternator can occur if:
Check the condition and tension of the alternator belt. • Engine is operated with battery cables
(See Adjusting The Alternator Belt on P age 60-31-1.) disconnected.
Replace the belt if it is worn or deteriorated. • Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
Inspect the alternator wiring harness and connectors at both cables from the battery.)
alternator. Harness and connectors must be clean and • Extra battery cables (booster cables) are
tight. connected wrong.
I-2023-1285
Check the fuse for the alternator in the fuse panel. If fuse
is burned, find the cause and repair/replace. If fuse is in
doubt, remove it and check for continuity.

Check the electrolyte level in the battery. Add distilled WARNING

water as needed. (Does not apply to m aintenance free
batteries.) Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
Verify the charge of the battery. Make sure battery is fully rubber gloves to keep acid off body.
charged.

Dealer Copy -- Not for Resale

In case of acid contact, wash immediately with water.
Disconnect the battery cables (negative first, then In case of eye contact get prompt medical attention
positive). Inspect the cable clamps and battery posts for and wash eye with clean, cool water for at least 15
corrosion. Remove acid or corrosion from the battery and minutes.
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to If electrolyte is taken internally drink large quantities
prevent corrosion. Reconnect the cable to the positive of water or milk! DO NOT induce vomiting. Get
terminal. prompt medical attention.
W-2065-1296
With the key off, connect a test light between the negative
battery post and the disconnected negative cable clamp.
W-2066-1296
1. If the test light does not light up, reattach the clamp
and proceed to alternator voltage test. (See Charging
WARNING
System Check on Page 60-31-2.)
Keep arcs, sparks flames and lighted tobacco away
2. If the test light lights up, there is a short (drain) in the from batteries. When jumping from booster battery
electrical system of the loader. The short must be make final connection (negative) at engine frame.
repaired before the charging system can be checked.
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 or charging.

Battery gas can explode and cause serious injury.

W-2066-1296

753 Bobcat Loader

60-31-2 Service Manual
450 of 726
ALTERNATOR (90 AMP) (CONT’D) The voltage must be higher than 13.5 volts but lower than
14.7 volts at 70° F (Alternator Temperature).
Charging System Check (Cont’d)
If the voltage is higher that 14.7 volts, proceed to th e
Figure 60-31-4 following high voltage test.

If the voltage is lower than 13.5 volts, run the engine at

2 high idle and recheck voltage. If voltage is still below 13.5
volts, proceed with the following low voltage test.

Low Voltage Test

Figure 60-31-6
1

P-30210

3. Disconnect the alternator B+ terminal (Item 1) and L

& S terminal connector (Item 2) [Figure 60-31-4] and
if the test light goes out, the alternator is faulty. If the

Dealer Copy -- Not for Resale

test light stays on, fin d the short in the system and
repair it.

P-30210
Alternator Voltage Test

Figure 60-31-5 Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-31-6] off the alternator.

Turn the remote start tool key to the ON position.

P-24560

Open tailgate.

Connect the r emote start tool to the loader. (See

REMOTE START on Page 10-60-1.)

Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-31-5].

753 Bobcat Loader

60-31-3 Service Manual
451 of 726
ALTERNATOR (90 AMP) (CONT’D) High Voltage Test

Low Voltage Test (Cont’d) Figure 60-31-8

Figure 60-31-7 1

P-24568

1
P-24566

2 P-24569 P-30212A

P-30212A
Turn engine OFF and remove the L & S Terminal
connector (Item 1) [Figure 60-31-6] off the alternator.
Check the voltage across the “L” terminal (Item 1) and
ground (Item 2) [Figure 60-31-7]. The voltage should be Check the continuity between the “S” terminal (Item 1)
what the battery voltage is. If not, check wire harness,

Dealer Copy -- Not for Resale

and the positive (+) terminal on the battery or starter
relay and fuses. If the wire harness, relay and fuses are terminal (Item 2) [Figure 60-31-8]. There should be
ok then remove alternator for replacement or repair. To continuity. If no continuity, replace wire harness.
repair, (See Removal And Installation on Page 60-31-5.)
If voltage is still above 14.7 volts at 70°F (Alternator
Temperature), then remove alternator for replacement or
repair. To repair, (See Removal And Installation on Page
60-31-5.)

753 Bobcat Loader

60-31-4 Service Manual
452 of 726
ALTERNATOR (90 AMP) (CONT’D) Figure 60-31-9

Removal And Installation

WARNING P-30210

Never work on a machine with the lift arms up unless Disconnect the red wire (Item 1) [Figure 60-31-9] from
the lift arms are secured by an approved lift arm the alternator which comes from the battery.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Disconnect the wiring harness connector (Item 2) [Figure
to fall and cause injury or death. 60-31-9] from the alternator.
W-2059-0598

Dealer Copy -- Not for Resale

Figure 60-31-10

1
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove 2
both cables from the battery.) 3
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
P-24543
Place jackstands under the rear corners of the loader.

Raise the lift arms and install an approved lift arm Remove the adjustment bolt (Item 1) [Figure 60-31-10]
support device. (See Installing Lift Arm Support Device from the mounting bracket.
on Page 10-20-1.)
Remove the alternator belt (Item 2) [Figure 60-31-10]
Raise the operator cab. (See Raising The Operator Cab from the alternator pulley.
on Page 10-30-1.)
Remove the mounting bolt (Item 3) [Figure 60-31-10].
Disconnect the negative (-) cable from the battery.

753 Bobcat Loader

60-31-5 Service Manual
453 of 726
ALTERNATOR (90 AMP) (CONT’D) Figure 60-31-13

Rectifier Continuity (Diode) Test

1
Figure 60-31-11

3 1
2

1 1

P-24527

1 Touch the probes to the terminals (Item 1) [Figure 60-31-

P-24416 13] of each diode and read the meter.

Reverse the probes to check the diode in the other

Remove the two screws (Item 1), nut/washer (Item 2) and direction.
the plastic cover (Item 3) [Figure 60-31-11] from the
alternator.

Dealer Copy -- Not for Resale

Meter readings should be different when probes are
reversed.
NOTE: In the diode tests there should be continuity
in one direction only. Meter readings should Figure 60-31-14
be different when probes are reversed. If the
diode being tested shows no continuity or
continuity in both directions, replace the
rectifier assembly.

Figure 60-31-12

1
1

P-24558

Touch one probe to the diode (Item 1) [Figure 60-31-14]

and the other probe to e ach heat sink and read the
meter.
P-24532
Reverse the probes to check the diode in the other
direction.
NOTE: Use the diode function (Item 1) [Figure 60-31-
12] on the multimeter. Meter readings should be different when probes are
reversed.

753 Bobcat Loader

60-31-6 Service Manual
454 of 726
ALTERNATOR (90 AMP) (CONT’D) Disassembly

Alternator Regulator Test Figure 60-31-17

Figure 60-31-15 1. Alternator 11. Bearing

2. Nut 12. Stator
3. Pulley 13. Bracket
4. Spacer 14. Sleeve
5. Bolt 15. Regulator
6. Bracket 16. Rectifier
7. Bolt 17. Cover
8. Bearing 18. Spacer
9. Retainer 19. Nut
10. Rotor
2 7

1
3
1 6

P-24533 47 13 14

2 12 5
Touch one probe to the “L” terminal (Item 1) and the other
probe to the ground (Item 2) [Figure 60-31-15]. 10 11

Dealer Copy -- Not for Resale

Figure 60-31-16 9
8

19
18

17
16
15
C-3529B

Disassemble the alternator [Figure 60-31-17].

P-24535
Remove the regulator cover.

Reverse the probes to check in the o ther direction Remove the four bolts holding halves together.
[Figure 60-31-16].
Pry the halves apart (use a press if needed).
There should be co ntinuity in one direction only. Meter
readings should be different when probes are reversed. If Use a soft jaw vise to hold rotor while removing pulley
there is no continuity or continuity in both directions, nut.
replace regulator.
Remove front case half from the rotor using a pl astic
hammer or press.

Unsolder the stator leads from the rectifier. Remove the

stator.

Unsolder the two leads between the rectifier and

regulator. Remove the regulator from rectifier.

753 Bobcat Loader

60-31-7 Service Manual
455 of 726
ALTERNATOR (90 AMP) (CONT’D) Rotor Continuity Test

Stator Continuity Test Figure 60-31-20

Figure 60-31-18

P-24524

P-24537
Touch the probes to the slip rings [Figure 60-31-20].

Use an ohmmeter to test the stator. The ohmmeter should read between 3.0-4.0 ohms.
Touch the probes to two of the bare stator wires [Figure

Dealer Copy -- Not for Resale

If there is no continuity replace the rotor.
60-31-18].

Move one of the probes to the third wire. Rotor Ground Test

The readings should be the same. Figure 60-31-21

If there is no continuity, replace the stator.

Stator Ground Test

Figure 60-31-19

P-24525

Touch one probe to one of the slip rings and the ot her
probe to the rotor shaft [Figure 60-31-21].

P-24538 There should be no continuity.

Replace the rotor if there is continuity.

Touch one probe to a bare stator lead and the other
probe to the bare metal surface of the stator [Figure 60-
31-19].

There should be no continuity.

Replace the stator if there is continuity.

753 Bobcat Loader

60-31-8 Service Manual
456 of 726
ALTERNATOR (90 AMP) (CONT’D)

Assembly

Figure 60-31-22

P-24557

Reverse the order of disassembly.

Do not assemble the rear case half.

Dealer Copy -- Not for Resale

Place the rotor in soft jaws when tightening the shaft nut
(Item 1) [Figure 60-31-22]. Tighten to 72 ± 14.5 ft.-lbs.
(98 ± 20 Nm) torque.

Install the rear case half and the remaining parts.

753 Bobcat Loader

60-31-9 Service Manual
457 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

60-31-10 Service Manual
458 of 726
STARTER (NIPPONDENSO) Removal And Installation

Checking Figure 60-40-3

Figure 60-40-1

Bat
S
M

Cranking 2
Motor

N-19441

A-1992
Stop the engine and open the rear door.

The key switch must be in the OFF position. Remove the negative (-) and positive (+) cables from the
battery.
The battery must be at full charge.

Dealer Copy -- Not for Resale

Remove the starter mounting bolt (Item 1) and
The cable connections on the battery must be clean and disconnect the ground wire (Item 2) [Figure 60-40-3]
tight. from the starter.

Connect a j umper wire between S te rminal and BAT

terminal [Figure 60-40-1].

If the starter turns but does not turn the en gine, the
starter drive has a defect.

Figure 60-40-2

Bat
S
M

Cranking
Motor

A-1991

Connect a ju mper wire between the M terminal and the

BAT terminal [Figure 60-40-2].

If the starter turns, the defect is in the solenoid.

If the starter does not turn, the starter is defective.

753 Bobcat Loader

60-40-1 Service Manual
459 of 726
STARTER (NIPPONDENSO) (CONT’D)

Removal And Installation (Cont’d)

Figure 60-40-4

4 2
3

N-19442

Disconnect the engine harness power wire and positive

(+) battery cable starter solenoid terminal (Item 1)

Dealer Copy -- Not for Resale

[Figure 60-40-4].

Disconnect the tan wire (Item 2) [Figure 60-40-4] from

the R terminal on the starter solenoid.

Disconnect the brown wire (Item 3) [Figure 60-40-4] from

the S terminal on the starter solenoid.

Remove the mounting bolts (Item 4) [Figure 60-40-4]

from the starter.

Remove the starter from the engine.

Installation: Tighten the three mounting bolts to 25-28

ft.-lbs. (34-38 Nm) torque.

Reverse the removal procedure to install the starter.

753 Bobcat Loader

60-40-2 Service Manual
460 of 726
STARTER (NIPPONDENSO) (CONT’D)

Parts Identification

9
1. Bearing
2. Armature 7
3. Bearing
4. Frame 5 8
6
5. Brush Spring
6. Brush Holder 12. Gasket
7. Cover 4 13. Switch
8. Bolt 14. Nut
3 15. Washer
9. Bolt
10. Bolt 2 16. Nut
11. Cover 17. Washer
1 18. Roller
19. Retainer
20. Idler Gear
21. Ball
11 10 22. Spring
12
15
14

Dealer Copy -- Not for Resale

16
18 17
19
20
13 15
16

23 14
22
21
36
35
34
23. Housing
33 24. Screw
32 25. Washer
26
25 26. O-ring
24 27. Housing
30 28. O-ring
28
29. Snap Ring
29 30. Collar
31 31. Pinion Gear
32. Spring Seat
29 33. Spring
27
34. Clutch
35. Spring
36. Pinion Shaft

d-2297

753 Bobcat Loader

60-40-3 Service Manual
461 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-7

Disassembly

Figure 60-40-5

1 N-15160

Remove the fr ame (Item 1) [Figure 60-40-7] from the

N-15158 magnetic switch.

Figure 60-40-8
Remove the cable (Item 1) [Figure 60-40-5] from the
magnetic switch.

Dealer Copy -- Not for Resale

Figure 60-40-6

1
1 1
N-15161

1
Remove the bolts (Item 1) from the brush cover (Item 2)
N-15159 [Figure 60-40-8].

Remove the cover (Item 2) [Figure 60-40-8].

Remove the bolts (Item 1) [Figure 60-40-6].

753 Bobcat Loader

60-40-4 Service Manual
462 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-11

Disassembly (Cont'd)
1
Figure 60-40-9

1
1
N-15162

Remove the bolts (Item 1) [Figure 60-40-11] from the

3 N-00980 starter housing.

Figure 60-40-12
Using a needle nose pliers, pull the brush springs (Item
1) back and remove the brushes (Item 2) [Figure 60-40-
1

Dealer Copy -- Not for Resale

9].

NOTE: The brushes are non-replaceable. If the

brushes are worn order a new brush holder
(for the negative brushes) and yoke (for the
positive brushes).

Remove the brush holder (Item 3) [Figure 60-40-9] from

the end of the armature.

Figure 60-40-10

N-15163

Remove the starter housing (Item 1) [Figure 60-40-12]

1 from the magnetic switch.

2
2
N-00981

Remove the armature (Item 1) [Figure 60-40-10] from

the frame.

Remove the bearings (Item 2) [Figure 60-40-10] from

both ends of the armature.

753 Bobcat Loader

60-40-5 Service Manual
463 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-15

Disassembly (Cont'd)

Figure 60-40-13

1
N-15166
1
Remove the O-ring (Item 1) [Figure 60-40-15].
N-15164
Figure 60-40-16

Remove the ball (Item 1) [Figure 60-40-13] from the

pinion shaft.

Dealer Copy -- Not for Resale

2
Figure 60-40-14

N-00987

Press down on t he pinion (Item 1) and retainer (Item 2)

1 [Figure 60-40-16].
N-15165

Tap the starter pinion/clutch assembly (Item 1) [Figure

60-40-14] out of the starter housing.

753 Bobcat Loader

60-40-6 Service Manual
464 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-19

Disassembly (Cont'd)

Figure 60-40-17
3

1 2

N-00989

Remove the pinion shaft (Item 1) and spring (Item 2) from

N-15011 the over running clutch (Item 3) [Figure 60-40-19].

Figure 60-40-20
Remove the snap ring (Item 1) [Figure 60-40-17].

Dealer Copy -- Not for Resale

Figure 60-40-18

1
3

1 N-15167

4 2
N-00988 Remove the spring (Item 1) [Figure 60-40-20] from the
magnetic switch housing.

Remove the retainer (Item 1) and pinion (Item 2) [Figure

60-40-18].

Remove the spring seat (Item 3) and spring (Item 4)

[Figure 60-40-18].

753 Bobcat Loader

60-40-7 Service Manual
465 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-23

Disassembly (Cont'd)

Figure 60-40-21

1
2
1

1 1 N-15150
3

Remove the bolts (Item 1) [Figure 60-40-23] from the

N-15168 magnetic switch.

Figure 60-40-24
Remove the idler gear (Item 1), retainer (Item 2) and
rollers (Item 3) [Figure 60-40-21] from the magnetic
switch housing.

Dealer Copy -- Not for Resale

Figure 60-40-22
1
3 2

N-15151

Remove the cover (Item 1), gasket (Item 2) and switch

1 (Item 3) [Figure 60-40-24].
N-15169

Remove the washer (Item 1) [Figure 60-40-22] from the

idler gear shaft.

753 Bobcat Loader

60-40-8 Service Manual
466 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-27

Inspection And Repair

Figure 60-40-25

N-00997

Armature Winding Continuity Test: Use a circuit tester,

B-14455 touch the probes to two commutator segments [Figure
60-40-27]. There should be continuity at any point. If
there is no c ontinuity, the winding is open-circuited,
Inspect the brush cover for discoloration, indication the replace the armature.
starter has been overheated.

Dealer Copy -- Not for Resale

Figure 60-40-28
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 [Figure 60-40-25]. A s hort circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.

Figure 60-40-26

B-14458

Commutator Run-Out Test: check the commutator run-

out as shown in [Figure 60-40-28].

Service Limit - 0.020 inch (0,4 mm)

If the commutator exceeds the service limit, repair as

needed.
N-00996

Armature Winding Ground Test: Use a c ircuit tester,

touch one probe to a commutator segment and the other
probe to t he armature core [Figure 60-40-26]. There
should be no continuity. If there is continuity, the armature
is grounded and must be replaced.

753 Bobcat Loader

60-40-9 Service Manual
467 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-30

Inspection And Repair (Cont'd)

Figure 60-40-29

N-00999

Check the field windings for wear and damage.

B-14460
Check all the connections for clean and tight solder joints.

Measure the segment mica depth (Item 1) [Figure 60-40- Field Winding Ground Test: Use a circuit tester, touch
29]. one probe to th e field winding end of th e brush and the

Dealer Copy -- Not for Resale

other probe to the surface of the frame [Figure 60-40-
Service Limit - 0.008 inch (0,2 mm) 30]. There should be no continuity. If there is continuity,
the field windings are grounded.
If it is worn, replace the armature.
Replace the frame.
Check the commutator surface for burned spots which
usually indicates an open-circuit, and correct it using Figure 60-40-31
#400 sand paper.

N-15005

Field Windings Continuity Test: Use a circuit tester, touch

one probe to the wire and the oth er probe to the brush
[Figure 60-40-31]. There should be continuity. If there is
no continuity, the field windings are open-circuited.

Replace the frame.

753 Bobcat Loader

60-40-10 Service Manual
468 of 726
STARTER (NIPPONDENSO) (CONT’D) Pull the pinion out (to the engaged position) [Figure 60-
40-33] and allow it to snap back to the retracted position.
Inspection And Repair (Cont'd) The pinion must fully return to the retracted position.

Figure 60-40-32 The following tests should be done without the armature
assembly. Install the magnetic switch in th e switch
housing.

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.

Figure 60-40-34

C
50
N-15006

Inspect the brushes for wear and damage.

Replace the brush holder and yoke if th e brushes need

Dealer Copy -- Not for Resale

replacement.
M.T.
Check brush spring, for damage or rust. Replace as
needed.
B-14471

Brush Holder Insulation Test: Use a c ircuit tester, touch

one probe to the positive brush holder plate and the other Pull-In Test: Connect the wires as shown in [Figure 60-
probe to th e holder plate [Figure 60-40-32]. There 40-34]. When connecting Terminal C and M.T. are
should be no continuity. If there is continuity, replace or closed, the pinion should engage.
repair.
Figure 60-40-35
Figure 60-40-33

C 50

M.T.

B-14470
N-15012

Hold-In Test: With the same conditions as in th e pull-in

NOTE: Assemble the over running clutch, pinion test, open the connecting Terminal C [Figure 60-40-35].
shaft, springs, and pinion for this test. The pinion should remain in the engaged position.

Inspect the pinion, it must rotate freely in the direction of

the starter rotation and lock in the opposite rotation.

753 Bobcat Loader

60-40-11 Service Manual
469 of 726
STARTER (NIPPONDENSO) (CONT’D) Clamp the starter in a v ise. Using a 1 2 volt battery and
ammeter, connect the positive wire of the battery, and the
Inspection And Repair (Cont'd) ammeter to the terminal [Figure 60-40-37]. Connect the
negative wire to th e starter body. Using a j umper wire,
Figure 60-40-36 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
C 50 less than the specified current.

Service Limit - 220 Amp. Maximum Draw

Assembly

Figure 60-40-38

M.T.

B-14469

Return Test: With the same conditions as in the hold-in

test, open the connecting Terminal 50 [Figure 60-40-36].
The pinion should return immediately.

Dealer Copy -- Not for Resale

M.T. Main Terminal to which the main cable
from the battery is connected.
C C - Terminal to which the wire from the 1 3
field windings is connected. 2 N-15151
50 50 - Terminal to which the wire from the
starting switch or stator relay is
connected. Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running
No Load Test clutch, and idler gear rollers.

Figure 60-40-37 Install the switch plunger (Item 1), gasket (Item 2) and
cover (Item 3) [Figure 60-40-38] on the switch housing.
Ammeter
Figure 60-40-39
50
M.T.

1
Starter B-14440

The following test should be done after reassembling the 1 N-15150

starter:

Install the bolts (Item 1) [Figure 60-40-39].

753 Bobcat Loader

60-40-12 Service Manual
470 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-42

Assembly (Cont'd)

Figure 60-40-40

N-15152
1
Install the roller/retainer assembly (Item 1) [Figure 60-
N-15169 40-42] on the idler gear shaft.

Figure 60-40-43
Install the washer (Item 1) [Figure 60-40-40] on the idler
gear shaft.

Dealer Copy -- Not for Resale

Figure 60-40-41

1
2

N-15153

Install the idler gear (Item 1) [Figure 60-40-43] over the

N-15007 retainer.

Install the rollers (Item 1) in the retainer (Item 2) [Figure

60-40-41].

753 Bobcat Loader

60-40-13 Service Manual
471 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-46

Assembly (Cont'd)

Figure 60-40-44
2

N-15010

1 Install the spring (Item 1) and spring seat (Item 2)

N-15167 [Figure 60-40-46] on the pinion shaft.

Figure 60-40-47
Install the spring (Item 1) [Figure 60-40-44] in th e
magnetic switch housing.

Dealer Copy -- Not for Resale

3
Figure 60-40-45

3 1

2 1

N-15011

Install the pinion (Item 1) and retainer (Item 2) [Figure

N-00989 60-40-47] on the pinion shaft.

Press down on the pinion (Item 1) and install the snap

Install the spring (Item 1) over the pinion shaft (Item 2). ring (Item 3) [Figure 60-40-47] on the pinion shaft.
Install the pinion shaft (Item 2) in the over running clutch
(Item 3) [Figure 60-40-45]. Pull the r etainer (Item 2) over the snap ring (Item 3)
[Figure 60-40-47].
Stand the clutch assembly on end.

753 Bobcat Loader

60-40-14 Service Manual
472 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-50

Assembly (Cont'd)

Figure 60-40-48

N-15164

Install the ball (Item 1) [Figure 60-40-50] in the end of

1
N-15166 the pinion shaft.

Figure 60-40-51
Install the O-ring (Item 1) [Figure 60-40-48] in the starter
housing.

Dealer Copy -- Not for Resale

Figure 60-40-49

1 N-15163

1 Install the starter housing (Item 1) [Figure 60-40-51] on

N-15165 the magnetic switch housing.

Install the pinion shaft/over running clutch assembly

(Item 1) [Figure 60-40-49] in the starter housing.

753 Bobcat Loader

60-40-15 Service Manual
473 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-54

Assembly (Cont'd)

Figure 60-40-52

1
1

N-15014

1 Install the bearings (Item 1) [Figure 60-40-53] & [Figure

N-15162 60-40-54] on both ends of the armature.

Figure 60-40-55
Install the bolts (Item 1) [Figure 60-40-52] in the starter
housing. Tighten the bolts to 60 -104 in.-lbs. (6,7-11,8
Nm) torque.

Dealer Copy -- Not for Resale

Figure 60-40-53
1

N-00981
1

Install the ar mature (Item 1) [Figure 60-40-55] in the

frame.
N-15013

753 Bobcat Loader

60-40-16 Service Manual
474 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-58

Assembly (Cont'd)

Figure 60-40-56
1

N-15156
1

Install the brush holder (Item 1) [Figure 60-40-58] on the

N-15154 end of the armature.

Figure 60-40-59
Install the frame/armature assembly (Item 1) [Figure 60-
40-56] on the housing.

Dealer Copy -- Not for Resale

Figure 60-40-57 2

1
1

N-15157

Using the needle nose pliers, pull the brush springs (Item
N-15155 1) back and install the brushes (Item 2) [Figure 60-40-
59].

NOTE: Make sure the notch (Item 1) in the frame

matches up with the notch (Item 2) [Figure 60-
40-57] in the housing.

753 Bobcat Loader

60-40-17 Service Manual
475 of 726
STARTER (NIPPONDENSO) (CONT’D) Figure 60-40-61

Assembly (Cont'd) 1

Figure 60-40-60

3
1

N-15158

2
2 Install the cable (Item 1) [Figure 60-40-61] on th e
3 N-15159 magnetic switch. Tighten the nut to 18-26 ft.-lbs. (24-35
Nm) torque.

Install the brush cover (Item 1) and bolts (Item 2) [Figure

60-40-60]. Tighten the bolts to 23-40 in.-lbs. (3,0-5,0 Nm)
torque.

Dealer Copy -- Not for Resale

Install the thru bolts (Item 3) [Figure 60-40-60]. Tighten
the bolts to 60-104 in.-lbs. (7-12 Nm) torque.

753 Bobcat Loader

60-40-18 Service Manual
476 of 726
STARTER (VALEO) Figure 60-41-3

Checking

Figure 60-41-1

2
1
Bat
S
M

Cranking
Motor
P-34673

Disconnect the negative cable from the battery. (See

A-1992 Removal And Installation on Page 60-20-1.)

Disconnect the S terminal on the starter (Item 1) [Figure

The key switch must be in the OFF position. 60-41-3].

The battery must be at full charge.

Dealer Copy -- Not for Resale

Hold-In Test: Use circuit tester, touch one probe to the S
terminal (Item 1) and one probe to th e mounting bolt
The cable connections on the battery must be clean and (Item 2) [Figure 60-41-3] on the magnetic switch
tight. (solenoid). If there is no c ontinuity replace the magnetic
switch (solenoid).
Connect a j umper wire between S te rminal and BAT
terminal [Figure 60-41-1]. Figure 60-41-4

If the starter turns but does not turn the en gine, the
starter drive has a defect. 2

Figure 60-41-2 1
P-34675

1
Bat
S
M

Cranking
P-34674
Motor

Disconnect the negative cable from the battery. (See

Removal And Installation on Page 60-20-1.)
A-1991
Disconnect the S terminal on the starter (Item 1) [Figure
60-41-4].
Connect a ju mper wire between the M terminal and the
BAT terminal [Figure 60-41-2]. Pull-In Test: Use circuit tester, touch one probe to the S
terminal (Item 1) and one probe to the st arter motor
If the starter turns, the defect is in the solenoid. terminal (Item 2) [Figure 60-41-4]. If there is no
continuity replace the magnetic switch (solenoid).
If the starter does not turn, the starter is defective.

753 Bobcat Loader

60-41-1 Service Manual
477 of 726
STARTER (VALEO) (CONT’D)

Removal And Installation

Figure 60-41-5

4 2

1
P-34385

Stop the engine and open the rear door.

Remove the negative (-) and positive (+) cables from the

Dealer Copy -- Not for Resale

battery.

Disconnect the gr ound wire (Item 1) [Figure 60-41-5]

from the starter.

Disconnect the engine harness power wire and positive

(+) battery cable from the starter solenoid terminal (Item
2) [Figure 60-41-5].

Installation: Tighten the nut to 10.8-12.3 ft.-lbs. (14,7-

16,7 Nm) torque.

Disconnect the tan wire (Item 3) [Figure 60-41-5] from

the R terminal on the starter solenoid.

Disconnect the brown wire (Item 4) [Figure 60-41-5] from

the S terminal on the starter solenoid.

Remove the mounting bolts (Item 5) [Figure 60-41-5]

from the starter.

Remove the starter from the engine.

Installation: Tighten the three mounting bolts to 25-28

ft.-lbs. (34-38 Nm) torque.

Reverse the removal procedure to install the starter.

753 Bobcat Loader

60-41-2 Service Manual
478 of 726
STARTER (VALEO) (CONT’D)

Parts Identification

1. Starter 30
2. Shaft 13. Lever
3. Gear 14. Gear
4. Washer 15. Bracket
5. Shaft 16. Spring
6. Stop Ring 34 17. Gear
33
7. Lever 18. Stop
8. Holder 19. Stop Ring
13
9. Spring 20. Ball
10. Spring 21. Armature
36 22. Washer
11. Plate
8* 11* 23. Seal
12. Seal 9*
10* 24. Yoke
31
32
7* 21

12 15
19

Dealer Copy -- Not for Resale

16
14
17
19 18
5

20
14

6
29
1 4
3
28
2
27

35
25. Holder
26. Bracket
26 27. Ring
22
28. Bolt
29. Bolt
23 25 30. Switch
31. Seal
23 32. Bolt
33. Washer
34. Nut
24 35. Boot
36. Bracket

* Not serviceable parts B-19824

753 Bobcat Loader

60-41-3 Service Manual
479 of 726
STARTER (VALEO) (CONT’D) Figure 60-41-8

Disassembly and Assembly

Figure 60-41-6

1
1

1
2
P-34596

Remove the bolts (Item 1) from the brush cover (Item 2)

P-34594 [Figure 60-41-8].

Remove the cover (Item 2) [Figure 60-41-8].

Remove the cable (Item 1) [Figure 60-41-6] from the
magnetic switch. Figure 60-41-9

Dealer Copy -- Not for Resale

Remove the bolts (Item 2) [Figure 60-41-6].

Installation: Tighten the bolts to 63-129 ft.lbs. (7,1-14,6 2

Nm) torque.

Figure 60-41-7

1
1 2
4

3
3
N-00980

Using a needle nose pliers, pull the brush springs (Item

1) back and remove the brushes (Item 2) [Figure 60-41-
9].

P-34595 NOTE: The brushes are non-replaceable. If the

brushes are worn order a new brush holder
(for the negative brushes) and yolk (for the
Remove the armature, yoke, brush holder and rear positive brushes).
bracket assemblies (Item 1) from the front assembly
(Item 2) [Figure 60-41-7]. Remove the brush holder (Item 3) [Figure 60-41-9] from
the end of the armature.
NOTE: When separating the parts there will be a steel
ball (Item 3) located at the end of the armature
shaft (Item 4) [Figure 60-41-7].

Installation: Apply grease to the s teel ball (Item 3) and

install into the end of the armature shaft (Item 4) [Figure
60-41-7] .

753 Bobcat Loader

60-41-4 Service Manual
480 of 726
STARTER (VALEO) (CONT’D) Figure 60-41-12

Disassembly and Assembly (Cont'd)

1
Figure 60-41-10
2
3

2 P-34600

Inspect the magnetic switch (Item 1), the spring (Item

P-34598 2),and the pl unger (Item 3) [Figure 60-41-12] for wear
and replace as needed.

Remove the armature (Item 1) [Figure 60-41-10] from Figure 60-41-13

the frame.

Dealer Copy -- Not for Resale

Remove the bearing (Item 2) [Figure 60-41-10] from the
end of the armature.

Figure 60-41-11

3 2

1
P-34601

Remove the center bracket (Item 1) [Figure 60-41-13]

P-34599

Remove the bolts (Item 1) [Figure 60-41-11] from the

magnetic switch.

Installation: Tighten bolts to 34-69 ft.-lbs. ( 3,8-7,8 Nm)

torque.

Remove the front assembly (Item 2) from the magnetic

switch (Item 3) [Figure 60-41-11].

753 Bobcat Loader

60-41-5 Service Manual
481 of 726
STARTER (VALEO) (CONT’D) Figure 60-41-16

Disassembly and Assembly (Cont'd)

Figure 60-41-14

1
3

2
2 2 4

P-34604

1 Remove the snap ring (Item 3) [Figure 60-41-15] &

P-34602 [Figure 60-41-16]

Remove the retainer (Item 2) [Figure 60-41-15] &

Remove the rubber retainer (Item 1) [Figure 60-41-14]. [Figure 60-41-16] and pinion (Item 1) [Figure 60-41-15]
& [Figure 60-41-16].
Remove the planetary gears (Item 2) [Figure 60-41-14]

Dealer Copy -- Not for Resale

and inspect for damage. Remove the spring (Item 4) [Figure 60-41-16].

Figure 60-41-15 Installation: Inspect all parts for wear and replace as
needed.

3 2

P-34603

Press down on the pi nion (Item 1) [Figure 60-41-15] &

[Figure 60-41-16] and retainer (Item 2) [Figure 60-41-
15] & [Figure 60-41-16].

753 Bobcat Loader

60-41-6 Service Manual
482 of 726
STARTER (VALEO) (CONT’D) Figure 60-41-19

Inspection And Repair

Figure 60-41-17

N-00997

Armature Winding Continuity Test: Use a circuit tester,

B-14455 touch the probes to two commutator segments [Figure
60-41-19]. There should be continuity at any point. If
there is no c ontinuity, the winding is open-circuited,
Inspect the brush cover for discoloration, indication the replace the armature.
starter has been overheated.

Dealer Copy -- Not for Resale

Figure 60-41-20
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 [Figure 60-41-17]. A s hort circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.

Figure 60-41-18

B-14458

Commutator Run-Out Test: check the commutator run-

out as shown in [Figure 60-41-20].

Service Limit - 0.003 inch (0,07 mm)

If the commutator exceeds the service limit, repair as

needed.
N-00996

Armature Winding Ground Test: Use a c ircuit tester,

touch one probe to a commutator segment and the other
probe to t he armature core [Figure 60-41-18]. There
should be no continuity. If there is continuity, the armature
is grounded and must be replaced.

753 Bobcat Loader

60-41-7 Service Manual
483 of 726
STARTER (VALEO) (CONT’D) Figure 60-41-22

Inspection And Repair (Cont'd)

Figure 60-41-21

N-00999

Check the field windings for wear and damage.

B-14460
Check all the connections for clean and tight solder joints.

Measure the segment mica depth (Item 1) [Figure 60-41- Field Winding Ground Test: Use a circuit tester, touch
21]. one probe to th e field winding end of th e brush and the

Dealer Copy -- Not for Resale

other probe to the surface of the frame [Figure 60-41-
Service Limit - 0.012 inch (0,3 mm) 22]. There should be no continuity. If there is continuity,
the field windings are grounded.
If it is worn, replace the armature.
Replace the frame.
Check the commutator surface for burned spots which
usually indicates an open-circuit, and correct it using Figure 60-41-23
#400 sand paper.

N-15005

Field Windings Continuity Test: Use a circuit tester, touch

one probe to the wire and the oth er probe to the brush
[Figure 60-41-23]. There should be continuity. If there is
no continuity, the field windings are open-circuited.

Replace the frame.

753 Bobcat Loader

60-41-8 Service Manual
484 of 726
STARTER (VALEO) (CONT’D) No Load Test

Inspection and Repair (Cont'd) Figure 60-41-25

Figure 60-41-24 Ammeter

S
M.T.

Starter B-14440

N-15006
The following test should be done after reassembling the
starter:
Inspect the brushes for wear and damage.
Clamp the starter in a v ise. Using a 1 2 volt battery and
Replace the brush holder and yoke if th e brushes need

Dealer Copy -- Not for Resale

ammeter, connect the positive wire of the battery, and the
replacement. ammeter to the terminal [Figure 60-41-25]. Connect the
negative wire to th e starter body. Using a j umper wire,
Check brush spring, for damage or rust. Replace as connect the S terminal to the main terminal.
needed.
The starter should show smooth and steady rotation
Brush Holder Insulation Test: Use a c ircuit tester, touch immediately after the pinion is engaged, it should draw
one probe to the positive brush holder plate and the other less than the specified current.
probe to th e holder plate [Figure 60-41-24]. There
should be no continuity. If there is continuity, replace or Service Limit - 1150 Amp. Maximum @ Stall Condition
repair.
Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running
clutch, and idler gear rollers.

753 Bobcat Loader

60-41-9 Service Manual
485 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

60-41-10 Service Manual
486 of 726
INSTRUMENT PANEL Figure 1

Left Panel 2
1
3
The left instrument panel is the sa me for both Standard
and the Deluxe Instrument Panels [Figure 1]. 4 5 6 7 8

The table below shows the DESCRIPTION and

FUNCTION / OPERATION for each of the components of
the left panel.

Press and h old LIGHTS Button (Item 4) [Figure 1] for

two seconds to view SERVICE CODES in the
HOURMETER/CODE DISPLAY (Item 2) [Figure 1]. If 12
more than one SERVICE CODE is present, the codes will 13
scroll on the HOURMETER/CODE DISPLAY. 14 9 10 11 B-15551

Ref. No Description Function / Operation

1 TEMPERATURE GAUGE Shows the engine coolant temperature.
2 HOURMETER / CODE DISPLAY /GLOW PLUG HOURMETER- Records operating hours of loader. CODE DISPLAY- Displays numeric
COUNTDOWN SERVICE CODES* relating to the loader monitoring system. COUNTDOWN- Glow
Plug time remaining.
3 FUEL GAUGE Shows the amount of fuel in the tank.
4 LIGHTS / HOLD FOR CODES LIGHTS- Press once for FRONT LIGHTS. Press a second time for FRONT AND

Dealer Copy -- Not for Resale

REAR lights. Press a third time to turn all lights off. HOLD FOR CODES- Press and
hold two seconds for display of SERVICE CODES*(Item 2). (CODES* show only when
there is an error found by loader monitoring system).
5 BUCKET POSITIONING (Option) Press to engage the BUCKET POSITIONING function. Press again to disengage.
Press and hold 2 seconds to view BASE or SHTDN (◆ SHUTDOWN) feature in
HOURMETER/CODE DISPLAY.
ATTACHMENT AUXILIARY HYDRAULICS
6 HIGH FLOW (Option) Press to engage the HIGH FLOW auxiliary hydraulics. Press again to disengage.
7 MAXIMUM FLOW / VARIABLE FLOW Press once to engage the VARIABLE FLOW auxiliary hydraulics. Press a second time
to engage MAXIMUM FLOW. Press a third time to disengage all auxiliary hydraulics.
[VARIABLE FLOW allows for slow-to-fast movement of auxiliary functions (The farther
you move the switch, the faster the movement of the auxiliary functions.) MAXIMUM
FLOW allows for only fast movement.]
8 AUXILIARY PRESSURE RELEASE Press and hold for two seconds.The engine will stop. Hydraulic pressure will be
released in the auxiliary circuit.
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (See Troubleshooting Guide on Page 60-90-4.)
9 PRESS TO OPERATE LOADER Press to activate BICS™ System when the Seat Bar is down and operator is seated in
the operating position.
10 SEAT BAR The light comes ON when the seat bar is down.
11 LIFT & TILT VALVE The light comes ON when the seat bar is down and the PRESS TO OPERATE Button
is pressed. The lift and tilt functions can be operated when the light is ON.
12 TRACTION The light comes ON when the seat bar is down, engine is running, and parking brake
is released. The loader can be moved forward or backward when the light is ON.
13 TRACTION LOCK OVERRIDE (Functions Only When Seat Bar Is Raised And The Engine Is Running) Press to
unlock the brakes. Allows you to use the control levers to move the loader forward or
backward when using the backhoe attachment or for the loader service.(See
TRACTION LOCK on Page 60-110-1.) Press a second time to lock the brakes.
14 ALARM The ALARM beeps when there is an Error, WARNING or ◆SHUTDOWN condition.
* See ELECTRICAL SYSTEM SUPPLEMENT for futher description of SERVICE CODES.
◆ SHUTDOWN feature only in Deluxe Right Panel or Factory Option with Standard Panel.

753 Bobcat Loader

60-50-1 Service Manual
487 of 726
INSTRUMENT PANEL (CONT'D) The right instrument panel shown [Figure 60-50-2] is the
Standard Panel.
Right Panel - (Standard) (With Key Switch)
The table below shows the Icons and other components
Figure 60-50-2 of the Right Standard Panel.

● ACD Icon will also be ON when the 7-pin/14-pin

15 17 19 21 23 25 27 Connector Harness (Opt./Acc.) is installed and the
selector switch is in the 14-pin position.

◆ SHUTDOWN feature only in Deluxe Right Panel or

16 18 20 22 24 26 28 Factory Option with Standard Panel. (Engine can be
restarted to move or relocate loader.)

* These functions are monitored and have SERVICE

CODES associated with them. (See DIAGNOSTICS on
Page 60-80-1 for descriptions of SERVICE CODES.)
29

B-15552

OPT. OR ICON/
REF. FUNCTION ALARM CODE CONDITION DESCRIPTION
STD. LIGHT

Dealer Copy -- Not for Resale

15 Advanced Hand Opt. ON 3 Beeps * Error Error with Advanced Hand Controls (AHC)
Controls (AHC)

Attachment Std. ON --- - --- Electrical controlled attachment is present.●

16 Control Std. FLASHING 3 Beeps * Error Error with Attachment Control Device (ACD)
Device (ACD)
General Std. ON 3 Beeps * Error Error with one or more engine or hydraulic functions.
17 Warning Std. ON 3 Beeps * WARNING Engine speed high or in shutdown.
^Opt. FLASHING Continuous * SHUTDOWN Engine speed very high. Engine will stop in 10 seconds.
18 NOT USED
Fuel Std. ON 3 Beeps * Error Fuel level sender system fault.
19 Level Std. ON 3 Beeps * WARNING Fuel level low.

Glow Std. ON --- - --- Glow plugs are energized.

20 Plugs Std. FLASHING 3 Beeps * Error Error with glow plugs

System Voltage Std. ON 3 Beeps * WARNING Voltage low, high or very high.
21
Seat Belt Std. ON --- - --- Light stays on for 45 seconds to remind operator to fasten seat belt.
22
Engine Std. ON 3 Beeps * Error Engine Oil Pressure sender out of range.
23 Oil Pressure Std. ON 3 Beeps * WARNING Engine oil level low.
◆Opt. FLASHING Continuous * SHUTDOWN Engine oil pressure very low. Engine will shutdown in 10 seconds.
Hydrostatic Std. ON 3 Beeps * Error Hydraulic oil pressure sender out of range.
24 Charge Std. ON 3 Beeps * WARNING Hydraulic oil pressure low.
Pressure ◆Opt. FLASHING Continuous * SHUTDOWN Hydraulic charge pressure very low. Engine will stop in 10 seconds.
Engine Std. ON 3 Beeps * Error Engine coolant sender out of range.
25 Coolant Std. ON 3 Beeps * WARNING Engine coolant temperature high.
Temperature ◆Opt. FLASHING Continuous * SHUTDOWN Engine coolant temperature very high. Engine will stop in 10 seconds.
Hydraulic Std. ON 3 Beeps * Error Hydraulic oil temperature out of range.
26 Oil Std. ON 3 Beeps * WARNING Hydraulic oil temperature high.
Temperature ◆Opt. FLASHING Continuous * SHUTDOWN Hydraulic oil temperature very high. Engine will stop in 10 seconds.
Engine Std. ON 3 Beeps * Error Air filter with high restriction.
27 Air Filter Std. FLASHING 3 Beeps * WARNING Air filter switch not connected.

Hydraulic Std. ON 3 Beeps * Error Hydraulic filter with high restriction.

Filter Std. FLASHING 3 Beeps * WARNING Hydraulic filter switch not connected.
28
29 Key Switch - - - - - Used to start and stop the engine.

753 Bobcat Loader

60-50-2 Service Manual
488 of 726
INSTRUMENT PANEL (CONT’D) Figure 60-50-4

Right Panel - (Deluxe) (With Keyless Start)

Figure 60-50-3

1 3

B-16656
4

The first screen you will see on your new loader will be as
6 5 B-15553 shown in [Figure 60-50-4].

When this screen is on the display you can enter the

1. Display Panel: The Display Panel is where all system password and start the e ngine or change the Display
setup, monitoring, troubleshooting, and error Panel setup features.
conditions are displayed.

Dealer Copy -- Not for Resale

NOTE: Your new loader (with Deluxe Instrument
2. Function Icons: The lower left area of the Deluxe Panel) will have a Owner Password. Your
Panel has the same Icons as the S tandard Panel dealer will provide you with this password.
(See Right Panel - (Standard) (With Key Switch) on Change the password to one that you will
Page 60-50-2.). These Icons are only visible when easily remember to prevent unauthorized use
the monitoring system has detected an error. of your loader. (See ELECTRICAL SYSTEM
SERVICE MANUAL.) Keep your password in a
3. Selection Buttons: The four Selection Buttons allow safe place for future needs.
you to select items from the Display Panel and scroll
through screens. Start Engine: Use the Keypad to enter the numbers
(letters) of y our password and press the RU N / ENT ER
4. Keypad: The numeric keypad (Item 4) [Figure 60-50- key (Item 5) [Figure 60-50-3].
3] has two functions:
Press and hold the START Button (Item 6) [Figure 60-
To enter a number code (password) to allow starting 50-3] until the engine starts.
the engine (Keyless Start).
Change Language: Press the Selection Button at the end
To enter a number as directed for further use of the of the arrow [Figure 60-50-4] to go to the next screen.
Display Panel.

753 Bobcat Loader

60-50-3 Service Manual
489 of 726
INSTRUMENTATION PANEL (CONT'D)

Right Panel- (Deluxe) (With Keyless Start) (Cont’d)

Figure 60-50-5

B-16655

Use the Keypad to s elect the number of t he language

[Figure 60-50-5].

Dealer Copy -- Not for Resale

Press EXIT. The s creen will return to [Figure 60-50-4].
You can then enter the password and start the engine.

753 Bobcat Loader

60-50-4 Service Manual
490 of 726
INSTRUMENTATION PANEL (CONT'D) Icon Description
Right Panel Setup Display Options (Deluxe) YES/
Answer yes/no to current setup question.
NO
Icon Identification Removes previously installed password.
CLEAR
Make selection by pressing SELECTION BUTTON SET Set accepts current installed password.
opposite the Icon.

Deluxe Panel Setup

Display Options

Press
TOOL/SETUP

Icon Description
LOCK / UNLOCK: Allows machine to be
locked/ unlocked. You must lock machine Press

Dealer Copy -- Not for Resale

to activate security system.
LOADER FEATURES
When system is unlocked, the user can
press RUN / ENTER then press START to
begin operation.
A valid password will need to be entered
at startup to run a locked machine.
TOOL / SETUP: Access system options. Press
DISPLAY OPTIONS
Use to set clock, check system warnings,
select language, set passwords, etc.
HELP: Access help on current menu
? item.
EXIT EXIT returns you to previous level menu.
11:23 CLOCK / JOB CLOCK: Press to clear or
0.0 lock job clock; TOOL /SETUP to set time.

UP ARROW: Goes backward one screen.

DOWN ARROW: Goes forward one Press
screen. ADJUST CONTRAST

OUTLINE ARROWS: No screen available

(backward / forward).

SELECTION ARROW: Use to select Press

menu item. UP or Down
Arrow to
Goes to the NEXT screen series. change contrast.
NEXT EXAMPLE: The next Active Warning
screen. Press EXIT to
return to
INFO Goes to more information about an
previous level
attachment. menu.

753 Bobcat Loader

60-50-5 Service Manual
491 of 726
INSTRUMENT PANEL (CONT'D)

Right Panel Setup Display Options (Deluxe) (Cont’d) Changing the Password (Cont’d)

All new mac hines with Deluxe Instrumentation arrive at

Bobcat Dealerships with the panel in locked mode. This
means that a password must be used to start the engine.

Passwords

For security purposes, your dealer may change the

password and also set it in the locked mode. Your
dealer will provide you with the password.
Enter Password on
Keypad
Owner Password: Allows for the full use of the loader
and to setup the Deluxe Panel. Owner can select a
password to allow starting & operating the loader and Press Enter to
modify the setup if the Deluxe Panel. Owner should Continue
change the password as soon as possible for security
of the loader.
Re-enter new
User Password: Allows starting and operating the password. Press
loader; cannot change password or any of the other Enter to Continue
setup features. (See left)

Dealer Copy -- Not for Resale

Changing the Password Right Instrument Panel
Display Screen

Press Enter to
Press
Continue
TOOL / SETUP
(See left)

Press PASSWORD More EXAMPLES:

UTILITIES Clocks
TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
CLOCKS
SET CLOCK
Use the keypad to set time.
Press RUN / ENTER to set clock.
Press EXIT to return to previous level menu.
Press RESET JOB CLOCK (Password required).
Press CLEAR to reset job clock to zero.
MODIFY OWNER
Press LOCK / UNLOCK to unlock.
or
MODIFY USER Enter Password and press RUN / ENTER.
Languages
TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
LANGUAGES
Select the language, press RUN / ENTER.
Press EXIT to return to previous level menu.

753 Bobcat Loader

60-50-6 Service Manual
492 of 726
INSTRUMENT PANEL (CONT'D)

Changing the Password (Cont’d)

Vitals (Monitor engine, hydraulic / hydrostatic,

electrical functions when engine is running.)

TOOL / SETUP
LOADER FEATURES
VITALS
Press SELECTION ARROW to select METRIC
or ENGLISH (M/E) readouts

You can monitor real-time readouts of:

Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Hydraulic Oil Temperature
System Voltage
Engine Speed

The Display Panel is easy to use. Continue to set

your own preferences for running / monitoring your

Dealer Copy -- Not for Resale

Bobcat Loader.

753 Bobcat Loader

60-50-7 Service Manual
493 of 726
INSTRUMENT PANEL IDENTIFICATION (CONT'D)

Option and Field Accessory Panels

POWER
2 3 4 5 6

FRONT
WIPER
PLUG

WIPER
1

USED

USED
REAR

USED
NOT

NOT

NOT
SIDE
CONSOLE
9
TURN SIGNAL
7 INDICATORS 10 11
8 HAZARD ROTATING
POWER
BOB-TACH NOT USED LIGHTS BEACON
Early Models

FRONT 12
CENTER POWER 9
PANEL BOB-TACH
11
TURN SIGNAL ROTATING
INDICATORS
13 10 BEACON
Later Models 8 HAZARD
PARKING
NOT USED BRAKE LIGHTS

Dealer Copy -- Not for Resale

7 14
ADVANCED
NOT USED
CONTROL
SYSTEM (ACS) b-16642
b-16641
b-15891 updated

Side Console
Ref.
No. Description Function / Operation
1 POWER PLUG Provides a 12V receptacle for accessories.
2 NOT USED ---
3 FRONT WIPER Press the top of the switch to start the front wiper (press and hold for wiper
fluid). Press the bottom of the switch to stop the wiper.
4 REAR WIPER Press the bottom of the switch to start the rear wiper. Press the top of the
switch to provide washer fluid to clean the rear window.
5 NOT USED ---
6 NOT USED ---
Front Center Panel
7 ADVANCED CONTROL
Press the top to select Hand Controls; bottom to select Foot Controls.
SYSTEM (ACS)
8 NOT USED ---
9 TURN SIGNAL
Indicates left or right TURN SIGNALS are ON.
INDICATORS
10 HAZARD LIGHTS Press the left side to turn the HAZARD LIGHTS ON; right side to turn OFF.
11 ROTATING BEACON Press the left side to turn the ROTATING BEACON ON; right side to turn OFF.
12 POWER BOB-TACH Press and hold the left side to disengage the Bob-Tach wedges. Press and
hold the right side to engage the wedges into the mounting frame holes.
13 PARKING BRAKE Press the top to engage the PARKING BRAKE; bottom to disengage.
14 NOT USED ---

753 Bobcat Loader

60-50-8 Service Manual
494 of 726
INSTRUMENT PANEL (CONT’D) Figure 60-50-7

Removal And Installation

Figure 60-50-6

1
1
1
1
1

1
LEFT N-18409

RIGHT
P-28360A

Remove the front light. (See Front Removal And Installation on Page 60-60-1.)
Remove the three mounting bolts (Item 1) [Figure 60-50- Figure 60-50-9
6] or [Figure 60-50-7].

Dealer Copy -- Not for Resale

Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels.

Figure 60-50-8
1

LEFT N-19351

1
Pull the left instrument panel down and disconnect the
wire harness connectors (Item 1) [Figure 60-50-8] or
[Figure 60-50-9] from the panel.

RIGHT N-19353
Remove the panel.

Reverse the removal procedure to install the instrument

panel.

753 Bobcat Loader

60-50-9 Service Manual
495 of 726
INSTRUMENT PANEL (CONT’D) Figure 60-50-11

Front Accessory Panel Removal And Installation

1
Figure 60-50-10

1 1 P-21945

Pull the front accessory panel down and disconnect the

P-21944 wire harness connector(s) (Item 1) [Figure 60-50-11]
from the switches.

Remove the two mounting bolts (Item 1) [Figure 60-50- Remove the panel.
10].

Dealer Copy -- Not for Resale

Reverse the r emoval procedure to i nstall the fr ont
Installation: Be careful to not overtighten the front accessory panel.
accessory panel mounting bolts to prevent damage to the
plastic panel.

753 Bobcat Loader

60-50-10 Service Manual
496 of 726
LIGHTS Figure 60-60-3

Front Removal And Installation

Figure 60-60-1

1
1

N-19351

Remove the bu lb (Item 1) [Figure 60-60-3] from the

N-19348 socket.

Reverse the above procedure to install the bulb.

Open the rear door.

Disconnect the negative(-) cable from the battery. (See

Dealer Copy -- Not for Resale

Removal And Installation on Page 60-20-1.)

Remove the light housing (Item 1) [Figure 60-60-1] from

the operator cab.

Figure 60-60-2

N-19349

Remove the bulb assembly (Item 1) [Figure 60-60-2]

from the light housing by turning bulb assembly a 1/ 4
turn.

753 Bobcat Loader

60-60-1 Service Manual
497 of 726
LIGHTS (CONT’D) Figure 60-60-5

Rear Removal And Installation

Figure 60-60-4

N-19339

Using care press the rear light and housing from the door
P-28888 [Figure 60-60-5].

Reverse this procedure for installation.

Remove the bulb assembly (Items 1 & 2) from the light
housing (Item 3) [Figure 60-60-4] by turning bulb
assembly a 1/4 turn.

Dealer Copy -- Not for Resale

753 Bobcat Loader

60-60-2 Service Manual
498 of 726
BOBCAT CONTROLLER

Identification Chart (S/N 515843086 & Below)

Dealer Copy -- Not for Resale

J1 J2 J3 J4
BLACK 18 PIN CONNECTOR WHITE 18 PIN CONNECTOR BLACK 30 PIN CONNECTOR WHITE 30 PIN CONNECTOR
(ALL BLUE WIRES) (MOSTLY BLUE AND PURPLE WIRES) (MULTI COLOR WIRES) (MOSTLY GREEN WIRES)

VIEWED FROM MATING END VIEWED FROM MATING END

X=NO CONNECTION X=NO CONNECTION

VIEWED FROM MATING END VIEWED FROM MATING END

X=NO CONNECTION X=NO CONNECTION

TS-1941
MC-2577

753 Bobcat Loader

60-70-1 Service Manual
499 of 726
BOBCAT CONTROLLER (CONT’D)

Identification Chart (S/N 515843087 & Above)

41 50 41
50
40 31 40 31
30 21 30 21
20 11 20 11
10 1 10 1

9 8 7 6 5 4 3 2 9 8 7 6 5 4 3 2
J1 J2
Controller

Dealer Copy -- Not for Resale

Harness Connector View Harness Connector View

41 50
41
31
J1 50
40 31 J2 40
21 30 21 30
11 20 11 20

1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

V-171/V-172

753 Bobcat Loader

60-70-2 Service Manual
500 of 726
BOBCAT CONTROLLER (CONT’D)

Identification Chart (S/N 515843087 & Above) (Cont’d)

Harness Connector View

41
J1 50
1400 8000 X 9800 X X 3420 7200 3520 X

31 X 8150 1130 9700 X 8550 3500 2100 6320 8110

40
21 X 4150 3010 9600 4730 4470 X 1120 4450 8210
30
11 X 8250 1110 9500 3400 6510 4200 4460 6210 8800
20
X X 3430 4910 X X X 6410 8510 4110

Dealer Copy -- Not for Resale

1 2 3 4 5 6 7 8 9 10
Harness Connector View

41 50
J2
4410 9410 4640 9340 3920 4500 X 3300 X X

31 X 4420 X 9350 3910 4840 X 2110 X 4940

40
21 4340 4430 9400 1900 3900 4830 X 3100 4320 4930
30
11 9110 4440 X 1200 9200 4820 X 3700 4310 4920
20
4360 X 4330 2900 9100 4810 9210 3200 4300 3600

1 2 3 4 5 6 7 8 9 10
V-172

753 Bobcat Loader

60-70-3 Service Manual
501 of 726
BOBCAT CONTROLLER (CONT'D) Figure 60-70-2

Removal And Installation

WARNING 1

Never work on a machine with the lift arms up 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 lift arms or attachment
to fall and cause injury or death.
W-2059-0598
S/N 515843087 & Above
P-43391
Lift and block the rear of the loader. (See LIFTING AND
BLOCKING THE LOADER on Page 10-10-1.)
Loosen the connector mounting bolts (Item 1)
Raise the lift arms and install an approved lift arm [Figure 60-70-1] and [Figure 60-70-2] from the bo bcat
support device. (See Installing Lift Arm Support Device controller.
on Page 10-20-1.)
Remove the connectors.
Stop the engine. Raise the seat bar.

Dealer Copy -- Not for Resale

NOTE: The connectors are keyed and will only plug
Raise the operator cab. (See Raising The Operator Cab in one way.
on Page 10-30-1.)
Figure 60-70-3
Figure 60-70-1

1
1

1
1

P-43390P
S/N 515843086 & Below
N-20858

Remove the three mount bolts (Item 1) [Figure 60-70-3]

of the system controller mounting bracket.

Remove the system controller.

Installation: Tighten the nuts to 25-28 ft.-lbs. (34-38 Nm)

torque.

753 Bobcat Loader

60-70-4 Service Manual
502 of 726
DIAGNOSTICS

Service Codes

The left instrument panel is the same for both the

Standard and Deluxe Instrument Panel Option [Figure
60-80-1].

Press and hold LIGHTS Button (Item 1) [Figure 60-80-1]

for two s econds to view SERVICE CODES in th e
HOURMETER/CODE DISPLAY (Item 2) [Figure 60-80-
1]. If mor e than one SERVICE CODE is present, the
codes will scroll on the HOURMETER/CODE DISPLAY.

The following is a list of the SERVICE CODES. T hese

CODES help analyze monitored functions of the Bobcat
loader. Some service procedures must be performed
ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.
(See ELECTRICAL SYSTEM SERVICE MANUAL FOR
troubleshooting charts and guides.)

Figure 60-80-1

Dealer Copy -- Not for Resale

1

B-15551B

753 Bobcat Loader

60-80-1 Service Manual
503 of 726
DIAGNOSTICS

Service Codes (Cont'd)

CODE DESCRIPTION CODE DESCRIPTION
16-06 Traction lock solenoid secondary short to ground 32-59 ACS lift actuator wrong direction
16-07 Traction lock solenoid secondary open circuit 32-60 ACS tilt actuator wrong direction
17–05 Hydraulic lock valve solenoid short to battery 32-61 ACS handle lock short to ground
17-06 Hydraulic lock valve solenoid short to ground 32-62 ACS handle lock short to battery
17-07 Hydraulic lock valve solenoid open circuit 32-63 ACS pedal lock short to ground
18-05 Spool lock solenoid short to battery 32-64 ACS pedal lock short to battery
18-06 Spool lock solenoid short to ground 32-65 ACS sensor supply voltage out of range
18-07 Spool lock solenoid open circuit 32-66 ACS battery out of range
19-02 Bucket position solenoid error ON 32-67 ACS switch flipped while operating
19-03 Bucket position solenoid error OFF 33-23 Constant data not calibrated
21-02 Glow plug error ON 34-04 Deluxe not downgraded in error
21-03 Glow plug error OFF 36-48 ACD multiple controllers present
22-02 Starter output error ON 44-02 Horn error ON
22-03 Starter output error OFF 44-03 Horn error OFF
23-02 Rear base solenoid error ON 45-02 Right blinker error ON
23-03 Rear base solenoid error OFF 45-03 Right blinker error OFF
24-02 Rear rod solenoid error ON 46-02 Left blinker error ON
24-03 Rear rod solenoid error OFF 46-03 Left blinker error OFF
25-02 Rear auxiliary relief solenoid error ON 47-21 8 volt reference out of range high
25-03 Front base solenoid error ON 47-22 8 volt reference out of range low
26-03 Front base solenoid error OFF 48-02 Front light output error on
27-02 Front rod solenoid error ON 48-03 Front light output error off

Dealer Copy -- Not for Resale

27-03 Front rod solenoid error OFF 49-02 Rear light output error on
28-02 Diverter solenoid error on 49-03 Rear light output error off
28-03 Diverter solenoid error off 60-21 Left thumb switch out of range high
30-28 Watchdog failure (internal) 60-22 Left thumb switch out of range low
31-28 Recovery mode failure (internal) 60-23 Left thumb switch not returning to neutral
32-31 AHC failure tilt actuator fault 64-02 Switched power relay error on
32-32 AHC failure tilt actuator wiring fault 64-03 Switched power relay error off
32-33 AHC failure tilt handle wiring fault 80-02 ACD output 'A' error ON
32-34 AHC failure tilt actuator not calibrated fault 80-03 ACD output 'A' error Off
32-35 AHC failure tilt handle not calibrated fault 81-02 ACD output 'B' error ON
32-36 AHC failure lilt actuator fault 81-03 ACD output' B' error OFF
32-37 AHC failure lilt actuator wiring fault 82-02 ACD output 'C' error ON
32-38 AHC failure lilt handle wiring fault 82-03 ACD output 'C' error OFF
32-39 AHC failure lilt actuator not calibrated fault 83-02 ACD output 'D' error ON
32-40 AHC failure lilt handle not calibrated fault 83-03 ACD output 'D' error OFF
32-41 AHC failure invalid frequency 84-02 ACD output 'E' error ON
32-04 ACS in error (ACS not communicating with 84-03 ACD output 'E' error OFF
Bobcat controller)
32-23 ACS not calibrated 85-02 ACD output 'F' ON
32-31 ACS tilt actuator fault 85-03 ACD output 'F' OFF
32-34 ACS tilt actuator not calibrated 86-02 ACD output 'G' ON
32-35 ACS tilt handle/pedal not calibrated 86-03 ACD output 'G' OFF
32-36 ACS lift actuator fault 87-02 ACD output ‘H' ON
32-39 ACS lift actuator not calibrated 87-03 ACD output ‘H' OFF
32-40 ACS lift handle/pedal not calibrated 90-02 Service tool output ‘C' error ON
32-49 ACS lift actuator short to ground 90-03 Service tool output 'C' error OFF
32-50 ACS tilt actuator short to ground 91-02 Service tool output ‘D' error ON
32-51 ACS lift actuator short to battery 91-03 Service tool output ‘D' error OFF
32-52 ACS tilt actuator short to battery 92-02 Service tool output ‘E' error ON
32-53 ACS lift handle/pedal short to ground 92-03 Service tool output ‘E; error OFF
32-54 ACS tilt handle/pedal short to ground 93-02 Service tool output ‘F' error ON
32-55 ACS lift handle/pedal short to battery 93-03 Service tool output ‘F' error OFF
32-56 ACS tilt handle/pedal short to battery
32-57 ACS lift actuator reduced performance
32-58 ACS tilt actuator reduced performance

753 Bobcat Loader

60-80-2 Service Manual
504 of 726
DIAGNOSTICS (CONT’D)

Service Codes (Cont’d)

The following word errors may also be displayed:

REPLY O ne or both instrument panel(s) not

communicating with the controller.
INPUT The controller not communicating with the left
instrument panel.
CODE The controller is asking for a password. (Deluxe
instrument panel only).
ERROR The wrong password was entered. (Deluxe
instrument panel only.)

Multiple SERVICE CODES and/or Abnormal

Symptoms can be caused by corroded or loose ground
connection. F lashing instrument panel lights, alarm
beeping, front & r ear lights flashing, low batery voltage,
loose battery connectors, could also indicate a po or
ground. Check all grounds before performing other
diagnostics.

Dealer Copy -- Not for Resale

753 Bobcat Loader

60-80-3 Service Manual
505 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

60-80-4 Service Manual
506 of 726
BICS™ SYSTEM 2. Raise the Seat Bar fully. All four BICS lights (Items 1,
2, 3, & 4) [Figure 60-90-1] [PRESS TO OP ERATE
Inspecting The BICS™ Controller (Engine STOPPED - LOADER, SEAT BAR, LIFT & TI LT VALVE and
Key ON) TRACTION*] on left instrument panel should be OFF
[Figure 60-90-1].

NOTE: Record what lights are blinking (if any) and

WARNING number of light flashes. (See Troubleshooting
Guide on Page 60-90-4.)
AVOID INJURY OR DEATH
Inspecting Deactivation Of The Auxiliary Hydraulics
The Bobcat Interlock Control System (BICS™) must
System (Engine STOPPED - Key ON)
deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
3. Sit in the operator's seat, lower the Seat Bar, and
modify the system.
W-2151-0394
press the PRESS TO OPERATE LOADER Button.
Press the a uxiliary hydraulics FLOW Button. The
auxiliary FLOW Button light will come ON. Raise the
Figure 60-90-1 Seat Bar. The light should be OFF.

Inspecting The Seat Bar Sensor (Engine RUNNING)

4. Sit in the operator's seat, lower the seat bar, engage

the parking brake pedal and fasten the seat belt.
5. Start the engine and operate at lo w idle. Press the

Dealer Copy -- Not for Resale

PRESS TO OPERATE LOADER Button. While
raising the lift arms, raise the Seat Bar fully. The lift
arms should stop. Repeat using the tilt function.

Inspecting The Traction Lock (Engine RUNNING)

6. Fasten the seat belt, disengage the parking brake

pedal, press the PRESS TO OPERATE LOADER
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 PRESS TO OPERATE LOADER Button.
7. Engage the pa rking brake pedal and move the
steering levers slowly forward and bac kward. The
TRACTION lock should be engaged.

NOTE: * The TRACTION light on the left instrument

panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER
1 2 3 4 Button is pressed and the parking brake is
disengaged.

B-15551

1. Sit in the operator's seat. Turn key ON (Standard

Panel), press RUN / ENTER Button (Deluxe Panel),
lower the Seat Bar and disengage the parking brake.
Press the PRESS TO OPE RATE LOADER Button.
Three BICS lights (Items 1, 3, & 4) [Figure 60-90-1]
[PRESS TO OPERATE LOADER, SEAT BAR, and
LIFT & TILT VALVE] on left instrument panel should
be ON [Figure 60-90-1].

753 Bobcat Loader

60-90-1 Service Manual
507 of 726
BICS™ SYSTEM (CONT’D)

Inspecting The Lift Arm By-Pass Control

8. Raise the lift arms 6 f eet (2 meters) off the ground.

Stop the engine.

Turn the lift arm by-pass control knob clockwise 1/4

turn. Pull up and hold the lift arm by-pass control knob
until the lift arms slowly lower.

Additional Inspection For Loaders With Advanced

Hand Controls (AHC)

9. Sit in the operator's seat and fasten the Seat Belt.

Lower the S eat Bar, start the e ngine and press the
PRESS TO OPERATE LOADER Button.
10. Raise the lift arms about 6 feet (2 meters) off the
ground.
11. Turn key OFF ( Standard Panel), press the STOP
Button (Deluxe Panel), and wait for the engine to
come to a complete stop.
12. Turn key ON (Standard Panel), press RUN /ENTER
Button (Deluxe Panel). Press the PRESS TO

Dealer Copy -- Not for Resale

OPERATE LOADER Button, move the left hand
control toward the operator. The lift arms should not
lower.
13. Move the right hand control away from the operator.
The bucket (or attachment) should not tilt forward.

753 Bobcat Loader

60-90-2 Service Manual
508 of 726
BICS™ SYSTEM (CONT’D)

Troubleshooting Chart
WARNING
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285

PROBLEM SOLUTION#
All indicator lights flashing 5
One of the indicator lights flashing 1
Intermittent indicator lights 2, 3, 4

SOLUTION SUGGESTIONS

1. Refer to BICS™ troubleshooting guide. (See Troubleshooting Guide on page 60-90-4.)

2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.
4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.

Dealer Copy -- Not for Resale

5. Possible low or high voltage.

753 Bobcat Loader

60-90-3 Service Manual
509 of 726
BICS™ (CONT’D) Figure 60-90-2

Troubleshooting Guide

The following chart shows the effects which can happen

to the loader, and the probable causes when the BICS
Instrument Panel lights are off. See [Figure 60-90-2] for 6
location of BICS lights and Ic ons. Have service
procedures performed ONLY BY QUALIFIED BOBCAT
SERVICE PERSONNEL.

Press and hold LIGHTS Button (Item 5) [Figure 60-90-2] 5

for two s econds to view SERVICE CODES in the
HOURMETER / CODE DISPLAY (Item 6) [Figure 60-90- 4
2]. If mor e than one SERVICE CODE is present, the 2
codes will scroll on the HOURMETER / CODE DISPLAY. 1 3 B-15551

Effect on SERVICE CODES Means System Error

Indicator Operation of (See Your Bobcat Dealer for Service)
Light ON Light OFF
Light Loader When No. of Service
Light is OFF Causes
Flashes Code
1 PRESS TO PRESS TO Lift, tilt and ---- ---- ----
OPERATE OPERATE traction
LOADER Button LOADER Button functions will

Dealer Copy -- Not for Resale

is pressed. is not pressed. not operate.

2 Seat Bar is Seat Bar is up. Lift and tilt 2 11-05 Seat Bar sensor circuit shorted to battery
down. functions will voltage*.
not operate. 3 11-06 Seat Bar sensor circuit shorted to ground.

3 Control valve can Control valve Lift, tilt and 1 17-07 Valve output circuit is open.
be used. cannot be used. traction 2 17-05 Valve output circuit shorted to battery voltage*.
functions will 3 17-06 Valve output circuit shorted to ground.
not operate.
3 17-06 Controller not grounded or intermittent ground.

4 Loader can be Loader cannot Loader cannot 1 16-07 Traction lock hold solenoid circuit is open.
moved forward & be moved be moved 2 16-05 Traction lock hold solenoid circuit shorted to
backward forward and forward and battery voltage*.
backward. backward. 3 16-06 Traction lock hold solenoid circuit shorted to
ground.
5 15-02 Traction lock pull solenoid circuit is shorted to
battery voltage* - ERROR ON (Should be OFF).
6 15-03 Traction lock pull solenoid circuit ERROR OFF
(Should be ON).
SEAT BAR LIFT & TILT VALVE TRACTION 03-09
Continuous System voltage low
Flashing 03-10 System voltage high
NOTES:

Multiple SERVICE CODES and/or Abnormal Symptoms can be caused by corroded or loose ground. Check grounds and
both battery connections.
ERROR OFF = shorted to ground or bad fuse, faulty wiring, faulty open relay, no voltage from relay to controller.
ERROR ON = shorted to battery voltage, faulty wiring, faulty closed relay.
*Normal BICS operating voltage is less than the electrical system voltage.

753 Bobcat Loader

60-90-4 Service Manual
510 of 726
SEAT BAR SENSOR

Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285

PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5

SOLUTION SUGGESTIONS
1. Check sensor wire connection.
2. Use the BICS™ sensor tester MEL 1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.

Dealer Copy -- Not for Resale

753 Bobcat Loader

60-100-1 Service Manual
511 of 726
SEAT BAR SENSOR (CONT’D) Figure 60-100-3

Test

Figure 60-100-1

1 P-4698

If there is no power light (Item 1) [Figure 60-100-3] on

N-18463 the sensor tester, check the tester or wiring harness.

Figure 60-100-4
Use Sensor Tester (MEL1428) and seat bar sensor tester
adatper (MEL1567) for the following procedure:

Dealer Copy -- Not for Resale

Connect the seat bar adapter sensor leads (MEL1567) to
the sensor tester.
1
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-100-1].

Figure 60-100-2

P-4699
1

Lower the seat bar. The Sensor Test light (Item 1)

[Figure 60-100-4] should illuminate.

Raise the seat bar. The Sensor Test light (Item 1) [Figure
N-19557
60-100-4] should go off.

If the above test fails, there is a problem with the seat bar
N-19558 sensor.

Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) inline, to the seat bar
sensor connectors. See inset [Figure 60-100-2]. Replace the Seat Bar Sensor. (See Removal And
Installation on Page 60-100-3.)
Turn the k ey to the O N position. DO NOT START THE
ENGINE. If the above test passes, run the seat bar sensor BICS
circuit test. (See BICS™ Circuit Test on Page 60-100-4.)
The toggle switch (Item 2) [Figure 60-100-3] can be in
either the Absent or Present position.

753 Bobcat Loader

60-100-2 Service Manual
512 of 726
SEAT BAR SENSOR (CONT’D) Remove the mounting bolt (Item 1) from the seat bar
mount (Item 2) [Figure 60-100-6].
Removal And Installation
Installation: Tighten the mounting bolt to 50-70 in.-lbs.
Figure 60-100-5 (5,6-7,9 Nm) torque.

Remove the sensor mounting bolt (Item 3) [Figure 60-

100-6] and nut.

IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095

Figure 60-100-7
P-43382

Remove the seat bar (Item 1) [Figure 60-100-5] from the 2

loader. (See Removal And Installation on Page 50-10-1.) 1
3

Dealer Copy -- Not for Resale

Figure 60-100-6

N-19383
3

Remove the keyed plastic bushing (Item 1), magnetic

bushing assembly (Item 2) and sensor bracket (Item 3)
[Figure 60-100-7].
1
Installation: Be sure the tabs on the pivot bushing are
positioned in the slotted hole (Item 1) [Figure 60-100-7]
of the seat bar.

Inspect all parts for damage and wear and replace if

necessary.
2
Reverse the removal procedure to install the seat bar
sensor.

N-19219

753 Bobcat Loader

60-100-3 Service Manual
513 of 726
SEAT BAR SENSOR (CONT’D) When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-100-9] on the sensor tester to
BICS™ Circuit Test the Present position.

Figure 60-100-8 NOTE: The sensor test light (Item 3) [Figure 60-100-9]
is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.

Figure 60-100-10

N-18463

Use Sensor Testers (MEL1428) and seat bar sensor

1
tester adapter (MEL1567) for the following procedure:

Dealer Copy -- Not for Resale

N-18409
Connect the seat bar sensor tester adapter MEL1567 to
the sensor tester.
The BICS seat bar indicator light (Item 1) [Figure 60-
Disconnect the seat bar sensor connector (Item 1) 100-10] should illuminate.
[Figure 60-100-8].
Figure 60-100-11
Connect Sensor Tester (Item 1) [Figure 60-100-9] inline
to the seat bar sensor connectors.

Turn the k ey to the O N position. DO NOT START THE

ENGINE.

Figure 60-100-9

P-4699
2

Move the toggle switch (Item 1) [Figure 60-100-11] on

1 the sensor tester to the Absent position.

The Seat Bar light (Item 1) [Figure 60-100-10] should go

P-4703 off.

If the above test fails, there is a problem with the Bobcat

If there is no power light on the sensor tester, check the controller or the wiring harness.
tester or wiring harness.

753 Bobcat Loader

60-100-4 Service Manual
514 of 726
TRACTION LOCK

Troubleshooting Chart
WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285

PROBLEM SOLUTION #
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7
Intermittent activation of traction lock. 8, 9, 10

SOLUTION SUGGESTIONS
1. Make sure brake pedal is not engaged.
2. Maneuver loader to allow brake discs to move and remove pressure on the brake wedge so it can retract.
3. If all lights indicate the brake should be released, but it doesn’t, check the brake 25 amp fuse.
When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of
4.
fuses. (See ELECTRICAL SYSTEM INFORMATION on Page 60-10-1.)

Dealer Copy -- Not for Resale

5. To test the solenoid, the pull coil should be.4 to.5 ohms and the hold coil 10.5 to 11.0 ohms.
6. Check brake solenoid and cover mounting hardware for the correct torque.
7. Remove brake cover and check wedges for binding in the wedge guides.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.

753 Bobcat Loader

60-110-1 Service Manual
515 of 726
TRACTION LOCK (CONT’D) Figure 60-110-1

Inspecting

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. 1 P-4712

Engage the parking brake pedal and move the steering

levers slowly forward and backward. The Traction lock 2
should be engaged.

Solenoid Removal And Installation P-4135

Remove the Do Not Modify sta-strap (P/N 6665527) from

WARNING the electric solenoid connector (Item 1) [Figure 60-110-
1].
AVOID INJURY OR DEATH Installation: Install a new Do Not Modify sta-strap on the
Do not modify the electrical wiring connected to the electric solenoid connector.
traction lock solenoid or any part of the traction lock

Dealer Copy -- Not for Resale

system. The traction lock provides the locking Figure 60-110-2
function of the parking brake. Service work on the
traction lock system should only be performed by a
qualified technician. Use only genuine Bobcat 2
Company parts if repair is necessary.
W-2165-0100

Raise the l oader operator cab. (See Raising The

Operator Cab on Page 10-30-1.)

NOTE: The loader control panel is removed for clarity 1

purpose only. The traction lock can be
removed without removing the control panel.

N-19077

Remove the two mounting bolts (Item 1) [Figure 60-110-

2] from the electric solenoid mounting bracket.

Installation: Tighten the mounting bolts to 25-28 ft.-lbs.

(34-38 Nm) torque.

Remove the electric solenoid (Item 2) [Figure 60-110-2]

from the chaincase cover.

753 Bobcat Loader

60-110-2 Service Manual
516 of 726
TRACTION LOCK (CONT’D) Figure 60-110-5

Solenoid Removal And Installation (Cont'd)

Figure 60-110-3

N-19079

Inspect the guides (Item 1) [Figure 60-110-5] for wear or

N-19078 damage. Replace if necessary .

Figure 60-110-6
Remove the bracket (Item 1) [Figure 60-110-3] from the
chaincase cover.

Dealer Copy -- Not for Resale

1
Installation: Tighten the mounting bolts to 2 5-28 ft.-lbs. 2
(34-38 Nm) torque.

Be sure the solenoid mounting bracket is installed in the 3

same position. The solenoid mounting surface has a
slight angle which tips the top of the solenoid toward the
rear of t he loader when installed correctly. See inset
photo [Figure 60-110-1].

Figure 60-110-4

P7926

1
Remove and inspect the compression spring (Item 1) and
spring cap washer (Item 2) [Figure 60-110-6] for wear or
damage. Replace if necessary. The spring may also stay
with the shaft when the electric solenoid and bracket are
removed from the chaincase.

Installation: Install the compression spring (Item 1)

[Figure 60-110-6] on the collar located on the electric
solenoid.

N-19108 Remove the traction lock assembly (Item 3) [Figure 60-

110-6] from the chaincase.

Remove the traction lock assembly (Item 1) [Figure 60-

110-4] from the chaincase.

753 Bobcat Loader

60-110-3 Service Manual
517 of 726
TRACTION LOCK (CONT’D) Guide Removal

Solenoid Removal And Installation (Cont'd) The part number listed will be needed to do the following
procedure:
Figure 60-110-7
P/N 6633583 - Polyurethane

2
3
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
1 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.
W-2059-0598

P-7964 Raise the loader lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)
Remove the shaft mounting bolt (Item 1), spring from the
assembly shaft (Item 2). Remove the wedge (Item 3) Raise the l oader operator cab. (See Raising The
[Figure 60-110-7] and inspect all parts for damage or

Dealer Copy -- Not for Resale

Operator Cab on Page 10-30-1.)
wear. Replace if necessary.
Disconnect and remove the engine speed control. (See
Installation: Thoroughly clean and dry the shaft Removal And Installation on Page 70-20-1.)
mounting bolt (Item 1), the shaft (Item 2) and wedge
(Item 3) [Figure 60-110-7]. Use LOCTITE #242 when Remove the control panel from the loader. (See Removal
assembling these parts to the traction lock assembly. and Installation on Page 50-100-1.)

Remove the traction lock solenoid assembly. (See

Solenoid Removal And Installation on Page 60-110-2.)
IMPORTANT
Failure to use LOCTITE may allow the traction lock
assembly to loosen up which can cause damage to WARNING
the traction lock system.
I-2090-1095 AVOID INJURY OR DEATH
Do not modify the electrical wiring connected to the
traction lock solenoid or any part of the traction lock
system. The traction lock provides the locking
function of the parking brake. Service work on the
traction lock system should only be performed by a
qualified technician. Use only genuine Bobcat
Company parts if repair is necessary.
W-2165-0100

753 Bobcat Loader

60-110-4 Service Manual
518 of 726
TRACTION LOCK (CONT’D) Figure 60-110-10

Guide Removal (Cont’d)

Figure 60-110-8 1

P11330

To remove the traction lock guides remove the four bolts

N-19079 (Item 1) [Figure 60-110-10].

Figure 60-110-11
Remove the c enter chaincase cover [Figure 60-110-8].
(See Center Cover Removal And Installation on Page 40- 1
30-3.)

Dealer Copy -- Not for Resale

3
Figure 60-110-9

1 2

2
P11332

Thoroughly clean the polyurethane from the chaincase

cover (Item 1), bolts (Item 2) and traction lock guides
P11331 (Item 3) [Figure 60-110-11] and dry.

NOTE: Bolt (Item 1) is on the rear of the chaincase

cover, notice the direction of the groove (Item
2) [Figure 60-110-9] in the traction lock
guides.

753 Bobcat Loader

60-110-5 Service Manual
519 of 726
TRACTION LOCK (CONT’D) Figure 60-110-14
INCORRECT CORRECT
Guide Installation

Figure 60-110-12
3

1 2

N-19106 N-19105

1 Install the traction lock guides (Item 1) to the chaincase

P11333 cover (Item 2) [Figure 60-110-14] using the four bolts
(removed earlier).

Apply a bead of polyurethane sealer (P/N 6633583) (Item Do not tighten at this time.
1) [Figure 60-110-12] around the bolt holes on the
blocks.

Dealer Copy -- Not for Resale

Figure 60-110-15

Figure 60-110-13

1
2

3 2

4 4

1 P11337

P11334
Install the traction wedge assembly (Item 1) into the
solenoid and traction lock guides (Item 2) [Figure 60-
Install the ele ctric solenoid/bracket assembly (Item 1) to 110-15].
the center chaincase cover (Item 2) [Figure 60-110-13].
After the bolts have been tightened recheck to make sure
NOTE: Bolt (Item 3) [Figure 60-110-13] & [Figure 60- the shaft assembly is moving freely in the guides.
110-14] represents the rear of the chaincase
cover. Remove the wedge assembly (Item 1) [Figure 60-110-
15].
Install and tighten the two bolts (Item 4) [Figure 60-110-
13]. NOTE: The wedge assembly must slide freely in the
grooves of the guides. Tighten the four guide
bolts to 90-100 ft.-lbs. (123-135 Nm) torque.

753 Bobcat Loader

60-110-6 Service Manual
520 of 726
TRACTION LOCK (CONT’D) Figure 60-110-18

Guide Installation (Cont'd)

Figure 60-110-16
1
2 1
2

N-19109

Install the wedge assembly (Item 1) [Figure 60-110-18]

P11334 into the grooves in the tr action lock guides making sure
that there is no binding.

Remove the two bol ts (Item 1) and remove the electric Install the gasket (Item 2) [Figure 60-110-18].
solenoid (Item 2) [Figure 60-110-16] from the center
chaincase cover.

Dealer Copy -- Not for Resale

Figure 60-110-17

N-19079

Install the chaincase cover (Item 1) using the ten

mounting bolts (Item 2) [Figure 60-110-17].

Tighten to 25-28 ft.-lbs. (34-38 Nm) torque.

NOTE: Thoroughly clean and dry the bolts and apply

LOCTITE #242.

753 Bobcat Loader

60-110-7 Service Manual
521 of 726
TRACTION LOCK (CONT’D)

Guide Installation (Cont'd)

Figure 60-110-19

1
2

P11341

Install the so lenoid mounting bracket assembly (Item 1)

on the chaincase cover using the two bolts (Item 2)
[Figure 60-110-19] and tighten to 25-28 ft.-lbs. (34-38

Dealer Copy -- Not for Resale

Nm) torque.

NOTE: Be sure the solenoid mounting bracket is

installed in the same position. The solenoid
mounting surface has a slight angle which
tips the top of the solenoid toward the rear of
the loader when installed correctly.

Install a new DO NOT MODIFY sta-strap (Item 3) [Figure

60-110-19] (P/N 6665527) on the electric solenoid
connector.

Install the control panel. (See Removal and Installation

on Page 50-100-1.)

Install the engine speed control. (See Removal And

Installation on Page 70-20-1.)

Lower operator cab. (See Lowering The Operator Cab on

Page 10-30-2.)

Perform the B ICS™ inspection procedure. (See BICS™

SYSTEM on Page 60-90-1.)

753 Bobcat Loader

60-110-8 Service Manual
522 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM Figure 60-120-3

Components Identification

Figure 60-120-1

1
1

P13797
2

AHC/PWM Controller (Item 1) [Figure 60-120-3].

N-17774 N-17783
Figure 60-120-4

Control Handle (Item1) [Figure 60-120-1].

Handle Control Unit (Item 2) [Figure 60-120-1].

Dealer Copy -- Not for Resale

1
Figure 60-120-2

P-21769B

AHC error indicator (Item 1) [Figure 60-120-4].

NOTE: The ADVANCED HAND CONTROL (AHC) icon

1 will illuminate when an error occurs. The error
N-19112
is stored as a service code. (See
DIAGNOSTICS on Page 60-80-1.)
Control Valve Actuators (Item 1) [Figure 60-120-2].

753 Bobcat Loader

60-120-1 Service Manual
523 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM
(CONT’D)

Troubleshooting Guide

The Advance Hand Control System (AHC) has a built-in diagnostic function which uses an icon on the right instrument
panel to indicate the condition of the AHC System. The system also records the alarm condition as a service code.

The control module continually checks the system in the order listed. The checks start with the lift handle controller and
then the lift actuator. If no problems are present, it will then check the tilt handle controller and the tilt actuator. The system
will stop its check at the first problem and then luminate the icon.

The system starts its diagnostics and calibration when the ignition key is turned ON.

The following list shows the probable causes when the icon is luminated.

Advanced General Fuel Level System Engine Oil Engine Air Filter
Hand Warning Voltage Pressure Coolant
Controls Temperature

Dealer Copy -- Not for Resale

Attachment Hydraulic Hydraulic Oil Hydraulic
Two Speed Glow Plugs Seatbelt Filter
Control Charge Temperature
Device Pressure

Advanced Hand Controls

Errors - lights soild with 3 beeps
32-31 - Tilt actuator fault
32-32 - Tilt actuator wiring fault
32-33 - Tilt handle wiring fault
32-34 - Tilt actuator not calibrated
32-35 - Tilt handle not calibrated
32-36 - Lift actuator fault
32-37 - Lift actuator wiring fault
32-38 - Lift handle wiring fault
32-39 - Lift actuator not calibrated
32-40 - Lift handle not calibrated
32-41 - Invalid Frequency
To see what error occurred. Check the service code on the left instrument panel. (See DIAGNOSTICS on Page 60-80-1.)

753 Bobcat Loader

60-120-2 Service Manual
524 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM
(CONT’D)

Parts Identification

C-428
C-430

Dealer Copy -- Not for Resale

C-431
C-429

P/N PIN DESCRIPTION P/N PIN DESCRIPTION

C-430 CONNECTOR, METRI-PACK C-428 CONNECTOR, 8 WAY PLUG
Orange/White A SWITCHED BATTERY POWER Dk Blue/White 1 LOW REFERENCE TO RESISTIVE
INPUTS
Black B GROUND Lt Green/White 2 SIGNAL FROM LIFT ACTUATOR
C-431 MALE, 10 WAY Dark Blue 3 HIGH REFERENCE TO RESISTIVE
INPUTS
Brown/Dk Green A SIGNAL FROM LIFT CONTROL 4 OPEN
HANDLE INPUT Brown/White 5 LIFT SPOOL ACTUATOR MOTOR (-)
Purple/Yellow B FLOAT SWITCH ON/OFF 6 OPEN
Pink/Dk Green C SIGNAL FROM TILT CONTROL HANDLE 7 OPEN
INPUT
Dk Blue D TILT HIGH REFERENCE TO RESISTIVE Brown/Yellow 8 LIFT SPOOL ACTUATOR MOTOR (+)
INPUTS
Dk Blue/White E TILT LOW REFERENCE TO RESISTIVE C-429 CONNECTOR, 8 WAY PLUG
INPUTS
Dk Blue/White F LIFT LOW REFERENCE TO RESISTIVE Dk Blue/White 1 LOW REFERENCE TO RESISTIVE
INPUTS INPUTS
Dk Blue G LIFT HIGH REFERENCE TO RESISTIVE Lt Blue/White 2 SIGNAL FROM TILT ACTUATOR
INPUTS
Purple/White H BICS™ INPUT STATUS Dk Blue 3 HIGH REFERENCE TO RESISTIVE
INPUTS
Purple/Red J AHC STATUS OUTPUT 4 OPEN
K OPEN Pink/White 5 TILT SPOOL ACTUATOR MOTOR (-)
6 OPEN
7 OPEN
Pink/Yellow 8 TILT SPOOL ACTUATOR MOTOR (+)

753 Bobcat Loader

60-120-3 Service Manual
525 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM Control Handle Unit Connector
(CONT'D)
Figure 60-120-7
AHC Controller Removal And Installation

Figure 60-120-5

1
N-17392
1
P13882 The wire connector (Item 1) [Figure 60-120-7] can be
removed from the handle control unit wires, use the
following procedure.
Remove the control panel from the loader. (See Removal
and Installation on Page 50-100-1.)

Dealer Copy -- Not for Resale

Figure 60-120-8
Disconnect the wiring harness connectors from the
controller (Item 1) [Figure 60-120-5].

Figure 60-120-6

1
1

P13725 P13732

Remove the wedge (Item 1) [Figure 60-120-8] from the

connector.
2 P13883

Remove the two mounting bolts (Item 1) [Figure 60-120-

6] from the controller mounting bracket.

Remove the controller from the loader.

Remove the four mounting bolts (Item 2) [Figure 60-120-

6] from the controller.

753 Bobcat Loader

60-120-4 Service Manual
526 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM Switch Handle Removal and Installation
(CONT'D)
Figure 60-120-10
Control Handle Unit Connector (Cont’d)

Figure 60-120-9

2 1

P13733

With a pointed tool, lift the tab (Item 1) [Figure 60-120-9]

and pull the wire from the connector.

Dealer Copy -- Not for Resale

Assembly: Install the wires into the c onnector as listed
below [Figure 60-120-9]:
1
1-Terminal - Red

2-Terminal - Black

3-Terminal - Green N-17786

Remove the handle control unit from the steering lever.

(See Control Handle Removal And Installation on P age
50-111-5.)

To remove the switch handle the c onnector (Item 1)

[Figure 60-120-10] must be removed from the wires, use
the following procedure:

753 Bobcat Loader

60-120-5 Service Manual
527 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM Figure 60-120-12
(CONT'D)

Switch Handle Removal and Installation (Cont'd)

Figure 60-120-11

3 1
2

1
1
P13735

1 Using a p ointed tool, press down on the tab (Item 1)

[Figure 60-120-12] and pull the wire from the connector.
P13725 P13732
Installation: Install the wires into the connector as listed
below [Figure 60-120-12]:
Remove the wedge (Item 1) [Figure 60-120-11] from the
connector.

Dealer Copy -- Not for Resale

Right Steering Lever Switch Handle
1-Terminal - Pink/Red
2-Terminal - Pink/Black
3-Terminal - Pink/Green

Left Steering Lever Switch Handle

1-Terminal - Brown/Red
2-Terminal - Brown/Black
3-Terminal - Brown/Green

753 Bobcat Loader

60-120-6 Service Manual
528 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM Installation: The wire colors of the steering lever
(CONT'D) harness are as follows:

Switch Handle Removal and Installation (Cont'd) Right Switch Handle

Figure 60-120-13 Ten-Pin Connector

A-Terminal - Orange
B-Terminal - White
1 C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Green
F-Terminal - White/Green
G-Terminal - Blank
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Blank

Three-Pin Connector
2 A-Terminal - Pink/Red
B-Terminal - Pink/Black
N-17779 C-Terminal - Pink/Lt. Green

Left Switch Handle

Disconnect the right switch handle connectors (Items 1 &
2) [Figure 60-120-13] from the loader wiring harness

Dealer Copy -- Not for Resale

Ten-Pin Connector
connectors.
A-Terminal - Orange
B-Terminal - Dk. Blue
Figure 60-120-14
C-Terminal - White
D-Terminal - Blank
E-Terminal - Blank
F-Terminal - Yellow/Red
G-Terminal - Yellow/Green
1 2
3 4 H-Terminal - Blank
J-Terminal - Blank
K-Terminal - Blank

Three-Pin Connector
A-Terminal - Brown/Red
B-Terminal - Brown/Black
C-Terminal - Brown/Lt. Green

Two-Pin Connector
N-17772
A-Terminal - Orange/Blue
B-Terminal - Orange/White
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 60-120-14] from loader wiring harness Five-Pin Connector
connectors. A-Terminal - Green
B-Terminal - Brown
Remove the connector locks and connectors from the C-Terminal - Blank
wires to remove the switch handle from the steering D-Terminal - Yellow
handle. E-Terminal - Blank

753 Bobcat Loader

60-120-7 Service Manual
529 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM Pull the switch handle and wiring harness assembly (Item
(CONT'D) 1) [Figure 60-120-16] from the steering lever.

Switch Handle Removal and Installation (Cont'd) Figure 60-120-17

Figure 60-120-15

2 2
1

N-17471

N-17382
Installation: When installing the switch handle and
wiring harness assembly into the steering handle, route
Roll the pistol grip handle cover (Item 1) [Figure 60-120- the harness (Item 1) [Figure 60-120-17] to assure proper
15] down.

Dealer Copy -- Not for Resale

return of the control handle to neutral position.
Using a s mall screwdriver, lift the handle tabs (Item 2) Actuators Disassembly And Assembly
[Figure 60-120-15] and slightly rotate the switch handle.
Figure 60-120-18
Figure 60-120-16

N-18940

Remove the actuator from the hydraulic control valve.

(See Actuator Removal And Installation on Page 20-41-
8.)

Check the mounting block (Item 1) [Figure 60-120-18]

and bolts for wear and replace as needed.

N-17383

753 Bobcat Loader

60-120-8 Service Manual
530 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM
(CONT'D)

Actuators Disassembly And Assembly (Cont’d)

Figure 60-120-19

1
N-17742 N-17741

Check the actuator wiring harness connector (Item 1)

[Figure 60-120-19] and replace if broken.

Dealer Copy -- Not for Resale

Installation: Install the wires into the connector as listed
below. The terminal numbers are written on the back of
the connector (Item 2) [Figure 60-120-19].

Lift and Tilt Actuator

1 - Terminal-Black/Green-Larger diameter wire (16
gauge)
2 - Terminal-Green-Larger diameter wire (16 gauge)
3 - Terminal-Red/Green-Larger diameter wire
(16 gauge)
4 - Terminal-Open
5 - Terminal-Red-Smaller diameter wire (18 gauge)
6 - Terminal-Open
7 - Terminal-Open
8 - Terminal-Black-Smaller diameter wire (18 gauge)

753 Bobcat Loader

60-120-9 Service Manual
531 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

60-120-10 Service Manual
532 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM (W/ Figure 60-121-3
PUSH BUTTON FLOAT)

Components Identification

Figure 60-121-1

P13797
2

AHC/PWM Controller (Item 1) [Figure 60-121-3].

P-30209 N-22797 Figure 60-121-4

Control Handle (Item 1) [Figure 60-121-1].

Dealer Copy -- Not for Resale

Handle Sensor (Item 2) [Figure 60-121-1].
1
Figure 60-121-2

P-21769B

AHC error indicator (Item 1) [Figure 60-121-4].

NOTE: The AHC icon will illuminate when an error

1 occurs. The error is stored as a service code.
N-19112 (See DIAGNOSTICS on Page 60-80-1.)

Control Valve Actuators (Item 1) [Figure 60-121-2].

753 Bobcat Loader

60-121-1 Service Manual
533 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM (W/
PUSH BUTTON FLOAT) (CONT'D)

Troubleshooting Guide

The Advance Hand Control System (AHC) has a built-in diagnostic function which uses an icon on the right instrument
panel to indicate the condition of the AHC SYSTEM (W/PUSH BUTTON FLOAT). The system also records the alarm
condition as a service code.

The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then
the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will
stop its check at the first problem and then luminate the icon.

The system starts its diagnostics and calibration when the ignition key is turned ON.

The following list shows the probable causes when the icon is luminated.

Advanced General Fuel Level System Engine Oil Engine Air Filter
Hand Warning Voltage Pressure Coolant
Controls Temperature

Dealer Copy -- Not for Resale

Attachment Hydraulic Hydraulic Oil Hydraulic
Two Speed Glow Plugs Seatbelt Filter
Control Charge Temperature
Device Pressure

Advanced Hand Controls

Errors - lights soild with 3 beeps
32-31 - Tilt actuator fault
32-32 - Tilt actuator wiring fault
32-33 - Tilt handle wiring fault
32-34 - Tilt actuator not calibrated
32-35 - Tilt handle not calibrated
32-36 - Lift actuator fault
32-37 - Lift actuator wiring fault
32-38 - Lift handle wiring fault
32-39 - Lift actuator not calibrated
32-40 - Lift handle not calibrated
32-41 - Invalid Frequency
To seeTo seeerror
what whatoccurred.
error occurred.
CheckCheck the service
the service code
code on the on
leftthe left instrument
instrument panel. panel. (See Diagnostics
(See DIAGNOSTICS on Page
Page 60-01.)
60-80-1.)

753 Bobcat Loader

60-121-2 Service Manual
534 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM (W/
PUSH BUTTON FLOAT) (CONT'D)

Controller Connector And Wire Identification

C-428
C-430

Dealer Copy -- Not for Resale

C-431
C-429

P/N PIN DESCRIPTION P/N PIN DESCRIPTION

C-430 CONNECTOR, METRI-PACK C-428 CONNECTOR, 8 WAY PLUG (LIFT) (TOP
ACTUATOR)
Orange/White A SWITCHED BATTERY POWER Dk Blue/White 1 LOW REFERENCE TO RESISTIVE
INPUTS
Black B GROUND Lt Green/White 2 SIGNAL FROM LIFT ACTUATOR
C-431 MALE, 10 WAY Dark Blue 3 HIGH REFERENCE TO RESISTIVE
INPUTS
Brown/Dk Green A SIGNAL FROM LIFT CONTROL 4 OPEN
HANDLE INPUT Brown/White 5 LIFT SPOOL ACTUATOR MOTOR (-)
Purple/Yellow B FLOAT SWITCH ON/OFF 6 OPEN
Pink/Dk Green C SIGNAL FROM TILT CONTROL HANDLE 7 OPEN
INPUT
Dk Blue D TILT HIGH REFERENCE TO RESISTIVE Brown/Yellow 8 LIFT SPOOL ACTUATOR MOTOR (+)
INPUTS
Dk Blue/White E TILT LOW REFERENCE TO RESISTIVE C-429 CONNECTOR, 8 WAY PLUG (TILT)
INPUTS (BOTTOM ACTUATOR)
Dk Blue/White F LIFT LOW REFERENCE TO RESISTIVE Dk Blue/White 1 LOW REFERENCE TO RESISTIVE
INPUTS INPUTS
Dk Blue G LIFT HIGH REFERENCE TO RESISTIVE Lt Blue/White 2 SIGNAL FROM TILT ACTUATOR
INPUTS
Purple/White H BICS™ INPUT STATUS Dk Blue 3 HIGH REFERENCE TO RESISTIVE
INPUTS
Purple/Red J AHC STATUS OUTPUT 4 OPEN
K OPEN Pink/White 5 TILT SPOOL ACTUATOR MOTOR (-)
6 OPEN
7 OPEN
Pink/Yellow 8 TILT SPOOL ACTUATOR MOTOR (+)

753 Bobcat Loader

60-121-3 Service Manual
535 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM (W/ Handle Sensor Removal And Installation
PUSH BUTTON FLOAT) (CONT'D)
Figure 60-121-7
AHC Controller Removal And Installation

Figure 60-121-5

P16581

1
P-13882 Lift the boot cover (Item 1) [Figure 60-121-7].

Figure 60-121-8
Remove the control panel from the loader. (See Removal
and Installation on Page 50-100-1.)

Dealer Copy -- Not for Resale

Disconnect the wiring harness connectors from the
controller (Item 1) [Figure 60-121-5].

Figure 60-121-6

1
N-22801

Disconnect the h arness connector (Item 1) [Figure 60-

121-8] from the handle sensor connector.

2 P13883

Remove the two mounting bolts (Item 1) [Figure 60-121-

6] from the controller mounting bracket.

Remove the controller from the loader.

Remove the four mounting bolts (Item 2) [Figure 60-121-

6] from the controller.

753 Bobcat Loader

60-121-4 Service Manual
536 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM (W/ Figure 60-121-11
PUSH BUTTON FLOAT) (CONT'D)

Handle Sensor Removal And Installation (Cont'd)

Figure 60-121-9

1
2

1 P-16580 N-22793

Remove the two p lastic spacers (Item 1) and the m etal

spacer (Item 2) [Figure 60-121-11] from the handle
N-22803 sensor.

Figure 60-121-12
Remove the handle sensor connector (Item 1) [Figure
60-121-9] from the clip.

Dealer Copy -- Not for Resale

NOTE: Pry out with a small screw driver and push the
connector down.

Figure 60-121-10 1

1 P16574

1
Remove the top mounting bolt (Item 1) [Figure 60-121-
12] from the handle sensor.

N-22790

Use an allen wrench, remove one of the two mounting

screws (Item 1) [Figure 60-121-10] from the handle
sensor.

753 Bobcat Loader

60-121-5 Service Manual
537 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM (W/ Handle Sensor Connector
PUSH BUTTON FLOAT) (CONT'D)
Figure 60-121-15
Handle Sensor Removal And Installation (Cont'd)

Figure 60-121-13

1
1
3

P16578

3 2
P16576 The wire connector (Item 1) [Figure 60-121-15] can be
removed from the handle sensor wires, use the following
procedure.
Remove the handle sensor (Item 1) [Figure 60-121-13]
from the handle assembly.

Dealer Copy -- Not for Resale

Figure 60-121-16
NOTE: The sensor (Item 1) [Figure 60-121-13] can
only be replaced as a complete assembly.

Check the spacers (Item 2) and screws (Item 3) [Figure

60-121-13] and replace as needed.

Figure 60-121-14

1
1

1
P13725 P13732

Remove the wedge (Item 1) [Figure 60-121-16] from the

connector.

N-22799

Installation: When installing the handle sensor into the

control handle, check the routing of the switch handle
wire harness (Item 1) [Figure 60-121-14] to assure
proper return of the control handle to neutral.

753 Bobcat Loader

60-121-6 Service Manual
538 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM (W/ Figure 60-121-19
PUSH BUTTON FLOAT) (CONT'D)

Handle Sensor Connector

Figure 60-121-17

2 3 1
1
P13725 P13732

Remove the wedge (Item 1) [Figure 60-121-19] from the

connector.
P13733
Figure 60-121-20
With a pointed tool, lift the tab (Item 1) [Figure 60-121-
17] and pull the wire from the connector.

Dealer Copy -- Not for Resale

Assembly: Install the wires into the c onnector as listed
below [Figure 60-121-17]:

1-Terminal - Red
3 1
2-Terminal - Black
2
3-Terminal - Green
1
Switch Handle Removal And Installation
P13735
Figure 60-121-18

Using a p ointed tool, press down on the tab (Item 1)

[Figure 60-121-20] and pull the wire from the connector.

Installation: Install the wires into the connector as listed

below [Figure 60-121-20]:

Right Control Lever Switch Handle

1-Terminal - Red/White
2-Terminal - Black/White
3-Terminal - Purple/White
1
Left Control Lever Switch Handle
1-Terminal - Red/White
N-22794 2-Terminal - Black/White
3-Terminal - Purple/White

To remove the s witch handle, the connector (Item 1)

[Figure 60-121-18] must be removed from the wires.

753 Bobcat Loader

60-121-7 Service Manual
539 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM (W/ Installation: The wire colors of the control lever harness
PUSH BUTTON FLOAT) (CONT'D) are as follows:

Switch Handle Removal And Installation (Cont'd) Right Switch Handle

Figure 60-121-21 Ten-Pin Connector

A-Terminal - Orange
B-Terminal - White
1 C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Blank
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Blank

Three-Pin Connector
2 A-Terminal - Pink/Red
B-Terminal - Pink/Black
N-17779 C-Terminal - Pink/Lt. Green

Left Switch Handle

Disconnect the right switch handle connectors (Items 1 &
2) [Figure 60-121-21] from the loader wiring harness

Dealer Copy -- Not for Resale

Ten-Pin Connector
connectors.
A-Terminal - Orange
B-Terminal - Dk. Blue
Figure 60-121-22
C-Terminal - White
D-Terminal - Purple
E-Terminal - Blank
F-Terminal - Tan
2 G-Terminal - Pink
1 3 H-Terminal - Blank
4
J-Terminal - Blank
K-Terminal - Blank

Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White

Two-Pin Connector
N-17772
A-Terminal - Black
B-Terminal - Red
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 60-121-22] from loader wiring harness Five-Pin Connector
connectors. A-Terminal - Dk. Green
B-Terminal - Brown
Remove the connector locks and connectors from the C-Terminal - Blank
wires to r emove the switch handle from the control D-Terminal - Yellow
handle. E-Terminal - Blank

753 Bobcat Loader

60-121-8 Service Manual
540 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM (W/ Figure 60-121-25
PUSH BUTTON FLOAT) (CONT'D)

Switch Handle Removal And Installation (Cont'd)

Figure 60-121-23

2 2

N-22794

1
Installation: When installing the switch handle and
wiring harness assembly into the control handle, route
N-22783 the harness (Item 1) [Figure 60-121-25] to assure proper
return of the control handle to neutral position.
Roll the pistol grip handle cover (Item 1) [Figure 60-121- Actuators Disassembly And Assembly
23] down.

Dealer Copy -- Not for Resale

Figure 60-121-26
Using a s mall screwdriver, lift the handle tabs (Item 2)
[Figure 60-121-23] and slightly rotate the switch handle.
1
Figure 60-121-24

N-18940

Remove the actuator from the hydraulic control valve.

N-22784 (See Actuator Removal And Installation on Page 20-41-
8.)

Pull the switch handle and wiring harness assembly (Item Check the mounting block (Item 1) [Figure 60-121-26]
1) [Figure 60-121-24] from the control lever. and bolts for wear and replace as needed.

753 Bobcat Loader

60-121-9 Service Manual
541 of 726
ADVANCED HAND CONTROL (AHC) SYSTEM (W/
PUSH BUTTON FLOAT) (CONT'D)

Actuators Disassembly And Assembly (Cont’d)

Figure 60-121-27

1
N-17742 N-17741

Check the actuator wiring harness connector (Item 1)

[Figure 60-121-27] and replace if broken.

Dealer Copy -- Not for Resale

Installation: Install the wires into the connector as listed
below. The terminal numbers are written on the back of
the connector (Item 2) [Figure 60-121-27].

Lift and Tilt Actuator

1 - Terminal-Black/Green-Larger diameter wire (16
gauge)
2 - Terminal-Green-Larger diameter wire (16 gauge)
3 - Terminal-Red/Green-Larger diameter wire
(16 gauge)
4 - Terminal-Open
5 - Terminal-Red-Smaller diameter wire (18 gauge)
6 - Terminal-Open
7 - Terminal-Open
8 - Terminal-Black-Smaller diameter wire (18 gauge)

753 Bobcat Loader

60-121-10 Service Manual
542 of 726
ADVANCED CONTROL SYSTEM (ACS) ADVANCED Figure 60-122-3
HAND CONTROL

Components Identification

Figure 60-122-1

1
2 1
P-21767

ACS Controller (Item 1) [Figure 60-122-3].

P-30209 P-24909 NOTE: The calibration procedure must be followed

when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Control Handle (Item1) [Figure 60-122-1]. Calibration Of The ACS System on Page 60-

Dealer Copy -- Not for Resale

123-14.)
Handle Sensor (Item 2) [Figure 60-122-1].
Figure 60-122-4
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60-
123-14.)
1
Figure 60-122-2

P-21769A

ACS error indicator (Item 1) [Figure 60-122-4].

NOTE: The ACS icon will illuminate when an error

occurs. The error is stored as a service code.
1 P-24203 (See DIAGNOSTICS on Page 60-80-1.)

Control Valve Actuators (Item 1) [Figure 60-122-2].

NOTE: The calibration procedure must be followed

when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60-
123-14.)

753 Bobcat Loader

60-122-1 service Manual
543 of 726
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)

Troubleshooting Guide

The Advanced Control System (ACS) has a built-in diagnostic function which uses an icon on the right instrument panel
to indicate the condition of the ACS SYSTEM. The system also records the alarm condition as a service code.

The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then
the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will
stop its check at the first problem and then luminate the icon.

The system starts its diagnostics and calibration when the ignition key is turned ON.

The following list shows the probable causes when the icon is luminated.
Advanced General Fuel Level System Engine Oil Engine Air Filter
Control Warning Voltage Pressure Coolant
System Temperature

Dealer Copy -- Not for Resale

Attachment Two Speed Glow Plugs Seat belt Hydraulic Hydraulic Oil Hydraulic
Control Charge Temperature Filter
Device Pressure

Advanced Control System

Errors - lights solid with 3 beeps 32-54 - Tilt handle/pedal short to ground
32-04 - ACS in error 32-55 - Lift handle/pedal short to battery
32-23 - ACS not calibrated 32-56 - Tilt handle/pedal short to battery
32-31 - Tilt actuator fault 32-57 - Lift actuator reduced performance
32-34 - Tilt actuator not calibrated 32-58 - Tilt actuator reduced performance
32-35 - Tilt handle/pedal not calibrated 32-59 - Lift actuator wrong direction
32-36 - Lift actuator fault 32-60 - Tilt actuator wrong direction
32-39 - Lift actuator not calibrated 32-61 - Handle lock short to ground
32-40 - Lift handle/ pedal not calibrated 32-62 - Handle lock short to battery
32-49 - Lift actuator short to ground 32-63 - Pedal lock short to ground
32-50 - Tilt actuator short to ground 32-64 - Pedal lock short to battery
32-51 - Lift actuator short to ground 32-65 - Sensor supply voltage out of range
32-52 - Tilt actuator short to battery 32-66 - Battery out of range
32-53 - Lift handle/pedal short to ground 32-67 - Switch flipped while operating

To see what error occurred. Check the service code on the left instrument panel. (See DIAGNOSTICS on Page 60-80-1.)

753 Bobcat Loader

60-122-2 Service Manual
544 of 726
ADVANCED CONTROL SYSTEM (ACS) ADVANCED
HAND CONTROL (CONT'D)

Controller, Connector And Wire Identification

G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
K J2

F E
G D A
E H B
C
A J2
B
D
J1
C
J3
J1 J2

Dealer Copy -- Not for Resale

P-21843

P/N PIN DESCRIPTION P/N PIN DESCRIPTION

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FORWARD
Orange B SWITCHED AHC POWER Red/White B UNSWITCHED AHC POWER
Green C HAND/FOOT INPUT Red/White C UNSWITCHED AHC POWER
Purple D CAN SIGNAL HIGH AHC Black D LIFT ACTUATOR REVERSE
Purple E CAN SIGNAL LOW AHC Green E HANDLE LOCK POWER
Purple F CAN SHIELD AHC Red F LIFT ACTUATOR FORWARD
Black G AHC GROUND Green G PEDAL LOCK POWER
Black H AHC GROUND Black H AHC GROUND
J2 CONNECTOR, METRI-PACK Black J AHC GROUND
A OPEN Black K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
Green E TILT SPOOL SIGNAL
Green F LIFT HANDLE SIGNAL
Green G TILT HANDLE SIGNAL
Green H LIFT SPOOL SIGNAL
Green J LIFT PEDAL SIGNAL
Green K TILT PEDAL SIGNAL

753 Bobcat Loader

60-122-3 service Manual
545 of 726
ADVANCED CONTROL SYSTEM (ACS) ADVANCED ADVANCED CONTROL SYSTEM (ACS)
HAND CONTROL (CONT'D) SELECTABLE HAND/FOOT CONTROL on
Page 60-123-1.)
ACS Controller Removal And Installation
Handle Sensor Connector
Figure 60-122-5
Figure 60-122-7

P-28964

P16578

Remove control panel. (See Removal and Installation on

Page 50-100-1.)

Dealer Copy -- Not for Resale

The wire connector (Item 1) [Figure 60-122-7] can be
removed from the handle sensor wires, use the following
Remove the two mounting bolts (Item 1) [Figure 60-122- procedure.
5] from the controller mounting bracket.
Figure 60-122-8
Figure 60-122-6

2
1
1
1

P13725 P13732
P-28966

Remove the wedge (Item 1) [Figure 60-122-8] from the

Lift controller out from mounting location. Disconnect the connector.
wiring harness connectors (Item 1) [Figure 60-122-6]
from the controller.

Remove two mounting bolts (Item 2) [Figure 60-122-6] to

remove controller from bracket.

Remove the controller from the loader.

NOTE: The calibration procedure must be followed

when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See

753 Bobcat Loader

60-122-4 Service Manual
546 of 726
ADVANCED CONTROL SYSTEM (ACS) ADVANCED Disconnect the h arness connector (Item 1) [Figure 60-
HAND CONTROL (CONT'D) 122-10] from the handle sensor connector.

Handle Sensor Connector (Cont’d) Disconnect the h arness connector (Item 2) [Figure 60-
122-10] from the blank handle connector.
Figure 60-122-9
Figure 60-122-11

1
2 3
1 1

1
P13733

P13725 P13732

With a pointed tool, lift the tab (Item 1) [Figure 60-122-9]

and pull the wire from the connector.

Dealer Copy -- Not for Resale

Remove the wedge (Item 1) [Figure 60-122-11] from the
harness connector (Gray) that connects to the handle
Assembly: Install the wires into the c onnector as listed sensor connector.
below [Figure 60-122-9]:
Figure 60-122-12
1-Terminal - Red

2-Terminal - Black

3-Terminal - Green

Switch Handle Removal

Figure 60-122-10 2
3 1

P13735

2 Using a p ointed tool, press down on the tab (Item 1)

1 [Figure 60-122-12] and pull the wire from the connector.

P-24909

NOTE: Switch handle can be removed and installed

while in loader.

753 Bobcat Loader

60-122-5 service Manual
547 of 726
ADVANCED CONTROL SYSTEM (ACS) ADVANCED Figure 60-122-15
HAND CONTROL (CONT'D)

Switch Handle Removal (Cont'd) 1

Figure 60-122-13

2
1
N-17779

1 Disconnect the right switch handle connectors (Items 1 &

2) [Figure 60-122-15] from the loader wiring harness
P13725 P13732 connectors.

Figure 60-122-16
Remove the wedge (Item 1) [Figure 60-122-13] from the
harness connector (Black) that connects to the blank

Dealer Copy -- Not for Resale

handle connector (Item 2) [Figure 60-122-10].

Figure 60-122-14 2
1 3
4

2
3 1
N-17772

1
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 60-122-16] from the loader wiring harness
P13735 connectors.

Use a pointed tool, press down on the tab (Item 1)

[Figure 60-122-14] and pull the wire from the connector.

753 Bobcat Loader

60-122-6 Service Manual
548 of 726
ADVANCED CONTROL SYSTEM (ACS) ADVANCED Figure 60-122-19
HAND CONTROL (CONT'D)

Switch Handle Removal (Cont'd)

Figure 60-122-17

2
2

P-24234

1
Pull harness (Item 1) [Figure 60-122-19] out the bottom
of the control lever tube.
N-22783
Switch Handle Installation
Roll the pistol grip handle cover (Item 1) [Figure 60-122- Figure 60-122-20
17] down.

Dealer Copy -- Not for Resale

Using a s mall screwdriver, lift the handle tabs (Item 2)
[Figure 60-122-17] and slightly rotate the switch handle.

Figure 60-122-18
Tape back 1/2 of Wires Tape 1/2 of Wires

N-24233

1 P-21699

When installing the ne w switch handle, tape the wire

terminals together.

N-22784 The switch handle comes with a 6 in ch piece of hea t

shrink tube side on the end of the wi res. Remove the
heat shrink tube from the end of the wires before routing
Pull the switch handle and wiring harness assembly (Item through handle and control lever tube.
1) [Figure 60-122-18] from the control lever.
NOTE: Leave all the other heat shrink tube on the
Cut the wires (Item 2) [Figure 60-122-18] below the wires for protection.
switch handle and remove switch handle.
Tape half of the wires back and half forward [Figure 60-
NOTE: Only cut the wires if the switch handle is bad 122-20] to keep the harness small enough to route
and needs replacement. If the switch handle is through the control lever tube.
good and just needs to be removed for control
handle or lever replacement, then remove the
connectors on the end of the harness and pull
switch handle up out of lever tube.

753 Bobcat Loader

60-122-7 service Manual
549 of 726
ADVANCED CONTROL SYSTEM (ACS) ADVANCED Inspect the wire terminal tabs (Item 2) [Figure 60-122-
HAND CONTROL (CONT'D) 22] and re-bend tabs if necessary.

Switch Handle Installation (Cont'd) Install the wires into the connectors as listed below:

Figure 60-122-21 Right Switch Handle

Ten-Pin Connector
A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
1 D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black

Three-Pin Connector
P-21700 A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
Install the new switch handle and wires from the top of
the control lever.

Dealer Copy -- Not for Resale

Left Switch Handle
Route wire (Item 1) [Figure 60-122-21] through the
Ten-Pin Connector
casting, along side the handle sensor and into the control
A-Terminal - Orange
lever tube.
B-Terminal - Dk. Blue
C-Terminal - White
NOTE: Do not pull the wire harness tight, allow a
D-Terminal - Purple
small amount of slack or slight bend at the
E-Terminal - Yellow/Red
handle pivot area. Verify the control handle
F-Terminal - Tan
returns to neutral position.
G-Terminal - Pink
H-Terminal - Orange/Black
Figure 60-122-22
J-Terminal - Blank
K-Terminal - Blank

Three-Pin Connector
A-Terminal - Red/White
2
B-Terminal - Black/White
C-Terminal - Purple/White

Two-Pin Connector
1 A-Terminal - Black
B-Terminal - Red

Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
P-21695
C-Terminal - Blank
D-Terminal - Yellow
Remove tape from wires for installation and install the 6 E-Terminal - Blank
inches of heat shrink tube (Item 1) [Figure 60-122-22]
approximately 3 inches into the control lever. Apply heat
to the exposed heat shrink tube.

753 Bobcat Loader

60-122-8 Service Manual
550 of 726
ADVANCED CONTROL SYSTEM (ACS) ADVANCED Figure 60-122-25
HAND CONTROL (CONT'D)

Switch Handle Installation (Cont'd)

Figure 60-122-23

3 1
2

P13735

Install the wires into the connectors as listed below:

1
N-17779 Left and Right Control Lever Switch Handle [Figure 60-
122-25]
1-Terminal - Red/White
Figure 60-122-24 2-Terminal - Black/White

Dealer Copy -- Not for Resale

3-Terminal - Purple/White

Figure 60-122-26
1

1
3
2
N-17772

Connect the handle harness connectors (Item 1) [Figure

P13735
60-122-23] & [Figure 60-122-24] to the loader harness
connectors.
Left and Right Control Lever Switch Handle [Figure 60-
122-26]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black

753 Bobcat Loader

60-122-9 service Manual
551 of 726
ADVANCED CONTROL SYSTEM (ACS) ADVANCED Figure 60-122-29
HAND CONTROL (CONT'D)

Switch Handle Installation (Cont'd)

Figure 60-122-27 2

1
N-17742 N-17741

Check the actuator wiring harness connector (Item 1)

[Figure 60-122-29] and replace if broken.
P-21804
Installation: Install the wires into the connector as listed
below. The terminal numbers are written on the back of
Connect the handle harness connector to the sensor and the connector (Item 2) [Figure 60-122-29].
blank handle connector [Figure 60-122-27].

Dealer Copy -- Not for Resale

Lift and Tilt Actuator
Actuators Disassembly And Assembly 1 - Terminal-Black/Green-Larger diameter wire (16
gauge)
Figure 60-122-28 2 - Terminal-Green-Larger diameter wire (16 gauge)
3 - Terminal-Red/Green-Larger diameter wire
(16 gauge)
1
4 - Terminal-Open
5 - Terminal-Red-Smaller diameter wire (18 gauge)
6 - Terminal-Open
7 - Terminal-Open
8 - Terminal-Black-Smaller diameter wire (18 gauge)

N-18940

Remove the actuator from the hydraulic control valve.

(See Actuator Removal And Installation on Page 20-41-
8.)

Check the m ounting block (Item 1) [Figure 60-122-28]

and bolts for wear and replace as needed.

753 Bobcat Loader

60-122-10 Service Manual
552 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Foot sensor (Item 2) [Figure 60-123-2].
HAND/FOOT CONTROL
NOTE: The calibration procedure must be followed
Components Identification when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Figure 60-123-1 Calibration Of The ACS System on Page 60-
123-14.)

Figure 60-123-3

1
1

P-30209 P-21879

The Advanced Control System (ACS) is a selectable foot/

1 P-24203
hand control system.

Dealer Copy -- Not for Resale

The ACS system allows the operator to quickly switch Control Valve Actuators (Item 1)[Figure 60-123-3].
between foot and hand control modes.
NOTE: The calibration procedure must be followed
Control Handle (Item 1) [Figure 60-123-1]. when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Handle sensor (Item 2) [Figure 60-123-1]. Calibration Of The ACS System on Page 60-
123-14.)
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal Figure 60-123-4
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60-
123-14.)

Figure 60-123-2

P-21767
1

ACS Controller (Item 1) [Figure 60-123-4].

P-30077 P-21939 NOTE: The calibration procedure must be followed

when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Foot control/sensor assembly (Item 1) [Figure 60-123-2]. Calibration Of The ACS System on Page 60-
123-14.)
753 Bobcat Loader
60-123-1 Service Manual
553 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT’D)

Components Identification (Cont’d)

Figure 60-123-5

P-21769A

ACS error indicator (Item 1) [Figure 60-123-5].

Dealer Copy -- Not for Resale

NOTE: The ACS icon will illuminate when an error
occurs. The error is stored as a service code.
(See DIAGNOSTICS on Page 60-80-1.)

753 Bobcat Loader

60-123-2 Service Manual
554 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT’D)

Troubleshooting Guide

The Advanced Control System (ACS) has a built-in diagnostic function which uses an icon on the right instrument panel
to indicate the condition of the ACS SYSTEM. The system also records the alarm condition as a service code.

The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then
the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will
stop its check at the first problem and then luminate the icon.

The system starts its diagnostics and calibration when the ignition key is turned on.

The following list shows the probable causes when the icon is luminated.
Advanced General Fuel Level System Engine Oil Engine Air Filter
Control Warning Voltage Pressure Coolant
System Temperature

Dealer Copy -- Not for Resale

Attachment Two Speed Glow Plugs Seat belt Hydraulic Hydraulic Oil Hydraulic
Control Charge Temperature Filter
Device Pressure

Advanced Control System

Errors - lights solid with 3 beeps 32-54 - Tilt handle/pedal short to ground
32-04 - ACS in error 32-55 - Lift handle/pedal short to battery
32-23 - ACS not calibrated 32-56 - Tilt handle/pedal short to battery
32-31 - Tilt actuator fault 32-57 - Lift actuator reduced performance
32-34 - Tilt actuator not calibrated 32-58 - Tilt actuator reduced performance
32-35 - Tilt handle/pedal not calibrated 32-59 - Lift actuator wrong direction
32-36 - Lift actuator fault 32-60 - Tilt actuator wrong direction
32-39 - Lift actuator not calibrated 32-61 - Handle lock short to ground
32-40 - Lift handle/ pedal short not calibrated 32-62 - Handle lock short to battery
32-49 - Lift actuator short to ground 32-63 - Pedal lock short to ground
32-50 - Tilt actuator short to ground 32-64 - Pedal lock short to battery
32-51 - Lift actuator short to battery 32-65 - Sensor supply voltage out of range
32-52 - Tilt actuator short to battery 32-66 - Battery out of range
32-53 - Lift handle/pedal short to ground 32-67 - Switch flipped while operating

To see what error occurred, check the service code on the left instrument panel. (See DIAGNOSTICS on Page 60-80-1.)

753 Bobcat Loader

60-123-3 Service Manual
555 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE
HAND/FOOT CONTROL (CONT’D)

Controller, Connector And Wire Identification

G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
K J2

F E
G D A
E H B
C
A J2
B
D
J1
C
J3
J1 J2

Dealer Copy -- Not for Resale

P-21843

P/N PIN DESCRIPTION P/N PIN DESCRIPTION

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FORWARD
Orange B SWITCHED AHC POWER Red/White B UNSWITCHED AHC POWER
Green C HAND/FOOT INPUT Red/White C UNSWITCHED AHC POWER
Purple D CAN SIGNAL HIGH AHC Black D LIFT ACTUATOR REVERSE
Purple E CAN SIGNAL LOW AHC Green E HANDLE LOCK POWER
Purple F CAN SHIELD AHC Red F LIFT ACTUATOR FORWARD
Black G AHC GROUND Green G PEDAL LOCK POWER
Black H AHC GROUND Black H AHC GROUND
J2 CONNECTOR, METRI-PACK Black J AHC GROUND
A OPEN Black K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
Green E TILT SPOOL SIGNAL
Green F LIFT HANDLE SIGNAL
Green G TILT HANDLE SIGNAL
Green H LIFT SPOOL SIGNAL
Green J LIFT PEDAL SIGNAL
Green K TILT PEDAL SIGNAL

753 Bobcat Loader

60-123-4 Service Manual
556 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Handle Sensor Connector
HAND/FOOT CONTROL (CONT’D)
Figure 60-123-8
ACS Controller Removal And Installation

Figure 60-123-6

P16578

P-28964 The wire connector (Item 1) [Figure 60-123-8] can be

removed from the handle sensor wires, use the following
procedure.
Remove control Panel. (See Removal and Installation on
Page 50-100-1.)

Dealer Copy -- Not for Resale

Figure 60-123-9
Remove the two mounting bolts (Item 1) [Figure 60-123-
6] from the controller mounting bracket.

Figure 60-123-7

2
1
1
2 1

P13725 P13732

Remove the wedge (Item 1) [Figure 60-123-9] from the

connector.
P-28966

Lift controller out from mounting location. Disconnect the

wiring harness connectors (Item 1) [Figure 60-123-7]
from the controller.
Remove two mounting bolts (Item 2) [Figure 60-123-7] to
remove controller from bracket.

Remove the controller from the loader.

NOTE: The calibration procedure must be followed

when replacing handle sensor, foot pedal
sensor, actuator or ACS Controller. (See
Calibration Of The ACS System on Page 60-
123-14.)

753 Bobcat Loader

60-123-5 Service Manual
557 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Disconnect the h arness connector (Item 1) [Figure 60-
HAND/FOOT CONTROL (CONT’D) 123-11] from the handle sensor connector.

Handle Sensor Connector (Cont’d) Disconnect the h arness connector (Item 2) [Figure 60-
123-11] from the handle lock solenoid connector.
Figure 60-123-10
Figure 60-123-12

1 2

3
1
1

1
P13733

P13725 P13732

With a pointed tool, lift the tab (Item 1) [Figure 60-123-

10] and pull the wire from the connector.

Dealer Copy -- Not for Resale

Remove the wedge (Item 1) [Figure 60-123-12] from the
harness connector (Gray) that connects to the handle
Installation: Install the wires into the connector as listed sensor connector.
below [Figure 60-123-10]:
Figure 60-123-13
1-Terminal - Red

2-Terminal - Black

3-Terminal - Green

Switch Handle Removal

Figure 60-123-11
1
3
2
1

P13735

Using a p ointed tool, press down on the tab (Item 1)

[Figure 60-123-13] and pull the wire from the connector.

2 1

P-28961

NOTE: Switch handle can be removed and installed

while in loader.

753 Bobcat Loader

60-123-6 Service Manual
558 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Figure 60-123-16
HAND/FOOT CONTROL (CONT’D)

Switch Handle Removal (Cont’d)

1
Figure 60-123-14

2
1
N-17779

1 Disconnect the right switch handle connectors (Items 1 &

2) [Figure 60-123-16] from the loader wiring harness
P13725 P13732 connectors.

Figure 60-123-17
Remove the wedge (Item 1) [Figure 60-123-14] from the
harness connector (Black) that connects to th e handle

Dealer Copy -- Not for Resale

lock solenoid connector.

Figure 60-123-15
1 2 3 4

1
3 N-17772
2
1
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 60-123-17] from the loader wiring harness
P13735 connectors.

Use a pointed tool, press down on the tab (Item 1)

[Figure 60-123-15] and pull the wire from the connector.

753 Bobcat Loader

60-123-7 Service Manual
559 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Figure 60-123-20
HAND/FOOT CONTROL (CONT’D)

Switch Handle Removal (Cont’d)

Figure 60-123-18

2 2

P-24234

1
Pull harness (Item 1) [Figure 60-123-20] out the bottom
of the control lever tube.
N-22783
Switch Handle Installation
Roll the pistol grip handle cover (Item 1) [Figure 60-123- Figure 60-123-21
18] down.

Dealer Copy -- Not for Resale

Using a s mall screwdriver, lift the handle tabs (Item 2)
[Figure 60-123-18] and slightly rotate the switch handle.

Figure 60-123-19
Tape back 1/2 of Wires Tape 1/2 of Wires

P-24233
P-21699
1

When installing the ne w switch handle, tape the wire

terminals together.

N-22784 The switch handle comes with a 6 in ch piece of hea t

shrink tube side on the end of the wi res. Remove the
heat shrink tube from the end of the wires before routing
Pull the switch handle and wiring harness assembly (Item through handle and control lever tube.
1) [Figure 60-123-19] from the control lever.
NOTE: Leave all the other heat shrink tube on the
Cut the wires (Item 2) [Figure 60-123-19] below the wires for protection.
switch handle and remove switch handle.
Tape half of the wires back and half forward [Figure 60-
NOTE: Only cut the wires if the switch handle is bad 123-21] to keep the harness small enough to route
and needs replacement. If the switch handle is through the control lever tube.
good and just needs to be removed for control
handle or lever replacement, then remove the
connectors on the end of the harness and pull
switch handle up out of lever tube.

753 Bobcat Loader

60-123-8 Service Manual
560 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Inspect the wire terminal tabs (Item 2) [Figure 60-123-
HAND/FOOT CONTROL (CONT’D) 23] and re-bend tabs if necessary.

Switch Handle Installation (Cont’d) Install the wires into the connectors as listed below:

Figure 60-123-22 Right Switch Handle

Ten-Pin Connector
A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
1
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/ Black

Three-Pin Connector
P-21700 A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
Install the new switch handle and wires from the top of
the control lever.

Dealer Copy -- Not for Resale

Left Switch Handle
Route wire (Item 1) [Figure 60-123-22] through the
Ten-Pin Connector
casting, along side the handle sensor and into the control
A-Terminal - Orange
lever tube.
B-Terminal - Dk. Blue
C-Terminal - White
NOTE: Do not pull the wire harness tight, allow a
D-Terminal - Purple
small amount of slack or slight bend at the
E-Terminal - Yellow/Red
handle pivot area. Verify the control handle
F-Terminal - Tan
returns to neutral position.
G-Terminal - Pink
H-Terminal - Orange/Black
Figure 60-123-23
J-Terminal - Blank
K-Terminal - Blank

Three-Pin Connector
2 A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White

Two-Pin Connector
1 A-Terminal - Black
B-Terminal - Red

Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
P-21695
C-Terminal - Blank
D-Terminal - Yellow
Remove tape from wires for installation and install the 6 E-Terminal - Blank
inches of heat shrink tube (Item 1) [Figure 60-123-23]
approximately 3 inches into the control lever. Apply heat
heat to the exposed heat shrink tube.

753 Bobcat Loader

60-123-9 Service Manual
561 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Install the wires into the connector as listed below:
HAND/FOOT CONTROL (CONT’D)
Figure 60-123-26
Switch Handle Installation (Cont’d)

Figure 60-123-24

1
3
2

P13735
1

N-17779 Left and Right Control Lever Switch Handle [Figure 60-
123-26]
1-Terminal - Red/White
Figure 60-123-25 2-Terminal - Black/White

Dealer Copy -- Not for Resale

3-Terminal - Purple/White

Figure 60-123-27
1

1
3
2
N-17772

Connect the handle harness connectors (Item 1) [Figure

P13735
60-123-24] & [Figure 60-123-25] to the loader harness
connectors.
Left and Right Control Lever Switch Handle [Figure 60-
123-27]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black

753 Bobcat Loader

60-123-10 Service Manual
562 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Figure 60-123-30
HAND/FOOT CONTROL (CONT’D)

Switch Handle Installation (Cont’d)

Figure 60-123-28 2

1
N-17742 N-17741

Check the actuator wiring harness connector (Item 1)

[Figure 60-123-30] and replace if broken.
P-21804
Installation: Install the wires into the connector as listed
below. The terminal numbers are written on the back of
Connect the h andle harness connectors to the sensor the connector (Item 2) [Figure 60-123-30].
and lock solenoid connectors [Figure 60-123-28].

Dealer Copy -- Not for Resale

Lift and Tilt Actuator
Actuators Disassembly And Assembly 1 - Terminal - Black/Green - Larger diameter wire (16
gauge)
Figure 60-123-29 2 - Terminal - Green - Larger diameter wire (16
gauge)
3 - Terminal - Red/Green - Larger diameter wire (16
1 gauge)
4 - Terminal - Open
5 - Terminal - Red - Smaller diameter wire (18 gauge)
6 - Terminal - Open
7 - Terminal - Open
8 - Black - Smaller diameter wire (18 gauge)

N-18940

Remove the actuator from the hydraulic control valve.

(See Actuator Removal And Installation on Page 20-41-
8.)

Check the m ounting block (Item 1) [Figure 60-123-29]

and bolts for wear and replace as needed.

753 Bobcat Loader

60-123-11 Service Manual
563 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Handle Lock Solenoid Disassembly And Assembly
HAND/FOOT CONTROL (CONT’D)
Figure 60-123-33
Handle Lock Solenoid Removal And Installation

Figure 60-123-31

2
1
P-21787

1
P-21836 Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-123-33].
Disconnect the ha rness connector (Item 1) [Figure 60- Installation: Apply a dr op of oil to the solenoid threads
123-31] from the handle sensor connector.

Dealer Copy -- Not for Resale

and tighten solenoid tp 35-40 ft.-lbs.(47-54 Nm) lubed
torque.
Disconnect the ha rness connector (Item 2) [Figure 60-
123-31] from the handle lock solenoid connector. Figure 60-123-34
Figure 60-123-32

P-21789
1
P-21832
Check the O -ring (Item 1) [Figure 60-123-34] for
damage. Replace as necessary.
Remove the two screws (Item 1) [Figure 60-123-32]
holding the handle lock solenoid to the handle.

Installation: Tighten the screws to 32-38 in.-lbs. (3,6-4,3

Nm) torque.

Remove handle lock solenoid assembly from handle.

753 Bobcat Loader

60-123-12 Service Manual
564 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Figure 60-123-37
HAND/FOOT CONTROL (CONT’D)

Handle Lock Solenoid Connector

Figure 60-123-35

1
2 3

P-21802

With a pointed tool, lift the tab (Item 1) [Figure 60-123-

37] and pull the wire from the connector.
1
P-21787
Installation: Install the wires into the connector as listed
below [Figure 60-123-37].
The wire connector (Item 1) [Figure 60-123-35] can be
removed from the solenoid, use the following procedure.

Dealer Copy -- Not for Resale

1 - Terminal - Black
2 - Terminal - Open
Figure 60-123-36 3 - Terminal - Black

1
1

P-21800 P-21801

Remove the wedge (Item 1) [Figure 60-123-36] from the

connector.

753 Bobcat Loader

60-123-13 Service Manual
565 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Figure 60-123-40
HAND/FOOT CONTROL (CONT’D)

Calibration Of The ACS System

Figure 60-123-38

B-16627

1
With the seat bar down, turn the ignition key on (keyless
panel choose RUN/ENTER) [Figure 60-123-39] and
P-24182 push the PRESS TO OPERATE button (Item 1) [Figure
60-123-40] to unlock the hand controls.
The new controller uses a calibration sequence to NOTE: Do not start the engine.
optimize the control system. The optimizing ensures full

Dealer Copy -- Not for Resale

spool stroke (full flow) while preventing over stroke Figure 60-123-41
(Loading) of the actuator.

NOTE: This calibration procedure must be followed

when replacing a handle sensor, foot pedal Stroke Both Handles Fully In and Hold Them
sensor, actuator or ACS controller. Failure to
calibrate after component replacement may
result in poor performance or reduced life of
actuator(s).

Switchable Hand/Foot Controls Calibration

Procedure

Switch the rocker switch (Item 1) [Figure 60-123-38] to

the hand control mode.
B-16628
Figure 60-123-39

Fully stroke both control handles in toward the center of

the cab and hold the handles there [Figure 60-123-41].

Turn the ignition key off (keyless panel power off).

Then Turn Key On

or

Press RUN/ENTER

B-16626

753 Bobcat Loader

60-123-14 Service Manual
566 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE NOTE: During the calibration cycle, the system will
HAND/FOOT CONTROL (CONT’D) beep three times. The calibration process
generates two codes 32-35 (Tilt handle not
Switchable Hand/Foot Controls Calibration calibrated) and 32-40 (lift handle not
Procedure (Cont’d) calibrated). Ignore these two codes, this is
normal during the calibration procedure.
Figure 60-123-42
Release the control handles.

NOTE: After pushing the PRESS TO OPERATE

button, the handle position does not affect the
calibration process.
Then Turn Key On
NOTE: The ACS controller cycles the actuators,
or records the values and optimizes the system
automatically in approximately 5 seconds.
Press RUN/ENTER
Calibration is complete.

Hand Controls Only Calibration Procedure

B-16626 Figure 60-123-44

Turn the i gnition key on (keyless panel choose RUN/

Dealer Copy -- Not for Resale

ENTER) [Figure 60-123-42]. Stroke Both Handles Fully In and Hold Them

NOTE: Do not start the engine.

Figure 60-123-43

B-16628

With the seat bar down and the ignition key off (keyless
panel power off), fully stroke both control handles in
toward the center of the cab and hold the handles there
1
[Figure 60-123-44].

B-16627

Push the PRESS TO OPERATE button (Item 1) [Figure

60-123-43] to begin the calibration.

NOTE: The ACS icon will light up and if you listen

closely the cycling of the actuators can be
heard. The ACS icon will stay lit until the
ignition key is cycled or the loader is started
and a function is operated.

753 Bobcat Loader

60-123-15 Service Manual
567 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Figure 60-123-46
HAND/FOOT CONTROL (CONT’D)

Hand Controls Only Calibration Procedure (Cont’d)

Figure 60-123-45

Then Turn Key On

or
1
Press RUN/ENTER
B-16627

Push the PRESS TO OPERATE button (Item 1) [Figure

60-123-46] to begin the calibration.
B-16626
NOTE: The ACS icon will light up and if you listen
closely the cycling of the actuators can be
Turn the i gnition key on (keyless panel choose RUN/ heard. The ACS icon will stay lit until the
ENTER) [Figure 60-123-45]. Do not start the engine.

Dealer Copy -- Not for Resale

ignition key is cycled or the loader is started
and a function is operated.

NOTE: During the calibration cycle, the system will

beep three times. The calibration process
generates two codes 32-35 (tilt handle not
calibrated) and 32-40 (lift handle not
calibrated). Ignore these two codes, this is
normal during the calibration procedure.

Release the control handles.

NOTE: After pushing the PRESS TO OPERATE

button, the handle position does not affect the
calibration process.

NOTE: The ACS controller cycles the actuators,

records the values and optimizes the system
automatically in approximately 5 seconds.

Calibration is complete.

753 Bobcat Loader

60-123-16 Service Manual
568 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Foot Sensor Connector
HAND/FOOT CONTROL (CONT’D)
Figure 60-123-49
Foot Sensor Disassembly And Assembly

Figure 60-123-47

1
P-24271

1
P-24269 The wire connector (Item 1) [Figure 60-123-49] can be
removed from the s ensor wires, use the fol lowing
procedure.
Remove the two bolts (Item 1) [Figure 60-123-47] from
the end of the foot sensor.

Dealer Copy -- Not for Resale

Figure 60-123-50
Installation: Tighten the bolts to 9 0 in.-lbs. (10,2 Nm)
torque. Apply LOCTITE 242 to the threads.
1
Figure 60-123-48

4 P-24272 P-24273

3
2
Remove the wedge (Item 1) [Figure 60-123-50] from the
connector.
1 P-24270

Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3), O-ring (Item 4) [Figure 60-123-48].

NOTE: Do not disassemble the sensor assembly

(Item 5) [Figure 60-123-48]. The sensor
assembly is a calibrated assembly and cannot
be serviced. Order through Bobcat Parts.

753 Bobcat Loader

60-123-17 Service Manual
569 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Figure 60-123-53
HAND/FOOT CONTROL (CONT’D)

Foot Sensor Connector (Cont’d)

1
Figure 60-123-51

2
3 1
2
P-30078

Disconnect the foot lock solenoid connector (Item 1)

[Figure 60-123-53] from the harness.
P-24274
Remove foot lock solenoid (Item 2) [Figure 60-123-53].
With a pointed tool, lift the tab (Item 1) [Figure 60-123- Installation: Apply a drop of oil on the solenoid threads
51] and pull the wire from the connector.

Dealer Copy -- Not for Resale

and tighten the so lenoid to 35-40 ft.-lbs. (47-54 Nm)
lubed torque.
Installation: Install the wires into the connector as listed
below [Figure 60-123-51]: Figure 60-123-54
1 - Terminal - Red
2 - Terminal - Black
3 - Terminal - Green

Foot Lock Solenoid Removal And Installation

Figure 60-123-52
2

P-21790

1 Check the O -ring (Item 1) [Figure 60-123-54] for

damage. Replace as necessary.

Foot Lock Solenoid Connector

P-30077
The wire connector (Item 2) [Figure 60-123-54] can be
removed from the solenoid wires, use the following
Remove the two bolts (Item 1) [Figure 60-123-52] from procedure.
the foot sensor shield.

Installation: Tighten the bolts to 80-90 in.-lbs. (9,0-10,2

Nm) torque.

753 Bobcat Loader

60-123-18 Service Manual
570 of 726
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE Figure 60-123-56
HAND/FOOT CONTROL (CONT’D)

Foot Lock Solenoid Connector (Cont’d)

Figure 60-123-55

1 3
2

P-21802
1
1
With a pointed tool, lift the tab (Item 1) [Figure 60-123-
56] and pull the wire from the connector.
P-21800 P-21801
Installation: Install the wires into the connector as listed
below [Figure 60-123-56]:
Remove the wedge (Item 1) [Figure 60-123-55] from the 1 - Terminal - Black
connector.

Dealer Copy -- Not for Resale

2 - Terminal - Open
3 - Terminal - Black

753 Bobcat Loader

60-123-19 Service Manual
571 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

60-123-20 Service Manual
572 of 726
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE

Controls Identification Chart

Attachment
xxxxxxxxx Harness
Switch Solenoid Number Attachment Harness
Terminal
Number Activated Connector
Left Side Activated Right Side
Control Handle Control Handle
Switches RH HFH Fourteen Pin Switches
Connector Viewed
1 1 1 1, 8 K from front
2 2 2 2 K (pin side of
connector)
*3 1 1 1, 8 K of loader.
4 2 2, 3 6, 7 K, A, D
5 1 1, 3 5, 7 K, A, C
6 1 1, 3 5, 7 K, E
7 1 1, 3 5, 7 K, F
8 1 1, 3 5, 7 K, G
9 1 1, 3 5, 7 K, H
B-16449
B-16447 10, 11, 12, - -- -- K
B-16448
13, 14

Dealer Copy -- Not for Resale

Early
Version

2 1

Later
Version 1

NOTE: All diagnostics must be done at the fourteen pin connector (Item 1).

On earlier versions, the switch (Item 2) must be in the fourteen pin position. The current Version ACD
(Attachment Control Device) without switch, automatically recognizes the use of the seven or fourteen pin
connector when connected.

The ACD (Attachment Control Device) Icon, located in the right instrument panel on the loader cab, must
be illuminated continuously.

If the ACD light flashes, check for diagnostic service codes. (See DIAGNOSTICS on Page 60-80-1.).

RH - Loaders with Rear Hydraulics Option.

* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.

* Terminal K is activated with Key switch ON.

753 Bobcat Loader

60-130-1 Service Manual
573 of 726
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
(CONT’D)
Solenoid Hyeraulic Wiring
Controls Identification Chart (Cont’d)
Number Coupler Color
1 Front Dk. Green
Female Red
2 Front Dk. Green/
Male Lt. Green
3 4
3 Diverter (Rear Yellow
Couplers)
7 4 Bleed-Rear Dk. Green/
5 Male & Female Yellow
1
3

Dealer Copy -- Not for Resale

MC-1494

NOTE: The key Switch fully left position activates solenoids number 1 and 4. The high flow rocker switch in the
left side instrument panel must be ON to activate solenoid number 8.

753 Bobcat Loader

60-130-2 Service Manual
574 of 726
 ENGINE SERVICE

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
ENGINE
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1 SERVICE
Blower Disassembly And Assembly. . . . . . . . . . . . . . . . . . 70-60-4
Blower Housing Grill Removal And Installation . . . . . . . . . 70-60-4
Drive Tension Pulley Removal And Installation . . . . . . . . . 70-60-1
Gearbox Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-12
Gearbox/Blower Housing Removal And Installation . . . . . 70-60-2
Gearbox Checking Backlash . . . . . . . . . . . . . . . . . . . . . . 70-60-16
Gearbox Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-7 DRIVE
Gearbox Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . 70-60-6 SYSTEM
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . . 70-80-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

ENGINE COMPONENTS AND TESTING. . . . . . . . . . . . . . . . 70-70-1

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-5

Dealer Copy -- Not for Resale

ELECTRICAL
Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1 SYSTEM &
Fuel Injection Pump Removal And Installation . . . . . . . . . 70-70-6 ANALYSIS
Fuel Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-13
Fuel Injector Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Fuel Injector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12 ENGINE
Fuel Injector Removal And Installation . . . . . . . . . . . . . . 70-70-10 SERVICE
Fuel Shut-Off Solenoid Adjusting. . . . . . . . . . . . . . . . . . . . 70-70-3
Fuel Shut-Off Solenoid Checking. . . . . . . . . . . . . . . . . . . . 70-70-3
Fuel Shut-Off Solenoid Removal And Installation . . . . . . . 70-70-4
Glow Plugs Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2 SPECIFICATIONS
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . 70-70-2
Rocker Arm And Shaft Checking . . . . . . . . . . . . . . . . . . . 70-70-14
Timing The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . 70-70-9
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . 70-70-13
Valve Timing Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-14

ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

FLYWHEEL AND HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . 70-90-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 70-90-2
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . 70-90-2

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

Continued On Next Page

753 Bobcat Loader

70-01 Service Manual
575 of 726
 ENGINE SERVICE (CONT’D)

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . 70-100-1

Checking Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . 70-100-15
Checking The Cylinder Bore . . . . . . . . . . . . . . . . . . . . . 70-100-24
Checking The Valve Guide . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . 70-100-19
Crankshaft And Bearings Removal And Installation . . . 70-100-20
Crankshaft Gear Removal And Installation . . . . . . . . . . 70-100-13
Cylinder Head Disassembly And Assembly. . . . . . . . . . . 70-100-2
Cylinder Head Removal And Installation . . . . . . . . . . . . . 70-100-1
Cylinder Head Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-3
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . 70-100-3
Fuel Camshaft Governor . . . . . . . . . . . . . . . . . . . . . . . . 70-100-13
Fuel Camshaft Removal And Installation . . . . . . . . . . . . 70-100-12
Idler Gear And Camshaft Removal And Installation. . . . . 70-100-9
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . 70-100-14
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-14

Dealer Copy -- Not for Resale

Piston And Connecting Rod Removal And Installation . 70-100-16
Reconditioning The Valve And Valve Seat. . . . . . . . . . . . 70-100-5
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-15
Rocker Arm And Shaft Checking . . . . . . . . . . . . . . . . . . . 70-100-6
Servicing The Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . 70-100-10
Servicing The Crankshaft And Bearings . . . . . . . . . . . . 70-100-21
Servicing The Idler Gear And Shaft . . . . . . . . . . . . . . . . 70-100-11
Servicing The Piston And Connecting Rod . . . . . . . . . . 70-100-17
Timing Gears Checking Backlash . . . . . . . . . . . . . . . . . 70-100-12
Timing Gearcase Cover Removal And Installation . . . . . 70-100-7
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Water Pump Disassembly And Assembly . . . . . . . . . . . 70-100-25

RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-91-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-91-1

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

753 Bobcat Loader

70-02 Service Manual
576 of 726
TROUBLESHOOTING

Chart

The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM CAUSE
Slow cranking speed. 1, 2, 3,54
Engine will not start. 2, 5, 6, 7, 8, 9, 11,12,13,14,15,16,19,27,28,29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16,17,19,20,21,23,24,25,27,28,29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53

Dealer Copy -- Not for Resale

Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11

753 Bobcat Loader

70-10-1 Service Manual
577 of 726
TROUBLESHOOTING (CONT’D)

Chart (Cont'd)

KEY TO CORRECT THE CAUSE

1. Alternator belt is loose or damaged. 28. Worn valve and seats.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the crankcase.
6. Fuel tank empty. 33. Switch/sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect flywheel alignment.

Dealer Copy -- Not for Resale

17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level too low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery

753 Bobcat Loader

70-10-2 Service Manual
578 of 726
ENGINE SPEED CONTROL Figure 70-20-2

Removal And Installation

WARNING P-4072

Never work on a machine with the lift arms up unless Pull the speed control away from the loader frame and
the lift arms are secured by an approved lift arm disconnect the speed control rod (Item 1) [Figure 70-20-
support device. Failure to use an approved lift arm 2] from the control.
support device can allow the lift arms or attachment
to fall and cause injury or death. Installation: Be sure to install the control rod in th e
W-2059-0598 bottom hole of the speed control.

Dealer Copy -- Not for Resale

Raise the lift arms and install an approved lift arm device. Figure 70-20-3
(See Installing Lift Arm Support Device on Page 10-20-
1.)

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)
1
Figure 70-20-1

2
1

P-4068
2

Installation: Install the stop bracket (Item 1) [Figure 70-

20-3] in the same location. It is necessary for the front
and rear stop on the bracket to be located correctly.

Reverse the removal procedure to install the engine

P-28843
speed control.

Remove the two mounting bolts (Item 1) [Figure 70-20-1] Disassembly

and nuts from the speed control mounting bracket.
Loosen the two control lever mounting bolts (Item 2)
Installation: Tighten the mounting bolts and nuts evenly [Figure 70-20-1] and remove the mounting nuts (Item 2)
until the speed control lever moves back and forth at a [Figure 70-20-3].
comfortable tension.
Assembly: Do not lubricate the engine speed control.

Replace any worn or damaged parts if necessary.

753 Bobcat Loader
70-20-1 Service Manual
579 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

70-20-2 Service Manual
580 of 726
MUFFLER Figure 70-30-2

Removal And Installation

Figure 70-30-1

2 P-28913

1 Remove the right side mounting bolt (Item 1) [Figure 70-

N-20866 30-2] from the muffler.

Installation: Tighten the muffler mounting bolts to 25-28

Open the rear door and raise the rear grill. ft.-lbs. (34-38 Nm) torque.

Remove the exhaust pipe clamp (Item 1) from the muffler

Dealer Copy -- Not for Resale

Remove the muffler from the loader.
(Item 2) [Figure 70-30-1].
Reverse the removal procedure to install the engine
Disconnect the exhaust pipe from the muffler. muffler.

Remove the left side mounting bolt (Item 3) [Figure 70-

30-1] from the muffler.

753 Bobcat Loader

70-30-1 Service Manual
581 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

70-30-2 Service Manual
582 of 726
AIR CLEANER Figure 70-40-3

Removal And Installation

Figure 70-40-1
1

P-28915

Remove the lower mounting bolt (Item 1) and engine

N-20867 harness mounting bracket (Item 2) [Figure 70-40-3] from
the air cleaner.

Disconnect the wire harness connector (Item 1) [Figure Remove the two up per mounting bolts (Item 3) [Figure
70-40-1] from the air cleaner sensor on the air cleaner. 70-40-2] from the top mount of the air cleaner.

Dealer Copy -- Not for Resale

Figure 70-40-2 Installation: Tighten the three mounting bolts to 25-28
ft.-lbs. (34-38 Nm) torque.
1 Remove the air cleaner from the engine compartment.

Reverse the removal procedure to install the air cleaner.

2
P-28914

Loosen the hose clamp (Item 1) [Figure 70-40-2] on the

air cleaner hose.

Loosen the clamp (Item 2) [Figure 70-40-2] from the

hose on the engine manifold.

753 Bobcat Loader

70-40-1 Service Manual
583 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

70-40-2 Service Manual
584 of 726
RADIATOR Figure 70-50-3

Removal And Installation

Stop the engine and open the rear door. 1

WARNING 2

Do not remove radiator cap when the engine is hot.

You can be seriously burned.
W-2070-1285

Figure 70-50-1 P-4200

1 Loosen the hose clamp (Item 1) [Figure 70-50-3] from

the left side radiator hose and disconnect the hose from
the radiator.

Remove the radiator mounting bolt (Item 2) [Figure 70-

50-3].

Dealer Copy -- Not for Resale

Figure 70-50-4

N-19200

2
Loosen the radiator cap (Item 1) [Figure 70-50-1] from 1
the radiator fill neck.

Remove the rear grill. (See Removal And Installation on

Page 50-60-2.)

Figure 70-50-2
P-4199

Loosen the hose clamp (Item 1) [Figure 70-50-4] from

the right side radiator hose and disconnect the hose from
the radiator.
1
Remove the radiator mounting bolt (Item 2) [Figure 70-
50-4].

Installation: Torque the radiator bolts to 11-13 ft.-lbs.

(15-17 Nm) torque.

P-3971

Open the drain valve (Item 1) [Figure 70-50-2] on th e

engine block and drain the coolant into a container.

753 Bobcat Loader

70-50-1 Service Manual
585 of 726
RADIATOR (CONT’D) Figure 70-50-7

Removal And Installation (Cont'd)

Figure 70-50-5
1

1 1

N-21149

Lift the radiator (Item 1) [Figure 70-50-7] up and remove

N-21147 it from the loader.

Reverse the above procedure to install the radiator.

Raise the o il cooler (Item 2) [Figure 70-50-5] and set it
up out of the way.

Dealer Copy -- Not for Resale

Figure 70-50-6

N-21148

Remove the two rubber stops (Item 1) [Figure 70-50-5] &

[Figure 70-50-6] from the top of the radiator.

753 Bobcat Loader

70-50-2 Service Manual
586 of 726
COOLING FAN Figure 70-60-3

Drive Tension Pulley Removal And Installation

1
Figure 70-60-1

P0581

Installation: Put a s mall amount of grease around the

P-0585 P0585 outside edge (Item 1) [Figure 70-60-3] on the grease
rings.

Loosen the idler pulley bolt (Item 1) [Figure 70-60-1]. Figure 70-60-4

Installation: Install the retainer bracket (Item 2) [Figure

Dealer Copy -- Not for Resale

6
70-60-1] for the fan belt at the 3 o'clock position.
3
Figure 70-60-2

1 4
3
2

1
5

N-00303

Remove the bolt (Item 1) [Figure 70-60-2] & [Figure 70-

60-4] from the idler pulley pivot arm (Item 6) [Figure 70-
P0582 60-4].

Remove the thrust washer (Item 2), O-rings (Item 3) and

Remove the spacers, bolt and washer from the arm spring (Item 4) [Figure 70-60-4].
[Figure 70-60-2].
Check all parts for damage or wear and replace them as
needed.

NOTE: When making any repairs, replace the bronze

bushing (Item 5) [Figure 70-60-4] with a new
style nylon bushing. Clean all parts and
assemble dry. Do not lubricate. (See Parts
Manual for correct part numbers.)

Installation: Reverse the removal procedure to install

the tension pulley.

753 Bobcat Loader

70-60-1 Service Manual
587 of 726
COOLING FAN (CONT’D) Figure 70-60-6

Gearbox/Blower Housing Removal And Installation

WARNING P-28921

Never work on a machine with the lift arms up unless Remove the nuts (Item 1) from the u-bolt which mounts
the lift arms are secured by an approved lift arm the fan belt shield (Item 2) [Figure 70-60-6] to the blower
support device. Failure to use an approved lift arm fan.
support device can allow the lift arms or attachment
to fall and cause injury or death. Remove the fan belt shield (Item 2) [Figure 70-60-6]
W-2059-0598 from the blower fan.

Dealer Copy -- Not for Resale

Put jackstands under the rear corners of the loader. Installation: The shield must not touch the fan belt.
Torque the nuts to 15-17 ft.-lbs. (21-23 Nm).
Raise the lift arms and install an approved lift arm device.
(See Installing Lift Arm Support Device on Page 10-20- Figure 70-60-7
1.)
1
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)

Remove the hy draulic fluid reservoir. (See Housing

Removal And Installation on Page 20-70-1.)

Figure 70-60-5
2

P-28922

1 Disconnect the breather hose (Item 1) [Figure 70-60-7]

from the electrical harnesses on the loader frame.

Installation: Make sure the breather hose is unrestricted

when routing.

Remove the fan drive belt (Item 2) [Figure 70-60-7] from

N-20631
the pulley on the blower fan.

Remove the left gas cylinder mounting bracket (Item 1)

[Figure 70-60-5]. (See Gas Cylinder Removal And
Installation on Page 50-20-1.)

753 Bobcat Loader

70-60-2 Service Manual
588 of 726
COOLING FAN (CONT’D) NOTE: Mounting bolts (Items 3 & 4) [Figure 70-60-9]
use wave washer (Item 1) [Figure 70-60-10] to
Gearbox/Blower Housing Removal And Installation prevent tubes and bolts from falling out of the
(Cont'd) housing during installation.

Figure 70-60-8 Figure 70-60-10

OIL LEVEL

P-43836 P-4301

NOTE: When checking the fan gearbox oil level, be Installation: Tighten the four mounting bolts to 25-28 ft.-

Dealer Copy -- Not for Resale

sure the level does not go above the top of the lbs. (34-38 Nm) torque.
shaft in the gearbox [Figure 70-60-8]. Use a
light colored 90W gear lube if the level is low. Figure 70-60-11

Figure 70-60-9

1 4

2
3 P13920

N-19376
Lower the blower fan from the housing until it rests on the
steering linkage plate [Figure 70-60-11].
Remove the two mounting bolts (Item 1) and the two
spacer tubes (Item 2) [Figure 70-60-9] from the blower
fan.

Remove the rear mounting bolt (Item 3) [Figure 70-60-9].

Remove the front mounting bolt (Item 4) [Figure 70-60-

9].

753 Bobcat Loader

70-60-3 Service Manual
589 of 726
COOLING FAN (CONT’D) Blower Housing Grill Removal And Installation

Gearbox/Blower Housing Removal And Installation Figure 70-60-13

(Cont'd)

Figure 70-60-12

P-43448

N-19378 To replace the blower housing grill, remove the four

mounting bolts (Item 1) [Figure 70-60-13] from the grill.

Remove the strip of sealant along the top of the blower Install the new grill and replace the mounting bolts.
housing [Figure 70-60-12].

Dealer Copy -- Not for Resale

Blower Disassembly And Assembly
Installation: Use R.T.V. sealant to r eseal the blower
housing. Figure 70-60-14

Loosen the el ectrical harnesses from the main frame of

the loader and the blower housing.

Installation: Attach the electrical harness to the main 1

frame. Attach the electrical harness to the blower housing
with cable ties to prevent damage to the harness
2
Slide the blower fan and housing forward and remove
both from the loader.

CD-9952

Remove the lock nut (Item 1) and spacer (Item 2) [Figure

70-60-14].

Installation: Tighten the nut to 45-55 ft.-lbs. (61-75 Nm)

torque.

753 Bobcat Loader

70-60-4 Service Manual
590 of 726
COOLING FAN (CONT’D) Figure 70-60-16

Blower Disassembly And Assembly (Cont’d)

WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
CD-9953

Figure 70-60-15
Remove the fan from the tapered shaft [Figure 70-60-
2 16].

Figure 70-60-17

Dealer Copy -- Not for Resale

1

1
P3006

1
Use the fol lowing procedure to remove the fan from the
shaft. CD-9954

Install the nut ( Item 1) [Figure 70-60-15] on the tapered

shaft to protect the shaft and threads. To remove the blower housing mounting plate, remove
the six bolts (Item 1) [Figure 70-60-17].
Install the puller on the fan as shown [Figure 70-60-15].

As the center bolt (Item 2) [Figure 70-60-15] is tightened,

periodically strike the bolt head to loosen the fan from the
shaft.

753 Bobcat Loader

70-60-5 Service Manual
591 of 726
COOLING FAN (CONT’D)

Gearbox Parts Identification

1. Seal
2. Snap Ring (Small)
3. Shims (1.0 inch O.D.)
4. Bearing
5. Shaft (Long)
6. Shims (2.0 inch O.D.)
7. Long Key
8. Shaft (Short)
9. Short Key
10. Long Housing
11. Nut 1
12. Gear
13. Washer
14. Screw 18
15. Square Shim
*16. Short Housing 1 2
17. Bolt 6
3 4
18. Snap Ring (Large)
19. Cap 5 7 4

Dealer Copy -- Not for Resale

20. Long Housing Assy.
21. Short Housing Assy.
22. Fill Plug 8
22

4
12
13
14
9
21
10 *16
11

15
20 17
12

4
13

14

18

19

* Individual Part not available. (See Note Page 70-60-7.) TS-1002A

753 Bobcat Loader

70-60-6 Service Manual
592 of 726
COOLING FAN (CONT’D) Figure 70-60-19

Gearbox Disassembly

NOTE: When repairing the gearbox order the

following as needed.

1. Complete Assembly
2. Long Housing Assembly Part Number
3. Long Housing Tag
4. Short Housing Assembly (See Note Below)
5. Internal Parts

NOTE: The short housing is only available as an

assembly. (See Gearbox Parts Identification
on Page 70-60-6.) (Order parts from Bobcat P2983
Parts Sales.)

NOTE: Be sure to count the number and thickness of Remove the four mounting bolts and the part number tag
shims during disassembly. Install the shims [Figure 70-60-19].
in the original location during assembly.
Remove the oil from the gearbox.
NOTE: Always replace seals during assembly.
Replace the parts in the gearbox as needed.

Dealer Copy -- Not for Resale

Remove the fan and blower housing mounting plate. (See
Gearbox/Blower Housing Removal And Installation on
WARNING
Page 70-60-2.)
AVOID INJURY OR DEATH
Wear safety goggles to prevent eye injury when
Long Housing
drilling or grinding.
W-2108-1186
Figure 70-60-18

Figure 70-60-20

2
1 3

P-37891

P2999
Loosen the set screws (Item 1) and remove the pulley
(Item 2) [Figure 70-60-18].
Drill an 1/ 8 inch (3 mm) hole in th e seal. Use a sl ide
Remove the long key (Item 3) [Figure 70-60-18]. hammer tool to remove the seal [Figure 70-60-20].

753 Bobcat Loader

70-60-7 Service Manual
593 of 726
COOLING FAN (CONT’D) Figure 70-60-23

Gearbox Disassembly (Cont'd)

Figure 70-60-21

P2966

Remove the screw and washer from the shaft [Figure 70-
P2964 60-23].

Figure 70-60-24
Remove the small snap ring [Figure 70-60-21].

Dealer Copy -- Not for Resale

Figure 70-60-22

P3004

P2963 Support the lower flange and press the shaft from the
bearing [Figure 70-60-24].

Remove the small shims [Figure 70-60-22]. NOTE: The gear and the other bearing (pulley end)
will be removed with the shaft.

753 Bobcat Loader

70-60-8 Service Manual
594 of 726
COOLING FAN (CONT’D) Figure 70-60-27

Gearbox Disassembly (Cont'd)

Figure 70-60-25

P2996

Drill an 1/ 8 inch (3 mm) hole in th e seal. Use a sl ide

P3298 hammer tool to remove the seal [Figure 70-60-27].

Figure 70-60-28
Support the bearing and press the shaft from the bearing
[Figure 70-60-25].

Dealer Copy -- Not for Resale

Short Housing

Figure 70-60-26

P2970

Remove the la rge snap ring from the fl ange end of the
housing [Figure 70-60-28].

P2997

Remove the end cap [Figure 70-60-26].

Use care not to damage the housing.

WARNING
AVOID INJURY OR DEATH
Wear safety goggles to prevent eye injury when
drilling or grinding.
W-2108-1186

753 Bobcat Loader

70-60-9 Service Manual
595 of 726
COOLING FAN (CONT’D) Figure 70-60-31

Gearbox Disassembly (Cont'd)

Figure 70-60-29

P2973

Remove the snap ring from the cap end of the housing
P2969 [Figure 70-60-31].

Figure 70-60-32
Remove the large shims from the housing [Figure 70-60-
29].

Dealer Copy -- Not for Resale

NOTE: Use the same size and thickness of shims
during assembly.

Figure 70-60-30

1
P2998

Press the shaft from the housing [Figure 70-60-32].

NOTE: Both bearings may come out of the housing

with the shaft. If one bearing remains in the
P2978 housing use a non metal object to tap the
bearing from the housing.

Remove the s crew and washer (Item 1) [Figure 70-60-

30] from the shaft.

753 Bobcat Loader

70-60-10 Service Manual
596 of 726
COOLING FAN (CONT’D) Figure 70-60-35

Gearbox Disassembly (Cont'd)

Figure 70-60-33

P2972

Remove the key from the shaft [Figure 70-60-35].

P3088

Press the bearing from the tapered end of the shaft

[Figure 70-60-33].

Dealer Copy -- Not for Resale

Figure 70-60-34

P3001

Press the bearing, shims and gear from the shaft [Figure
70-60-34].

753 Bobcat Loader

70-60-11 Service Manual
597 of 726
COOLING FAN (CONT’D) Figure 70-60-38

Gearbox Assembly
NOTE: (See Gearbox Disassembly on Page 70-60-7.)
when ordering parts for the Fan Gearbox.

NOTE: Do not install the seals and cap in the housing

until after the backlash has been checked.
NOTE: Use care when pressing the bearings into the
aluminum housing. The housing can be
damaged if too much pressure is used.
NOTE: For procedures requiring the use of LOCTITE
#242 adhesive, thoroughly clean and dry
affected parts before the application of
LOCTITE #242.
P2962
Long Housing
Figure 70-60-36
Install a be aring on th e long keyed end of the shaft
[Figure 70-60-38].

Support the lower bearing and press the other bearing in

the housing until the bearings seat in the housing [Figure
70-60-38].

Dealer Copy -- Not for Resale

Figure 70-60-39

P2961

Press a bearing on the short keyed end of the long shaft

[Figure 70-60-36].

Figure 70-60-37

P2963

Install on the bearing, the same number and size shims

that were removed during disassembly [Figure 70-60-
39].

P2960

Install the long housing on the shaft [Figure 70-60-37].

Be sure the bearing is seated in the bore at the lower end

of the housing.
753 Bobcat Loader
70-60-12 Service Manual
598 of 726
COOLING FAN (CONT’D) Figure 70-60-42

Gearbox Assembly (Cont'd)

Figure 70-60-40

P2967

Align the key and gear. While supporting the bearing on

P2964 the other end, press the gear on the shaft until it seats
against the bearing [Figure 70-60-42].

Install the small snap ring in the groove above the shims Figure 70-60-43
[Figure 70-60-40].

Dealer Copy -- Not for Resale

Figure 70-60-41

P2966

P2965 Install the washer (Item 1) [Figure 70-60-43].

Put liquid adhesive (LOCTITE #242) on the screw

Install the gear key in the flange end of the shaft [Figure threads. Install and tighten the screw [Figure 70-60-43].
70-60-41].

753 Bobcat Loader

70-60-13 Service Manual
599 of 726
COOLING FAN (CONT’D) Figure 70-60-46

Gearbox Assembly (Cont'd)

Short Housing

Figure 70-60-44

P2970

Install the large snap ring in the groove above the shims
[Figure 70-60-46].

P2968 Figure 70-60-47

Install a bearing in the flanged end of the housing

Dealer Copy -- Not for Resale

[Figure 70-60-44].

Figure 70-60-45

P2971

Install the short key (Item 1) [Figure 70-60-47].

Align and press the gea r on the sh aft (teeth toward the
P2969 tapered end of the shaft) [Figure 70-60-47].

Install the la rge shims on the bearing (flanged end)

[Figure 70-60-45]

753 Bobcat Loader

70-60-14 Service Manual
600 of 726
COOLING FAN (CONT’D) Figure 70-60-50

Gearbox Assembly (Cont'd)

Figure 70-60-48

P2977

Install on the shaft, the same number and size shims that
P2975 were removed during disassembly [Figure 70-60-50].

Figure 70-60-51
After the gear is seated, drive the key down inside the
gear key way [Figure 70-60-48].

Dealer Copy -- Not for Resale

NOTE: This will prevent damage to the shims when
the bearing is installed later.

Figure 70-60-49

P2974

Install a bearing on the gear end of the shaft [Figure 70-

60-51].

P2976

Install the shaft in the housing, tapered end in the bearing

at the round flange end of the housing [Figure 70-60-49].

753 Bobcat Loader

70-60-15 Service Manual
601 of 726
COOLING FAN (CONT’D) The backlash tolerance between the gears should be
0.005-0.008 inch (0,127-0,203 mm).
Gearbox Assembly (Cont'd)
To check the gear backlash use the following procedure:
Figure 70-60-52
Figure 70-60-54

P2973

P2987

Install the snap ring in the groove above the be aring

[Figure 70-60-52]. Put the short housing in a vise, square flange facing up

Dealer Copy -- Not for Resale

as shown [Figure 70-60-54].
Figure 70-60-53
Figure 70-60-55

P2978
P2981

Install the washer (Item 1) on the shaft. Put liquid

adhesive (LOCTITE #242) on the s crew threads and Install the same size and number of s quare shims (if
install the screw [Figure 70-60-53]. present during disassembly) between the two housings
[Figure 70-60-55].
Gearbox Checking Backlash
Set the long housing on the short housing with the
NOTE: For procedures requiring the use of LOCTITE sealant (LOCTITE #242) which is a gasket eliminator that
#242 adhesive, thoroughly clean and dry cures to flexible seal between the mounting surfaces.
affected parts before the application of
LOCTITE #242. NOTE: If square shims are used, put a small amount
of (LOCTITE #242) on both sides of all shims.

753 Bobcat Loader

70-60-16 Service Manual
602 of 726
COOLING FAN (CONT’D) Figure 70-60-58

Gearbox Checking Backlash (Cont'd)

Figure 70-60-56

Part Number
1
Tag

P-37892

Put the fan nut (Item 1) [Figure 70-60-58] on the shaft

P2983 and tighten snugly.

Install a lo cking pliers on the fan nut an d support the

Install the four mounting bolts through the flange holes handle against the long housing [Figure 70-60-58].
[Figure 70-60-56].

Dealer Copy -- Not for Resale

Install the part number tag [Figure 70-60-56].

Install and tighten the nuts to 25-28 ft.-lbs. (34-38 Nm)

torque.

Figure 70-60-57

1.0”
(25,4 mm)

1
P-37894

Install the long key (Item 1) and the pulley (Item 2)

[Figure 70-60-57].

Install a bolt in the set screw hole to maintain a 1.0 inch

(25,4 mm) distance from the shaft center to the bolt head
(to be used with a dial indicator) [Figure 70-60-57].

753 Bobcat Loader

70-60-17 Service Manual
603 of 726
COOLING FAN (CONT’D) Figure 70-60-60

Gearbox Checking Backlash (Cont'd)

Figure 70-60-59

1
P3089

When the backlash is correct, install the seals, cap and

P-37893 gear oil as follows:

Remove the bolts from the flanges and separate the two
Using a m agnetic based dial indicator mounted on a housings.
bench vise, touch the dial stem on the bolt (Item 1)

Dealer Copy -- Not for Resale

[Figure 70-60-59]. Put liquid adhesive (LOCTITE #242) on the outside
diameter of the seal(s) [Figure 70-60-60].
Hold the locking pliers against the l ong housing and
rotate the p ulley back and forth to r ead the dial gauge
[Figure 70-60-59].

If the backlash is GREATER than 0.008 inch (0,203 mm),

do the following:

1. Remove a square shim(s) (if present) between the

two housings.

2. Remove a large shim(s) from the tapered end of the

short shaft and add a small shim (s) of the same
thickness between the bearing and the gear on the
screw end of the shaft.

If the backlash is LESS than 0.005 inch (0,127 mm) do

the following:

1. Add a square shim(s) between the two housings.

2. Remove a small shim(s) between the bearing and the

gear on the screw end of the short shaft and add a
large shim(s) of the same thickness between the snap
ring and the bearing on the tapered end of the shaft.

753 Bobcat Loader

70-60-18 Service Manual
604 of 726
COOLING FAN (CONT’D)

Gearbox Checking Backlash (Cont'd)

Figure 70-60-61

LONG HOUSING

P2985

Figure 70-60-62
SHORT HOUSING

Dealer Copy -- Not for Resale

P2986

Install the seal(s) flush with the housing surface [Figure

70-60-61] & [Figure 70-60-62].

Clean any oil from the flange surface.

Install the long housing on the short housing flange.

Install the four bolts and part number tag.

Install and tighten the nuts to 25-28 ft.-lbs. (34-38 Nm)

torque.

NOTE: When filling the fan gearbox with oil, be sure

the level does not go above the top of the
shaft in the gearbox. Use a light colored 90W
gear lube.

753 Bobcat Loader

70-60-19 Service Manual
605 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

70-60-20 Service Manual
606 of 726
ENGINE COMPONENTS AND TESTING Disconnect the fuel stop solenoid.

Compression Checking Crank the engine with the starter at cranking speed.

Figure 70-70-1 Compression Pressure should be 412-469 PSI (2840-

3233 kPa)

Allowable Limit (minimum) is 370 PSI (2255 kPa)

1 No more than 10% variance among cylinders.

If the measurement is below the allowable limit, check the

cylinder, piston ring, top clearance, valve and cylinder
head.

Figure 70-70-3

P-4305

The tools listed will be nee ded to do the fol lowing

procedure:

Dealer Copy -- Not for Resale

MEL10630 - Engine Compression Kit
MEL1352 - Compression Adapter

The engine must be at operating temperature.

Remove the glow plugs. (See Glow Plugs Removal And

P-4309
Installation on Page 70-70-2.)

Install the co rrect compression adapter (Item 1) [Figure Push the button on the compression gauge to r elease
70-70-1] into the cylinder head. pressure [Figure 70-70-3].

Figure 70-70-2 Connect the fuel stop solenoid.

P-4308

Connect the compression gauge to the adapter [Figure

70-70-2].

Make sure the engine speed control is set at low idle.

753 Bobcat Loader

70-70-1 Service Manual
607 of 726
ENGINE COMPONENTS AND TESTING (CONT’D) Glow Plugs Removal And Installation

Glow Plugs Checking Figure 70-70-6

Figure 70-70-4
1

3
2

P-4300

P-4304
Disconnect the negative (-) cable from the battery.

Disconnect the glow plug cables and leads. Clean the area around the plugs.

Use an ohmmeter to check the glow plugs [Figure 70-70-

Dealer Copy -- Not for Resale

Remove the nut (Item 1) [Figure 70-70-6] from the top of
4]. each glow plug.

Figure 70-70-5 Disconnect the engine harness wire (Item 2) [Figure 70-
70-6] from the glow plug.

Remove the glow plug connecting strap (Item 3) [Figure

70-70-6].

Figure 70-70-7

P-4310

Touch one probe to the end of the glow plug and the
other probe to the body of glow plug [Figure 70-70-5].

The reading must be between 1 and 2 ohms [Figure 70-

P-4302
70-4]. If the resistance is infinite, the coil of the glow plug
is broken.
Loosen and remove the glow plug (Item 1) [Figure 70-
Repeat the procedure for each glow plug. 70-7].

Reconnect the glow plug cable and leads. Installation: Tighten the glow plug to 1 4.5-18.1 ft.-lbs.
(19,6-24,5 Nm) torque.

753 Bobcat Loader

70-70-2 Service Manual
608 of 726
ENGINE COMPONENTS AND TESTING (CONT’D) Figure 70-70-10

Glow Plugs Removal And Installation (Cont’d)

Figure 70-70-8

N-20822

The reading between Red to Black must be between 10.5

P-4307 and 11 ohms [Figure 70-70-10].

The reading between White to Black must be between

Photo [Figure 70-70-8] shows the glow plug assembly .4-.5 ohms.
removed from the engine. Inspect the glow plugs and
replace when necessary.

Dealer Copy -- Not for Resale

Reconnect connector (Item 1) [Figure 70-70-9].

Installation: Reverse the removal procedure to install Fuel Shut-Off Solenoid Adjusting
the glow plugs.
Figure 70-70-11
Fuel Shut-Off Solenoid Checking

Figure 70-70-9
Linkage Lever
0.050”
(1,27 mm)

Stop

B-13704
1

N-20583 Adjust shut-off linkage for maximum distance of 0.05 0

inch (1,27 mm) between the lever and stop when
solenoid plunger is seated [Figure 70-70-11].
Stop the engine and open the rear door [Figure 70-70-9].

Disconnect the connector (Item 1) [Figure 70-70-9] from

the fuel shut-off solenoid.

Use an ohmmeter to check the fuel shut-off solenoid.

753 Bobcat Loader

70-70-3 Service Manual
609 of 726
ENGINE COMPONENTS AND TESTING (CONT’D) Figure 70-70-13

Fuel Shut-Off Solenoid Removal And Installation

Figure 70-70-12
1

1 N-20821

Remove the linkage mounting nut (Item 1) [Figure 70-70-

N-20583 13] from the fuel injector pump.

Removing the mounting bolts (Item 2) [Figure 70-70-13]

Stop the engine and open the rear door. of the fuel shut-off solenoid.

Disconnect the connector (Item 1) [Figure 70-70-12].

Dealer Copy -- Not for Resale

Installation: Reverse the above procedure to install the
fuel shut-off solenoid.

753 Bobcat Loader

70-70-4 Service Manual
610 of 726
ENGINE COMPONENTS AND TESTING (CONT’D) Turn the flywheel to increase the pressure. If the pressure
can not r each the allowable limit, replace the
Checking INJECTION PUMP assembly.

The injection pump contains parts which have a very Fuel Tightness of Pump Element
close tolerance and its operation has a d irect effect on
Allowable Limit 2133-1990 PSI (14707-13721kPa)
the performance of the engine.

Measure the time needed to decrease the pressure from

2133-1990 PSI (14707 -13721 kPa). If the measurement
WARNING is less than the allowable limit, replace the D ELIVERY
VALVE.
Diesel fuel or hydraulic fluid under pressure can Fuel Tightness of Delivery Valve
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible. Allowable Limit 5 Seconds
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

The tools listed will be nee ded to do the fol lowing

procedure:

Dealer Copy -- Not for Resale

MEL1237 - Adapter Fuel Line
MEL1173A - Pressure Gauge

To check the discharge pressure at the fuel injection

pump, use the following procedure:

Disconnect a high pressure fuel line from the injection

pump. Loosen the other end of the same fuel line so it
can be turned away from the fitting.

Figure 70-70-14

B-8235

Connect the adapter fuel line (Item 1) [Figure 70-70-14]

to the fitting and connect the pressure gauge (Item 2)
[Figure 70-70-14].

753 Bobcat Loader

70-70-5 Service Manual
611 of 726
ENGINE COMPONENTS AND TESTING (CONT’D) Figure 70-70-17

Fuel Injection Pump Removal And Installation

IMPORTANT
Do not bend the high pressure fuel injection tubes 2
when removing or installing them. 1
I-2029-0289

Figure 70-70-15

1 P-4312

Disconnect the fuel inlet hose (Item 1) and the fuel return
hose (Item 2) [Figure 70-70-17] from the injection pump
vent.

Figure 70-70-18

Dealer Copy -- Not for Resale

P-4319
1
Clean the area around the injection pump thoroughly.

Disconnect the high pressure fuel lines (Item 1) [Figure

70-70-15] from the fuel injectors.

Figure 70-70-16
P-4316

Cap the inlets on the injection pump vent where the

hoses were removed [Figure 70-70-18].

Remove the high pressure fuel lines (Item 1) [Figure 70-

70-18] from the injection pump.

P-4306

Disconnect the fuel shut-off linkage (Item 1) [Figure 70-

70-16].

753 Bobcat Loader

70-70-6 Service Manual
612 of 726
ENGINE COMPONENTS AND TESTING (CONT’D) Figure 70-70-20

Fuel Injection Pump Removal And Installation

(Cont'd)

IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
1 2

Figure 70-70-19
P-4357

2
Remove the four mounting bolts (Item 1) and two nuts
(Item 2) [Figure 70-70-20] from the injection pump.

Installation: Tighten the mounting bolts to 16-20 ft.-lbs.

(22-27 Nm) torque.

Dealer Copy -- Not for Resale

Figure 70-70-21

P-4356

2
Remove the seven mounting bolts (Item 1) from the
intake manifold (Item 2) [Figure 70-70-19].

Installation: Tighten the mounting bolts to 1 6-20 ft.-lbs.

(22-27 Nm) torque. 1

Remove the intake manifold from the engine.

P-4359
Installation: Replace the manifold gasket if it is worn or
damaged.
Remove the injection pump (Item 1) [Figure 70-70-21]
and shim(s) from the engine.

NOTE: The pin (Item 2) [Figure 70-70-21] located on

the control rack, needs to be installed
correctly during installation. (See Fuel
Injection Pump Removal And Installation
(Cont'd) on Page 70-70-8.) for correct
installation.

753 Bobcat Loader

70-70-7 Service Manual
613 of 726
ENGINE COMPONENTS AND TESTING (CONT’D) Figure 70-70-24

Fuel Injection Pump Removal And Installation

(Cont'd)

IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289

Figure 70-70-22
P-4364

Install the s him(s) (Item 1) [Figure 70-70-24] on the

injection pump mounting surface. (See Timing The
Injection Pump on Page 70-70-9.) for information on
1 number of shims used.

Figure 70-70-25

Dealer Copy -- Not for Resale

P-4363 1

Remove the side cover (Item 1) [Figure 70-70-22] from

the injection pump chamber.

Figure 70-70-23
2

P-4360

Install the injection pump in the engine.

1
Put the pin (Item 1) on the control rack in the slot of the
fork lever (Item 2) [Figure 70-70-25] located inside the
injection pump chamber.

P-4362
IMPORTANT
If the pin is not correctly installed in the fork lever,
Be sure the spring (Item 1) [Figure 70-70-23] is located the engine will run over maximum speed, resulting in
in the injection pump chamber as shown. serious damage to the engine.
I-2086-1195

753 Bobcat Loader

70-70-8 Service Manual
614 of 726
ENGINE COMPONENTS AND TESTING (CONT’D) Figure 70-70-27

Timing The Injection Pump

1
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289

Timing the injection pump is done by changing the

number of shi ms between the injection pump and the
injection pump mounting surface. P-4361

Disconnect the number one cylinder high pressure line

from the injection pump. Install a short plastic tube (Item 1) [Figure 70-70-27] in
the number one cylinder port of the injection pump. The
Figure 70-70-26 tube should fit securely in the port and point upward.

Figure 70-70-28

Dealer Copy -- Not for Resale

18°
14.5 ° Rotation
2

1 MC-1542A
1 Rotation
Direction

P-4306

P-4315
Disconnect the fuel shut-off linkage (Item 1) [Figure 70-
70-26] from the injection pump.
Rotate the engine in the direction shown [Figure 70-70-
Turn the fuel supply lever (Item 2) [Figure 70-70-26] to 28].
the ON position (to the right).
Continue rotation until flywheel timing mark just appears
in the window (Item 1) [Figure 70-70-28].

NOTE: The flywheel has two timing marks. The first

mark to appear in the window with the rotation
shown is 18°. The first mark is used for 753,
763, 773 (Non Turbo) loaders.

Rotate slowly until fuel just starts to flow upward into the
plastic tube.

At this instant, the 18° BTDC timing mark on the flywheel

should be aligned with the mark in the window (Item 1)
[Figure 70-70-28].

753 Bobcat Loader

70-70-9 Service Manual
615 of 726
ENGINE COMPONENTS AND TESTING (CONT’D)

Timing The Injection Pump (Cont’d)

IMPORTANT
Figure 70-70-29
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289

1
Figure 70-70-30

P-4364

Add or subtract shim(s) (Item 1) [Figure 70-70-29] as

needed to adjust the fuel delivery timing.

Dealer Copy -- Not for Resale

P-4311
NOTE: Adding or removing one shim will vary the
timing by 1.5°. Adding shims retards timing.
Figure 70-70-31
Fuel Injector Removal And Installation

WARNING
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 1
from a physician familiar with this injury.
W-2072-0496
P-4318

The following are some problems caused by faulty

injectors: Disconnect the fuel return hose (Item 1) [Figure 70-70-
30] & [Figure 70-70-31] from the injectors.
- Engine is hard to start or will not start
- Rough engine operation and idle
- Engine will not have full power
- Excessive exhaust smoke

753 Bobcat Loader

70-70-10 Service Manual
616 of 726
ENGINE COMPONENTS AND TESTING (CONT’D) Figure 70-70-34

Fuel Injector Removal And Installation (Cont'd)

Figure 70-70-32

1
1

P-4354

Remove the injector (Item 1) [Figure 70-70-34] from the

P-4330 cylinder head.

Installation: Tighten the Injector to 36- 50 ft.-lbs. (49-68

Disconnect the high pressure fuel lines (Item 1) [Figure Nm).
70-70-32] from the fuel injectors and from the injection
pump.

Dealer Copy -- Not for Resale

Figure 70-70-35

Remove the high pressure fuel lines from the engine.

Figure 70-70-33

2 1

P-4358
2

Photo [Figure 70-70-35] shows the injector nozzle

P-4353 removed from the cylinder. Inspect the in jector and
replace if necessary.

Remove the retainer nut from the top of the fuel injectors Installation: Be sure the nozzle cap (Item 1) and copper
(Item 1) [Figure 70-70-33]. washer (Item 2) [Figure 70-70-35] are in the correct
position. Replace the nozzle cap and copper washer
Remove the fue l return tube (Item 2) [Figure 70-70-33] when installing new or used injectors.
from the fuel injectors.

753 Bobcat Loader

70-70-11 Service Manual
617 of 726
ENGINE COMPONENTS AND TESTING (CONT’D) Fuel Injector Disassembly

Fuel Injector Checking Figure 70-70-37

IMPORTANT
Do not disassemble or test the fuel injector nozzles
unless you have the correct service and testing 1
tools.
I-2027-0284 2
3
The tool listed will be ne eded to d o the following (1) Nozzle Holder
procedure: 4
5 (2) Adjusting Washer
(3) Nozzle Spring
OEM1064 - Injector Nozzle Tester (4) Push Rod
6
(5) Distance Piece
Check for inside leakage. Operate the hand lever until the (6) Nozzle Piece
7
pressure is 1850 PSI (12755 kPa). Keep the nozzle (7) Nozzle Retaining Nut
under this pressure for 10 seconds, check to see if fuel
leaks from the nozzle. If fuel leaks, replace the nozzle. PI-9981

Dealer Copy -- Not for Resale

Figure 70-70-36
Disassemble and clean the injector nozzle.

The nozzle release pressure can be adjusted by adding

or removing spacer(s) (Item 2) from the top of the nozzle
CORRECT WRONG spring (Item 3) [Figure 70-70-37].

Each spacer will change the release pressure by about

142 PSI (980 kPa).
Fuel Injection Pressure 1991-2133 PSI
(13728-14707 kPa)

A-2621

Check that the spray pattern is correct [Figure 70-70-36]:

1. Fuel does not come out the side of the nozzle.

2. Drops of fuel are not present at the nozzle.

3. The injector has an even flow coming from the nozzle.

753 Bobcat Loader

70-70-12 Service Manual
618 of 726
ENGINE COMPONENTS AND TESTING (CONT’D) NOTE: The clearance is measured between the
rocker arm and valve stem tip (Item 3) [Figure
Fuel Injector Assembly 70-70-39].

Figure 70-70-38 Adjust the valve clearance as follows:

0.008 inch (0,20 mm) Intake & Exhaust

Figure 70-70-40

1 2 3 4 5 6 7 8

A-2513

Assemble the injector nozzle. Connect the nozzle to the

tester with the nozzle down [Figure 70-70-38]. B-5569

Dealer Copy -- Not for Resale

Operate the hand lever at a slow rate and record the
opening pressure. If th e pressure is not c orrect, Figure 70-70-41
disassemble the nozzle and add or remove spacers (Item
2) [Figure 70-70-37] as needed.
Cylinder Number 1 2 3 4
When the injector nozzle is assembled, tighten the nozzle
body to 43-58 ft.-lbs. (59-79 Nm) torque.

Valve Clearance Adjustment Valve Number 1 2 3 4 5 6 7 8

Figure 70-70-39

Valve
I = Intake I E I E I E I E
E = Exhaust

2 1
Use the following sequence to set the valves [Figure 70-
70-40] & [Figure 70-70-41]:

a. With the rocker arm rocking (valves 7 & 8) on No. 4

cylinder set clearance at No. 1 cylinder (valves 1 & 2).

3 b. With the rocker arm rocking (valves 3 & 4) on No. 2

B-5568
cylinder set clearance at No. 3 cylinder (valves 5 & 6).

Adjust the valve clearance as follows: c. With the rocker arm rocking (valves 1 & 2 ) on No. 1
cylinder set clearance at No. 4 cylinder (valves 7 & 8).
Loosen the lock nut (Item 1) [Figure 70-70-39].
d. With the rocker arm rocking (valves 5 & 6) on No. 3
Turn the ad justment screw (Item 2) [Figure 70-70-39] cylinder set clearance at No. 2 cylinder (valves 3 & 4).
until the correct clearance is obtained.

753 Bobcat Loader

70-70-13 Service Manual
619 of 726
ENGINE COMPONENTS AND TESTING (C0NT’D) Valve Timing Checking

Rocker Arm And Shaft Checking Figure 70-70-43

Figure 70-70-42 4

5
2
1 3 1
2
(1) Idle Gear
(2) Idle Collar
(3) External Snap Ring
(4) Cam Gear
B-14341
(5) Camshaft
B-3697
Stop the engine and open the rear door.

Measure the rocker arm I.D. (Item 1) [Figure 70-70-42] Remove the engine. (See Removal And Installation on
with the inside micrometer. Page 70-80-1.)

Dealer Copy -- Not for Resale

Measure the rocker arm shaft O.D. (Item 2) [Figure 70- Remove the timing gearcase cover. (See Timing
70-42] with a outside micrometer. Gearcase Cover Removal And Installation on Page 70-
100-7.)
If the clearance exceeds the allowable limit, replace the
bushing. Make sure the timing marks are in correct alignment
[Figure 70-70-43].
If the clearance still exceeds the allowable limit after the
bushing is replaced, replace the rocker arm shaft.
Oil Clearance Between 0.0006-0.0018 inch
Rocker Arm & Shaft (0,016-0,045 mm)

Allowable Limit 0.006 inch (0,15 mm)

Rocker Arm Shaft O.D. 0.5501-0.5506 inch
(13, 973-13,984 mm)
Rocker Arm I.D. 0.5512-0.5519 inch
(14,0-14,018 mm)

753 Bobcat Loader

70-70-14 Service Manual
620 of 726
ENGINE Figure 70-80-1

Removal And Installation

N-19437

WARNING
Disconnect the engine harness connector (Item 1)
Never work on a machine with the lift arms up unless [Figure 70-80-1] from the h arness. If th ere is no
the lift arms are secured by an approved lift arm connector, remove the harness from the engine.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment Remove the air cleaner. (See Removal And Installation
to fall and cause injury or death. on Page 70-40-1.)

Dealer Copy -- Not for Resale

W-2059-0598
Remove the muffler. (See Removal And Installation on
Put jackstands under the rear corners of the loader. Page 70-30-1.)

Raise the lift arms and install an approved lift arm Figure 70-80-2
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Raise the operator cab. (See Raising The Operator Cab 1

on Page 10-30-1.)

Drain the hydraulic reservoir. (See Replacing Hydraulic 2

Fluid on Page 10-120-3.)

Disconnect the steering linkage. (See Linkage Removal

And Installation on Page 50-110-3.)

Remove the battery from the loader. (See Removal And

Installation on Page 60-20-1.) 1
P-4194
Drain the engine coolant from the cooling system. (See
RADIATOR on Page 70-50-1.)
Mark the four drive motor hoses (Item 1) [Figure 70-80-
2] for correct installation.

Disconnect the four drive motor hoses (Item 1) [Figure

70-80-2] from the hydrostatic pump.

Disconnect the motor case drain hose (Item 2) [Figure

70-80-2] from the hydrostatic pump.

753 Bobcat Loader

70-80-1 Service Manual
621 of 726
ENGINE (CONT’D) Figure 70-80-5

Removal And Installation (Cont'd)

Figure 70-80-3

P-4197

Remove the mounting bolt (Item 1) [Figure 70-80-5] and

N-19539 nut from the left front engine mount.

Installation: Tighten the mounting bolts to 70 ft.-lbs. (95

Disconnect the wire harness connector (Item 1) [Figure Nm) torque.
70-80-3] from the fuel level sender on the fuel tank.

Dealer Copy -- Not for Resale

Figure 70-80-6
Figure 70-80-4

2
3
P-43249
N-20873

Disconnect the hand pump (Item 1) [Figure 70-80-6]

Disconnect the INLET hose (Item 1) [Figure 70-80-4] from the fuel line connected to the fuel tank. Cap the fuel
from the fitting on the hydraulic pump. lines.

Disconnect the o utlet tubeline (Item 2) [Figure 70-80-4]

to the main control valve, from the fitting on the hydraulic
pump.

Remove the mounting bolt (Item 3) [Figure 70-80-4] and

nut from the right front engine mount.

753 Bobcat Loader

70-80-2 Service Manual
622 of 726
ENGINE (CONT’D) Figure 70-80-9

Removal And Installation (Cont'd)

Figure 70-80-7 1

P-4218
1

Disconnect the radiator hoses (Item 1) [Figure 70-80-8]

P-4195 & [Figure 70-80-9] from the engine.

Figure 70-80-10
Disconnect the fuel return hose (Item 1) [Figure 70-80-7]
from the injector.

Dealer Copy -- Not for Resale

Figure 70-80-8

P-4215

Remove the m ounting bolt and nut (Item 1) [Figure 70-

P-4204 80-10] from the left rear engine mount.

Installation: Tighten the mounting bolt to 70 ft.-lbs. (95

Nm) torque.

753 Bobcat Loader

70-80-3 Service Manual
623 of 726
ENGINE (CONT’D) Figure 70-80-13

Removal And Installation (Cont'd)

Figure 70-80-11
3

P-43238
1

Disconnect the rear light harness connectors (Item 1)

P-43849 [Figure 70-80-13] from the engine harness.

Remove the belt shield mounting bolts (Item 2) [Figure

Remove the mo unting bolt and nut (Item 1) [Figure 70-
70-80-13].
80-11] from the right rear engine mount.

Dealer Copy -- Not for Resale

Installation: Tighten the mounting bolts to 25-28 ft.-lbs.
Installation: Tighten the mounting bolt to 70 ft.-lbs. (95
(34-38 Nm) torque.
Nm) torque.
Remove the belt shield.
Figure 70-80-12
Disconnect the engine speed control rod (Item 3) [Figure
70-80-13] from the linkage.

Remove the coolant overflow bottle (Item 4) [Figure 70-

80-13].

N-15533

Disconnect the ground cable (Item 1) [Figure 70-80-12]

from the loader frame.

753 Bobcat Loader

70-80-4 Service Manual
624 of 726
ENGINE (CONT’D) Figure 70-80-15

Removal And Installation (Cont'd)

Figure 70-80-14
1
13”

2.5”

1-1/2” I.S. Dia.

2-1/2” O.S. Dia.

2.5”
1/4” (4)
1-1/2” Square Tubing
1/4” Wall Thickness Thick Gusset

1”
16”

4”

2”

Dealer Copy -- Not for Resale

45° 9”
1”

4”
2”

1”
.5”
P-4216
.375”
Use Two 3/8”x 1-1/4” Bolts
for Drilled and Tapped Holes. MC-1799C
Install the chain hoist on the eyelet (Item 1) [Figure 70-
80-15] of the removal tool.
A tool needs to fabricated to be used in the removal
procedure. This tool allows the engine/hydrostatic pump Fasten a chain to other end of the removal tool with two
assembly to be lifted evenly for easier removal. Use the bolts as shown in [Figure 70-80-15].
dimensions shown in [Figure 70-80-14] to make the
engine removal tool. Fasten securely one end of the chain to one of the lifting
brackets on the engine [Figure 70-80-15].

Fasten securely the other end of t he chain to the other

lifting bracket on the engine [Figure 70-80-15].

NOTE: You may need to adjust the chain which

fastens to the engine a couple of times to
reach the correct lifting position.

Remove the engine/hydrostatic pump assembly from the

loader.

Reverse the removal procedure to install the engine.

753 Bobcat Loader

70-80-5 Service Manual
625 of 726
ENGINE (CONT’D) Figure 70-80-17

Engine Mount Replacement

Engine
Mounting
Figure 70-80-16 Bracket
Washer
2
1
Loader Engine
3 Frame Mount

Spacer
5 Snubbing
Washer
MC-1765
6

Install the new engine mount as shown in the cut away

7 side view [Figure 70-80-17].
MC-1771

Tighten the mounting bolts to 70 ft.-lbs. (95 Nm) torque.

Use the fo llowing procedure to in stall new engine
mounts:

Dealer Copy -- Not for Resale

Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount
locations.

Replace all four engine mounts two front and two rear.

Use the parts shown to i nstall the n ew engine mounts

[Figure 70-80-16]:

Square Nut - (Item 1) - Used on left side engine mounts

Hex Nut - (Item 2) - Used on right side engine mounts
Mount Washer - (Item 3)
Engine Mount - (Item 4)
Tube Spacer - (Item 5)
Snubbing Washer - (Item 6)
Mounting Bolt - (Item 7)

753 Bobcat Loader

70-80-6 Service Manual
626 of 726
FLYWHEEL AND HOUSING Figure 70-90-3

Flywheel Removal And Installation

Figure 70-90-1

1
1
3

1
2

P-4234

Remove the six mounting bolts (Item 1) from the engine

P-4230 flywheel (Item 2) [Figure 70-90-3].

Installation: Apply engine oil to the threads and seats

Remove the three belt shield clips (Item 1) [Figure 70- before tightening. Tighten to 72-80 ft.-lbs. (98-108 Nm)
90-1] and remove the shield from the drive belt housing. torque.

Dealer Copy -- Not for Resale

Figure 70-90-2 Remove the flywheel from the engine.

Installation: Be sure to al ign the ho le (Item 3) [Figure

70-90-3] in the flywheel with the pin located on the
crankshaft.
1
Reverse the removal procedure to install the flywheel.

P-4223

Loosen and remove the dr ive belt tensioner (Item 1)

[Figure 70-90-2].

Remove the drive belt. (Refer to Contents Page 30-01 for

drive belt adjustment procedure.)

753 Bobcat Loader

70-90-1 Service Manual
627 of 726
FLYWHEEL AND HOUSING (CONT’D) Housing Removal And Installation

Ring Gear Removal And Installation Remove the RPM sensor. (See RPM SENSOR on Page
70-91-1.)
Figure 70-90-4
Figure 70-90-5

1
P-4237

P-4223

NOTE: Photo’s may be different but the procedure is

the same for all models. Loosen the drive belt tensioner bolt (Item 1) [Figure 70-

Dealer Copy -- Not for Resale

90-5] from the housing and remove the drive belt.
Remove the flywheel. (See Flywheel Removal And
Installation on Page 70-90-1.) Installation: Tighten the bolt to 25-28 ft.-lbs. (34-38 Nm)
torque.
Installation:
Adjust the drive belt. (See Adjusting on Page 30-50-1.)
The ring gear (Item 1) [Figure 70-90-4] on the flywheel is
an interference fit. Heat the ring gear enough to expand Figure 70-90-6
the gear. Hit the ring gear evenly around the gear to
remove it from the flywheel.

Clean the outer surface of the flywheel thoroughly so the

new ring gear will fit smoothly onto the flywheel.

Clean the new ring gear and heat it to a temperature of

450°-500° F. (232°-260°C.)

Fit the ring gear on the flywheel and be sure the gear is
seated correctly.
1

P-4234

Remove the six flywheel mounting bolts (Item 1) [Figure

70-90-6] and remove the engine flywheel.

Installation: Apply engine oil to the threads and seats

before tightening. Tighten the mounting bolts to 72-80 ft.-
lbs. (98-108 Nm) torque.

753 Bobcat Loader

70-90-2 Service Manual
628 of 726
FLYWHEEL AND HOUSING (CONT’D) Installation: Tighten the mounting nut to 175-200 ft.-lbs.
(237-271 Nm) torque.
Housing Removal And Installation (Cont’d)
Figure 70-90-9
Figure 70-90-7

2 3

1
P-4235
P-4233

Install a puller on the drive pulley and remove the pulley

Remove the seven smaller mounting bolts (Item 1) from the hydrostatic pump shaft [Figure 70-90-9].
[Figure 70-90-7] which fastens the housing on the
engine.

Dealer Copy -- Not for Resale

Installation: Install the pulley key in the shaft before
installing the drive pulley.
Installation: Tighten the mounting bolts to 3 5-40 ft.-lbs.
(48-54 Nm) torque. Figure 70-90-10
Remove the two l arger bolts (Item 2) [Figure 70-90-7]
which fastens the housing on the engine.

Installation: Tighten the mounting bolts to 6 0-65 ft.-lbs.

(82-88 Nm) torque.
2
Remove the starter (Item 3) [Figure 70-90-7] from the
drive belt housing. (See Removal And Installation on
Page 60-40-1 OR See Removal And Installation on Page
60-41-2)
1
Figure 70-90-8

P-4238

Remove the two mounting bolts (Item 1) [Figure 70-90-

10] from the drive belt housing which mounts the
hydrostatic pump to the housing. Support the pump to
prevent it from falling when the mounting bolts are
removed.

1 Installation: Tighten the mounting bolts to 65-70 ft.-lbs.

(88-95 Nm) torque.

P-4236
Remove the drive belt tensioner (Item 2) [Figure 70-90-
10] from the d rive belt housing (See Tensioner Pulley
Removal And Installation on Page 30-50-4.)
Remove the hydrostatic pump drive pulley mounting nut
(Item 1) [Figure 70-90-8] and washer.
753 Bobcat Loader
70-90-3 Service Manual
629 of 726
FLYWHEEL AND HOUSING (CONT’D)

Housing Removal And Installation (Cont’d)

Figure 70-90-11

P-4231

Remove the mounting bolt (Item 1) [Figure 70-90-11]

from engine coolant tubeline mounting bracket which is
attached to the belt shield housing.

Dealer Copy -- Not for Resale

Installation: Tighten the mounting bolt to 25-28 ft.-lbs.
(34-38 Nm) torque.

Remove the blower fan drive belt tensioner assembly

(Item 2) [Figure 70-90-11] from the housing. (See Blower
Disassembly And Assembly on Page 70-60-4.)

Remove the drive belt housing.

Reverse the removal procedure to install the drive belt

housing.

753 Bobcat Loader

70-90-4 Service Manual
630 of 726
RPM SENSOR

Adjustment

Figure 70-91-1

P-34731

When reinstalling the RPM sensor, turn the rpm sensor

(Item 1) [Figure 70-91-1] in unt il it makes contact with
the engine flywheel.

Dealer Copy -- Not for Resale

Turn the j am nut (Item 2) [Figure 70-91-1] until it
contacts the flywheel housing. The jam nut should not be
tightened, it needs to turn with the RPM sensor when the
sensor is turned back out for adjustment.

Figure 70-91-2

P-34732

Turn the RPM sensor and the jam nut out from the
flywheel. Set a clearance of .050 inch (1,27 mm) between
the jam nut and the housing with a feeler gauge (Item 1)
[Figure 70-91-2].

NOTE: New RPM sensors have a plastic tip which is

used as a gauge during installation. The feeler
gauge method is not used. The plastic tip is
designed to come off after the engine is
started.

753 Bobcat Loader

70-91-1 Service Manual
631 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

70-91-2 Service Manual
632 of 726
RECONDITIONING THE ENGINE Figure 70-100-3
Cylinder Head Removal And Installation

Figure 70-100-1

B-14333

Remove the water return hose [Figure 70-100-3].

PI9982A Figure 70-100-4

Remove the nuts from the valve cover, remove the valve
cover and gasket [Figure 70-100-1].

Dealer Copy -- Not for Resale

14 6 3 11
Figure 70-100-2
18 10 2 7 15

17 9 1 8 16
13 5 4 12

FRONT
2 PI9985A

Remove the cylinder head bolts in order of # 18 to # 1

[Figure 70-100-4].
B-14332A B-14332
Installation: Put oil on the bolt threads. Tighten the bolts
in the correct sequence of #1 to #18 to 68-72 ft.-lbs. (93-
Remove the fu el injector nozzles. (See Fuel Injector 98 Nm) torque.
Removal And Installation on Page 70-70-10.)
Remove the glow plugs. (See Glow Plugs Removal And NOTE: Retighten the cylinder head bolts in the
Installation on Page 70-70-2.) correct sequence after the engine has been
run for 30 minutes.
Remove the belt shield. (See Shield Removal And
Installation on Page 30-50-1.)

Remove the alternator. (See Removal And Installation on

Page 60-30-4.)

Remove the r ocker arm and shaft assembly (Item 1)

[Figure 70-100-2].

Remove the push rods (Item 2) [Figure 70-100-2].

Remove the intake and exhaust manifolds.

753 Bobcat Loader

70-100-1 Service Manual
633 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-7

Cylinder Head Removal And Installation (Cont’d)

5
Figure 70-100-5
4

3
6
2 1

Valve Spring
Retainer
Seal
Collets Cap
B-4122A

Remove the valve cap (Item 1) [Figure 70-100-6] &

B-14334 [Figure 70-100-7] and valve spring collet (Item 2)
[Figure 70-100-6] & [Figure 70-100-7].

Remove the cylinder head from the engine block. Remove the valve spring retainer (Item 3) [Figure 70-
100-6] & [Figure 70-100-7] and the spring (Item 4)
Installation: Always use new head gasket and new O-

Dealer Copy -- Not for Resale

[Figure 70-100-6] & [Figure 70-100-7].
ring. Make sure the O-ring is seated over the dowel
[Figure 70-100-5]. Remove the se al (Item 6) [Figure 70-100-6] & [Figure
70-100-7] and the v alve (Item 5) [Figure 70-100-6] &
Cylinder Head Disassembly And Assembly [Figure 70-100-7].

Figure 70-100-6 Figure 70-100-8

1
4
3

5 6 2
PI9987A B-3643

Use a va lve spring compressor to compress the valve Remove the thermostat housing. Remove the thermostat
spring [Figure 70-100-6]. from the cylinder head [Figure 70-100-8].

753 Bobcat Loader

70-100-2 Service Manual
634 of 726
RECONDITIONING THE ENGINE (CONT’D) Cylinder Head Top Clearance

Cylinder Head Servicing Figure 70-100-11

Figure 70-100-9

2
1

1
2 3

PI9989A

A-2735
Install the cy linder head gasket. Put the piston (Item 1)
[Figure 70-100-11] being checked at T.D.C.
Clean the surface of the cylinder head.
Put three pieces of 0.060 inch (1,5 mm) diameter solder
Put a straight edge (Item 1) [Figure 70-100-9] on the

Dealer Copy -- Not for Resale

(Item 2) [Figure 70-100-11] on the top of the piston. Use
cylinder head. grease to hold them in position.

NOTE: Do not put the straight edge across the NOET: Position the solder so they do not touch the
combustion chambers. valves.

Put the feeler gauge (Item 2) [Figure 70-100-9] between Turn the piston to bottom dead center.
the straight edge and the surface of the cylinder head.
Install the cylinder head and tighten to the correct torque
Figure 70-100-10 in the correct sequence. (See Cylinder Head Removal
And Installation on Page 70-100-1.)

Turn the crankshaft until the pis ton exceeds T.D.C.

Remove the cylinder head.

Remove the solder wire (Item 3) [Figure 70-100-11] and

measure it.

If the measurement exceeds the specifications, check the

oil clearance of the crank pin journal or the piston pin.
Top Clearance 0.022-0.025 inch (0,55-0,7 mm)

PI9988

Put the straight edge on t he cylinder head’s four sides

and two diagonal as shown in figure [Figure 70-100-10].

The maximum distortion of the hea d surface is ±0.002

inch (± 0,05 mm). If the measurement exceeds the
specification, replace the cylinder head.

753 Bobcat Loader

70-100-3 Service Manual
635 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-14

Checking The Valve Guide

Figure 70-100-12

B-14335

Remove the carbon from the valve guide.

B-3634
Measure the valve stem O.D. [Figure 70-100-14].

Remove the valve and spring from the c ylinder head. Measure the valve guide I.D. [Figure 70-100-14].
(See Cylinder Head Disassembly And Assembly on Page
70-100-2.)

Dealer Copy -- Not for Resale

Calculate the clearance, if the clearance exceeds the
allowable limit, replace the valve and/or valve guide.
Clean the valve seat and combustion chamber.
Valve Guide I.D. 0.3156-0.3161 inch
Install the valve into the guide. Measurement the valve (8,015-8,03 mm)
recessing or protrusion with a de pth gauge [Figure 70- Valve Stem O.D. 0.3134-0.3142 inch
100-12]. (7,96-7,98 mm)
Clearance Between Valve 0.0016-0.0026 inch
Figure 70-100-13 Stem and Guide (0,04-0,07 mm)
Allowable Limit 0.004 inch (0,1 mm)
2 3
Figure 70-100-15

7.87” (200 mm)

1 1
3.15” (80 mm) 1.57”
0.787” 0.51-0.511” (40 mm)
(20 mm) (12,96-12,98 mm)

1. Cylinder Head Surface 0.295-0.303”

2. Recessing (7,5-7,7 mm)

3. Protrusion
0.393”
0.2” (10,0 mm) 0.71”
PI9990A (5,0 mm) (18,0 mm)

If the measurement exceeds the allowable limit, replace

0.31”
the valve or cylinder head [Figure 70-100-13]. (8,0 mm)
0.59”
(15,0 mm)
0.51”
(13,0 mm)
MC-1364
Protrusion 0.002 inch (0,05 mm)
Recessing 0.006 inch (0,15 mm)
To remove and replace the valve guide, make the driver
Allowable Limit (Recessing) 0.016 inch (0,4 mm)
tool as shown in figure [Figure 70-100-15].

753 Bobcat Loader

70-100-4 Service Manual
636 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-18

Checking The Valve Guide (Cont’d)

Figure 70-100-16

Exhaust

Intake
15° 45° 60°
1

PI9994A
2
Grind the valve seat surface in the c ylinder head to th e
PI9992A correct angle [Figure 70-100-18].

Figure 70-100-19
Press the used valve guide out of the cylinder head using
the special driver tool [Figure 70-100-16]. 1 2

Dealer Copy -- Not for Resale

Put oil on the outside diameter of the new valve guide. 15° 30°
Press the new valve guide into the cylinder head from the

Exhaust

Intake
top side. Use the special driver tools (Items 1 & 2)
[Figure 70-100-16], press the new guide until the tool
contacts the cylinder head.
3
Ream the valve guide to the correct specifications.

Reconditioning The Valve And Valve Seat

(a)
Figure 70-100-17
(a)
PI9995A

Check the seat surface and valve face (Item 1) [Figure

70-100-19].

If the seat surface is too wide, use a 15 degree cutter on

the exhaust and a 30 degree cutter on the intake (Item 2)
to get the correct width (Item 3) [Figure 70-100-19].
Valve Seat Width
Intake (a) 0.084 inch (2,12 mm)
Exhaust (a) 0.084 inch (2,12 mm)
Valve Seat & Face Angle
PI9993 Intake 60°
Exhaust 45°
Grind the valve face to the correct angle using a valve
refacer [Figure 70-100-17].

753 Bobcat Loader

70-100-5 Service Manual
637 of 726
RECONDITIONING THE ENGINE (CONT’D) Read the compressed load on the gauge. If the
measurement exceeds allowable limit, replace the spring.
Valve Spring Setting Length 1.378 inch (35,0 mm)
Setting Load 26.4 lbs. (117,6 N)
Figure 70-100-20
Allowable Limit 22.5 lbs. (100,0 N)

Rocker Arm And Shaft Checking

Figure 70-100-22

2 1

B-3680

Measure the length of the valve spring. If the

measurement is less than the allowable limit, replace the
spring [Figure 70-100-20].

Dealer Copy -- Not for Resale

B-3697
Free Length 1.642-1.661 inch (41,7-42,2 mm)
Allowable Limit 1.622 inch (41,2 mm)
Measure the rocker arm I.D. (Item 1) [Figure 70-100-22]
with the inside micrometer.
Put the spring on a flat surface, place a square on the
side of the spring [Figure 70-100-20]. Measure the rocker arm shaft O.D. (Item 2) [Figure 70-
100-22] with a outside micrometer.
Rotate the spring and measure the maximum tilt. If th e
measurement exceeds the allowable limit, replace the If the clearance still exceeds the allowable limit, replace
spring. the bushing.
Tilt 0.040 inch (1,0 mm) If the clearance still exceeds the allowable limit after the
bushing is replaced, replace the rocker arm shaft.
Figure 70-100-21 Oil Clearance Between 0.0006-0.0015 inch
Rocker Arm & Shaft (0,016-0,038 mm)
Allowable Limit 0.006 inch (0,15 mm)
Rocker Arm Shaft 0.5501-0.5506 inch
O.D. (13,973-13,984 mm)
Rocker Arm I.D. 0.5512-0.5519 inch
(14,0-14,01 mm)

A-2759

Place the spring on a tester and compress to s pecified

length [Figure 70-100-21].

753 Bobcat Loader

70-100-6 Service Manual
638 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-25

Timing Gearcase Cover Removal And Installation

Figure 70-100-23
2

1
3 1
2
B-14338

Remove the start spring (Item 1) from the fork lever (Item
B-14336 2) [Figure 70-100-25].

Installation: Be ca reful; do not drop the sp ring into the

Remove the fue l injection pump. (See Fuel Injection gearcase.
Pump Removal And Installation on Page 70-70-6.)

Dealer Copy -- Not for Resale

Figure 70-100-26
Remove the cylinder head, rocker arms and push rods.
(See Cylinder Head Removal And Installation on P age
70-100-1.)

Disconnect the two governor springs (Items 1 & 2) from

the fork lever (Item 3) [Figure 70-100-23].

Figure 70-100-24

B-3694

Remove the crankshaft pulley nut.

Installation: Tighten the nut to 101-116 ft.-lbs. (137-157

Nm) torque.

B-14337 Use a pu ller and remove the crankshaft pulley [Figure

70-100-26].

Remove the speed control plate with the governor

springs [Figure 70-100-24].

753 Bobcat Loader

70-100-7 Service Manual
639 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-29

Timing Gearcase Cover Removal And Installation

(Cont’d)
1
Figure 70-100-27 2

B-14340

Remove the crankshaft oil slinger (Item 1), O-ring (Item

2) and collar (Item 3) [Figure 70-100-29].
B-14339
Figure 70-100-30

Remove the bolts from the timing gearcase cover.

Dealer Copy -- Not for Resale

Installation: Tighten the bolts to 13-15 ft.-lbs. (18-20
Nm) torque.

Figure 70-100-28

O-rings
Oil Seal

B-3617A

Installation: Install new O-rings and oil seal into the

timing gearcase cover [Figure 70-100-30].

NOTE: When a new timing gearcase cover is

B-4095 installed, to establish the correct position of
the injection pump fuel rack stop before
removing it from the old timing gearcase
Remove the timing gearcase cover [Figure 70-100-28]. cover, the distance from the machined
surface of the gearcase (Gasket surface) to
the end of the stop should be measured. The
stop should then be installed in the new
gearcase and set to the same distance that
was previously measured. Do not try to test
operate the engine to establish if it has
enough power. The adjustment must be set by
a qualified service personnel for the injection
pump.

753 Bobcat Loader

70-100-8 Service Manual
640 of 726
RECONDITIONING THE ENGINE (CONT’D) Align the holes on th e camshaft gear with the camshaft
retainer plate bolts.
Idler Gear And Camshaft Removal And Installation
Remove the bolts.
Figure 70-100-31
Installation: Tighten the camshaft retainer bolts to 17-20
4 ft.-lbs. (23-27 Nm) torque.

Figure 70-100-33
5

1
3
2
1 Idle Gear
2. Idle Collar
3 External Snap Ring
4 Cam Gear
5 Camshaft
B-14341

Remove the timing gearcase cover. (See Timing

Gearcase Cover Removal And Installation on Page 70-
B-3655
100-7.)

Dealer Copy -- Not for Resale

Remove the snap ring (Item 3) from the idler gear shaft Remove the camshaft from the engine block [Figure 70-
(Item 1) [Figure 70-100-31]. 100-33].

Installation: Make sure the timing marks are in c orrect Figure 70-100-34
alignment when installing timing gears. See circled areas
in [Figure 70-100-31].

Figure 70-100-32

0.003-0.009”
(0,07-0,22mm) PI-10002

2
Installation: Check the camshaft end play, if the
B-3699 clearance exceeds the allowable limit, replace the
camshaft retainer plate [Figure 70-100-34].

Remove the idler gear (Item 1) [Figure 70-100-32]. Camshaft End Play 0.003-0.009 inch (0,07-0,22 mm)
Allowable Limit 0.012 inch (0,3 mm)
Remove the idler gear collar (Item 2) [Figure 70-100-32].

Remove the idler gear shaft mounting bolts.

Installation: Tighten the mounting bolts to 1 7-20 ft.-lbs.

(23-27 Nm) torque.

753 Bobcat Loader

70-100-9 Service Manual
641 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-37

Servicing The Camshaft

Figure 70-100-35

B-5001

Measure the cam lobes at their highest point [Figure 70-

B-3620 100-37].

If the measurement is less than the allowable limit,

Measure the camshaft bearing in the engine block replace the camshaft.
[Figure 70-100-35].
Cam Lobe Height 1.318 inches (33,47 mm)

Dealer Copy -- Not for Resale

Figure 70-100-36 Allowable Limit 1.316 inches (33,42 mm)

Figure 70-100-38

A-2761

Measure the camshaft journal [Figure 70-100-36]. A-2760

Calculate the oil clearance. If the clearance exceeds the

allowable limit, replace the camshaft. Put the camshaft in V-blocks. Install a di al indicator
[Figure 70-100-38] on the camshaft bearing surface.
Bearing I.D. 1.5748-1.5758 inches
(40,0-40,03) mm) Turn the camshaft at a s low rate. If the m isalignment
Journal O.D. 1.5722-1.5728 inches exceeds the allowable limit, replace the camshaft.
(39,93-39,95) mm)
Camshaft Alignment
Oil Clearance of 0.002-0.0036 inch Allowable Limit 0.004 inch (0,01 mm)
Camshaft Journal (0,05-0,09) mm)
Allowable Limit 0.006 inch (0,15) mm)

753 Bobcat Loader

70-100-10 Service Manual
642 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-40

Servicing The Idler Gear And Shaft

1.378” (35 mm)
Figure 70-100-39
6.38” (162 mm)
1.575” 1.575”
(40 mm) (40 mm)

1.258-1.259”
(31,96-35,97 mm)

1.413-1.415”
(35,9-35,95 mm)

MC-1366

To replace the idler gear bushing, make a driver tool as

PI-10003 shown in figure [Figure 70-100-40].

Figure 70-100-41
Measure the O.D. of the idler gear shaft [Figure 70-100-
39].

Dealer Copy -- Not for Resale

Measure the I.D. of the idler gear bushing [Figure 70-
100-39].

If the clearance exceeds the allowable limit, replace the

bushing.
Idler Gear Shaft O.D. 1.258-1.259 inches
(31,96-31,98 mm)
Idler Gear Bushing I.D. 1.2598-1.2608 inches
(32,0-32,03 mm)
Clearance Between Idler 0.001-0.0026 inch
Shaft & Gear Bushing (0,025-0,07 mm)
PI-10004
Allowable Limit 0.004 inch (0,1 mm)

Use a press and special driver tool, to r emove the ol d

bushing and install the new bushing [Figure 70-100-41].

753 Bobcat Loader

70-100-11 Service Manual
643 of 726
RECONDITIONING THE ENGINE (CONT’D) Fuel Camshaft Removal And Installation

Timing Gears Checking Backlash Figure 70-100-43

Figure 70-100-42
2

B-14342

PI-10005
Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
When the gears are installed, check the backlash of the 100-7.)
gears.

Dealer Copy -- Not for Resale

Remove the idler gear. (See Idler Gear And Camshaft
Install a dial indicator [Figure 70-100-42]. Removal And Installation on Page 70-100-9.)

Hold one gear while turning the other gear [Figure 70- Remove the bolt (Item 1) from the retainer plate (Item 2)
100-42]. [Figure 70-100-43].

If the backlash exceeds the allowable limit, check the oil Installation: Tighten the bolt to 60 -72 in.-lbs. (6,8-8,1
clearance of the shaft and gear. If the oil clearance is Nm) torque.
correct, replace the gear.
Crank Gear & 0.0016-0.0044 inch Remove the fuel camshaft retainer plate (Item 2) [Figure
Idle Gear (0,042-0,112 mm) 70-100-43].
Allowable Limit 0.006 inch (0,15 mm)
Figure 70-100-44
Cam Gear & 0.0016-0.0045 inch
Idle Gear (0,042-0,115 mm)
Allowable Limit 0.006 inch (0,15 mm)
Injection Pump Gear & 0.0016-0.0045 inch
Idle Gear (0,042-0,115 mm)
Allowable Limit 0.006 inch (0,15 mm)
Oil Pump Gear & 0.0016-0.0043 inch
Crank Gear (0,042-0,109 mm) 1
Allowable Limit 0.006 inch (0,15 mm)

B-14343

Remove the fuel camshaft and fork lever assembly (Item

1) [Figure 70-100-44] at the same time.

753 Bobcat Loader

70-100-12 Service Manual
644 of 726
RECONDITIONING THE ENGINE (CONT’D) Crankshaft Gear Removal And Installation

Fuel Camshaft Governor Figure 70-100-46

Figure 70-100-45

5 4
1

3
2 9

12
6
7
B-3686
8 10
11
Remove the timing gearcase cover. (See Timing
13 Gearcase Cover Removal And Installation on Page 70-
1. Start Spring 100-7.)
2. Governor Spring

Dealer Copy -- Not for Resale

3. Governor Spring Remove the idler gear. (See Idler Gear And Camshaft
4. Fork Lever Removal And Installation on Page 70-100-9.)
5. Fork Lever
6. Fork Lever Shaft Remove the crankshaft gear with a puller [Figure 70-
7. Fork Lever Holder 100-46].
8. Governor Lever
9. Fuel Camshaft. Remove the crankshaft key.
10. Governor Ball Case
11. Steel Balls Installation: Install the crankshaft key. Heat the
12. Governor Sleeve crankshaft gear to 176°F (80°C) and fit it on the
13. Steel Ball PI-10008A
crankshaft.

The governor serves to keep the engine speed constant

by automatically adjusting the amount of fuel supplied to
the engine according to changes in the load.

Disassemble and assemble the governor and fuel

camshaft as shown in figure [Figure 70-100-45].

Check all the parts for wear or damage and replace as

needed.

753 Bobcat Loader

70-100-13 Service Manual
645 of 726
RECONDITIONING THE ENGINE (CONT’D) Oil Pump Service

Oil Pump Removal And Installation Figure 70-100-48

Figure 70-100-47

B-3616

B-3658
Measure the clearance between the lobes of the inner
rotor and outer rotor [Figure 70-100-48].
Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70- Figure 70-100-49
100-7.)

Dealer Copy -- Not for Resale

Remove the crankshaft gear.

Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 70-100-47].

Installation: Tighten the nut on the oil pump shaft to 46-

54 ft.-lbs. (62-73 Nm) torque.

Remove the oil pump mounting bolts. Remove the oil

pump (Item 2) [Figure 70-100-47].

Installation: Tighten the oil pump mounting bolts to 60-

72 in.-lbs. (6,9-8,1 Nm) torque. A-2732

Measure the c learance between the outer rotor and

pump body [Figure 70-100-49].

If the c learance exceeds the allowable limit, replace the

oil pump.
Clearance Between 0.0039-0.0063 inch
Inner & Outer Rotor (0,10-0,16 mm)
Clearance Between 0.0043-0.0075 inch
Outer Rotor & Body (0,11-0,19 mm)

753 Bobcat Loader

70-100-14 Service Manual
646 of 726
RECONDITIONING THE ENGINE (CONT’D) Remove the oil pressure sensor.

Oil Pump Service (Cont’d) Install a pressure gauge [Figure 70-100-51].

Figure 70-100-50 Start the engine and run until it is at operating

temperature.

If the oil pressure is less than the a llowable limit, check

the following items:

* Engine Oil Level Low

* Oil Pump Defective
* Oil Galley Plugged
* Oil Strainer Plugged
* Excessive Clearance at the Rod & Main Bearings
* Relief Valve Stuck

At Idle Speed 7 PSI (49 kPa)

Allowable Limit
PI-10009 At IdleSpeed 14 PSI (97 kPa)
At Rated Speed 43-64 PSI (294-441 kPa)
Put a piece of press gauge on the rotor face [Figure 70- Allowable Limit 36 PSI (245 kPa)
100-50].

Dealer Copy -- Not for Resale

Relief Valve
Install the cover and tighten the bolts.
Figure 70-100-52
Remove the c over carefully. Measure the wi dth of th e
press gauge [Figure 70-100-50].

If the clearance exceeds the allowable limit, replace the

oil pump.
2 3
End Clearance 0.0041-0.0059 inch
(0,11-0,15 mm)

Checking Engine Oil Pressure

Figure 70-100-51
1

PI-10011A

The relief valve prevents damage of the lubricating

system due to hig h pressure. This relief valve is a ball
type.

Remove the valve seat (Item 2), ball (Item 3) and spring
(Item 1) [Figure 70-100-52].

Check the parts for wear or damage and replace as

needed.
PI-10010

753 Bobcat Loader

70-100-15 Service Manual
647 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-54

Piston And Connecting Rod Removal And

Installation

Figure 70-100-53

1
PI-10013A PI-10013B

Remove the rod cap and bearing [Figure 70-100-54].

B-14344 Use a h ammer handle and push the piston/connecting

rod assembly out of th e cylinder bore [Figure 70-100-
54].
Remove the cylinder head. (See Cylinder Head Removal
And Installation on Page 70-100-1.)

Dealer Copy -- Not for Resale

NOTE: Make sure the pistons are marked so they will
be returned to the same cylinder bore.
Remove the top edge from the cylinder bore with a ridge
reamer. Figure 70-100-55

Remove the oil pin.

Remove the oil pump strainer (Item 1) [Figure 70-100-

53].

Turn the flywheel and put a pair of connecting rods at

82.8

bottom dead center.

Remove the connecting rod bolts.

Installation: Tighten the connecting rod bolts to the

82.8

following torque.
W/O Flange Bolt 27-30 ft.-lbs. (37-41 Nm)
A-2903A
W/Flange Bolt 33-36 ft.-lbs. (45-49 Nm)

Installation: When inserting the piston into the cylinder,

face the mark on the connecting rod to the injection pump
[Figure 70-100-55].

Repeat the pr ocedure to remove the other piston/

connecting rod assemblies from the engine block.

753 Bobcat Loader

70-100-16 Service Manual
648 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-58

Piston And Connecting Rod Removal And 3 4

Installation (Cont’d)

Figure 70-100-56
1
2 5
2

PI-10014B

Installation: When reassembling, align the marks (Item

4 1) on the connecting rod and piston (Item 2). Heat the
B-3621 piston to 176 -212°F (80-100°C.) and tap the pi ston pin
into position. Place the piston rings so that there are gaps
every 120 degrees (Items 3, 4 & 5) [Figure 70-100-58]
Remove the piston rings [Figure 70-100-56]. with no gap facing the piston pin in the cylinder.

Dealer Copy -- Not for Resale

Remove the snap ring (Item 3) and piston pin (Item 1) Servicing The Piston And Connecting Rod
[Figure 70-100-56].
Figure 70-100-59
Separate the piston (Item 2) from the connecting rod
(Item 4) [Figure 70-100-56].

Figure 70-100-57

180°

1
A-2733
3

Measure the I.D. of the piston pin bore in both horizontal

PI-10015A PI-10015B and vertical directions [Figure 70-100-59].

If the measurement exceeds the allowable limit, replace

Installation: When installing new rings, assemble the the piston.
ring so the mark (Item 1) near the gap faces the top of the
piston. When installing the oil ring, place the expander Piston Pin Bore I.D. 0.9843-0.9848 inch
joint (Item 2) on the opposite side of the oil ring gap (Item (25,0-25,014 mm)
3) [Figure 70-100-57]. Allowable Limit 0.9862 inch (25,05 mm)

753 Bobcat Loader

70-100-17 Service Manual
649 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-61

Servicing The Piston And Connecting Rod (Cont’d)

6.38” (162 mm)
Figure 70-100-60 1.063” (27 mm)

0.984-0.985”
1.098-1.1004” (25,0-25,011 mm)
1.378” (35 mm) (27,9-27,95 mm)

2
MC-1366

To replace the connecting rod small end bushing, make a

1
B-3633 driver tool as shown in [Figure 70-100-61].

Figure 70-100-62
Measure the O.D. of the piston pin (Item 1) [Figure 70-
100-60].

Dealer Copy -- Not for Resale

Measure the I.D. of the connecting rod small end (Item 2)
[Figure 70-100-60].

Calculate the oil clearance. If the clearance exceeds the

allowable limit, replace the bushing. If it still exceeds the
specifications, replace the piston pin.
Piston Pin O.D. 0.9843-0.9847 inch
(25,0-25,011 mm)
Small End Bushing I.D. 0.9852-0.9858 inch.
(25,03-25,04 mm)
Clearance Between 0.0006-0.0015 inch
PI-10016
Piston Pin & Small End (0,014-0,038 mm)
Bushing
Allowable Limit 0.0059 inch (0,15mm) Use a press and special driver tool to remove the small
end bushing [Figure 70-100-62].

Installation: Clean the small end bushing and bore. Put

oil on the bushing and press into the connecting rod until
it is flush [Figure 70-100-62]

753 Bobcat Loader

70-100-18 Service Manual
650 of 726
RECONDITIONING THE ENGINE (CONT’D) If the c learance exceeds the allowable limit, replace the
piston.
Servicing The Piston And Connecting Rod (Cont’d)
Comp. Ring 0.0037-0.0047 inch
Figure 70-100-63 (0,093-0,120mm)
Allowable Limit. 0.0079 inch (0,20 mm)
Oil Ring 0.0008-0.002 inch
(0,02-0,052 mm)
Allowable Limit. 0.0059 inch (0,15 mm)

Connecting Rod Alignment

Figure 70-100-65

B-3622

Install new piston ring into the lower part of the c ylinder
bore. Measure the ring gap with a feeler gauge [Figure

Dealer Copy -- Not for Resale

70-100-63].

If the gap exceeds the allowable limit, replace the

cylinder liner.

Comp. Ring Gap 0.0118-0.0177 inch B-4067

(0,3-0,45 mm)
Oil Ring Gap 0.010-0.018 inch
NOTE: The small end bushing is the basis of this
(0,25-0,45 mm)
check, check the bushing for wear before
Allowable Limit 0.0492 inch (1,25 mm) going this check.

Install the piston pin into the connecting rod.

Figure 70-100-64
Install the connecting rod on a 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 plate,
measure the space between the ga uge and face plate
[Figure 70-100-65].

If the measurement exceeds the allowable limit, replace

the connecting rod.
Rod Alignment 0.002 inch (0,05 mm)

PI-10017

Remove the carbon from the ring grooves. Measure the

clearance between the ring and groove with a feel er
gauge [Figure 70-100-64].

753 Bobcat Loader

70-100-19 Service Manual
651 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-68

Crankshaft And Bearings Removal And Installation

Figure 70-100-66

B-9565

Before removing the crankshaft/main bearings, check the

B-3648 end play. Install a dial indicator. Measure the end play by
moving the crankshaft back and forth [Figure 70-100-
68].
Remove the piston and connecting rod assemblies. (See
Piston And Connecting Rod Removal And Installation on If the measurement exceeds the allowable limit, replace
Page 70-100-16.)

Dealer Copy -- Not for Resale

the thrust washers.

Remove the engine flywheel. (See Flywheel Removal End Play 0.0059-0.0122 inch
And Installation on Page 70-90-1.) (0,15-0,31 mm)
Allowable Limit 0.0197 inch (0,5 mm)
Remove the bolts which fasten the bearing case cover to
the block.
Figure 70-100-69
Installation: Tighten the bearing case cover bolts to 13-
15 ft.-lbs. (18-21 Nm) torque.

Install two bolts into the bearing case cover and pull the
cover out [Figure 70-100-66].
2
Figure 70-100-67

1
2 B-14346

Remove the main bearing case bolt (Item 1) [Figure 70-

100-69].

Installation: Make alignment of the b earing case hole

B-14345 (Item 2) [Figure 70-100-69] with the hole in the block.
Put oil on the bolt threads and tighten to 51-54 ft.-lbs.
(69-73 Nm) torque.
Installation: When installing the co ver (Item 1), make
sure the c asting mark (Item 2) [Figure 70-100-67] is in
the down position.

753 Bobcat Loader

70-100-20 Service Manual
652 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-72

Crankshaft And Bearings Removal And Installation

(Cont’d)

Figure 70-100-70

PI-10021

Installation: When installing the main bearing case

assemblies, face the mark FLYWHEEL to th e flywheel
PI-10020 side of the engine block [Figure 70-100-72]. Be sure the
thrust washers with its oil grooves face outward.

Remove the crankshaft/main bearing assembly from the Servicing The Crankshaft And Bearings
engine block [Figure 70-100-70].

Dealer Copy -- Not for Resale

Figure 70-100-73
Mark the bearing case halves for correct installation.

Figure 70-100-71

A-2763

B-4092 Put the crankshaft on V-blocks. Install a dial indicator on

the center journal [Figure 70-100-73].

Remove the two bearing case bolts [Figure 70-100-71]. Turn the crankshaft at a slow rate.

Remove the bearing case and bearing. If the misalignment exceeds the allowable limit, replace
the crankshaft.
Installation: Tighten the bearing case bolts to 34-38 ft.-
lbs. (46-52 Nm) torque. Alignment (Allowable Limit) 0.00079 inch (0,02 mm)

753 Bobcat Loader

70-100-21 Service Manual
653 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-76

Servicing The Crankshaft And Bearings (Cont’d)

Figure 70-100-74

120

PI-10022

Check the wear on the crankshaft sleeve [Figure 70-100-

A-2727 76].

If the wear exceeds the allowable limit or the seal leaks

Tighten the connecting rod cap bolts as follows: oil, replace the sleeve.
W/O Flange Bolt 27-30 ft.-lbs. (37-41 Nm) Wear of Sleeve 0.004 inch (0,1 mm)

Dealer Copy -- Not for Resale

W/Flange Bolt 33-36 ft.-lbs. (45-49 Nm)

Figure 70-100-77
Figure 70-100-75

2
2
1 3

PI-10023A PI-10023B

A-2716

The special tool set (Kubota Code Number: 07916-

Measure the crankpin O.D.[Figure 70-100-75]. 32091) will be needed to replace the crankshaft sleeve.

Calculate the oil clearance. Remove the sleeve.

Crankpin Bearing I.D. 1.8504-1.8522 inches Install the sleeve guide (Item 1) and stop (Item 2) [Figure
(47,0-47,046 mm) 70-100-77].
Crankpin O.D. 1.8488-1.8494 inches
(46,96-46,98 mm) Heat the sleeve to about 300°F (150°C). install the sleeve
Oil Clearance. 0.0009-0.0034 inch on the crankshaft using the special driver tool (Item 3)
(0,025-0,087 mm) [Figure 70-100-77].

753 Bobcat Loader

70-100-22 Service Manual
654 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-80

Servicing The Crankshaft And Bearings (Cont’d) REMOVAL TOOL

5.31” (135 mm)

Figure 70-100-78 0.8”

(20 mm)

2.83”
(72 mm) 2.0413-2.0433”
(51,85-51,90 mm)

0.8” (20 mm)

2.2328-2.2402”
1.57” R (56,85-56,90 mm)
(40 mm) 0.4”
(10 mm)

MC-1367

To remove the front bearing make the driver tool as

B-3631A shown in figure [Figure 70-100-80].

Figure 70-100-81
Measure the I.D. of the No.1 crankshaft bearing [Figure
INSTALLATION
70-100-78].
TOOL

Dealer Copy -- Not for Resale

5.12” (130 mm)
Figure 70-100-79
0.8”
(20 mm)
0.35”
(9 mm)
2.83” 2.2382-2.2402*”
(72 mm) (56,85-56,90 mm)

0.8” (20 mm)

2.0412-2.0433”
1.57” R (51,85-51,90 mm)
(40 mm) 0.4”
(10 mm) MC-1365

To install the front bearing make the driver tool as shown

B-3618 in [Figure 70-100-81]

Measure the O.D. of the crankshaft journal [Figure 70-

100-79].

Calculate the clearance.

If the clearance exceeds the allowable limit, replace the

crankshaft bearing.
Bearing I.D. 2.0465-2.0488 inch
(51,98-52,04 mm)
Journal O.D. 2.0441-2.0449 inch
(51,92-51,94 mm)
Oil Clearance 0.0016-0.0046 inch
(0,04-0,12 mm)
Allowable Limit 0.0079 inch (0,2 mm)

753 Bobcat Loader

70-100-23 Service Manual
655 of 726
RECONDITIONING THE ENGINE (CONT’D) If the c learance exceeds the allowable limit, replace the
crankshaft bearing.
Servicing The Crankshaft And Bearings (Cont’d)
Crankshaft Journal O.D. 2.0441-2.0449 inch
Figure 70-100-82 (51,92-51,94 mm)
Bearing I.D. 2.0465-2.0482 inch
0.165-0.177” (51,98-52,03 mm)
(4,2-4,5 mm) Oil Clearance 0.0016-0.0041 inch
(0,04-0,10 mm)
Allowable Limit 0.0079 inch (0,2 mm)

Checking The Cylinder Bore

Figure 70-100-84

PI-10024A

Remove the front bearing (Item 1) [Figure 70-100-82]

with the special removal tool.

Dealer Copy -- Not for Resale

Installation: Clean the new bearing and bore, apply oil
on them. Install the ne w bearing with the installation
driver tool [Figure 70-100-82].

Figure 70-100-83 B-4066

Use a ga uge to c heck the inside measurement of th e

cylinder bore [Figure 70-100-84].

Figure 70-100-85

PI-10025

Clean the crankshaft journal and b earing. Put a s trip of

press gauge on the center journal.

Install the main bearing case halves and tighten the bolts. A-2717

Remove the bearing case halves.

Measure the s ix points as shown in [Figure 70-100-85]
Measure the flattened press gauge [Figure 70-100-83]. to find the maximum wear.
The specification is 3.4252-3.4261 inches (87,0-87,022
mm). The wear limit is +0.0059 inch (+0,15 mm).

If the cylinder bore is not within specifications, re-bore the

cylinder for oversize piston.

753 Bobcat Loader

70-100-24 Service Manual
656 of 726
RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-88

Water Pump Disassembly And Assembly

Figure 70-100-86

B-5325

Drive the shaft out of the impeller side of the water pump
B-5318 housing [Figure 70-100-88].

Figure 70-100-89
Remove the water pump from the timing gearcase cover
[Figure 70-100-86].

Dealer Copy -- Not for Resale

Figure 70-100-87

A-2783A

Install the new seals [Figure 70-100-89]. Install the shaft.

B-5324A
Installation: Put the water pump in a vise and tighten the
nut to 50-57 ft.-lbs. (68-77 Nm) torque. Always use a new
Put the water pump in a vise and remove the nut [Figure gasket when installing the wa ter pump on th e timing
70-100-87]. gearcase cover.

Remove the pu lley using a puller. Remove the key and

snap ring.

753 Bobcat Loader

70-100-25 Service Manual
657 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

70-100-26 Service Manual
658 of 726
 HEATER

BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1

Checking The Electrical System . . . . . . . . . . . . . . . . . . . . 80-30-3
Cleaning The Heater Coil. . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1 HEATER
Engine Coolant By-Passing The Heater Valve . . . . . . . . . 80-30-8
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . 80-30-8

COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

HEATER COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1 DRIVE
SYSTEM
HEATER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 80-70-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Wire Connector Removal and Installation . . . . . . . . . . . . . 80-70-4

HEATER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 80-50-2

Dealer Copy -- Not for Resale

ELECTRICAL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1 SYSTEM &
ANALYSIS
HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 80-80-2
Removal and Installation (Cont’d) . . . . . . . . . . . . . . . . . . . 80-80-2 ENGINE
SERVICE
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Filter Elements Removal And Installation . . . . . . . . . . . . . 80-20-1

SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . 80-40-1 SPECIFICATIONS

Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . 80-40-1

753 Bobcat Loader

80-01 Service Manual
659 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

80-02 Service Manual
660 of 726
COMPONENTS Figure 80-10-3

Identification

Figure 80-10-1
1

N-22100
1
Heater Blower: The blower (Item 1) [Figure 80-10-3] is
P-28906 used to push air through the heater and into the cab.

Figure 80-10-4
Heater Unit: The heater (Item 1) [Figure 80-10-1] is
located behind the loader cab. The unit delivers the warm
air for heat into the cab. The unit contains the blower and

Dealer Copy -- Not for Resale

heater coil. 1

Figure 80-10-2

2 3
1

N-20876

Control Panel: The panel (Item 1) [Figure 80-10-4] has

two separate components.

N-22092 Fan Switch: This is a four position rotary switch (Item 2)

[Figure 80-10-4]. When the fan switch is in the off
position the heat valve will operate, as it is controlled by
Heater Coil: The heater coil (Item 1) [Figure 80-10-2] the ignition power.
supplies the warm air into the cab by passing air through
the coil. Potentiometer: The potentiometer (Item 3) [Figure 80-
10-4] controls the Hea ter Valve (Item 1) [Figure 80-10-
5]from fully Off to fully On. This can be used for defrost of
the windows and temperature control.

753 Bobcat Loader

80-10-1 Service Manual
661 of 726
COMPONENTS (CONT’D)

Identification (Cont'd)

Figure 80-10-5

P-43854

Heater Valve: The heater valve (Item 1) [Figure 80-10-5]

is used to control the amount of engine coolant that flows
to the heater coil.

Dealer Copy -- Not for Resale

753 Bobcat Loader

80-10-2 Service Manual
662 of 726
REGULAR MAINTENANCE Figure 80-20-3

Filter Elements Removal And Installation Earlier

Figure 80-20-1

Earlier 1

P-21905

Figure 80-20-4
P-21904
Later

Figure 80-20-2
1

Dealer Copy -- Not for Resale

Later

P-28819

1 Remove the filter cover and filter (Item 1) [Figure 80-20-

P-28818 3] & [Figure 80-20-4] from the loader.

Remove the two mount bolts (Item 1) [Figure 80-20-1] &

[Figure 80-20-2] from the fresh air filter cover at the rear
of the loader cab.

753 Bobcat Loader

80-20-1 Service Manual
663 of 726
REGULAR MAINTENANCE (CONT’D) Figure 80-20-7

Filter Elements Removal And Installation (Cont'd)

Figure 80-20-5
Earlier

N-22153
1

Remove the two retaining knobs (Item 1) [Figure 80-20-

P-21906 7] from the recirculating air filter cover, at the back of the
cab.

Figure 80-20-6 Remove the r etaining cover (Item 2) [Figure 80-20-7]

Later from the loader cab.

Dealer Copy -- Not for Resale

Figure 80-20-8

P-28820

Remove the filter (Item 1) [Figure 80-20-5] & [Figure 80-

P-21907
20-6] from the cover.

The fresh air filter must be cleaned sometimes as often Remove the recirculating air filter (Item 1) [Figure 80-20-
as twice a day, depending on the operating environment. 8] from the rear of the cab.
The filter can be cleaned by removing and shaking it. A
small amount of a ir pressure can be used to clean the
filter. However the fresh air filter should be changed at
least 2-4 times per year in normal conditions. In
extremely dusty conditions the fresh air filter may need to
be changed weekly.

753 Bobcat Loader

80-20-2 Service Manual
664 of 726
REGULAR MAINTENANCE (CONT’D)

Filter Elements Removal And Installation (Cont'd)

Figure 80-20-9

N-22274

The recirculating air filter [Figure 80-20-9] is made of

open cell foam and should be cleaned with water. A mild
detergent may also be used. It does not require cleaning

Dealer Copy -- Not for Resale

as frequently as the fresh air intake filter.

Reverse the removal procedure to install the filter

element.

753 Bobcat Loader

80-20-3 Service Manual
665 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

80-20-4 Service Manual
666 of 726
BASIC TROUBLESHOOTING Figure 80-30-2

Cleaning The Heater Coil

There are two di fferent methods when cleaning the

heater coil. The EARLY style requires you to remove the
whole heater assembly to access the heater coil. The
LATER style only requires the removal of the rear cover
1
(Item 2) [Figure 80-30-1], the whole heater unit does not
need to be removed.

If your rear cover has the six mounting screws (Item 1)

[Figure 80-30-1] visable, then you have the LATER
style. Only the rear cover needs to be removed to access
the heater coil for cleaning.
P-43852
LATER STYLE:

Figure 80-30-1 The heater coil (Item 1) [Figure 80-30-2], can now b e
cleaned with low pressure water or air. High pressure
may damage the fins of the heater.

EARLY STYLE:

Dealer Copy -- Not for Resale

1 2 Figure 80-30-3

P-43853

Loosen the six mounting screws for the rear cover (Item
1
1) [Figure 80-30-1]. The screws do not ne ed to be
completely removed, they are secured on the back with
plastic retaining washers. N-22130

Remove the cover.

Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Raise the operator cab. (See Raising The Operator Cab

on Page 10-30-1.)

Remove the mount bolt (Item 1) [Figure 80-30-3] from

the left side cab access cover.

Remove the access cover (Item 2) [Figure 80-30-3] from

the loader.

753 Bobcat Loader

80-30-1 Service Manual
667 of 726
BASIC TROUBLESHOOTING (CONT’D) Figure 80-30-6

Cleaning The Heater Coil (Cont'd)

Figure 80-30-4
1

1
P-30103

Remove the two mounting nuts (Item 1) [Figure 80-30-

N-22129 6].

Figure 80-30-7
Disconnect the blower fan wiring connector (Item 1)
[Figure 80-30-4] from the loader wiring harness.

Dealer Copy -- Not for Resale

1
Figure 80-30-5

P-30105
1

Remove the Heater Unit from the rear of the cab. Place it
P-30104 on the fenders of the loader supported with 2x4's
(blocking) [Figure 80-30-7].

Remove the two mounting nuts (Item 1) [Figure 80-30- Remove the six mount bolts (Item 1) [Figure 80-30-7] &
5]. [Figure 80-30-8] from the rear cover.

753 Bobcat Loader

80-30-2 Service Manual
668 of 726
BASIC TROUBLESHOOTING (CONT’D) Checking The Electrical System

Cleaning The Heater Coil (Cont'd) NOTE: The key must be put in the ON position when
checking for power in circuits.
Figure 80-30-8
Figure 80-30-10

1
P-30106

N-22130

Remove the rear cover from the unit.

Remove the mount bolt (Item 1) [Figure 80-30-10] from

Dealer Copy -- Not for Resale

Figure 80-30-9 the left side cab access cover.

Remove the access cover (Item 2) [Figure 80-30-10]

from the loader.
1
Figure 80-30-11

P-30107

With air or water, clean the heater coil (Item 1) [Figure

80-30-9].
N-22129

Disconnect the blower fan wiring connector (Item 1)

[Figure 80-30-11] from the loader wiring harness.

753 Bobcat Loader

80-30-3 Service Manual
669 of 726
BASIC TROUBLESHOOTING (CONT’D) Figure 80-30-14

Checking The Electrical System (Cont'd)

Figure 80-30-12 1

1
1

N-20876

Remove the three mount screws (Item 1) [Figure 80-30-

N-22260 14] from the cab control panel.

Figure 80-30-15
Check the loader harness (Item 1) [Figure 80-30-12] for
voltage. The voltage should be 12 volts.

Dealer Copy -- Not for Resale

If there is no v oltage at the wiring harness, check the
harness for broken wires or blown fuse.

Figure 80-30-13

P-28920

1 Remove the control panel and wiring harness from the

cab [Figure 80-30-15].

N-22260

If there is voltage at the wiring harness, check the

resistance to th e blower fan at the blower fan wiring
connector (Item 1) [Figure 80-30-13].

If there is no resistance value replace the blower fan.

(See Removal And Installation on Page 80-70-1.)

If there is a resistance value check the climate controls at

the control panel inside the loader cab.

753 Bobcat Loader

80-30-4 Service Manual
670 of 726
BASIC TROUBLESHOOTING (CONT’D) With the switch in the 1 position, there should be
resistance between C terminal and the B terminal,
Checking The Electrical System (Cont'd) between the C terminal and the L terminal a nd also
between the B terminal and the L terminal frame [Figure
Figure 80-30-16 80-30-17].

With the switch in the 2 position, there should be

resistance between C terminal and the B terminal,
1 between the C terminal and the M terminal and also
between the B and the M terminal frame [Figure 80-30-
17].

With the switch in the 3 position, there should be

resistance between C terminal and the B terminal,
between the C terminal and the H terminal and also
between the B terminal and the H terminal frame [Figure
80-30-17].

If any of the above resistance tests fail, replace the

P-28918 blower switch.

If the above resistance tests are good, check the

Disconnect the loader wiring harness (Item 1) [Figure potentionmeter.
80-30-16] from the blower switch.

Dealer Copy -- Not for Resale

Figure 80-30-18
Check the loader harness for voltage. The voltage should
be 12 volts.

If there is no v oltage at the wi ring harness, check the

harness for broken wires or blown fuse.
1
Figure 80-30-17

C
H

B
P-28920
M

L The potentiometer will affect the operation of the heater.

If heater valve does not o pen, or close, check the

potentiometer.
N-22288
At the loader cab, disconnect the loader harness (Item 1)
[Figure 80-30-18] from the potentiometer.
If there is voltage at the wiring harness, check the blower
switch [Figure 80-30-17] for resistance.

With the switch in the OFF position, there should be

resistance between L terminal and the H terminal frame.

753 Bobcat Loader

80-30-5 Service Manual
671 of 726
BASIC TROUBLESHOOTING (CONT’D) Figure 80-30-21

Checking The Electrical System (Cont'd)

Figure 80-30-19

1
N-22201

The white wire B, (Item 1) [Figure 80-30-21], on the

P-28919 potentiometer, is a resistor wire.

Figure 80-30-22
Check the loader harness (Item 1) [Figure 80-30-19] for
voltage. The voltage should be 12 volts.

Dealer Copy -- Not for Resale

If there is no v oltage at the wiring harness, check the
harness for broken wires or blown fuse.

Figure 80-30-20

A C
N-22175

To check the resistance of the white wire, turn the

B potentiometer control (Item 1) [Figure 80-30-22] to the
full A/C position.

N-22290

If there is voltage at the wiring harness, check the

potentiometer [Figure 80-30-20] for resistance.

The resistance should be 10 K Ohm's between wire

terminal A and wire terminal C frame [Figure 80-30-20].

If no resistance is found replace the potentiometer.

753 Bobcat Loader

80-30-6 Service Manual
672 of 726
BASIC TROUBLESHOOTING (CONT’D) Figure 80-30-25

Checking The Electrical System (Cont'd)

Figure 80-30-23

A C

A C
B

N-22290
B

Check the resistance between the wire terminal A and

N-22290 wire terminal B frame [Figure 80-30-25] should be
approximately 39 K Ohm's.

The resistance between the wir e terminal A and wire Check the resistance between the wire terminal C and
terminal B frame [Figure 80-30-23] should be wire terminal B frame [Figure 80-30-25] should be
approximately 49 K Ohm's.

Dealer Copy -- Not for Resale

approximately 49 K Ohm's.

Check the resistance between the wire terminal C and If the resistance is not found replace the potentiometer.
wire terminal B frame [Figure 80-30-23] should be
approximately 39 K Ohm's.

Figure 80-30-24

N-22175

To check the resistance of the w hite wire, turn the

potentiometer control (Item 1) [Figure 80-30-24] to the
full Heater position.

753 Bobcat Loader

80-30-7 Service Manual
673 of 726
BASIC TROUBLESHOOTING (CONT’D) Heater Valve Not Opening Or Closing

Engine Coolant By-Passing The Heater Valve Figure 80-30-28

Figure 80-30-26

2
1
1

N-20876

N-20876

Raise the lift arms and install an approved lift arm

Raise the lift arms and install an approved lift arm support device. (See Installing Lift Arm Support Device
support device. (See Installing Lift Arm Support Device on Page 10-20-1.)
on Page 10-20-1.)

Dealer Copy -- Not for Resale

Turn the fan switch (Item 1) to po sition 1. Turn the
Turn the fan switch (Item 1) [Figure 80-30-26] to th e temperature control (Item 2) [Figure 80-30-28] to the
High Speed position, with the loader ignition switch OFF. High cold position, with the loader ignition switch OFF.

Raise the operator cab. (See Raising The Operator Cab Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) on Page 10-30-1.)

Connect the r emote start tool to the loader. (See Connect the r emote start tool to th e loader. (See
REMOTE START on Page 10-60-1.) REMOTE START on Page 10-60-1.)
Figure 80-30-27

P-43854

Start the loader and run at high idle, for ten minutes.

Check the h eater hose (Item 1) [Figure 80-30-27] for

temperature.

If the hose is hot, the heater valve is leaking by, and

needs to be replaced.

753 Bobcat Loader

80-30-8 Service Manual
674 of 726
BASIC TROUBLESHOOTING (CONT’D)

Heater Valve Not Opening Or Closing (Cont’d)

Figure 80-30-29

P-43855A P-43854A

Place the remote start tool on the left fender of the

loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-29], as the key of

Dealer Copy -- Not for Resale

the remote start tool is turned to the ON position without
starting the loader. The heater valve should rotate. Place
a mark on the loader shaft.

Turn the key of the remote start tool to the OFF position
and remove the remote start tool from fender.

Lower operator cab.

Turn the temperature control (Item 2) [Figure 80-30-28]

to the High Heater position, with the loader ignition switch
OFF.

Raise the operator cab.

Place the remote start tool on the left fender of the

loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-30-29], as the key of
the remote start is turned to the ON position without
starting the loader. The heater valve should rotate.

If it does not rotate, check the potentiometer for proper

function. (See Checking The Electrical System on Page
80-30-3.)

Replace the heater valve. (See Removal and Installation

(Cont’d) on Page 80-80-2.)

753 Bobcat Loader

80-30-9 Service Manual
675 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

80-30-10 Service Manual
676 of 726
SYSTEM TROUBLESHOOTING CHART

Blower Motor Does Not Operate

POSSIBLE CAUSE INSPECTION SOLUTION

1. Blown Fuse. Inspect the fuse/wiring. Replace fuse/repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or
connection. connector.
3. Fan motor malfuntion. Check the lead wires from the motor with a circuit tester. Replace Motor.
4. Resistor malfuntion. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.

Blower motor operators normally, but air flow is insufficient

POSSIBLE CAUSE INSPECTION SOLUTION

1. Air leak. Check to make sure air hoses are properly hooked to Repair or adjust.
Louvers, and air ducts.

Dealer Copy -- Not for Resale

753 Bobcat Loader

80-40-1 Service Manual
677 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

80-40-2 Service Manual
678 of 726
HEATER UNIT Figure 80-50-3

Removal And Installation

Figure 80-50-1

P-30104

1
Remove the two mounting nuts (Item 1) [Figure 80-50-
N-22130 3].

Figure 80-50-4
Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Dealer Copy -- Not for Resale

Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)

Remove the mount bolt (Item 1) [Figure 80-50-1] from

the left side cab access cover.
1
Remove the access cover (Item 2) [Figure 80-50-1] from
the loader.

Figure 80-50-2
P-30103

Remove the two mounting nuts (Item 1) [Figure 80-50-

4].

N-22129

Disconnect the blower fan wiring connector (Item 1)

[Figure 80-50-2] from the loader wiring harness.

753 Bobcat Loader

80-50-1 Service Manual
679 of 726
HEATER UNIT (CONT’D) Disassembly And Assembly

Removal And Installation (Cont'd) Figure 80-50-6

Figure 80-50-5

1
1

P-30149

P-30108
Remove the six mount bolts (Item 1) [Figure 80-50-6]
from the heater unit rear cover.
Remove the heater unit from the rear of the cab. Support
heater unit by placing blocks across the fr ame [Figure Remove the rear cover from the unit.

Dealer Copy -- Not for Resale

80-50-5].
Reverse the disassembly procedure to assemble the
Remove the heater hoses (Item 1) [Figure 80-50-5] from heater unit.
the heater coil.

Installation: Tighten the heater hoses to 22 ft.-lbs. (29,8

Nm) torque.

Remove the heater unit from the loader.

Reverse the removal procedure to install the heater unit.

753 Bobcat Loader

80-50-2 Service Manual
680 of 726
HEATER COIL Figure 80-60-2

Removal And Installation

Figure 80-60-1
1 1

2
1

N-22093

Remove the rear cover from the heater unit. (See

P-30108 Disassembly And Assembly on Page 80-50-2.)

Remove the three mount bolts (Item 1) [Figure 80-60-2]

Raise the lift arms and install an approved lift arm and remove the mount plate from the end of the unit.
support device. (See Installing Lift Arm Support Device
on Page 10-20-1.)

Dealer Copy -- Not for Resale

Remove the two mount bolts (Item 2) [Figure 80-60-2]
that support the heater coil tubelines to the unit.
Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.) Figure 80-60-3

Remove the he ater unit from the back of the cab. (See
Removal And Installation on Page 80-50-1.)

Mark the h eater hoses (Item 1) [Figure 80-60-1] for

proper installation.

Remove the two heater hoses from the heater coil. 1

Cap the hoses and the heater coil with hydraulic caps
and plugs to prevent coolant loss from the system.

Installation: Tighten the two heater hose fittings to 22 ft.-

lbs. (29,8 Nm) torque.
N-22094

Remove the two mount bolts (Item 1) [Figure 80-60-3]

from the heater coil.

Remove the heater coil from the unit.

Reverse the removal procedure to install the heater coil.

753 Bobcat Loader

80-60-1 Service Manual
681 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

80-60-2 Service Manual
682 of 726
HEATER FAN Figure 80-70-3
Removal And Installation

Figure 80-70-1
1

N-22098

If the metal is not cut out on the housing, mark the area
N-22096
(Item 1) [Figure 80-70-3] and remove it with a metal
shears.
Raise the lift arms and install an approved lift arm
support device. (See Installing Lift Arm Support Device Figure 80-70-4
on Page 10-20-1.)

Dealer Copy -- Not for Resale

Raise the operator cab. (See Raising The Operator Cab
on Page 10-30-1.)

Remove the he ater unit from the back of the cab. (See
Removal And Installation on Page 80-50-1.) 1

NOTE: The heater fan assembly can be removed from

the heater unit without disconnecting the
heater plumbing. The unit is removed here for
photo clarity.

Remove the grommet (Item 1) [Figure 80-70-1] from the

side of the evaporator/heater unit.

Figure 80-70-2 N-22099

Remove the blower fan wiring harness and grommet

(Item 1) [Figure 80-70-4] from the unit.

N-22097

NOTE: On some early heater units the metal was not

cut out, so the blower wiring harness (Item 1)
[Figure 80-70-2] could not be removed without
removing the wiring connector.

753 Bobcat Loader

80-70-1 Service Manual
683 of 726
HEATER FAN (CONT’D) Remove the fan motor assembly from the housing.

Removal And Installation (Cont'd) Figure 80-70-7

Figure 80-70-5

1
2

N-22107

N-22100
Check the blower housing (Item 1) and fan motor mount
(Item 2) [Figure 80-70-7] for wear and r eplace as
Remove the three mount bolts (Item 1) [Figure 80-70-5] needed.
from the blower fan housing.

Dealer Copy -- Not for Resale

Figure 80-70-8
Remove the blower fan housing from the heater unit.
1
Reverse the removal procedure to install the heater fan.

Disassembly And Assembly 1

Figure 80-70-6

N-22108
1 1

Remove the outside rings (Item 1) and fan wheel covers

(Item 2) [Figure 80-70-8] from the fan motor and blower
wheels.

2 N-22102

Remove the eight mount bolts (Item 1) [Figure 80-70-6]

from the blower wheel cover.

Remove the blower wheel cover from the fan housings.

Remove the four mount bolts (Item 2) [Figure 80-70-6]

from the fan motor mount.

Remove the fan motor mount.

753 Bobcat Loader

80-70-2 Service Manual
684 of 726
HEATER FAN (CONT’D) Figure 80-70-11

Disassembly And Assembly (Cont'd)

Figure 80-70-9

N-22112

Remove the outside blower wheel clamp (Item 1) [Figure

N-22109 80-70-10] & [Figure 80-70-11] from the blower wheel.

Figure 80-70-12
Inspect the end rings and fan wheel covers for wear and
replace as needed [Figure 80-70-9].

Dealer Copy -- Not for Resale

Figure 80-70-10

N-22111

Remove the inside blower wheel clamp (Item 1) [Figure

N-22110 80-70-12] from the blower wheel.

753 Bobcat Loader

80-70-3 Service Manual
685 of 726
HEATER FAN (CONT’D) Figure 80-70-15

Disassembly And Assembly (Cont'd)

Figure 80-70-13

1 1
2

N-22104

Remove the plastic wedge (Item 1) [Figure 80-70-14] &

N-22116 [Figure 80-70-15] from the center of the blower fan motor
wiring connector.

NOTE: Before removing blower wheels, mark their Figure 80-70-16

orientation to ensure they are assembled

Dealer Copy -- Not for Resale

back on the correct side and the fins are
facing the same direction.
1
Remove the blower wheel (Item 1) and inside ring (Item
2) [Figure 80-70-13] from the blower fan motor shaft.

Repeat the procedure for the other blower wheel.

Wire Connector Removal and Installation

1
Figure 80-70-14 1 1

N-22105

With a pointed screw driver lightly press in on the tabs

1 (Item 1) [Figure 80-70-16] and remove the individual
wires from the connector.

Reverse the disassembly procedure to assemble the

heater fan.

N-22103

753 Bobcat Loader

80-70-4 Service Manual
686 of 726
HEATER FAN (CONT’D)

Wire Connector Removal and Installation (Cont'd)

Figure 80-70-17

N-22106

The wiring code for the blower fan connector [Figure 80-
70-17] is:

Dealer Copy -- Not for Resale

Number on Connector Wire Color
1 Orange
2 Red
3 Yellow
4 Black
5 Open
6 Open

Reverse the r emoval procedure to i nstall the wi re

connector.

753 Bobcat Loader

80-70-5 Service Manual
687 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

80-70-6 Service Manual
688 of 726
HEATER VALVE Figure 80-80-2

Removal and Installation

Figure 80-80-1
1
3

2
4

3
N-22155

1
Remove the three mount bolts (Item 1) [Figure 80-80-2]
P-43867 from the heater valve actuator.

Figure 80-80-3
Disconnect the loader wiring harness (Item 1) [Figure
80-80-1] from the heater valve.

Dealer Copy -- Not for Resale

Remove the relay mounting screw (Item 2) [Figure 80-
80-1] from the h eater valve. Remove the relay, and
replace the screw.
2 1
Remove the two coolant hoses (Item 3) [Figure 80-80-1]
from the heater valve.

Cap the hoses and the heater valve with caps and plugs
to prevent coolant loss from the system.

Remove the two mount bolts (Item 4) [Figure 80-80-1]

from the heater valve mount bracket. N-22156

Remove the he ater valve and mount bracket from the

loader. Remove the actuator (Item 1) and the three mounting
spacers (Item 2) [Figure 80-80-3] from the heater valve
mount plate.

753 Bobcat Loader

80-80-1 Service Manual
689 of 726
HEATER VALVE (CONT’D) Figure 80-80-6

Removal and Installation (Cont’d)

Figure 80-80-4

1
N-22159

Remove the two mounting bolts (Item 1) [Figure 80-80-6]

N-22157 from the heater valve.

Figure 80-80-7
Remove the three mounting bolts (Item 1) [Figure 80-80-
4] from the heater valve mount plate.

Dealer Copy -- Not for Resale

Disassembly And Assembly

Figure 80-80-5

1
1

N-22160

Remove the heater valve mount bracket (Item 1) [Figure

80-80-7] from the heater valve.

N-22158 Replace the parts as needed.

Remove the mount plate (Item 1) [Figure 80-80-5] from

the heater valve bracket.

753 Bobcat Loader

80-80-2 Service Manual
690 of 726
 SPECIFICATIONS

CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-60-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 SPECIFICATIONS

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Crankshaft Re-Grind Data . . . . . . . . . . . . . . . . . . . . . . SPEC-20-5
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 DRIVE
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 SYSTEM
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4

Dealer Copy -- Not for Resale

ELECTRICAL
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4 SYSTEM &
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 ANALYSIS
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Valve Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
ENGINE
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-40-1 SERVICE
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-2
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-40-1
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-5 SPECIFICATIONS
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-40-2
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-2

HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . SPEC-50-1

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1

LOADER SPECIFICATIONS (753) . . . . . . . . . . . . . . . . . . SPEC-10-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5

Continued On Next Page

753 Bobcat Loader

SPEC-01 Service Manual
691 of 726
 SPECIFICATIONS (CONT’D)

TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . SPEC-30-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . SPEC-30-2
Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . SPEC-30-1
Torque For Kubota Metric Bolts . . . . . . . . . . . . . . . . . . SPEC-30-2

Dealer Copy -- Not for Resale

753 Bobcat Loader

SPEC-02 Service Manual
692 of 726
LOADER SPECIFICATIONS (753)

Machine Dimensions

• Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types.
All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

Dealer Copy -- Not for Resale

27°

P-43851

A 10-16.5 TIRES-60.3 in. (1524 mm)

10-16.5 TIRES WITH INSET RIMS-54 in. (1372 mm)
31.5-13-16.5 TIRES-60 in. (1524 mm)
B 10-16.5 TIRES-50.3 in. (1278 mm)
10-16.5 TIRES WITH INSET RIMS-44 in. (1118 mm)
31.5-13-16.5 TIRES-46.3 in. (1176 mm)
C 54 in. BUCKET WIDTH-55.0 in. (1398 mm)
62 in. BUCKET WIDTH-62.0 in. (1575 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.

753 Bobcat Loader

SPEC-10-1 Service Manual
693 of 726
LOADER SPECIFICATIONS (753) (CONT’D)

Performance

Rated Operating Capacity (SAE) 1300 lbs. (612 kg)

Tipping Load (SAE Rating) 2600 lbs. (1179 kg)
Operating Weight 4740 lbs. (2150 kg)
SAE Breakout Force - Lift 2750 lbs. (12233 N)
- Tilt 2800 lbs. (12455 N)
Axel Torque 4700 ft.-lbs. (6373 Nm)
Travel Speed 0-6.6 MPH (10,6 km/hr.)

Controls

Vehicle Steering Direction and speed controlled by two hand levers.

Loader Hydraulics
Lift and Tilt Controlled by separate foot pedals or optional hand controls.
Front Auxiliary (Std.) Controlled by electrical switch on RH steering lever.
Rear Auxiliary (Option) Controlled by electrical switch on LH steering lever.
Engine Hand lever throttle: Key-type starter switch and shutdown.
Starting Aid Glow Plug-Automatically activated by Std. or Deluxe instrumentation.

Dealer Copy -- Not for Resale

Service Brake Two independent hydrostatic systems controlled by two hand operated steering
levers.
Secondary Brake One of the hydrostatic transmissions.
Parking Brake (Earlier), foot operated pedal. (Later) Push Button.

Engine

Make/Model KUBOTA V2203-EB

Fuel/Cooling Diesel/Liquid
Horsepower @ 2650 RPM (SAE) Net: 43.5 HP (32.4 kW) Gross: 49.0 HP (36.5 kW)
Torque @ 1600 RPM (SAE) Net: 107 ft.-lbs. (145 Nm) Gross: 114 ft.-lbs. (155 Nm)
Number of Cylinders Four
Displacement 134.0 cu. in. (2195 cu. cm.)
Bore/Stroke 3.425/3.638 (87/92.4)
Lubrication Gear Pump Pressure System W/Filter
Crankcase Ventilation Open
Air Cleaner Dry replaceable cartridge w/seperate safety element
Ignition Diesel-Compression
Maximum Governed RPM 2650 RPM
Low Idle 1125-1175 RPM
High Idle 2710-2850 RPM

753 Bobcat Loader

SPEC-10-2 Service Manual
694 of 726
LOADER SPECIFICATIONS (753) (CONT’D)

Hydraulic System

Pumps Engine driven, Gear type

Pump Capacity (Aluminum) 14.8 GPM (56 L/min.) @ 2800 RPM
Pump Capacity (Cast Iron) 15.7 GPM (59 L/min.) @ 2800 RPM
System Relief at Quick Couplers 2500-2600 PSI (17237-17926 kPa)
Filter Full flow replaceable, 3 micron synthetic media element
Hydraulic Cylinders Doubleacting;
Tilt cylinder has cushioning feature on dump & rollback
Bore Diameter: Lift Cylinder (2) 2.00 (50,8)
Tilt Cylinder (1) 3.50 (88,9)
Rod Diameter: Lift Cylinder (2) 1.25 (31,8)
Tilt Cylinder (1) 1.50 (38,1)
Stroke: Lift Cylinder (2) 26.57 (668,5)
Tilt Cylinder (1) 14.50 (368,3)
Control Valve 3-spool, open center type w/float detent on lift and electrically controlled
auxiliary spool.
Fluid Lines SAE standard tubelines, hoses and fittings.

Dealer Copy -- Not for Resale

Fluid Type Bobcat Fluid (P/N 6563328). If fluid is not available, use 10W-30/10W-40 Class
SE motor oil for temperatures above 0°F (-18°C) or 5W-30 motor oil for
temperatures below 0°F (-18°C).
Hydraulic Function Time:
Raise Lift Arms 2.9 Seconds
Lower Lift Arms 2.3 Seconds
Bucket Dump 2.3 Seconds
Bucket Rollback 2.0 Seconds

753 Bobcat Loader

SPEC-10-3 Service Manual
695 of 726
LOADER SPECIFICATIONS (753) (CONT’D)

Electrical

Alternator Belt driven, 55 amp.(Earlier) or 90 amp.(Later), open

Battery 12 volt, 600 cold cranking amps. @ 0°F. (-18°C);
115 minute reserve capacity at 25 amps.
Starter (Nippondenso) 12 volt; Gear Reduction Type; 3.62 HP (2,7 kW)
Starter (Valeo) 12 volt; Gear Reduction Type; 4.02 HP (3,0 kW)
Instrumentation Gauges: Hourmeter, Fuel, Engine Temperature.
Warning lights: Engine Coolant Temperature, Engine Oil Pressure, Hydraulic
Oil Temperature & Charge Pressure, Hydraulic Filter, Engine Air Filter,
Seat Belt, Fuel Level, General Warning, System Voltage.
Indicators: Attachment Control Device (ACD), Advanced Hand Controls (AHC)
or Advanced Control System (ACS), BICS Functions, glow plugs, Headlights,
Bucket Positioning, Attachment Auxiliary Hydraulics modes
Optional Deluxe Instrumentation:
* Same gauges and warning lights as standard Instrumentation.
*Additional bar-type gauges for: Engine Oil Pressure, System Voltage,
Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Incl.: Keyless Start with password capability, Digital Clock,
Attachments, Attachments Information, Digital Tachometer, High Flow & Two-
Speed Lockouts, Multi-Language Display, Help Screens, Diagnostic Capability

Dealer Copy -- Not for Resale

& Engine/Hydraulic Systems Shutdown Function.

Drive System

Main Drive Hydrostatic 4 wheel drive

Transmission Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing
hydrostatic motors.
Final Drive #80 HS endless roller chain & sprockets in sealed chaincase with oil lubrication.
Total Engine to Wheel Reduction 33:1
Axle Size 2.00 (50,8)
Wheel Bolts (8) 9/16”

753 Bobcat Loader

SPEC-10-4 Service Manual
696 of 726
LOADER SPECIFICATIONS (753) (CONT’D)

Capacities

Cooling System W/O Heater 9.2 qts. (8,7 L)

With Heater 9.8 qts. (9,3 L)
Fuel 14 gals. (53,0 L)
Engine Oil W/Filter 7.5 qts. (7,1 L)
Hydraulic Reservoir 14 qts.(13,0 L)
Hydraulic/Hydrostatic System 6 gals. (22,0 L)
W/Reservoir
Chaincase Reservoir 8 gals. (30,0 L)

Tires

Standard 10.00-16.5, 6 or 8 ply rating with steel cap

Flotation 31.5x13-16.5
Solid 10.00-16.5 Poly Foam Filled
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.

Dealer Copy -- Not for Resale

753 Bobcat Loader

SPEC-10-5 Service Manual
697 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

SPEC-10-6 Service Manual
698 of 726
ENGINE SPECIFICATIONS

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Fuel Injection Nozzles

Opening Pressure 1991-2133 PSI (13721-14707 kPa)

Fuel Tightness Nozzle Seat Dry Nozzle at 1849 PSI (12749 kPa)

Fuel Injection Pump

Fuel Tightness Plunger 10 sec: initial pressure 2133-1990 PSI (14707-13721 kPa)
Limit Permitted 5 seconds
Injection Timing 17-19 degrees B.T.D.C.
High Idle 2860-3000 RPM
Low Idle 1125-1175 RPM

Cylinder Head

Cylinder Head Surface Distortion 0.002 (0,05) Max.

Thickness of Gasket (Used) 0.0453-0.0492 (1,15-1,25)
(New) 0.0512-0.0551 (1,3-1,4)

Dealer Copy -- Not for Resale

Top Clearance (Piston to Head) 0.022-0.028 (0,55-0,70)
Compression 412-469 PSI (2840-3234 kPa)
Allowable Limit 370 PSI (2350 kPa)
Difference Between Cylinders 10%

Valves

Valve Seat Width (Intake & Exhaust) 0.084 (2,12)

Valve Seat Angle Intake 60 degrees, Exhaust 45 degrees
O.D. of Valve Stems 0.3134-0.3140 (7,96-7,98)
I.D. of Valve Guides 0.3156-0.3161 (8,015-8,03)
Clearance Between Valve Stem & Guide 0.0016-0.0026 (0,04-0,07)
Allowable Limit 0.004 (0,1)
Valve Clearance (Cold) 0.0071-0.0087 (0,18-0,22)
Valve Recessing (Protrusion) 0.002 (0,05)
(Recess) 0.006 (0,15)

753 Bobcat Loader

SPEC-20-1 Service Manual
699 of 726
ENGINE SPECIFICATIONS (CONT’D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Valve Springs

Free Length 1.642-1.661 (41,7-42,2)

Allowable Limit 1.622 (41,2)
Fitted Length 1.378 (35,0)
Compress to Fitted Length 26.4 lbs. (117,6 N)
Allowable Limit 22.5 lbs. (100,0 N)

Valve Timing

Intake Valve (Open) 12 degrees B.T.D.C.

(Close) 36 degrees A.T.D.C.
Exhaust Valve (Open) 60 degrees B.T.D.C.
(Close) 12 degrees A.T.D.C.

Rocker Arms

O.D. of Rocker Arm Shaft 0.5501-0.5506 (13,973-13,984)

I.D. of Rocker Arm Bushings 0.5512-0.5519 (14-14,018)

Dealer Copy -- Not for Resale

Clearance Between Rocker Arm & Bushing 0.0006-0.0018 (0,016-0,045)
Allowable Limit 0.006 (0,15)

Camshaft

Journal O.D. 1.5722-1.5728 (39.934-39,95)

Bearing I.D. 1.5748-1.5758 (40,0-40,025)
Oil Clearance 0.002-0.0036 (0,05-0,091)
Allowable Limit 0.006 (0,15)
Alignment Allowable Limit 0.0004 (0,01)
Cam Lobe Height 1.318 (33,47)
Allowable Limit 1.316 (33,42)
End Clearance 0.0028-0.0087 (0,07-0,22)
Allowable Limit 0.012 (0,3)

Tappet

Clearance Between Tappet & Guide 0.0008-0.0024 (0,02-0,062)

Tappet O.D. 0.9433-0.9441 (23,959-23,98)
Tappet Guide I.D. 0.9449-0.9457 (24,0-24,021)

753 Bobcat Loader

SPEC-20-2 Service Manual
700 of 726
ENGINE SPECIFICATIONS (CONT’D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Cylinders

Cylinder Bore I.D. 3.4252-3.4261 (87,00-87,022)

Allowable Limit +0.0059 (+0,15)

Piston Rings

Ring Gap (Top & 2nd Ring) 0.0118-0.0177 (0,3-0,45)

Limit Permitted 0.0492 (1,25)
Ring Gap (Oil Ring) 0.098-0.077 (0,25-0,45)
Limit Permitted 0.0492 (1,25)
Side Clearance of Ring Groove:
Top Ring 0.0037-0.0047 (0,093-0,12)
Second Ring 0.0037-0.0047 (0,094-0,12)
Oil Ring 0.0008-0.002 (0,02-0,052)

Pistons

Piston Pin Bore 0.9843-0.9848 (25,0-25.013)

Dealer Copy -- Not for Resale

Limit Permitted 0.9862 (25,05)

Connecting Rod

Piston Pin O.D. 0.9843-0.9847 (25,002-25,011)

Small End Bushing I.D. 0.9852-0.9858 (25,025-25,04)
Clearance Between Piston Pin & Small End Bushing 0.0006-0.0015 (0,014-0,038)
Allowable Limit 0.0059 (0,15 mm)
Connecting Rod Alignment Allowable Limit 0.002 (0,05)

Oil Pump

Oil Pressure Rated RPM 43-64 PSI (294-441 kPa)

Limit Permitted 36 PSI (248 kPa)
Idle Speed 14 PSI (98 kPa)
Limit Permitted 7 PSI (49 kPa)
Clearance Between Inner Rotor & Outer Rotor 0.0039-0.0063 (0,1-0,16)
Outer Rotor & Pump Body 0.0043-0.0075 (0,11-0,19)
End Clearance Between Inner Rotor & Cover 0.0041-0.0059 (0,105-0,15)

753 Bobcat Loader

SPEC-20-3 Service Manual
701 of 726
ENGINE SPECIFICATIONS (CONT’D)

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.

Crankshaft

Crankshaft Alignment Limit Permitted 0.00079 (0,02)

Oil Clearance Between Journal & Bearing #1 0.0016-0.0046 (0,04-0,118)
Limit Permitted 0.0079 (0,2)
Journal O.D. #1 2.0441-2.0449 (51,921-51,94)
Bearing I.D. #1 2.0465-2.0488 (51,98-52,04)
Oil Clearance Between Journal & Bearing #2 0.0016-0.0041 (0,04-0,104)
Limit Permitted 0.0079 (0,2)
Journal O.D. #2 2.0441-2.0449 (51,92-51,94)
Bearing I.D. #2 2.0465-2.0482 (51,98-52,02)
Oil Clearance Between Crank Pin & Bearing 0.0009-0.0034 (0,025-0,087)
Limit Permitted 0.008 (0,2)
Crank Pin O.D. 1.8488-1.8494 (46,96-46,97)
Crank Pin Bearing I.D. 1.8504-1.8522 (47,0-47,046)
Crankshaft Side Clearance 0.0059-0.0122 (0,15-0,31)
Limit Permitted 0.0197 (0,5)

Dealer Copy -- Not for Resale

Timing Gear

Timing Gear Backlash:

Crank Gear-Idle Gear 0.0016-0.0044 (0,042-0,112)
Idle Gear-Cam Gear 0.0016-0.0045 (0,042-0,115)
Idle Gear-Injection Pump Gear 0.0016-0.0045 (0,042-0,115)
Crank Gear-Oil Pump Gear 0.0016-0.0043 (0,042-0,109)
Limit Permitted 0.006 (0,15)
Clearance Between Idle Gear Shaft & Idle Gear Bushing 0.001-0.0026 (0,025-0,066)
Limit Permitted 0.004 (0,10)
Idle Gear Side Clearance Idle Gear 0.008-0.020 (0,2-0,51)

Thermostat

Valve Opening Temperature 157-163°F (70-73°C)

Valve Fully Open 185°F (85°C)

753 Bobcat Loader

SPEC-20-4 Service Manual
702 of 726
ENGINE SPECIFICATIONS (CONT'D) 5. The crank journal must be fine-finished to higher than
(0.000016in.-S).
Crankshaft Re-Grind Data
6. The crank journal side surface must be fine-finished
If the standard size bearing cannot be employed due to to higher than (0.000016in.-S).
excessive wear of th e crankpin and crank journal use
undersize or oversize bearings. Figure SPEC-20-1

For undersize or oversize bearing use, follow the

precautions noted below.

Grind the crankpin and journal with a w heel which has

specified round corner and width without shoulder
[Figure SPEC-20-1].

1. 0.1299-0.1457 in. Radius (3,3-3,7 mm Radius)

2. 0.1102-0.1260 in. Radius (2,8-3,2 mm Radius)

3. Be sure to chamfer the oil hole circumference to

0.0394-0.0591in. Radius (1,0-1,5 mm Radius) with an
oil stone. PI-10026A

4. The crankpin must be fine finished to higher than

Dealer Copy -- Not for Resale

(0.000016in.-S).

CRANKSHAFT PROCESSING
SIZE CODE NO. NAME OF BEARING BEARING MARK
DIM.
-0.008” Crankshaft Bearing 1 A 2.0363-2.037”
020 US
(-0,2 mm) 17331-2391-1 0.008” minus (0,2 minus) (51,721-51,74mm)
-0.008” Crankshaft Bearing 2
020 US
(-0,2 mm) 17331-2393-1 0.008” minus (0,2 minus)
-0.016” Crankshaft Bearing 1 2.0284-2.0291”
040 US
(-0,4 mm) 17331-2392-1 0.016” minus (0,4 minus) (51,521-51.54mm)
-0.016” Crankshaft Bearing 2
040 US
(-0,4 mm) 17331-2394-1 0.016” minus (0,4 minus)
-0.008” Crank Pin Bearing B 1.8409-1.8415”
020 US
(-0,2 mm) 17331-2297-1 0.008” minus (0,2 minus) (46,759-46,775 mm)
-0.016” Crank Pin Bearing 1.8330-1.8337”
040 US
(-0,4 mm) 17331-2298-1 0.016” minus (0,4 minus) (46,559-46,575 mm)
Thrust Bearing 1-0.008”plus C 1.0315-1.0335”
+0.008” 15221-2395-1 (0,2 mm plus) (26,20-26,25 mm)
020 OS
(+0,2 mm) Thrust Bearing 2-0.008”plus
19202-2397-1 (0,2 mm plus)
Thrust Bearing 1-0.016”plus 040 OS 1.0394-1.0413”
+0.016” 15221-2396-1 (0,4 mm plus) (26,40-26,45 mm)
(+0,4 mm) Thrust Bearing 2-0.016”plus
19202-2398-1 (0,4 mm plus)

753 Bobcat Loader

SPEC-20-5 Service Manual
703 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

SPEC-20-6 Service Manual
704 of 726
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
SAE GRADE 5 SAE GRADE 8
SIZE
INCH. .250 80-90 110-120
LBS. (9,0-10,2) (12,4-13,6)
(Nm) .3125 180-200 215-240
(20,3-22,6) (24,2-27-1)
FOOT .375 25-28 35-40
LBS. (34-38) (47-54)
(Nm) .4375 40-45 60-65
(54-61) (81-88)
.500 65-70 90-100
(88-95) (122-136)
.5625 90-100 125-140
(122-136) (170-190)
.625 125-140 175-190
(170-190) (240-260)

Dealer Copy -- Not for Resale

.750 220-245 300-330
(300-330) (410-450)
.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 2000-2200 3450-3800
(2720-2980) (4680-5150)
1.750 2500-2750 4300-4900
(3390-3730) (5830-6500)
1.875 3150-3500 5500-6100
(4270-4750) (5830-6500)
2.000 3800-4200 6500-7200
(5150-5700) (8800-9800)

753 Bobcat Loader

SPEC-30-1 Service Manual
705 of 726
TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)

Torque For General Metric Bolts

THREAD PROPERTY CLASS

NOM. DIA 8.8 10.9 12.9
- NM LBF-FT NM LBF-FT NM LBF-FT
M4 3,5-2,5 2.5-2.0 4,2-3,8 3.1-2.8 5,3-4,7 3.9-3.5
M5 6,5-5,5 5.0-4.0 8,4-7,6 6.2-5.6 9,5-8,5 7.0-6.2
M6 10,5-9,5 7.5-7.0 13,7-12,3 10.1-9.1 15,8-14,2 11.6-10.4
M7 17-15 12.5-11.0 22-20 16.2-14.7 26,3-23,7 19.5-17.5
M8 26-24 19-18 32,6-29,4 24.0-21.7 39-35 28.5-25.5
M10 47-43 35-32 63-57 46.5-42.0 79-71 58.5-52.5
M12 85-75 60-55 115-105 85-78 137-123 110-91
M14 140-125 100-90 180-160 133-118 210-190 155-140
M16 210-190 155-140 285-255 210-188 330-300 245-225
M18 290-260 215-190 385-345 285-255 460-420 340-310
M20 410-370 300-275 550-490 405-360 650-590 490-440
M22 550-500 400-370 740-760 545-560 880-800 650-590
M24 700-640 520-470 950-850 700-625 1120-1000 830-730
M27 1030-930 760-680 1370-1230 1000-900 1630-1470 1200-1100

Dealer Copy -- Not for Resale

M30 1400-1260 1030-930 1900-1700 1400-1250 2200-2000 1600-1500
M33 1900-1720 1400-1270 2500-2300 1850-1700 3100-2700 2300-2000
M36 2450-2200 1800-1620 3200-2900 2400-2200 3900-3500 3900-2600

NOTE: Use the torque value for the part having the lesser property class when a fastener and nut are used
together but have a different property class.

Torque For Kubota Metric Bolts

THREAD SIZE MATERIAL

(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)
M 10 x 1.25 13-18 ft.-lbs. 22-30 ft.-lbs. 36-50 ft.-lbs.
(18-24 Nm) (30-41 Nm) (49-68 Nm)
M 12 x 1.25 22-30 ft.-lbs. 40-54 ft.-lbs. 69-87 ft.-lbs.
(30-41 Nm) (54-73 Nm) (94-118 Nm)
M 14 x 1.25 36-50 ft.-lbs. 58-80 ft.-lbs. 116-137 ft.-lbs.
(49-68 Nm) (79-108 Nm) (157-186 Nm)

753 Bobcat Loader

SPEC-30-2 Service Manual
706 of 726
HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC- 40-2

O-ring Face Seal Connection O-ring Face Seal Tightening Torque

x x *
Tubeline x TORQUE
Outside x Ft.-lbs.
IMPORTANT Diameter
1/4”
Thread Size
9/16” - 18
(Nm)
13 (18)
When repairing hydrostatic and hydraulic systems, 3/8” 11/16” - 16 22 (30)
clean the work area before disassembly and keep all 1/2” 13/16” - 16 40 (54)
parts clean. Always use caps and plugs on hoses,
5/8” 1” - 14 60 (81)
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 3/4” 1-3/16” - 12 84 (114)
I-2003-0888 7/8” 1-3/16” - 12 98 (133)
1” 1-7/16” - 12 118 (160)
Figure SPEC-40-1
1-1/4” 1-11/16” - 12 154 (209)

1-1/2” 2” - 12 163 (221)

Dealer Copy -- Not for Resale

B-7575

When the fitting is tightened, you can feel when the fitting
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 [Figure
SPEC-40-1].

753 Bobcat Loader

SPEC-40-1 Service Manual
707 of 726
HYDRAULIC CONNECTION SPECIFICATIONS Flare Fitting
(CONT’D)
Figure SPEC- 40-4
Straight Thread O-ring Fitting

Figure SPEC- 40-3

1
Nut Nut

Washer 2
Washer
O-ring
O-ring
TS-1619

A-1852 Use the following procedure to tighten the flare fitting:

Tighten the nut until it makes contact with the seat. Make
Lubricate the O-ring before installing the fitting. Loosen a mark across the flats of both the male and female parts
the jam nut and install the fitting. Tighten the jam nut until

Dealer Copy -- Not for Resale

of the connection (Item 1) [Figure SPEC- 40-4].
the washer is tight against the surface [Figure SPEC-
40-3]. Use the chart below to find the correct tightness needed
(Item 2) [Figure SPEC- 40-4]. If the fitting leaks after
Tubelines And Hoses tightening, disconnect it and inspect the seat area for
damage.
Replace any tubelines that are bent or flattened. They will
restrict flow, which will slow hydraulic action and cause Flare Fitting Tightening Torque
heat.
Tubeline TORQUE
Outside Thread Size Ft.-Lbs.
Replace hoses which show signs of wea r, damage or
Diameter (Nm)
weather cracked rubber.
1/4” 7/16” - 20 13 (18)
Always use two wrenches when loosening and tightening 5/16” 1/2” - 20 17 (23)
hose or tubeline fittings. 3/8” 9/16” - 18 22 (30)
1/2” 3/4” - 16 40 (54)
5/8” 7/8” - 14 60 (54)
3/4” 1-1/16” - 12 84 (114)
7/8” 1-3/16” - 12 98 (133)
1” 1-5/16” - 12 118 (160)
1-1/4” 1-5/8” - 12 154 (209)
1-1/2” 1-7/8” - 12 163 (221)
2” 2-1/2” - 12 252 (342)

753 Bobcat Loader

SPEC-40-2 Service Manual
708 of 726
HYDRAULIC CONNECTION SPECIFICATIONS
(CONT’D)
O-Ring Flare Fitting Tightening Torque
O-ring Flare Fitting *
Tubeline TORQUE
Outside Thread Size Ft.-Lbs.
Figure SPEC- 40-5
Diameter (Nm)
O-ring Flare 1/4” 7/16” - 20 13 (18)
Primary 5/16” 1/2” - 20 17 (23)
Seal 3/8” 9/16” - 18 22 (30)
1/2” 3/4” - 16 40 (54)
5/8” 7/8” - 14 60 (54)
3/4” 1-1/16” - 12 84 (114)
7/8” 1-3/16” - 12 98 (133)
1” 1-5/16” - 12 118 (160)
1-1/4” 1-5/8” - 12 154 (209)
1-1/2” 1-7/8” - 12 163 (221)
Secondary 2” 2-1/2” - 12 252 (342)
Seal
P13009
*If a tor que wrench is used to tighten a n ew fitting to a
used hose/tubeline.
The flare is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at

Dealer Copy -- Not for Resale

*If a torque wrench is used to tighten a used fitting to a
the connection [Figure SPEC- 40-5]. new hose/tubeline.

If necessary, the O-ring-flare fitting can be used without *If a tor que wrench is used to tighten a n ew fitting to a
an O-ring. new hose/tubeline.

Figure SPEC-40-6 **If using the hex flat tightening method to tighten a new
fitting to a new hose/tubeline.
Hex Flat Tightening Method
**If using the hex flat tightening method to tighten a new
fitting to a used hose/tubeline.
1
***If using the hex flat tightening method to tighten a used
fitting to a new hose/tubeline.

TS-1619

Use the following procedure to ti ghten the O -ring flare

fitting.

Tighten the nut un til it c ontacts with the seat. Make a

mark across the fla ts of both the male and female parts
of the connection (Item 1) [Figure SPEC-40-6].

Use the chart below to find the correct tightness needed

(Item 2) [Figure SPEC-40-6]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
damage.

753 Bobcat Loader

SPEC-40-3 Service Manual
709 of 726
HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC- 40-8
(CONT’D)

O-ring Flare Fitting (Cont’d)

2
Figure SPEC- 40-7

Copper Bonnet Orifice

1
P13573
1

Always remove the O-ring (Item 1) from the flare face

as shown.[Figure SPEC- 40-8]
P13572
An O-ring (Item 2) [Figure SPEC- 40-8] is added to the
flat boss of the fitting to seal the connection in this
NOTE: O-ring flare fittings are not recommended in application.
all applications. Use the standard flare fittings

Dealer Copy -- Not for Resale

in these applications.

Do not use a O-ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at th e
bonnet may distort the flare face and prevent it from
sealing.

Use a standard flare fitting (Item 1) [Figure SPEC- 40-7]

as shown.

When a O-ring flare fitting is used as a straight thread

port adapter the O-ring flare face is not used to seal. The
O-ring may come off the fitting and enter the system.

753 Bobcat Loader

SPEC-40-4 Service Manual
710 of 726
HYDRAULIC CONNECTION SPECIFICATIONS (763) Use the fo llowing procedure to tig hten the port seal
(CONT’D) fitting:

Port Seal Fitting Port seal and nut, wa sher and O-ring (O-ring Boss)
fittings use the same tightening torque valve chart.
Figure SPEC- 40-9
If a torque wrench cannot be us ed, use the fol lowing
method.

Tighten the nut until it just makes metal to metal contact,

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.

NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate
Nut Seals guideline.
to Fitting
NOTE: Port seal fittings are not recommended in all
applications. Use O-ring boss fittings in these
Nut Seals applications.

Dealer Copy -- Not for Resale

to Port

Secondary O-ring Seal

P13008

The nut is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC- 40-9].

The hex portion of the nut does not contact the surface of
the component when the nut is tight.

Port Seal and O-ring Boss

Tightening Torque
Torque Ft.-Lbs.
Thread Size
(Nm)
7/16” 13 (18)
9/16” - 18 22 (30)
3/4” - 16 40 (54)
7/8” - 14 60 (81)
1-1/16” - 12 84 (114)
1-3/16” - 12 98 (133)
1-5-16” - 12 118 ( 160)
1-7/16” - 12 154 ( 209)
1-5/8” - 12 163 (221)

753 Bobcat Loader

SPEC-40-5 Service Manual
711 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

SPEC-40-6 Service Manual
712 of 726
HYDRAULIC FLUID SPECIFICATIONS When temperatures below zero degree F (-18°C) are
common, the loader must be k ept in a warm building.
Specifications Extra warm-up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will
Use Bobcat hydraulic transmission fluid (P/N 6563328). If not flow easily and it makes action on the hydraulic
this fluid is not available, use 10W-30 or 10W-40 SAE function slower. Loss of fl uid flow to the h ydrostatic
Motor Oil (5W-30 for 0°F [-18°C] and Below). transmission pump (indicated by TRANS light ON) can
cause transmission damage in less than 60 seconds.
DO NOT use automatic transmission fluids in the loader
or permanent damage to the transmission will result.

WARNING
WARNING During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
Diesel fuel or hydraulic fluid under pressure can five minutes at less than half throttle. This warm-up
penetrate skin or eyes, causing serious injury or period is necessary for foot pedal operation and safe
death. Fluid leaks under pressure may not be visible. stopping. Do not operate controls during warm-up
Use a piece of cardboard or wood to find leaks. Do period.
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention When temperatures are below -20°F (-30°C), the
from a physician familiar with this injury. hydrostatic oil must be heated or kept warm. The
W-2072-0496 hydrostatic system will not get enough oil at low

Dealer Copy -- Not for Resale

temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285

753 Bobcat Loader

SPEC-50-1 Service Manual
713 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

SPEC-50-2 Service Manual
714 of 726
CONVERSIONS

Decimal And Millimeter Equivalents

Dealer Copy -- Not for Resale

U.S. To Metric Conversion

753 Bobcat Loader

SPEC-60-1 Service Manual
715 of 726
 Dealer Copy -- Not for Resale

753 Bobcat Loader

SPEC-60-2 Service Manual
716 of 726
 ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No:753-1

Date: 2 November 2001

Product: Bobcat Loader
Model: 753
Manual No: 6900976 (10-01)

Please discard your old 753 Service Manual (P/N 6900976) DATED 11-99 and replace it with the revised 753 G
Series Service Manual (P/N 6900976) Dated 11-01.

Dealer Copy -- Not for Resale

Printed in U.S.A.
717 of 726
718 of 726
Dealer Copy -- Not for Resale
 ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: 753-2

Date: 10 April 2003
Product: Bobcat Loader
Model: 753
Manual No: 6900976 (4-03)

Please discard your old 753 Service Manual (P/N 6900976) Dated 11-01 and replace it with the
revised 753 G Series Service Manual (P/N 6900976) Dated 4-03.

Dealer Copy -- Not for Resale

Printed in U.S.A.
719 of 726
720 of 726
Dealer Copy -- Not for Resale
 ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: 753-3

Date: 23 March 2006
Product: Bobcat Loader
Model: 753
Manual No: 6900976 (4-03)

753 Service Manual (P/N 6900976) Dated (2-06) contains updated service information which replaces the previous
753 Service Manual (P/N 6900976) Dated (4-03).

Dealer Copy -- Not for Resale

Printed in U.S.A.
721 of 726
722 of 726
Dealer Copy -- Not for Resale
 ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: 753-4

Date: 15 September 2010
Product: Bobcat Loader
Model: 753
Manual No: 6900976 (9-10)

The following Sections are a revision to the above Service Manual.

COVER

Dealer Copy -- Not for Resale

SPEC-10

Printed in U.S.A.
723 of 726
724 of 726
Dealer Copy -- Not for Resale
 ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
REVISION SALES MANAGER

NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.

Revision No: 753-4

Date: 3 Oct 2012
Product: Bobcat Loader
Model: 753
Manual No: 6900976 (10-12)

Dealer Copy -- Not for Resale

The following Sections are a revision to the above Service Manual.

COVER

725 of 726
726 of 726
Dealer Copy -- Not for Resale