Bobcat Loaders 763, 763 High Flow, 773, 773 High Flow, 773 Turbo (G Series) Repair Service Manual + Operation & Maintenance Manual
Bobcat Loaders 763, 763 High Flow, 773, 773 High Flow, 773 Turbo (G Series) Repair Service Manual + Operation & Maintenance Manual
Complete repair service manuals with electrical wiring diagrams for Bobcat Loaders 763, 763 High Flow, 773, 773 High Flow, 773 Turbo (G Series), with technical information to maintain, diagnose, repair, and service like professional mechanics.
Bobcat Loaders 763, 763 High Flow, 773, 773 High Flow, 773 Turbo (G Series) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MAIN SECTIONS
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATION
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATER
SPECIFICATIONS
Total Pages: 7,681 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
6900091 (5-11) - 763, 763 High Flow Service Manual.pdf
6900091 (6-12) - 763, 763 High Flow Service Manual.pdf
6900091 (6-97) - 763, 763 High Flow Service Manual.pdf
6900092 (6-12) - 773 Service Manual.pdf
6900092 (6-97) - 773 Service Manual.pdf
6900371 (8-00) - 763, 763 High Flow Operation & Maintenance Manual.pdf
6900372 (5-01) - 773 Operation & Maintenance Manual.pdf
6900788 (9-00) - 763, 763 High Flow Operation & Maintenance Manual.pdf
6900789 (9-00) - 773 Operation & Maintenance Manual.pdf
6900834 (3-06) - 773, 773 High Flow, 773 Turbo (G Series) Service Manual.pdf
6900834 (6-12) - 773, 773 High Flow, 773 Turbo (G Series) Service Manual.pdf
6900842 (12-06) - 773, 773 High Flow Operation & Maintenance Manual.pdf
6900939 (5-05) - 773 G-Series Parts Manual.pdf
6900971 (7-03) - 763, 763 High Flow Operation & Maintenance Manual.pdf
6900977 (2-06) - 763, 763 High Flow (G Series) Service Manual.pdf
6900977 (6-12) - 763, 763 High Flow (G Series) Service Manual.pdf
6901277 (10-01) - 773, 773 Turbo Operation & Maintenance Manual.pdf
TABLE OF CONTENTS
6900091 (5-11) - 763, 763 High Flow Service Manual....2
MAINTENANCE SAFETY....4
ALPHABETICAL INDEX....6
CONTENTS....8
FOREWORD....10
SAFETY INSTRUCTIONS....12
FIRE PREVENTION....13
SERIAL NUMBER LOCATIONS....14
LOADER SERIAL NUMBER....14
ENGINE SERIAL NUMBER....14
DELIVERY REPORT....14
BOBCAT LOADER IDENTIFICATION....15
PREVENTIVE MAINTENANCE....16
SERVICE SCHEDULE....18
LIFTING AND BLOCKING THE LOADER....19
Procedure....19
TRANSPORTING THE BOBCAT LOADER....20
TOWING THE LOADER....20
STOPPING THE BOBCAT LOADER....20
LIFTING THE LOADER....21
Single Point Lift....21
LIFT ARM SUPPORT DEVICE....22
Engaging The Lift Arm Support Device....22
Disengaging The Lift Arm Support Device....23
OPERATOR CAB....24
Description....24
Emergency Exit....24
Raising The Operator Cab....25
Lowering The Operator Cab....26
SEAT BAR RESTRAINT SYSTEM (Foot Pedals)....27
Description....27
Seat Bar Inspection....27
Seat Bar Maintenance....27
SEAT BAR RESTRAINT SYSTEM (Mechanical Hand Controls)....28
Description....28
Seat Bar Inspection....28
Seat Bar Maintenance....28
SEAT BAR RESTRAINT SYSTEM (Advanced Hand Controls)....29
Description....29
Seat Bar Inspection....29
Seat Bar Maintenance....29
AIR CLEANER SERVICE....30
Replacing Filter Element....30
FUEL SYSTEM....32
Fuel Specifications....32
Filling The Fuel Tank....32
Fuel Filter....32
Removing Air From The Fuel System....33
ENGINE LUBRICATION SYSTEM....34
Checking Engine Oil....34
Oil Chart....34
Replacing Oil And Filter....34
ENGINE COOLING SYSTEM....36
Cleaning The Cooling System....36
Checking The Coolant Level....36
Replacing The Coolant....37
ALTERNATOR BELT....38
Adjusting The Alternator Belt....38
FAN GEARBOX....38
Checking And Maintaining....38
HYDRAULIC/HYDROSTATIC SYSTEM....39
Checking And Adding Fluid....39
Replacing Hydraulic/Hydrostatic Filter....39
Replacing Hydraulic Fluid....40
Hydraulic Reservoir Breather Cap....41
SPARK ARRESTOR MUFFLER....42
Cleaning Procedure....42
TIRE MAINTENANCE....43
Wheel Nuts....43
Tire Rotation....43
Tire Mounting....43
FINAL DRIVE TRANSMISSION (CHAINCASE)....44
Checking And Adding Oil....44
Replacing Oil In The Chaincase....44
DRIVE BELT....45
Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler....45
Adjusting The Drive Belt Equipped With The Fixed Drive Idler....47
Drive Belt Replacement....48
LUBRICATION OF THE BOBCAT LOADER....49
Procedure....49
BOBTACH....51
Inspection And Maintenance....51
REMOTE START SWITCH....52
Procedure....52
HYDRAULIC SYSTEM....54
HYDRAULIC/HYDROSTATIC SCHEMATICS....58
TROUBLESHOOTING....86
HYDRAULIC SYSTEM INFORMATION....87
Tightening Procedure....87
LIFT CYLINDER(S)....88
Checking The Lift Cylinder(s) For Internal Leakage....88
Removal And Installation....88
TILT CYLINDER....89
Checking The Tilt Cylinder For Internal Leakage....89
Removal And Installation....89
Rod End Seal Replacement....90
HYDRAULIC CYLINDER IDENTIFICATION....91
Lift Cylinder Components....91
Tilt Cylinder Components....92
HYDRAULIC CYLINDERS....93
Disassembly....93
Assembly....95
BICS VALVE (S/N 512220298 & Above, 512440721 & Above and 512612258 & Above)....101
Removal....101
Lift Arm ByPass Orifice Disassembly....102
Check Valve Disassembly....102
Lock Valve Disassembly....103
BICS Valve Solenoid Disassembly....104
BICS Valve Solenoid Assembly....105
Lock Valve Assembly....106
Check Valve Assembly....106
Lift Arm ByPass Orifice Assembly....107
Installation....108
CONTROL VALVE (S/N 512220298 & Above, 512440721 & Above and 512612258 & Above)....109
Removal And Installation....109
Identification Chart....112
Disassembly....113
Lift Base End Restrictor Disassembly....113
Load Check Valve Disassembly....113
Main Relief Valve Disassembly....114
Port Relief Valve Disassembly....115
AntiCavitation Valve Disassembly....116
Rubber Boot Disassembly....117
Lift Spool And Detent Disassembly....118
Tilt Spool And Centering Spring Disassembly....121
Auxiliary Spool Disassembly....123
Auxiliary Electric Solenoid Disassembly....124
PortAuxiliary Section Disassembly....125
Cleaning And Inspection....125
PortAuxiliary Section Assembly....126
Auxiliary Electric Solenoid Assembly....126
Auxiliary Spool Assembly....127
Tilt Spool And Centering Spring Assembly....128
Lift Spool And Detent Assembly....130
Rubber Boot Assembly....132
AntiCavitation Valve Assembly....133
Port Relief Valve Assembly....134
Main Relief Valve Assembly....135
Load Check Valve Assembly....135
Spool Seal Installation....137
CONTROL VALVE (S/N 512220297 & Below,512440720 & Below and 512612257 & Below)....138
Removal And Installation....138
Identification Chart....141
Disassembly And Assembly....142
Load Check Valve....142
Main Relief Valve....143
Port Relief Valve....143
AntiCavitation Valve....144
Rubber Boot....145
Lift Spool Detent....146
Tilt Centering Spring....150
Auxiliary Spool....151
Auxiliary Electric Solenoid....152
Plug/Port Relief Valve....153
Inspection....153
Identification And Installation Of Spool Seal....154
MAIN RELIEF VALVE....155
Checking....155
Adjustment....156
Removal And Installation....156
HYDRAULIC PUMP....157
Removal And Installation....157
Checking The Output Of The Hydraulic Pump....159
Checking The Output Of The High Flow Hydraulic Pump (763H)....161
Disassembly And Assembly....162
Inspection....164
Identification....164
Removal And Installation (763H)....165
Identification (763H)....168
Disassembly And Assembly (763H)....169
HYDRAULIC FILTER HOUSING....172
Removal And Installation....172
HYDRAULIC FLUID RESERVOIR....173
Removal And Installation....173
CONTROL PEDALS....174
Removal And Installation....174
Pedal Adjustment....174
SELECT VALVE (763H)....175
Checking the Main Relief Valve in High Horsepower Select Valve....175
Removal And Installation....176
Disassembly And Assembly (New Style Valve)....178
Solenoid Testing (New Style Valve)....179
Disassembly And Assembly (Old Style Valve)....180
Solenoid Testing (Old Style Valve)....181
PEDAL INTERLOCK LINKAGE....182
Removal And Installation....182
Adjustment....183
LIFT LOCK BYPASS VALVE....184
Removal And Installation (S/N 512220298 & Above, S/N 512440721 & Above, S/N 512612258 & Above)....184
Removal And Installation (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)....186
Disassembly And Assembly (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)....187
TILT LOCK VALVE....188
Removal And Installation (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)....188
Disassembly And Assembly (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)....190
HYDROSTATIC SYSTEM....192
TROUBLESHOOTING....194
HYDROSTATIC SYSTEM INFORMATION....195
Replenishing Valve Function....195
Checking Charge Pressure....195
CONTROL PANEL....196
Removal And Installation....196
Steering Shock Removal And Installation....197
Steering Shaft Removal And Installation....197
Steering Shaft Disassembly And Assembly....197
Steering Lever Removal And Installation....198
Rubber Boot Replacement....198
STEERING LINKAGE....199
Removal And Installation....199
Steering Linkage Adjustment....201
Steering Neutral Adjustment....203
HYDROSTATIC DRIVE MOTOR....205
Removal And Installation....205
Identification (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)....206
Disassembly And Assembly (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)....207
nspection (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)....212
Timing The Hydrostatic Motor (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)....213
HYDROSTATIC MOTOR 30 SERIES....214
Identification (S/N 512218844 & Above, S/N 512612192 & Above, & S/N 512440646 & Above)....214
Disassembly (S/N 512218844 & Above, S/N 512612192 & Above, & S/N 512440646 & Above)....215
Assembly (S/N 512218844 & Above, S/N 512612192 & Above, & S/N 512440646 & Above)....220
HYDROSTATIC PUMP....226
Removal And Installation....226
Identification MODEL: 763....229
Disassembly And Assembly....231
Inspection....239
Swashplate PreLoad....241
DRIVE BELT HOUSING....242
Removal And Installation....242
SPRING LOADED DRIVE BELT TENSIONER PULLEY....244
Removal And Installation....244
Identification....245
Disassembly....246
Assembly....247
FIXED DRIVE BELT TENSIONER PULLEY....249
Removal And Installation....249
Identification....250
Disassembly....251
Assembly....253
Checking Pulley End Play....257
OIL COOLER....257
Removal And Installation....257
DRIVE SYSTEM....258
PARKING BRAKE....260
Removal And Installation....260
Disassembly And Assembly....260
PARKING BRAKE DISC....261
Removal And Installation....261
TRACTION LOCK GUIDES....262
Disassembly....262
Assembly....263
CHAINCASE FLUID....265
Removing Oil From The Chaincase....265
CHAINCASE COVERS....266
Center Chaincase Cover Removal And Installation....266
Front Chaincase Cover Removal And Installation....267
Rear Chaincase Cover Removal And Installation....267
MOTOR CARRIER....268
Shaft Seal Replacement....268
Removal And Installation....270
Disassembly....271
Assembly....272
AXLE SEAL....276
Removal And Installation....276
AXLE, SPROCKET AND BEARINGS....278
Removal And Installation....278
DRIVE CHAIN....282
Removal....282
MAIN FRAME....284
SEAT BAR (W/GAS CYLINDER)....286
Removal And Installation....286
Assembly....288
Compressing the Gas Cylinder....289
SEAT BAR (W/COMPRESSION SPRING)....290
Removal And Installation....290
Assembling Components....293
Compression Spring Disassembly And Assembly....293
OPERATOR CAB GAS CYLINDER....294
Removal And Installation....294
Disassembly And Assembly....294
OPERATOR CAB....295
Removal And Installation....295
OPERATOR SEAT....298
Removal And Installation....298
BOBTACH....299
Removal And Installation....299
BobTach Lever And Wedge....301
BobTach Stops....302
LIFT ARMS....303
Removal And Installation....303
REAR GRILL....307
Removal And Installation....307
FUEL TANK....308
Removal And Installation....308
Fuel Level Sender....309
REAR DOOR....310
Removal And Installation (2 piece door)....310
Removal And Installation (One Piece Door)....311
Hood Removal And Installation (Two Piece Door)....312
Door Latch Removal And Installation....312
Door Latch And Catch Adjustment....313
REAR LIGHTS....314
Removal and Installation (One Piece Door)....314
ELECTRICAL SYSTEM....316
ELECTRICAL SCHEMATICS....322
TROUBLESHOOTING....347
ELECTRICAL SYSTEM INFORMATION....348
Description....348
Fuse Location (Standard & BOSS Option)....348
BATTERY....349
Removal And Installation....349
Servicing The Battery....350
Using A Booster Battery (Jump Starting)....351
ALTERNATOR....352
Alternator Output Test....352
Rectifier (Diode) Test....353
Alternator Regulator Test....353
Removal And Installation....354
Adjusting The Alternator Belt....354
Disassembly And Inspection....355
Stator Continuity Test....355
Stator Ground Test....355
Rotor Continuity Test....356
Rotor Ground Test....356
Rectifier Continuity (Diode) Test....356
Assembly....357
STARTER (DELCO REMY)....358
Removal And Installation....358
Checking The Starter....358
Parts Identification....359
Disassembly And Assembly....360
Cleaning And Inspection....362
STARTER (DENSO)....363
Parts Identification....363
Disassembly....364
Inspection And Repair....369
No Load Test....372
Assembly....372
STANDARD INSTRUMENT PANEL....379
Removal And Installation....379
FRONT LIGHTS....380
Removal And Installation....380
RELAY SWITCHES....381
Location....381
ENGINE SERVICE....383
TROUBLESHOOTING....385
ENGINE SPEED CONTROL....386
Removal And Installation....386
Disassembly....386
RADIATOR....387
Removal And Installation....387
ENGINE MUFFLER....388
Removal And Installation....388
BLOWER HOUSING/FAN GEARBOX....389
Removal And Installation....389
Tension Pulley Removal And Installation....392
Blower Fan Disassembly And Assembly....393
FAN GEARBOX....395
Identification....395
Disassembly....396
Assembly....401
Checking Backlash....406
AIR CLEANER....409
Removal And Installation....409
ENGINE....410
Removal And Installation....410
Engine Mount Replacement....415
FLYWHEEL....416
Removal And Installation....416
Flywheel Ring Gear....416
ENGINE COMPRESSION....417
Checking....417
GLOW PLUGS....418
Checking The Glow Plugs....418
Removal And Installation....419
FUEL INJECTION PUMP....420
Checking The Injection Pump....420
Adjusting ShutOff Linkage....420
Removal And Installation....421
Timing The Injection Pump....424
FUEL INJECTION NOZZLES....425
Removal And Installation....425
Checking The Injector Nozzle....427
CYLINDER HEAD....428
Removal And Installation....428
Disassembly And Assembly....429
Servicing The Cylinder Head....430
Top Clearance....430
VALVE, VALVE SEAT AND GUIDE....431
Checking The Valve Guide....431
Reconditioning The Valve And Valve Seat....432
Valve Spring....433
VALVE CLEARANCE....434
Adjustment....434
ROCKER ARM AND SHAFT....434
Checking....434
TIMING GEARCASE COVER....435
Removal And Installation....435
IDLER GEAR AND CAMSHAFT....437
Removal And Installation....437
Servicing The Camshaft....438
Servicing The Idler Gear And Shaft....439
TIMING GEARS....440
Checking Backlash....440
FUEL CAMSHAFT....441
Removal And Installation....441
Governor....441
CRANKSHAFT GEAR....442
Removal And Installation....442
OIL PUMP....442
Removal And Installation....442
Oil Pump Service....442
Checking Engine Oil Pressure....443
Relief Valve....443
PISTON AND CONNECTING ROD....444
Removal And Installation....444
Servicing The Piston And Connecting Rod....445
Connecting Rod Alignment....447
CRANKSHAFT AND BEARINGS....448
Removal And Installation....448
Servicing The Crankshaft And Bearings....449
CYLINDER BORE....453
Checking The Cylinder Bore....453
WATER PUMP....454
Disassembly and Assembly....454
SYSTEMS ANALYSIS....455
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) (S/N 512235900 & Above), (S/N 512442000 & Above), (S/N 512613600 & Above)....457
Inspecting The BICS Controller....457
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED Key ON)....457
Inspecting The Seat Bar Sensor (Engine RUNNING)....457
Inspecting The Traction Lock (Engine RUNNING)....457
Inspecting The Lift Arm ByPass Control....457
Additional Inspection For Loaders With Advanced Hand Controls....457
Troubleshooting Chart....458
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) (S/N 512235899 & Below ), (S/N 512441999 & Below), (S/N 512613599 & Below)....459
Inspecting The BICS Controller....459
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED Key ON)....459
Inspecting The Seat And Seat Bar Sensors (Engine Running)....459
Inspecting The Traction Lock (Engine Running)....459
Inspecting The Lift Arm ByPass Control....459
Maintenance....460
Troubleshooting Chart....461
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....462
Troubleshooting Guide....462
BICS CONTROLLER....462
TRACTION LOCK....463
SEAT SENSOR....464
SEAT BAR SENSOR....465
SEAT SENSOR....466
Seat Sensor Test....466
Removal And Installation....467
BICS Controller Seat Sensor Circuit Test....468
BICS SYSTEM CONTROLLER....469
Removal And Installation....469
SEAT BAR SENSOR....470
Seat Bar Sensor Test....470
Removal And Installation....471
BICS Controller Seat Bar Sensor Circuit Test....472
TRACTION LOCK....473
Removal And Installation....473
BOSS DIAGNOSTIC TOOL....475
Procedure....475
SENDER AND SENSOR....475
Service Checks....475
RPM SENSOR....475
Adjustment....475
MONITOR SERVICE CODES....476
TROUBLESHOOTING THE BOSS & LCD DISPLAY....479
OPERATION SENSING SYSTEM UNIT....480
Removal And Installation....480
BOSS INSTRUMENT PANEL....481
Removal And Installation....481
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE....482
Controls Identification Chart....482
SPECIFICATIONS....483
SKID STEER LOADER SPECIFICATIONS....485
PERFORMANCE....485
CONTROLS....485
ENGINE....485
HYDRAULIC SYSTEM....486
ELECTRICAL....486
DRIVE SYSTEM....486
CAPACITIES....486
TIRES....486
ENGINE SPECIFICATIONS....487
Fuel Injection Nozzles....487
Fuel Injection Pump....487
Cylinder Head....487
Valves....487
Valve Springs....487
Valve Timing....487
Rocker Arms....487
Camshaft....488
Tappet....488
Cylinders....488
Piston Rings....488
Pistons....488
Connecting Rod....488
Oil Pump....488
Crankshaft....489
Crankshaft....489
Thermostat....489
Crankshaft ReGrind Data....490
Torque For General Metric Bolts....491
HYDRAULIC CONNECTION SPECIFICATIONS....492
Oring Face Seal Connection....492
Straight Thread Oring Fitting....492
Tubelines And Hoses....492
Flare Fitting....492
Oring Flare Fitting....493
Port Seal Fitting....495
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS....496
TORQUE SPECIFICATIONS FOR LOADER....497
STANDARD TORQUE SPECIFICATIONS FOR BOLTS....498
DECIMAL AND MILLIMETER EQUIVALENTS....499
U.S. TO METRIC CONVERSION....499
ADVANCE HAND CONTROL SYSTEM (AHC)....501
ADVANVED HANDCONTROL ELECTRICAL SCHEMATICS....503
AHC COMPONENTS....513
Identification....513
TROUBLESHOOTING (AHC)....514
ACTUATOR VOLTAGE TEST....516
Procedure....516
HANDLE CONTROL UNIT TEST....519
Procedure....519
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....522
ADVANCED HAND CONTROLS (AHC)....522
AHC/PWM CONTROLLER....523
Removal And Installation....523
Test....523
Description....524
Conditions....525
Troubleshooting Chart....525
Handle Testing....526
Solenoid Coil Testing....526
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)....527
Control Handle Unit Removal And Installation....527
Control Unit Connector....530
Switch Handle Removal And Installation....531
AHC Handle Removal And Installation....534
AHC Handle Disassembly And Assembly....535
AHC Steering Lever Removal And Installation....536
AHC Steering Lever Boot....536
Actuators Removal And Installation....537
Actuators Disassembly And Assembly....538
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/PUSH BUTTON FLOAT)....539
Components Identification....539
Controller Connector And Wire Identification....540
AHC/PWM Controller Removal And Installation....541
Handle Sensor Removal And Installation....542
Handle Sensor Connector....544
Switch Handle Removal And Installation....545
Control Handle Removal And Installation....548
Control Handle Disassembly And Assembly....549
Control Lever Removal And Installation....550
Control Lever Boot....551
Actuators Disassembly And Assembly....552
BICS VALVE....553
Lift Arm ByPass Orifice....553
Check Valve....554
Lock Valve....554
BICS Valve Solenoid....555
Removal And Installation....556
HYDRAULIC CONTROL VALVE....557
Removal And Installation....557
Identification Chart....559
Disassembly And Assembly....560
Load Check Valve....560
Lift Base End Restrictor....560
Main Relief Valve....561
Port Relief Valve (Lift)....562
AntiCavitation/Port Relief Valve....562
Port Relief Valve (Tilt)....563
AntiCavitation Valve....563
Rubber Boot....564
Lift And Tilt Spool....565
Inspection....567
Auxiliary Spool....568
Auxiliary Electrical Solenoid....569
Spool Seal Installation....570
HPort Auxiliary Section....571
SERVICE MANUAL REVISIONS....573
763, 763H1....573
763, 763H2....575
763, 763H3....577
763, 763H4....579
763, 763H-5....581
6900091 (6-12) - 763, 763 High Flow Service Manual....583
MAINTENANCE SAFETY....585
ALPHABETICAL INDEX....587
CONTENTS....589
FOREWORD....591
SAFETY INSTRUCTIONS....593
FIRE PREVENTION....594
SERIAL NUMBER LOCATIONS....595
LOADER SERIAL NUMBER....595
ENGINE SERIAL NUMBER....595
DELIVERY REPORT....595
BOBCAT LOADER IDENTIFICATION....596
PREVENTIVE MAINTENANCE....597
SERVICE SCHEDULE....599
LIFTING AND BLOCKING THE LOADER....600
Procedure....600
TRANSPORTING THE BOBCAT LOADER....601
TOWING THE LOADER....601
STOPPING THE BOBCAT LOADER....601
LIFTING THE LOADER....602
Single Point Lift....602
LIFT ARM SUPPORT DEVICE....603
Engaging The Lift Arm Support Device....603
Disengaging The Lift Arm Support Device....604
OPERATOR CAB....605
Description....605
Emergency Exit....605
Raising The Operator Cab....606
Lowering The Operator Cab....607
SEAT BAR RESTRAINT SYSTEM (Foot Pedals)....608
Description....608
Seat Bar Inspection....608
Seat Bar Maintenance....608
SEAT BAR RESTRAINT SYSTEM (Mechanical Hand Controls)....609
Description....609
Seat Bar Inspection....609
Seat Bar Maintenance....609
SEAT BAR RESTRAINT SYSTEM (Advanced Hand Controls)....610
Description....610
Seat Bar Inspection....610
Seat Bar Maintenance....610
AIR CLEANER SERVICE....611
Replacing Filter Element....611
FUEL SYSTEM....613
Fuel Specifications....613
Filling The Fuel Tank....613
Fuel Filter....613
Removing Air From The Fuel System....614
ENGINE LUBRICATION SYSTEM....615
Checking Engine Oil....615
Oil Chart....615
Replacing Oil And Filter....615
ENGINE COOLING SYSTEM....617
Cleaning The Cooling System....617
Checking The Coolant Level....617
Replacing The Coolant....618
ALTERNATOR BELT....619
Adjusting The Alternator Belt....619
FAN GEARBOX....619
Checking And Maintaining....619
HYDRAULIC/HYDROSTATIC SYSTEM....620
Checking And Adding Fluid....620
Replacing Hydraulic/Hydrostatic Filter....620
Replacing Hydraulic Fluid....621
Hydraulic Reservoir Breather Cap....622
SPARK ARRESTOR MUFFLER....623
Cleaning Procedure....623
TIRE MAINTENANCE....624
Wheel Nuts....624
Tire Rotation....624
Tire Mounting....624
FINAL DRIVE TRANSMISSION (CHAINCASE)....625
Checking And Adding Oil....625
Replacing Oil In The Chaincase....625
DRIVE BELT....626
Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler....626
Adjusting The Drive Belt Equipped With The Fixed Drive Idler....628
Drive Belt Replacement....629
LUBRICATION OF THE BOBCAT LOADER....630
Procedure....630
BOBTACH....632
Inspection And Maintenance....632
REMOTE START SWITCH....633
Procedure....633
HYDRAULIC SYSTEM....635
HYDRAULIC/HYDROSTATIC SCHEMATICS....639
TROUBLESHOOTING....667
HYDRAULIC SYSTEM INFORMATION....668
Tightening Procedure....668
LIFT CYLINDER(S)....669
Checking The Lift Cylinder(s) For Internal Leakage....669
Removal And Installation....669
TILT CYLINDER....670
Checking The Tilt Cylinder For Internal Leakage....670
Removal And Installation....670
Rod End Seal Replacement....671
HYDRAULIC CYLINDER IDENTIFICATION....672
Lift Cylinder Components....672
Tilt Cylinder Components....673
HYDRAULIC CYLINDERS....674
Disassembly....674
Assembly....676
BICS VALVE (S/N 512220298 & Above, 512440721 & Above and 512612258 & Above)....682
Removal....682
Lift Arm ByPass Orifice Disassembly....683
Check Valve Disassembly....683
Lock Valve Disassembly....684
BICS Valve Solenoid Disassembly....685
BICS Valve Solenoid Assembly....686
Lock Valve Assembly....687
Check Valve Assembly....687
Lift Arm ByPass Orifice Assembly....688
Installation....689
CONTROL VALVE (S/N 512220298 & Above, 512440721 & Above and 512612258 & Above)....690
Removal And Installation....690
Identification Chart....693
Disassembly....694
Lift Base End Restrictor Disassembly....694
Load Check Valve Disassembly....694
Main Relief Valve Disassembly....695
Port Relief Valve Disassembly....696
AntiCavitation Valve Disassembly....697
Rubber Boot Disassembly....698
Lift Spool And Detent Disassembly....699
Tilt Spool And Centering Spring Disassembly....702
Auxiliary Spool Disassembly....704
Auxiliary Electric Solenoid Disassembly....705
PortAuxiliary Section Disassembly....706
Cleaning And Inspection....706
PortAuxiliary Section Assembly....707
Auxiliary Electric Solenoid Assembly....707
Auxiliary Spool Assembly....708
Tilt Spool And Centering Spring Assembly....709
Lift Spool And Detent Assembly....711
Rubber Boot Assembly....713
AntiCavitation Valve Assembly....714
Port Relief Valve Assembly....715
Main Relief Valve Assembly....716
Load Check Valve Assembly....716
Spool Seal Installation....718
CONTROL VALVE (S/N 512220297 & Below,512440720 & Below and 512612257 & Below)....719
Removal And Installation....719
Identification Chart....722
Disassembly And Assembly....723
Load Check Valve....723
Main Relief Valve....724
Port Relief Valve....724
AntiCavitation Valve....725
Rubber Boot....726
Lift Spool Detent....727
Tilt Centering Spring....731
Auxiliary Spool....732
Auxiliary Electric Solenoid....733
Plug/Port Relief Valve....734
Inspection....734
Identification And Installation Of Spool Seal....735
MAIN RELIEF VALVE....736
Checking....736
Adjustment....737
Removal And Installation....737
HYDRAULIC PUMP....738
Removal And Installation....738
Checking The Output Of The Hydraulic Pump....740
Checking The Output Of The High Flow Hydraulic Pump (763H)....742
Disassembly And Assembly....743
Inspection....745
Identification....745
Removal And Installation (763H)....746
Identification (763H)....749
Disassembly And Assembly (763H)....750
HYDRAULIC FILTER HOUSING....753
Removal And Installation....753
HYDRAULIC FLUID RESERVOIR....754
Removal And Installation....754
CONTROL PEDALS....755
Removal And Installation....755
Pedal Adjustment....755
SELECT VALVE (763H)....756
Checking the Main Relief Valve in High Horsepower Select Valve....756
Removal And Installation....757
Disassembly And Assembly (New Style Valve)....759
Solenoid Testing (New Style Valve)....760
Disassembly And Assembly (Old Style Valve)....761
Solenoid Testing (Old Style Valve)....762
PEDAL INTERLOCK LINKAGE....763
Removal And Installation....763
Adjustment....764
LIFT LOCK BYPASS VALVE....765
Removal And Installation (S/N 512220298 & Above, S/N 512440721 & Above, S/N 512612258 & Above)....765
Removal And Installation (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)....767
Disassembly And Assembly (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)....768
TILT LOCK VALVE....769
Removal And Installation (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)....769
Disassembly And Assembly (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)....771
HYDROSTATIC SYSTEM....773
TROUBLESHOOTING....775
HYDROSTATIC SYSTEM INFORMATION....776
Replenishing Valve Function....776
Checking Charge Pressure....776
CONTROL PANEL....777
Removal And Installation....777
Steering Shock Removal And Installation....778
Steering Shaft Removal And Installation....778
Steering Shaft Disassembly And Assembly....778
Steering Lever Removal And Installation....779
Rubber Boot Replacement....779
STEERING LINKAGE....780
Removal And Installation....780
Steering Linkage Adjustment....782
Steering Neutral Adjustment....784
HYDROSTATIC DRIVE MOTOR....786
Removal And Installation....786
Identification (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)....787
Disassembly And Assembly (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)....788
nspection (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)....793
Timing The Hydrostatic Motor (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)....794
HYDROSTATIC MOTOR 30 SERIES....795
Identification (S/N 512218844 & Above, S/N 512612192 & Above, & S/N 512440646 & Above)....795
Disassembly (S/N 512218844 & Above, S/N 512612192 & Above, & S/N 512440646 & Above)....796
Assembly (S/N 512218844 & Above, S/N 512612192 & Above, & S/N 512440646 & Above)....801
HYDROSTATIC PUMP....807
Removal And Installation....807
Identification MODEL: 763....810
Disassembly And Assembly....812
Inspection....820
Swashplate PreLoad....822
DRIVE BELT HOUSING....823
Removal And Installation....823
SPRING LOADED DRIVE BELT TENSIONER PULLEY....825
Removal And Installation....825
Identification....826
Disassembly....827
Assembly....828
FIXED DRIVE BELT TENSIONER PULLEY....830
Removal And Installation....830
Identification....831
Disassembly....832
Assembly....834
Checking Pulley End Play....838
OIL COOLER....838
Removal And Installation....838
DRIVE SYSTEM....839
PARKING BRAKE....841
Removal And Installation....841
Disassembly And Assembly....841
PARKING BRAKE DISC....842
Removal And Installation....842
TRACTION LOCK GUIDES....843
Disassembly....843
Assembly....844
CHAINCASE FLUID....846
Removing Oil From The Chaincase....846
CHAINCASE COVERS....847
Center Chaincase Cover Removal And Installation....847
Front Chaincase Cover Removal And Installation....848
Rear Chaincase Cover Removal And Installation....848
MOTOR CARRIER....849
Shaft Seal Replacement....849
Removal And Installation....851
Disassembly....852
Assembly....853
AXLE SEAL....857
Removal And Installation....857
AXLE, SPROCKET AND BEARINGS....859
Removal And Installation....859
DRIVE CHAIN....863
Removal....863
MAIN FRAME....865
SEAT BAR (W/GAS CYLINDER)....867
Removal And Installation....867
Assembly....869
Compressing the Gas Cylinder....870
SEAT BAR (W/COMPRESSION SPRING)....871
Removal And Installation....871
Assembling Components....874
Compression Spring Disassembly And Assembly....874
OPERATOR CAB GAS CYLINDER....875
Removal And Installation....875
Disassembly And Assembly....875
OPERATOR CAB....876
Removal And Installation....876
OPERATOR SEAT....879
Removal And Installation....879
BOBTACH....880
Removal And Installation....880
BobTach Lever And Wedge....882
BobTach Stops....883
LIFT ARMS....884
Removal And Installation....884
REAR GRILL....888
Removal And Installation....888
FUEL TANK....889
Removal And Installation....889
Fuel Level Sender....890
REAR DOOR....891
Removal And Installation (2 piece door)....891
Removal And Installation (One Piece Door)....892
Hood Removal And Installation (Two Piece Door)....893
Door Latch Removal And Installation....893
Door Latch And Catch Adjustment....894
REAR LIGHTS....895
Removal and Installation (One Piece Door)....895
ELECTRICAL SYSTEM....897
ELECTRICAL SCHEMATICS....903
TROUBLESHOOTING....929
ELECTRICAL SYSTEM INFORMATION....930
Description....930
Fuse Location (Standard & BOSS Option)....930
BATTERY....931
Removal And Installation....931
Servicing The Battery....932
Using A Booster Battery (Jump Starting)....933
ALTERNATOR....934
Alternator Output Test....934
Rectifier (Diode) Test....935
Alternator Regulator Test....935
Removal And Installation....936
Adjusting The Alternator Belt....936
Disassembly And Inspection....937
Stator Continuity Test....937
Stator Ground Test....937
Rotor Continuity Test....938
Rotor Ground Test....938
Rectifier Continuity (Diode) Test....938
Assembly....939
STARTER (DELCO REMY)....940
Removal And Installation....940
Checking The Starter....940
Parts Identification....941
Disassembly And Assembly....942
Cleaning And Inspection....944
STARTER (DENSO)....945
Parts Identification....945
Disassembly....946
Inspection And Repair....951
No Load Test....954
Assembly....954
STANDARD INSTRUMENT PANEL....961
Removal And Installation....961
FRONT LIGHTS....962
Removal And Installation....962
RELAY SWITCHES....963
Location....963
ENGINE SERVICE....965
TROUBLESHOOTING....967
ENGINE SPEED CONTROL....968
Removal And Installation....968
Disassembly....968
RADIATOR....969
Removal And Installation....969
ENGINE MUFFLER....970
Removal And Installation....970
BLOWER HOUSING/FAN GEARBOX....971
Removal And Installation....971
Tension Pulley Removal And Installation....974
Blower Fan Disassembly And Assembly....975
FAN GEARBOX....977
Identification....977
Disassembly....978
Assembly....983
Checking Backlash....988
AIR CLEANER....991
Removal And Installation....991
ENGINE....992
Removal And Installation....992
Engine Mount Replacement....997
FLYWHEEL....998
Removal And Installation....998
Flywheel Ring Gear....998
ENGINE COMPRESSION....999
Checking....999
GLOW PLUGS....1000
Checking The Glow Plugs....1000
Removal And Installation....1001
FUEL INJECTION PUMP....1002
Checking The Injection Pump....1002
Adjusting ShutOff Linkage....1002
Removal And Installation....1003
Timing The Injection Pump....1006
FUEL INJECTION NOZZLES....1007
Removal And Installation....1007
Checking The Injector Nozzle....1009
CYLINDER HEAD....1010
Removal And Installation....1010
Disassembly And Assembly....1011
Servicing The Cylinder Head....1012
Top Clearance....1012
VALVE, VALVE SEAT AND GUIDE....1013
Checking The Valve Guide....1013
Reconditioning The Valve And Valve Seat....1014
Valve Spring....1015
VALVE CLEARANCE....1016
Adjustment....1016
ROCKER ARM AND SHAFT....1016
Checking....1016
TIMING GEARCASE COVER....1017
Removal And Installation....1017
IDLER GEAR AND CAMSHAFT....1019
Removal And Installation....1019
Servicing The Camshaft....1020
Servicing The Idler Gear And Shaft....1021
TIMING GEARS....1022
Checking Backlash....1022
FUEL CAMSHAFT....1023
Removal And Installation....1023
Governor....1023
CRANKSHAFT GEAR....1024
Removal And Installation....1024
OIL PUMP....1024
Removal And Installation....1024
Oil Pump Service....1024
Checking Engine Oil Pressure....1025
Relief Valve....1025
PISTON AND CONNECTING ROD....1026
Removal And Installation....1026
Servicing The Piston And Connecting Rod....1027
Connecting Rod Alignment....1029
CRANKSHAFT AND BEARINGS....1030
Removal And Installation....1030
Servicing The Crankshaft And Bearings....1031
CYLINDER BORE....1035
Checking The Cylinder Bore....1035
WATER PUMP....1036
Disassembly and Assembly....1036
SYSTEMS ANALYSIS....1037
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) (S/N 512235900 & Above), (S/N 512442000 & Above), (S/N 512613600 & Above)....1039
Inspecting The BICS Controller....1039
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED Key ON)....1039
Inspecting The Seat Bar Sensor (Engine RUNNING)....1039
Inspecting The Traction Lock (Engine RUNNING)....1039
Inspecting The Lift Arm ByPass Control....1039
Additional Inspection For Loaders With Advanced Hand Controls....1039
Troubleshooting Chart....1040
