(S/N: 512212001 thru 512249999 – S/N: 512440001 thru 512449999 – S/N: 512612001 thru 512619999)
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This workshop repair service manual PDF download for the 763/763H Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
Bobcat Loader 763/763H BICS
S/N: 512212001 thru 512249999
S/N: 512440001 thru 512449999
S/N: 512612001 thru 512619999
TABLE OF CONTENTS :
FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
SYSTEMS ANALYSIS
SPECIFICATIONS
ADVANCED HAND CONTROL SYSTEM
SERVICE MANUAL REVISIONS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6900091 (5-11)
Total Pages : 581
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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
SERIAL NUMBER LOCATIONS
LOADER SERIAL NUMBER
ENGINE SERIAL NUMBER
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
SERVICE SCHEDULE
LIFTING AND BLOCKING THE LOADER
Procedure
TRANSPORTING THE BOBCAT LOADER
TOWING THE LOADER
STOPPING THE BOBCAT LOADER
LIFTING THE LOADER
Single Point Lift
LIFT ARM SUPPORT DEVICE
Engaging The Lift Arm Support Device
Disengaging The Lift Arm Support Device
OPERATOR CAB
Description
Emergency Exit
Raising The Operator Cab
Lowering The Operator Cab
SEAT BAR RESTRAINT SYSTEM (Foot Pedals)
Description
Seat Bar Inspection
Seat Bar Maintenance
SEAT BAR RESTRAINT SYSTEM (Mechanical Hand Controls)
Description
Seat Bar Inspection
Seat Bar Maintenance
SEAT BAR RESTRAINT SYSTEM (Advanced Hand Controls)
Description
Seat Bar Inspection
Seat Bar Maintenance
AIR CLEANER SERVICE
Replacing Filter Element
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Oil Chart
Replacing Oil And Filter
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking The Coolant Level
Replacing The Coolant
ALTERNATOR BELT
Adjusting The Alternator Belt
FAN GEARBOX
Checking And Maintaining
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Replacing Hydraulic/Hydrostatic Filter
Replacing Hydraulic Fluid
Hydraulic Reservoir Breather Cap
SPARK ARRESTOR MUFFLER
Cleaning Procedure
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Tire Mounting
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
Replacing Oil In The Chaincase
DRIVE BELT
Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler
Adjusting The Drive Belt Equipped With The Fixed Drive Idler
Drive Belt Replacement
LUBRICATION OF THE BOBCAT LOADER
Procedure
BOB–TACH
Inspection And Maintenance
REMOTE START SWITCH
Procedure
HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
TROUBLESHOOTING
HYDRAULIC SYSTEM INFORMATION
Tightening Procedure
LIFT CYLINDER(S)
Checking The Lift Cylinder(s) For Internal Leakage
Removal And Installation
TILT CYLINDER
Checking The Tilt Cylinder For Internal Leakage
Removal And Installation
Rod End Seal Replacement
HYDRAULIC CYLINDER IDENTIFICATION
Lift Cylinder Components
Tilt Cylinder Components
HYDRAULIC CYLINDERS
Disassembly
Assembly
BICS™ VALVE (S/N 512220298 & Above, 512440721 & Above and 512612258 & Above)
Removal
Lift Arm By–Pass Orifice Disassembly
Check Valve Disassembly
Lock Valve Disassembly
BICS™ Valve Solenoid Disassembly
BICS™ Valve Solenoid Assembly
Lock Valve Assembly
Check Valve Assembly
Lift Arm By–Pass Orifice Assembly
Installation
CONTROL VALVE (S/N 512220298 & Above, 512440721 & Above and 512612258 & Above)
Removal And Installation
Identification Chart
Disassembly
Lift Base End Restrictor Disassembly
Load Check Valve Disassembly
Main Relief Valve Disassembly
Port Relief Valve Disassembly
Anti–Cavitation Valve Disassembly
Rubber Boot Disassembly
Lift Spool And Detent Disassembly
Tilt Spool And Centering Spring Disassembly
Auxiliary Spool Disassembly
Auxiliary Electric Solenoid Disassembly
Port–Auxiliary Section Disassembly
Cleaning And Inspection
Port–Auxiliary Section Assembly
Auxiliary Electric Solenoid Assembly
Auxiliary Spool Assembly
Tilt Spool And Centering Spring Assembly
Lift Spool And Detent Assembly
Rubber Boot Assembly
Anti–Cavitation Valve Assembly
Port Relief Valve Assembly
Main Relief Valve Assembly
Load Check Valve Assembly
Spool Seal Installation
CONTROL VALVE (S/N 512220297 & Below,512440720 & Below and 512612257 & Below)
Removal And Installation
Identification Chart
Disassembly And Assembly
Load Check Valve
Main Relief Valve
Port Relief Valve
Anti–Cavitation Valve
Rubber Boot
Lift Spool Detent
Tilt Centering Spring
Auxiliary Spool
Auxiliary Electric Solenoid
Plug/Port Relief Valve
Inspection
Identification And Installation Of Spool Seal
MAIN RELIEF VALVE
Checking
Adjustment
Removal And Installation
HYDRAULIC PUMP
Removal And Installation
Checking The Output Of The Hydraulic Pump
Checking The Output Of The High Flow Hydraulic Pump (763H)
Disassembly And Assembly
Inspection
Identification
Removal And Installation (763H)
Identification (763H)
Disassembly And Assembly (763H)
HYDRAULIC FILTER HOUSING
Removal And Installation
HYDRAULIC FLUID RESERVOIR
Removal And Installation
CONTROL PEDALS
Removal And Installation
Pedal Adjustment
SELECT VALVE (763H)
Checking the Main Relief Valve in High Horsepower Select Valve
Removal And Installation
Disassembly And Assembly (New Style Valve)
Solenoid Testing (New Style Valve)
Disassembly And Assembly (Old Style Valve)
Solenoid Testing (Old Style Valve)
PEDAL INTERLOCK LINKAGE
Removal And Installation
Adjustment
LIFT LOCK BY–PASS VALVE
Removal And Installation (S/N 512220298 & Above, S/N 512440721 & Above, S/N 512612258 & Above)
Removal And Installation (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)
Disassembly And Assembly (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)
TILT LOCK VALVE
Removal And Installation (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)
Disassembly And Assembly (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)
HYDROSTATIC SYSTEM
TROUBLESHOOTING
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function
Checking Charge Pressure
CONTROL PANEL
Removal And Installation
Steering Shock Removal And Installation
Steering Shaft Removal And Installation
Steering Shaft Disassembly And Assembly
Steering Lever Removal And Installation
Rubber Boot Replacement
STEERING LINKAGE
Removal And Installation
Steering Linkage Adjustment
Steering Neutral Adjustment
HYDROSTATIC DRIVE MOTOR
Removal And Installation
Identification (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)
Disassembly And Assembly (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)
nspection (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)
Timing The Hydrostatic Motor (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)
HYDROSTATIC MOTOR 30 SERIES
Identification (S/N 512218844 & Above, S/N 512612192 & Above, & S/N 512440646 & Above)
Disassembly (S/N 512218844 & Above, S/N 512612192 & Above, & S/N 512440646 & Above)
Assembly (S/N 512218844 & Above, S/N 512612192 & Above, & S/N 512440646 & Above)
HYDROSTATIC PUMP
Removal And Installation
Identification MODEL: 763
Disassembly And Assembly
Inspection
Swashplate Pre–Load
DRIVE BELT HOUSING
Removal And Installation
SPRING LOADED DRIVE BELT TENSIONER PULLEY
Removal And Installation
Identification
Disassembly
Assembly
FIXED DRIVE BELT TENSIONER PULLEY
Removal And Installation
Identification
Disassembly
Assembly
Checking Pulley End Play
OIL COOLER
Removal And Installation
DRIVE SYSTEM
PARKING BRAKE
Removal And Installation
Disassembly And Assembly
PARKING BRAKE DISC
Removal And Installation
TRACTION LOCK GUIDES
Disassembly
Assembly
CHAINCASE FLUID
Removing Oil From The Chaincase
CHAINCASE COVERS
Center Chaincase Cover Removal And Installation
Front Chaincase Cover Removal And Installation
Rear Chaincase Cover Removal And Installation
MOTOR CARRIER
Shaft Seal Replacement
Removal And Installation
Disassembly
Assembly
AXLE SEAL
Removal And Installation
AXLE, SPROCKET AND BEARINGS
Removal And Installation
DRIVE CHAIN
Removal
MAIN FRAME
SEAT BAR (W/GAS CYLINDER)
Removal And Installation
Assembly
Compressing the Gas Cylinder
SEAT BAR (W/COMPRESSION SPRING)
Removal And Installation
Assembling Components
Compression Spring Disassembly And Assembly
OPERATOR CAB GAS CYLINDER
Removal And Installation
Disassembly And Assembly
OPERATOR CAB
Removal And Installation
OPERATOR SEAT
Removal And Installation
BOB–TACH
Removal And Installation
Bob–Tach Lever And Wedge
Bob–Tach Stops
LIFT ARMS
Removal And Installation
REAR GRILL
Removal And Installation
FUEL TANK
Removal And Installation
Fuel Level Sender
REAR DOOR
Removal And Installation (2 piece door)
Removal And Installation (One Piece Door)
Hood Removal And Installation (Two Piece Door)
Door Latch Removal And Installation
Door Latch And Catch Adjustment
REAR LIGHTS
Removal and Installation (One Piece Door)
ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
TROUBLESHOOTING
ELECTRICAL SYSTEM INFORMATION
Description
Fuse Location (Standard & BOSS® Option)
BATTERY
Removal And Installation
Servicing The Battery
Using A Booster Battery (Jump Starting)
ALTERNATOR
Alternator Output Test
Rectifier (Diode) Test
Alternator Regulator Test
Removal And Installation
Adjusting The Alternator Belt
Disassembly And Inspection
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Rectifier Continuity (Diode) Test
Assembly
STARTER (DELCO REMY)
Removal And Installation
Checking The Starter
Parts Identification
Disassembly And Assembly
Cleaning And Inspection
STARTER (DENSO)
Parts Identification
Disassembly
Inspection And Repair
No Load Test
Assembly
STANDARD INSTRUMENT PANEL
Removal And Installation
FRONT LIGHTS
Removal And Installation
RELAY SWITCHES
Location
ENGINE SERVICE
TROUBLESHOOTING
ENGINE SPEED CONTROL
Removal And Installation
Disassembly
RADIATOR
Removal And Installation
ENGINE MUFFLER
Removal And Installation
BLOWER HOUSING/FAN GEARBOX
Removal And Installation
Tension Pulley Removal And Installation
Blower Fan Disassembly And Assembly
FAN GEARBOX
Identification
Disassembly
Assembly
Checking Backlash
AIR CLEANER
Removal And Installation
ENGINE
Removal And Installation
Engine Mount Replacement
FLYWHEEL
Removal And Installation
Flywheel Ring Gear
ENGINE COMPRESSION
Checking
GLOW PLUGS
Checking The Glow Plugs
Removal And Installation
FUEL INJECTION PUMP
Checking The Injection Pump
Adjusting Shut–Off Linkage
Removal And Installation
Timing The Injection Pump
FUEL INJECTION NOZZLES
Removal And Installation
Checking The Injector Nozzle
CYLINDER HEAD
Removal And Installation
Disassembly And Assembly
Servicing The Cylinder Head
Top Clearance
VALVE, VALVE SEAT AND GUIDE
Checking The Valve Guide
Reconditioning The Valve And Valve Seat
Valve Spring
VALVE CLEARANCE
Adjustment
ROCKER ARM AND SHAFT
Checking
TIMING GEARCASE COVER
Removal And Installation
IDLER GEAR AND CAMSHAFT
Removal And Installation
Servicing The Camshaft
Servicing The Idler Gear And Shaft
TIMING GEARS
Checking Backlash
FUEL CAMSHAFT
Removal And Installation
Governor
CRANKSHAFT GEAR
Removal And Installation
OIL PUMP
Removal And Installation
Oil Pump Service
Checking Engine Oil Pressure
Relief Valve
PISTON AND CONNECTING ROD
Removal And Installation
Servicing The Piston And Connecting Rod
Connecting Rod Alignment
CRANKSHAFT AND BEARINGS
Removal And Installation
Servicing The Crankshaft And Bearings
CYLINDER BORE
Checking The Cylinder Bore
WATER PUMP
Disassembly and Assembly
SYSTEMS ANALYSIS
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (S/N 512235900 & Above), (S/N 512442000 & Above), (S/N 512613600 & Above)
Inspecting The BICS™ Controller
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
Inspecting The Seat Bar Sensor (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The Lift Arm By–Pass Control
Additional Inspection For Loaders With Advanced Hand Controls
Troubleshooting Chart
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (S/N 512235899 & Below ), (S/N 512441999 & Below), (S/N 512613599 & Below)
Inspecting The BICS™ Controller
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
Inspecting The Seat And Seat Bar Sensors (Engine Running)
Inspecting The Traction Lock (Engine Running)
Inspecting The Lift Arm By–Pass Control
Maintenance
Troubleshooting Chart
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Troubleshooting Guide
BICS CONTROLLER
TRACTION LOCK
SEAT SENSOR
SEAT BAR SENSOR
SEAT SENSOR
Seat Sensor Test
Removal And Installation
BICS™ Controller Seat Sensor Circuit Test
BICS™ SYSTEM CONTROLLER
Removal And Installation
SEAT BAR SENSOR
Seat Bar Sensor Test
Removal And Installation
BICS™ Controller Seat Bar Sensor Circuit Test
TRACTION LOCK
Removal And Installation
BOSS® DIAGNOSTIC TOOL
Procedure
SENDER AND SENSOR
Service Checks
RPM SENSOR
Adjustment
MONITOR SERVICE CODES
TROUBLESHOOTING THE BOSS® & LCD DISPLAY
OPERATION SENSING SYSTEM UNIT
Removal And Installation
BOSS® INSTRUMENT PANEL
Removal And Installation
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
SPECIFICATIONS
SKID STEER LOADER SPECIFICATIONS
PERFORMANCE
CONTROLS
ENGINE
HYDRAULIC SYSTEM
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
ENGINE SPECIFICATIONS
Fuel Injection Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Valve Timing
Rocker Arms
Camshaft
Tappet
Cylinders
Piston Rings
Pistons
Connecting Rod
Oil Pump
Crankshaft
Crankshaft
Thermostat
Crankshaft Re–Grind Data
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O–ring Face Seal Connection
Straight Thread O–ring Fitting
Tubelines And Hoses
Flare Fitting
O–ring Flare Fitting
Port Seal Fitting
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
TORQUE SPECIFICATIONS FOR LOADER
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION
ADVANCE HAND CONTROL SYSTEM (AHC)
ADVANVED HANDCONTROL ELECTRICAL SCHEMATICS
AHC COMPONENTS
Identification
TROUBLESHOOTING (AHC)
ACTUATOR VOLTAGE TEST
Procedure
HANDLE CONTROL UNIT TEST
Procedure
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
ADVANCED HAND CONTROLS (AHC)
AHC/PWM CONTROLLER
Removal And Installation
Test
Description
Conditions
Troubleshooting Chart
Handle Testing
Solenoid Coil Testing
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)
Control Handle Unit Removal And Installation
Control Unit Connector
Switch Handle Removal And Installation
AHC Handle Removal And Installation
AHC Handle Disassembly And Assembly
AHC Steering Lever Removal And Installation
AHC Steering Lever Boot
Actuators Removal And Installation
Actuators Disassembly And Assembly
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/PUSH BUTTON FLOAT)
Components Identification
Controller Connector And Wire Identification
AHC/PWM Controller Removal And Installation
Handle Sensor Removal And Installation
Handle Sensor Connector
Switch Handle Removal And Installation
Control Handle Removal And Installation
Control Handle Disassembly And Assembly
Control Lever Removal And Installation
Control Lever Boot
Actuators Disassembly And Assembly
BICS™ VALVE
Lift Arm By–Pass Orifice
Check Valve
Lock Valve
BICS™ Valve Solenoid
Removal And Installation
HYDRAULIC CONTROL VALVE
Removal And Installation
Identification Chart
Disassembly And Assembly
Load Check Valve
Lift Base End Restrictor
Main Relief Valve
Port Relief Valve (Lift)
Anti–Cavitation/Port Relief Valve
Port Relief Valve (Tilt)
Anti–Cavitation Valve
Rubber Boot
Lift And Tilt Spool
Inspection
Auxiliary Spool
Auxiliary Electrical Solenoid
Spool Seal Installation
H–Port Auxiliary Section
SERVICE MANUAL REVISIONS
763, 763H–1
763, 763H–2
763, 763H–3
763, 763H–4
763, 763H-5
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Bobcat 763/763H Skid-Steer Loader Repair Service Manual – 6900091.pdf
Source : Sitelux.com
