Bobcat 763 763 High Flow 773 773 High Flow 773 Turbo G Series Loader Workshop Repair Service Manual PDF - MBOB763773.zip

Full service manuals featuring electrical schematics for the Bobcat 763, 763 High Flow, 773, 773 High Flow, and 773 Turbo (G Series) Loaders, offering the technical detail needed to maintain, troubleshoot, fix, and service these machines the way professional technicians do.

The Bobcat 763, 763 High Flow, 773, 773 High Flow, and 773 Turbo (G Series) Loader workshop service repair manual contains:

* 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: 7,680 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...1

MAINTENANCE SAFETY...3

ALPHABETICAL INDEX...5

CONTENTS...7

FOREWORD...9

SAFETY INSTRUCTIONS...11

FIRE PREVENTION...12

SERIAL NUMBER LOCATIONS...13

LOADER SERIAL NUMBER...13

ENGINE SERIAL NUMBER...13

DELIVERY REPORT...13

BOBCAT LOADER IDENTIFICATION...14

PREVENTIVE MAINTENANCE...15

SERVICE SCHEDULE...17

LIFTING AND BLOCKING THE LOADER...18

Procedure...18

TRANSPORTING THE BOBCAT LOADER...19

TOWING THE LOADER...19

STOPPING THE BOBCAT LOADER...19

LIFTING THE LOADER...20

Single Point Lift...20

LIFT ARM SUPPORT DEVICE...21

Engaging The Lift Arm Support Device...21

Disengaging The Lift Arm Support Device...22

OPERATOR CAB...23

Description...23

Emergency Exit...23

Raising The Operator Cab...24

Lowering The Operator Cab...25

SEAT BAR RESTRAINT SYSTEM (Foot Pedals)...26

Description...26

Seat Bar Inspection...26

Seat Bar Maintenance...26

SEAT BAR RESTRAINT SYSTEM (Mechanical Hand Controls)...27

Description...27

Seat Bar Inspection...27

Seat Bar Maintenance...27

SEAT BAR RESTRAINT SYSTEM (Advanced Hand Controls)...28

Description...28

Seat Bar Inspection...28

Seat Bar Maintenance...28

AIR CLEANER SERVICE...29

Replacing Filter Element...29

FUEL SYSTEM...31

Fuel Specifications...31

Filling The Fuel Tank...31

Fuel Filter...31

Removing Air From The Fuel System...32

ENGINE LUBRICATION SYSTEM...33

Checking Engine Oil...33

Oil Chart...33

Replacing Oil And Filter...33

ENGINE COOLING SYSTEM...35

Cleaning The Cooling System...35

Checking The Coolant Level...35

Replacing The Coolant...36

ALTERNATOR BELT...37

Adjusting The Alternator Belt...37

FAN GEARBOX...37

Checking And Maintaining...37

HYDRAULIC/HYDROSTATIC SYSTEM...38

Checking And Adding Fluid...38

Replacing Hydraulic/Hydrostatic Filter...38

Replacing Hydraulic Fluid...39

Hydraulic Reservoir Breather Cap...40

SPARK ARRESTOR MUFFLER...41

Cleaning Procedure...41

TIRE MAINTENANCE...42

Wheel Nuts...42

Tire Rotation...42

Tire Mounting...42

FINAL DRIVE TRANSMISSION (CHAINCASE)...43

Checking And Adding Oil...43

Replacing Oil In The Chaincase...43

DRIVE BELT...44

Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler...44

Adjusting The Drive Belt Equipped With The Fixed Drive Idler...46

Drive Belt Replacement...47

LUBRICATION OF THE BOBCAT LOADER...48

Procedure...48

BOB–TACH...50

Inspection And Maintenance...50

REMOTE START SWITCH...51

Procedure...51

HYDRAULIC SYSTEM...53

HYDRAULIC/HYDROSTATIC SCHEMATICS...57

TROUBLESHOOTING...85

HYDRAULIC SYSTEM INFORMATION...86

Tightening Procedure...86

LIFT CYLINDER(S)...87

Checking The Lift Cylinder(s) For Internal Leakage...87

Removal And Installation...87

TILT CYLINDER...88

Checking The Tilt Cylinder For Internal Leakage...88

Removal And Installation...88

Rod End Seal Replacement...89

HYDRAULIC CYLINDER IDENTIFICATION...90

Lift Cylinder Components...90

Tilt Cylinder Components...91

HYDRAULIC CYLINDERS...92

Disassembly...92

Assembly...94

BICS™ VALVE (S/N 512220298 & Above, 512440721 & Above and 512612258 & Above)...100

Removal...100

Lift Arm By–Pass Orifice Disassembly...101

Check Valve Disassembly...101

Lock Valve Disassembly...102

BICS™ Valve Solenoid Disassembly...103

BICS™ Valve Solenoid Assembly...104

Lock Valve Assembly...105

Check Valve Assembly...105

Lift Arm By–Pass Orifice Assembly...106

Installation...107

CONTROL VALVE (S/N 512220298 & Above, 512440721 & Above and 512612258 & Above)...108

Removal And Installation...108

Identification Chart...111

Disassembly...112

Lift Base End Restrictor Disassembly...112

Load Check Valve Disassembly...112

Main Relief Valve Disassembly...113

Port Relief Valve Disassembly...114

Anti–Cavitation Valve Disassembly...115

Rubber Boot Disassembly...116

Lift Spool And Detent Disassembly...117

Tilt Spool And Centering Spring Disassembly...120

Auxiliary Spool Disassembly...122

Auxiliary Electric Solenoid Disassembly...123

Port–Auxiliary Section Disassembly...124

Cleaning And Inspection...124

Port–Auxiliary Section Assembly...125

Auxiliary Electric Solenoid Assembly...125

Auxiliary Spool Assembly...126

Tilt Spool And Centering Spring Assembly...127

Lift Spool And Detent Assembly...129

Rubber Boot Assembly...131

Anti–Cavitation Valve Assembly...132

Port Relief Valve Assembly...133

Main Relief Valve Assembly...134

Load Check Valve Assembly...134

Spool Seal Installation...136

CONTROL VALVE (S/N 512220297 & Below,512440720 & Below and 512612257 & Below)...137

Removal And Installation...137

Identification Chart...140

Disassembly And Assembly...141

Load Check Valve...141

Main Relief Valve...142

Port Relief Valve...142

Anti–Cavitation Valve...143

Rubber Boot...144

Lift Spool Detent...145

Tilt Centering Spring...149

Auxiliary Spool...150

Auxiliary Electric Solenoid...151

Plug/Port Relief Valve...152

Inspection...152

Identification And Installation Of Spool Seal...153

MAIN RELIEF VALVE...154

Checking...154

Adjustment...155

Removal And Installation...155

HYDRAULIC PUMP...156

Removal And Installation...156

Checking The Output Of The Hydraulic Pump...158

Checking The Output Of The High Flow Hydraulic Pump (763H)...160

Disassembly And Assembly...161

Inspection...163

Identification...163

Removal And Installation (763H)...164

Identification (763H)...167

Disassembly And Assembly (763H)...168

HYDRAULIC FILTER HOUSING...171

Removal And Installation...171

HYDRAULIC FLUID RESERVOIR...172

Removal And Installation...172

CONTROL PEDALS...173

Removal And Installation...173

Pedal Adjustment...173

SELECT VALVE (763H)...174

Checking the Main Relief Valve in High Horsepower Select Valve...174

Removal And Installation...175

Disassembly And Assembly (New Style Valve)...177

Solenoid Testing (New Style Valve)...178

Disassembly And Assembly (Old Style Valve)...179

Solenoid Testing (Old Style Valve)...180

PEDAL INTERLOCK LINKAGE...181

Removal And Installation...181

Adjustment...182

LIFT LOCK BY–PASS VALVE...183

Removal And Installation (S/N 512220298 & Above, S/N 512440721 & Above, S/N 512612258 & Above)...183

Removal And Installation (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)...185

Disassembly And Assembly (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)...186

TILT LOCK VALVE...187

Removal And Installation (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)...187

Disassembly And Assembly (S/N 512220297 & Below, S/N 512440720 & Below, S/N 512612257 & Below)...189

HYDROSTATIC SYSTEM...191

TROUBLESHOOTING...193

HYDROSTATIC SYSTEM INFORMATION...194

Replenishing Valve Function...194

Checking Charge Pressure...194

CONTROL PANEL...195

Removal And Installation...195

Steering Shock Removal And Installation...196

Steering Shaft Removal And Installation...196

Steering Shaft Disassembly And Assembly...196

Steering Lever Removal And Installation...197

Rubber Boot Replacement...197

STEERING LINKAGE...198

Removal And Installation...198

Steering Linkage Adjustment...200

Steering Neutral Adjustment...202

HYDROSTATIC DRIVE MOTOR...204

Removal And Installation...204

Identification (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)...205

Disassembly And Assembly (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)...206

nspection (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)...211

Timing The Hydrostatic Motor (S/N 512218843 & Below, S/N 512612191 & Below & S/N 512440645 & Below)...212

HYDROSTATIC MOTOR 30 SERIES...213

Identification (S/N 512218844 & Above, S/N 512612192 & Above, & S/N 512440646 & Above)...213

Disassembly (S/N 512218844 & Above, S/N 512612192 & Above, & S/N 512440646 & Above)...214

Assembly (S/N 512218844 & Above, S/N 512612192 & Above, & S/N 512440646 & Above)...219

HYDROSTATIC PUMP...225

Removal And Installation...225

Identification MODEL: 763...228

Disassembly And Assembly...230

Inspection...238

Swashplate Pre–Load...240

DRIVE BELT HOUSING...241

Removal And Installation...241

SPRING LOADED DRIVE BELT TENSIONER PULLEY...243

Removal And Installation...243

Identification...244

Disassembly...245

Assembly...246

FIXED DRIVE BELT TENSIONER PULLEY...248

Removal And Installation...248

Identification...249

Disassembly...250

Assembly...252

Checking Pulley End Play...256

OIL COOLER...256

Removal And Installation...256

DRIVE SYSTEM...257

PARKING BRAKE...259

Removal And Installation...259

Disassembly And Assembly...259

PARKING BRAKE DISC...260

Removal And Installation...260

TRACTION LOCK GUIDES...261

Disassembly...261

Assembly...262

CHAINCASE FLUID...264

Removing Oil From The Chaincase...264

CHAINCASE COVERS...265