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

Bobcat Loaders 763, 763 High Flow, 773, 773 High Flow, 773 Turbo (G Series) Repair Service Manual + Operation & Maintenance Manual

This comprehensive repair service manual set, complete with electrical wiring diagrams, covers the Bobcat Loaders 763, 763 High Flow, 773, 773 High Flow, and 773 Turbo (G Series). Inside you'll find the technical data needed to maintain, troubleshoot, fix, and service these machines just as a professional mechanic would.

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