Bobcat 763/763H Skid-Steer Loader Repair Service Manual - 6900091

(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


This Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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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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