Bobcat 763 & 763 High Flow G Series Loader Service Manual 6900977 (6-12) – PDF DOWNLOAD

Description

Bobcat 763 & 763 High Flow G Series Loader Service Manual 6900977 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 763 & 763 High Flow G Series Loader Service Manual 6900977 (6-12) – PDF DOWNLOAD

Language : English
Pages : 754
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 763 & 763 High Flow G Series Loader Service Manual 6900977 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
Fire Prevention 13
SERIAL NUMBER LOCATION 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 15
BOBCAT LOADER IDENTIFICATION 16
SAFETY AND MAINTENANCE 17
LIFTING AND BLOCKING THE LOADER 19
Procedure 19
LIFT ARM SUPPORT DEVICE 21
Installing Lift Arm Support Device 21
Removing The Lift Arm Support Device 22
OPERATOR CAB 25
Description 25
Raising The Operator Cab 25
Lowering The Operator Cab 26
Emergency Exit 27
TRANSPORTING THE BOBCAT LOADER 29
Procedure 29
TOWING THE LOADER 31
Procedure 31
REMOTE START 33
Procedure 33
SERVICE SCHEDULE 37
Chart 37
AIR CLEANER SERVICE 39
Checking 39
Replacing Filter Element(s) 39
ENGINE COOLING SYSTEM 41
Cleaning The Cooling System 41
Checking The Coolant Level 42
Replacing The Coolant 42
FUEL SYSTEM 45
Fuel Specifications 45
Filling the Fuel Tank 45
Fuel Filter 46
Removing Air From The Fuel System 46
Checking Engine Oil 47
Oil Chart 47
Replacing Oil And Filter 47
HYDRAULIC/HYDROSTATIC SYSTEM 49
Checking And Adding Fluid 49
Replacing Hydraulic/Hydrostatic Filter 50
Replacing Hydrostatic Motor Case Drain Filter(s) 50
Replacing Hydraulic Fluid 51
Breather Cap 52
FINAL DRIVE TRANSMISSION (CHAINCASE) 53
Checking And Adding Oil 53
Removing The Oil 53
FAN GEARBOX 55
Checking And Maintaining 55
BOB-TACH 57
Inspection And Maintenance 57
LUBRICATION OF THE BOBCAT LOADER 59
Procedure 59
Pivot Pins 60
TIRE MAINTENANCE 61
Wheel Nuts 61
Rotating 61
Mounting 61
SPARK ARRESTOR MUFFLER 63
Servicing 63
HYDRAULIC SYSTEM 65
HYDRAULIC/HYDROSTATIC SCHEMATICS 69
HYDRAULIC SYSTEM INFORMATION 73
Tighten Procedures 77
Troubleshooting Chart 78
CYLINDER (LIFT) 79
Checking 79
Removal And Installation 80
Identification 81
Disassembly 82
Assembly 83
CYLINDER (TILT) 87
Checking 87
Removal And Installation 87
Rod End Pivot Pin Bushing And Seal Replacement 89
Identification 90
Disassembly 91
Assembly 92
CYLINDER (POWER BOB-TACH) 95
Checking 95
Removal And Installation 96
Parts Identification 97
Disassembly 98
Assembly 99
MAIN RELIEF VALVE 103
Checking 103
Adjustment 104
Removal And Installation 105
HYDRAULIC CONTROL VALVE (FOOT CONTROL) 107
Removal And Installation (S/N 512262999 & Below) 107
Removal And Installation (S/N 512263000 & Above) 111
BICS™ Valve, Removal And Installation 115
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation 116
BICS™ Valve, Check Valve Removal And Installation 117
BICS™ Valve, Lock Valve Removal And Installation 118
BICS™ Valve, Solenoid Removal And Installation 119
BICS™ Valve, Solenoid Testing 120
Identification Chart 121
Load Check Valve 122
Main Relief Valve 123
Port Relief Valve 124
Anti-Cavitation Valve/Port Relief Valve 125
Anti-Cavitation Valve 126
Rubber Boot 127
Lift And Tilt Lock Block Removal And Installation 127
Lift Spool And Detent 128
Tilt Spool Removal And Installation 137
Auxiliary Spool Removal And Installation 139
Auxiliary Electric Solenoid 140
Port-Auxiliary Section 141
Cleaning And Inspection 141
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) 143
Description 143
Removal And Installation (S/N 512262999 & Below) 143
Removal And Installation (S/N 512263000 & Above) 146
Actuator Removal And Installation 150
BICS™ Valve, Removal And Installation 150
BICS™ Valve, Lift Arm By-Pass Orifice Removal and Installation 152
BICS™ Valve, Check Valve Removal and Installation 153
BICS™ Valve, Lock Valve Removal and Installation 154
BICS™ Valve, Solenoid Removal and Installation 155
BICS™ Valve, Solenoid Testing 156
Identification Chart (AHC) 157
Identification Chart (ACS) 158
Lift Base End Restrictor 159
Load Check Valve 159
Main Relief Valve 160
Port Relief Valve 161
Anti-Cavitation Valve/Port Relief Valve 162
Anti-Cavitation Valve 163
Lift Spool Removal And Installation 164
Tilt Spool Removal And Installation 165
Lift And Tilt Spool Disassembly And Assembly 166
Auxiliary Spool Removal And Installation 167
Auxiliary Electric Solenoid 168
Port-Auxiliary Section 169
Cleaning And Inspection 169
LIFT ARM BY-PASS CONTROL VALVE 171
Inspecting 171
Removal And Installation 171
Disassembly And Assembly 172
HYDRAULIC PUMP (ALUMINUM) 173
Checking The Output Of The Hydraulic Pump 173
Removal And Installation 175
Parts Identification 177
Disassembly And Assembly 178
Inspection 180
HYDRAULIC PUMP (ALUMINUM HI-FLOW) 181
Removal And Installation 181
Parts Identification 184
Disassembly And Assembly 185
HYDRAULIC PUMP (CAST IRON) 189
Check The Output Of The Hydraulic Pump Without Power Bob-Tach 189
Check The Output Of The Hydraulic Pump With Power Bob-Tach 191
Removal And Installation 193
Identification 197
Disassembly And Assembly 198
HYDRAULIC/HYDROSTATIC FILTER 203
Housing Removal And Installation 203
HYDRAULIC FLUID RESERVOIR 205
Fluid Removal 205
Removal And Installation (S/N 512264899 & Below) 206
Removal And Installation (S/N 512264900 & Above) 207
BUCKET POSITION VALVE 209
Solenoid Removal And Installation 209
Solenoid Testing 209
Removal And Installation 210
Disassembly And Assembly 211
SELECT VALVE 213
Checking The High Flow Pump Relief Valve 213
Removal And Installation 214
Disassembly And Assembly 216
Solenoid Testing 220
REAR AUXILIARY DIVERTER VALVE (SINGLE SHUTTLE) 221
Removal And Installation 221
Disassembly 223
Inspection 224
Solenoid Testing 224
Assembly 224
REAR AUXILIARY DIVERTER VALVE (DUAL SHUTTLE) 225
Removal And Installation 225
Disassembly And Assembly 227
Solenoid Testing 230
Inspection 230
POWER BOB-TACH BLOCK (S/N 512267827 & BELOW) 231
Removal And Installation 231
Disassembly And Assembly 232
POWER BOB-TACH BLOCK (S/N 512267828 & ABOVE) 241
Removal And Installation 241
Disassembly And Assembly 243
FRONT AUXILIARY PRESSURE RELIEF BLOCK 247
Removal And Installation 247
Disassembly And Assembly 248
Solenoid Testing 249
Solenoid Inspection 249
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 251
Removal and Installation 251
Disassembly And Assembly 251
HYDROSTATIC SYSTEM 253
HYDROSTATIC SYSTEM INFORMATION 255
Troubleshooting Chart 255
Replenishing Valve Function 256
HYDROSTATIC MOTOR 257
Removal And Installation 257
Parts Identification 259
Disassembly 260
Assembly 265
Prior to assembly: 265
Carrier Shaft Seal Replacement 271
Carrier Removal And Installation 273
Carrier Parts Identification 275
Carrier Disassembly 276
Carrier Assembly 277
CHARGE PRESSURE 281
Sender Removal And Installation 281
Checking Charge Pressure 281
Adjusting 281
HYDROSTATIC PUMP 283
Replenishing/High Pressure Relief Valve 283
Removal And Installation 284
Parts Identification (Right Half) 286
Parts Identification (Left Half) 288
Hydraulic Pump Removal And Installation 290
Pump Separation 291
Disassembly 292
Assembly 298
DRIVE BELT 305
Shield Removal And Installation 305
Adjusting 306
Drive Belt Replacement 307
Tensioner Pulley Removal And Installation 308
Tensioner Pulley Parts Identification 309
Tensioner Pulley Disassembly 310
Tensioner Pulley Assembly 311
OIL COOLER 313
Removal and Installation 313
DRIVE SYSTEM 315
DRIVE COMPONENTS 317
Axle Seal Removal And Installation 317
Axle Sprocket And Bearings Removal And Installation 319
Chain Removal And Installation 324
CHAINCASE 327
Checking And Adding Oil 327
Removing The Oil 327
Front Cover Removal And Installation 328
Center Cover Removal And Installation 329
Rear Cover Removal And Installation 330
BRAKE 331
Pedal Removal And Installation 331
Pedal Disassembly And Assembly 332
Disk Removal And Installation 333
Switch Operated Parking Brake 334
MAIN FRAME 335
SEAT BAR 339
Removal And Installation 339
Assembling Components 341
Compression Spring Disassembly And Assembly 343
OPERATOR CAB 345
Gas Cylinder Removal And Installation 345
Gas Cylinder Disassembly 346
Removal And Installation 347
OPERATOR SEAT 349
Removal And Installation 349
Seat Belt Removal And Installation 349
OPERATOR SEAT (SUSPENSION) 351
Removal And Installation 351
Slide Rail Removal And Installation 352
Cushion Removal And Installation 352
Back Removal And Installation 353
Shock Removal And Installation 354
BOB-TACH 355
Removal And Installation 355
Bob-Tach Lever And Wedge 357
Bob-Tach Stops 359
LIFT ARM 361
Removal And Installation 361
REAR GRILL 367
Gas Cylinder Removal And Installation 367
Removal And Installation 368
REAR DOOR 369
Removal And Installation 369
Door Latch And Catch Adjustment (S/N 512261535 & Below) 370
Door Latch Removal And Installation (S/N 512261535 & Below) 371
Striker Removal and Installation (S/N 512261536 & Above) 372
Striker Disassembly and Assembly (S/N 512261536 & Above) 372
Adjusting The Striker (S/N 512261536 & Above) 372
Latch Removal and Installation (S/N 512261536 & Above) 373
FUEL TANK 375
Removal And Installation 375
Fuel Level Sender 376
CONTROL PEDALS 377
Removal And Installation 377
Pedal Adjustment 377
Crossbar Linkage Removal And Installation 378
Lift Foot Pedal Linkage Removal And Installation 379
Tilt Foot Pedal Linkage Removal And Installation 380
CONTROL PEDALS (ACS) 381
Foot Sensor Removal And Installation 381
Foot Pedal Removal And Installation 382
Foot Pedal Linkage Disassembly And Assembly 382
CONTROL PANEL 383
Removal and Installation 383
Shock Removal And Installation 385
Shaft Removal And Installation 385
Shaft Disassembly And Assembly 386
Linkage Removal And Installation 387
Linkage Adjustment 389
Linkage Neutral Adjustment 393
CONTROL HANDLE 397
Control Lever Removal And Installation 397
Control Lever Boot 397
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) 399
Components Identification 399
Control Handle Unit Removal And Installation 400
Control Handle Removal And Installation 403
Control Handle Disassembly And Assembly 403
Control Lever Removal And Installation 404
Control Lever Boot 405
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) W/PUSH BUTTON FLOAT 407
Components Identification 407
Handle Sensor Removal And Installation 407
Control Handle Removal And Installation 409
Control Handle Disassembly And Assembly 410
Control Lever Removal And Installation 411
Control Lever Boot 412
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL 413
Components Identification 413
Handle Sensor Removal And Installation 413
Control Handle Removal and Installation 417
Control Handle Disassembly and Assembly 418
Control Lever Removal and Installation 419
Control Lever Boot 420
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL 421
Components Identification 421
Handle Sensor Removal And Installation 421
Control Handle Removal And Installation 425
Control Handle Disassembly And Assembly 426
Control Lever Removal And Installation 426
Control Lever Boot 427
ELECTRICAL SYSTEM & ANALYSIS 429
ELECTRICAL SCHEMATICS 435
ELECTRICAL SYSTEM INFORMATION 433
763 Wiring Schematics 433
Troubleshooting Chart 447
Description 448
Fuse Location 449
Relay Switch Location 449
Solenoid Test 450
BATTERY 451
Removal And Installation 451
Servicing 452
Using A Booster Battery (Jump Starting) 453
ALTERNATOR (55 AMP) 455
Adjusting The Alternator Belt 455
Alternator Output Test 455
Rectifier (Diode) Test 456
Alternator Regulator Test 456
Removal And Installation 458
Disassembly 459
Stator Continuity Test 459
Stator Ground Test 459
Rotor Continuity Test 460
Rotor Ground Test 460
Rectifier Continuity (Diode) Test 460
Assembly 461
ALTERNATOR (90 AMP) 463
Adjusting The Alternator Belt 463
Alternator Identification 463
Charging System Check 464
Alternator Voltage Test 465
Low Voltage Test 465
High Voltage Test 466
Removal And Installation 467
Rectifier Continuity (Diode) Test 468
Alternator Regulator Test 469
Disassembly 470
Stator Continuity Test 470
Stator Ground Test 471
Rotor Continuity Test 471
Rotor Ground Test 471
Assembly 471
STARTER (NIPPONDENSO) 473
Checking 473
Removal And Installation 473
Parts Identification 475
Disassembly 476
Inspection And Repair 481
No Load Test 485
Assembly 485
STARTER (VALEO) 493
Checking 493
Removal And Installation 494
Parts Identification 495
Disassembly and Assembly 496
Inspection And Repair 499
No Load Test 501
INSTRUMENT PANEL 503
Left Panel 503
Right Panel (Standard) (With Key Switch) 504
Right Panel – (Deluxe) (With Keyless Start) 505
Right Panel Setup Display Options (Deluxe) 507
Passwords 508
Option And Field Accessory Panels 510
Removal And Installation 511
Front Accessory Panel Removal And Installation 512
LIGHTS 513
Front Removal And Installation 513
Rear Removal And Installation 514
BOBCAT CONTROLLER 515
Identification Chart (S/N 512263854 & Below) 515
Identification Chart (S/N 512263855 & Above) 516
Removal And Installation 518
DIAGNOSTICS 521
Service Codes 521
BICS™ SYSTEM 527
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 527
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 527
Inspecting The Seat Bar Sensor (Engine RUNNING) 527
Inspecting The Traction Lock (Engine RUNNING) 527
Inspecting The Lift Arm By-Pass Control 528
Additional Inspection For Loaders With Advanced Hand Controls (AHC) 528
Troubleshooting Chart 529
Troubleshooting Guide 530
SEAT BAR SENSOR 531
Troubleshooting Chart 531
Test 532
Removal And Installation 533
BICS™ Circuit Test 535
TRACTION LOCK 537
Troubleshooting Chart 537
Inspecting 538
Solenoid Removal And Installation 538
Guide Removal 541
Guide Installation 542
ADVANCE HAND CONTROL (AHC) SYSTEM 545
Components Identification 545
Troubleshooting Guide 546
Parts Identification 547
AHC Controller Removal And Installation 548
Handle Control Unit Connector 548
Switch Handle Removal And Installation 549
Actuators Disassembly And Assembly 553
ADVANCED HAND CONTROL (AHC) SYSTEM (W/ PUSH BUTTON FLOAT) 555
Components Identification 555
Troubleshooting Guide 556
Controller Connector And Wire Identification 557
AHC Controller Removal And Installation 558
Handle Sensor Removal And Installation 558
Handle Sensor Connector 560
Switch Handle Removal And Installation 561
Actuators Disassembly And Assembly 564
ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL 565
Components Identification 565
Troubleshooting Guide 566
Controller, Connector And Wire Identification 567
ACS Controller Removal And Installation 568
Handle Sensor Connector 568
Switch Handle Removal 569
Switch Handle Installation 572
Actuators Disassembly and Assembly 575
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROL 577
Components Identification 577
Troubleshooting Guide 579
Controller, Connector And Wire Identification 580
ACS Controller Removal And Installation 581
Handle Sensor Connector 581
Switch Handle Removal 582
Switch Handle Installation 585
Actuators Disassembly and Assembly 588
Handle Lock Solenoid Removal And Installation 589
Handle Lock Solenoid Disassembly And Assembly 589
Handle Lock Solenoid Connector 590
Calibration Of The ACS System 591
Switchable Hand/Foot Controls Calibration Procedure 591
Hand Controls Only Calibration Procedure 593
Foot Sensor Disassembly And Assembly 594
Foot Sensor Connector 594
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE 597
Controls Identification Chart 597
ENGINE SERVICE 599
TROUBLESHOOTING 601
Chart 601
ENGINE SPEED CONTROL 603
Removal And Installation 603
Disassembly 603
MUFFLER 605
Removal And Installation 605
AIR CLEANER 607
Removal And Installation 607
RADIATOR 609
Removal And Installation 609
COOLING FAN 611
Drive Tension Pulley Removal And Installation 611
Gearbox/Blower Housing Removal And Installation 612
Blower Housing Grill Removal And Installation 615
Blower Disassembly And Assembly 615
Gearbox Parts Identification 617
Gearbox Disassembly 618
Gearbox Assembly 622
Gearbox Checking Backlash 627
ENGINE COMPONENTS AND TESTING 631
Compression Checking 631
Glow Plugs Checking 632
Glow Plugs Removal And Installation 633
Fuel Shut-Off Solenoid Checking 633
Fuel Shut-Off Solenoid Adjusting 634
Fuel Shut-Off Solenoid Removal And Installation 634
Checking 635
Fuel Injection Pump Removal And Installation 636
Timing The Injection Pump 639
Fuel Injector Removal And Installation 640
Fuel Injector Checking 642
Fuel Injector Disassembly 643
Fuel Injector Assembly 643
Valve Clearance Adjustment 644
Rocker Arm And Shaft Checking 645
Valve Timing Checking 645
ENGINE 647
Removal And Installation 647
Engine Mount Replacement 652
FLYWHEEL AND HOUSING 653
Flywheel Removal And Installation 653
Ring Gear Removal And Installation 654
Housing Removal And Installation 654
RPM SENSOR 657
Adjustment 657
RECONDITIONING THE ENGINE 659
Cylinder Head Removal And Installation 659
Cylinder Head Disassembly And Assembly 660
Cylinder Head Servicing 661
Cylinder Head Top Clearance 661
Checking The Valve Guide 662
Reconditioning The Valve And Valve Seat 663
Valve Spring 664
Rocker Arm And Shaft Checking 665
Timing Gearcase Cover Removal And Installation 665
Idler Gear And Camshaft Removal And Installation 668
Servicing The Camshaft 669
Servicing The Idler Gear And Shaft 670
Timing Gears Checking Backlash 671
Fuel Camshaft Removal And Installation 672
Fuel Camshaft Governor 672
Crankshaft Gear Removal And Installation 673
Oil Pump Removal And Installation 673
Oil Pump Service 674
Checking Engine Oil Pressure 675
Relief Valve 675
Piston And Connecting Rod Removal And Installation 676
Servicing The Piston And Connecting Rod 677
Connecting Rod Alignment 680
Crankshaft And Bearings Removal And Installation 680
Servicing The Crankshaft And Bearings 682
Checking The Cylinder Bore 685
Water Pump Disassembly And Assembly 686
HEATER 687
COMPONENTS 689
Identification 689
REGULAR MAINTENANCE 691
Filter Elements Removal And Installation 691
BASIC TROUBLESHOOTING 695
Cleaning The Heater Coil 695
Checking The Electrical System 696
Engine Coolant By-Passing The Heater Valve 701
Heater Valve Not Opening Or Closing 701
SYSTEM TROUBLESHOOTING CHART 703
HEATER UNIT 705
Removal And Installation 705
Disassembly And Assembly 706
HEATER COIL 707
Removal And Installation 707
HEATER FAN 709
Removal And Installation 709
Disassembly And Assembly 710
Wire Connector Removal and Installation 712
HEATER VALVE 715
Removal and Installation 715
Disassembly And Assembly 716
SPECIFICATIONS 717
LOADER SPECIFICATIONS 719
Loader Dimensions 719
Performance 720
Controls 720
Engine 720
Hydraulic System 721
Electrical 722
Drive System 722
Capacities 722
Tires 723
ENGINE SPECIFICATIONS 725
Fuel Injection Nozzles 725
Fuel Injection Pump 725
Cylinder Head 725
Valves 725
Valve Springs 725
Valve Timing 726
Rocker Arms 726
Camshaft 726
Tappet 726
Cylinders 726
Piston Rings 727
Pistons 727
Connecting Rod 727
Oil Pump 727
Crankshaft 728
Timing Gear 728
Thermostat 728
Crankshaft Re-Grind Data 729
TORQUE SPECIFICATIONS FOR BOLTS 731
Torque For General SAE Bolts 731
Torque For General Metric Bolts 732
Torque For Kubota Metric Bolts 732
HYDRAULIC CONNECTION SPECIFICATIONS 733
O-ring Face Seal Connection 733
Straight Thread O-ring Fitting 734
Tubelines And Hoses 734
Flare Fitting 734
O-ring Flare Fitting 735
Port Seal Fitting 737
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 739
Specifications 739
CONVERSIONS 741
Decimal And Millimeter Equivalents 741
U S To Metric Conversion 742
SMR 743
Revision No: 763/763H-1 743
Revision No: 763-2 745
Revision No: 763-3 747
Revision No: 763-4 749
Revision No: 763-5 751
Revision No: 763-6 753

DESCRIPTION:

Bobcat 763 & 763 High Flow G Series Loader Service Manual 6900977 (6-12) – PDF DOWNLOAD

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS:

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

Contact us: [email protected]

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V