Bobcat 763, 763H Repair Manual [Skid Steer Loader] (512212001-…)

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Description

Revised Factory [6900091] Workshop Repair Service Manual For Bobcat 763, 763H Skid Steer Loader. Detailed Step by Step Instructions, diagrams, illustrations make easy any repair, Overhaul, Disassembly and Assembly, Testing, Adjustment, Replacement and Change, Inspection and Adjustment, etc.

= Printable,
= Zoom able,
= Clickable index,
= Bookmarks,
= Searchable Text

MODELS Covered

Bobcat 763

Bobcat 763 High Flow

Serial Number 512212001 – 512249999
Serial Number 512440001 – 512449999
Serial Number 512612001 – 512619999

SECTIONS covered

* Preventive Maintenance

Air Cleaner Service
Replacing Filter Element
Alternator Belt
Adjusting The Alternator Belt
Bobtach
Inspection And Maintenance
Drive Belt
Adjusting The Drive Belt Equipped With
The Fixed Drive Idler
Adjusting The Drive Belt Equipped With
The Spring Loaded Drive Idler
Drive Belt Replacement
Engine Cooling System
Cleaning The Cooling System
Checking The Coolant Level
Replacing The Coolant
Engine Lubrication System
Checking Engine Oil
Replacing Oil And Filter
Fan Gearbox
Checking And Maintaining
Final Drive Transmission (Chaincase)
Checking And Adding Oil
Removing Oil From The Chaincase
Fuel System
Filling The Fuel Tank
Fuel Filter
Fuel Specifications
Removing Air From The Fuel System
Hydraulic/Hydrostatic System
Checking And Adding Fluid
Replacing Hydraulic/Hydrostatic Filter
Hydraulic Reservoir Breather Cap
Replacing Hydraulic Fluid
Lift Arm Support Device
Disengaging The Lift Arm Support Device
Engaging The Lift Arm Support Device
Lifting And Blocking The Loader
Procedure
Lifting The Loader
Single Point Lift
Lubrication Of The Loader
Procedure
Operator Cab
Description
Lowering The Operator Cab
Raising The Operator Cab
Emergency Exit
Remote Start Switch
Procedure
Seat Bar Restraint System (Advanced Hand Controls)
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 (Foot Pedals)
Description
Seat Bar Inspection
Seat Bar Maintenance
Service Schedule
Chart
Spark Arrestor Muffler
Cleaning Procedure
Stopping The Bobcat Loader
Tire Maintenance
Tire Mounting
Tire Rotation
Wheel Nuts
Towing The Loader
Procedure
Transporting The Loader
Procedure

* Hydraulic System

Bics™ Valve
Bics Valve Solenoid Assembly & Disassembly
Check Valve Assembly & Disassembly
Installation
Lift Arm Bypass Orifice Assembly & Disassembly
Lock Valve Assembly & Disassembly,Removal
Control Pedals
Pedal Adjustment Removal And Installation
Anticavitation Valve Assembly & Disassembly
Auxiliary Electric Solenoid Assembly & Disassembly
Auxiliary Spool
Assembly
Disassembly
Cleaning And Inspection
Disassembly
Identification Chart
Lift Base End Restrictor
Disassembly
Lift Spool And Detent Assembly & Disassembly
Load Check Valve Assembly & Disassembly
Main Relief Valve Assembly & Disassembly
Port Auxiliary Section Assembly & Disassembly
Port Relief Valve Assembly & Disassembly
Removal And Installation
Rubber Boot Assembly & Disassembly
Spool Seal Installation
Tilt Spool And Centering Spring Assembly & Disassembly
Hydraulic Cylinder Identification
Lift Cylinder Components
Tilt Cylinder Components
Hydraulic Cylinders Assembly & Disassembly
Hydraulic Filter Housing
Removal And Installation
Hydraulic Fluid Reservoir
Removal And Installation
Hydraulic Pump
Checking The Output Of The Hydraulic Pump
Checking The Output Of The High Flow Hydraulic Pumps (H)
Disassembly And Assembly
Disassembly And Assembly (H)
Inspection
Identification
Identification (H)
Removal And Installation
Removal And Installation (H)
Hydraulic System Information
Tightening Procedure
Lift Cylinder(S)
Checking The Lift Cylinder(S) For Internal Leakage
Removal And Installation
Lift Lock Bypass Valve
Disassembly And Assembly
Adjustment
Removal And Installation
Select Valve (H)
Checking The Main Relief Valve In High Horsepower Select Valve
Disassembly And Assembly (New Style Valve)
Disassembly And Assembly (Old Style Valve)
Removal And Installation
Solenoid Testing (New Style Valve)
Solenoid Testing (Old Style Valve)
Tilt Cylinder
Checking The Tilt Cylinder For Internal Leakage
Removal And Installation
Rod End Seal Replacement
Troubleshooting
Chart
Tilt Lock Valve
Disassembly And Assembly
Removal And Installation

* Hydrostatic System

Control Panel
Removal And Installation
Rubber Boot Replacement
Steering Lever Removal And Installation
Steering Shaft Removal And Installation
Steering Shaft Disassembly And Assembly
Steering Shock Removal And Installation
Drive Belt Housing
Removal And Installation
Fixed Drive Belt Tensioner Pulley
Assembly
Checking Pulley End Play
Disassembly
Identification
Removal And Installation
Hydrostatic Drive Motor
Disassembly And Assembly
Identification
Inspection
Removal And Installation
Timing The Hydrostatic
Hydrostatic Drive MotorSeries
Assembly
Disassembly
Identification
Hydrostatic Pump
Disassembly And Assembly
Identification
Inspection
Removal And Installation
Swashplate Preload
Hydrostatic System Information
Checking Charge Pressure
Replenishing Valve Function
Oil Cooler
Removal And Installation
Spring Loaded Drive Belt Tensioner Pulley
Assembly
Disassembly
Identification
Removal And Installation
Steering Linkage
Removal And Installation
Steering Linkage Adjustment
Steering Neutral Adjustment
Troubleshooting
Chart

* Drive System

Axle Seal
Removal And Installation
Axle, Sprocket And Bearings
Removal And Installation
Chaincase Covers
Center Chaincase Cover Removal And Installation
Front Chaincase Cover Removal And Installation
Rear Chaincase Cover Removal And Installation
Chaincase Fluid
Removing Oil From The Chaincase
Drive Chain
Removal And Installation
Motor Carrier
Assembly
Disassembly
Removal And Installation
Shaft Seal Replacement
Parking Brake
Disassembly And Assembly
Removal And Installation
Parking Brake Disc
Removal And Installation
Traction Lock Guides
Assembly
Disassembly

* Main Frame

Bobtach
Bobtach Stops
Bobtach Lever And Wedge
Removal And Installation
Fuel Tank
Fuel Level Sender
Removal And Installation
Lift Arms
Removal And Installation
Operator Cab
Removal And Installation
Operator Cab Gas Cylinder
Disassembly And Assembly
Removal And Installation
Operator Seat
Removal And Installation
Rear Door
Bumper Removal And Installation
Door Latch Removal And Installation
Door Latch And Catch Adjustment
Hood Removal And Installation
Removal And Installation
Rear Grill
Removal And Installation
Seat Bar (W/Compression Springs)
Assembly Components
Compression Spring Disassembly And Assembly
Removal And Installation
Seat Bar (W/Gas Cylinder)
Assembly
Compressing The Gas Cylinder
Removal And Installation
Rear Lights
Removal And Installation

* Electrical System

Alternator
Adjusting The Alternator Belt
Alternator Output Test
Alternator Regulator Test
Assembly
Disassembly And Inspection
Rectifier Continuity (Diode) Test
Rectifier (Diode) Test
Removal And Installation
Rotor Continuity Test
Rotor Ground Test
Stator Continuity Test
Stator Ground Test
Battery
Removal And Installation
Servicing The Battery
Using A Booster Battery (Jump Starting)
Electrical System Information
Description
Fuse Location (Standard & Boss® Option)
Front Lights
Removal And Installation
Relay Switches
Location
Standard Instrument Panel
Removal And Installation
Starter (Delco Remy)
Checking The Starter
Cleaning And Inspection
Disassembly And Assembly
Parts Identification
Removal And Installation
Starter (Denso)
Assembly
Disassembly
Inspection And Repair
No Load Test
Parts Identification
Troubleshooting
Chart

* Electrical System

Alternator
Adjusting The Alternator Belt
Alternator Output Test
Alternator Regulator Test
Assembly
Disassembly And Inspection
Rectifier Continuity (Diode) Test
Rectifier (Diode) Test
Removal And Installation
Rotor Continuity Test
Rotor Ground Test
Stator Continuity Test
Stator Ground Test
Battery
Removal And Installation
Servicing The Battery
Using A Booster Battery (Jump Starting)
Electrical System Information
Description
Fuse Location (Standard & Boss® Option)
Front Lights
Removal And Installation
Relay Switches
Location
Standard Instrument Panel
Removal And Installation
Starter (Delco Remy)
Checking The Starter
Cleaning And Inspection
Disassembly And Assembly
Parts Identification
Removal And Installation
Starter (Denso)
Assembly
Disassembly
Inspection And Repair
No Load Test
Parts Identification
Troubleshooting
Chart

* Systems Analysis

Bobcat Interlock Control System (Bics™)
(S/N& Below), (S/N& Below), (S/N& Below)
Inspecting The Deactivation Of The Auxiliary Hydraulics System
(Engine StoppedKey On)
Inspecting The Bics™ System Controller
(Engine StoppedKey On)
Inspecting The Seat And Seat Bar Sensors (Engine Running)
Inspecting The Traction Lock (Engine Running)
Inspecting The Lift Arm Bypass Control
Maintenance
Troubleshooting Chart
Bobcat Interlock Control System (Bics™)
Troubleshooting Guide
Bics Controller
Seat Bar Sensor
Seat Sensor
Traction Lock
Bics™ System Controller
Removal And Installation
Electrical/Hydraulic Controls Reference
Controls Identification Chart
Seat Bar Sensor
Bics™ Controller Seat Sensor Circuit Test
Removal And Installation
Seat Bar Sensor Test
Seat Sensor
Bics™ Controller Seat Sensor Circuit Test
Removal And Installation
Seat Sensor Test
Traction Lock
Removal And Installation
Bobcat Operation Sensing System (Boss®)
Boss® Diagnostic Tool
Procedure
Boss® Instrument Panel
Removal And Installation
Monitor Service Codes
Alphabetic Codes
Numeric Codes
Service Codes
Operation Sensing System Unit
Removal And Installation
Rpm Sensor
Adjustment
Sender And Sensor
Service Checks
Component
Troubleshooting The Boss® & Lcd Display
Chart

* Specifications

Decimal & Millimeter Equivalents
Chart
Engine Specifications
Camshaft
Connecting Rod
Crankshaft
Crankshaft Regrind Data
Cylinders
Cylinder Head
Fuel Injector Nozzle
Fuel Injection Pump
Oil Pump
Pistons
Piston Rings
Rocker Arms
Tappet
Thermostat
Timing Gear
Torque For General Metric Bolts
Valves
Valve Springs
Valve Timing
Hydraulic/Hydrostatic Fluid Specifications
Specifications
Hydraulic Connection Specifications
Flare Fitting
Oring Face Seal Connection
Oring Flare Fitting
Port Seal Fitting
Straight Thread Oring Fitting
Tubelines And Hoses
Loader Specifications
Capacities
Controls
Drive System
Electrical
Engine
Hydraulic System
Performance
Specifications
Tires
Standard Torque Specifications For Bolts
Chart
Torque Specifications For Loader
Specifications
Us To Metric Conversion
Chart

* Advance Hand Control System (Ahc)

Actuator Voltage Test
Procedure
Ahc Components
Identification
Ahc/Pwm Controller
Conditions
Decription
Handle Testing
Removal And Installation
Solenoid Coil Testing
Test
Troubleshooting Chart
Bobcat Interlock Control System (Bics™)
Troubleshooting Chart
Bics™ Valve
Bics™ Valve Solenoid
Check Valve
Lift Arm Bypass Orifice
Lock Valve
Removal And Installation
Control Handle (Advanced Hand Control) (Ahc)
Actuators Disassembly And Assembly
Actuators Removal And Installation
Ahc Handle Removal And Installation
Ahc Handle Disassembly And Assembly
Ahc Steering Lever Boot
Ahc Steering Lever Removal And Installation
Control Handle Unit Removal And Installation
Control Unit Connector
Switch Handle Removal And Installation
Control Handle (Advanced Hand Control) (Ahc)
(W/Push Button Float
Actuators Disassembly And Assembly
Ahc/Pwm Controller Removal And Installation
Ahc/Pwm Controller Test
Components Identification
Control Handle Disassembly And Assembly
Control Handle Removal And Installation
Control Lever Boot
Control Lever Removal And Installation
Controller Connector And Wire Identification
Handle Sensor Connector
Handle Sensor Removal And Installation
Switch Handle Removal And Installation
Handle Control Unit Test
Procedure
Hydraulic Control Valve
Anticavitation/Port Relief Valve
Anticavitation Valve
Auxiliary Electrical Solenoid
Auxiliary Spool
Disassembly And Assembly
Hport Auxiliary Section
Identification Chart
Inspection
Lift And Tilt Spool
Lift Base End Restrictor
Load Check Valve
Main Relief Valve
Port Relief Valve (Lift)
Port Relief Valve (Tilt)
Removal And Installation
Rubber Boot
Spool Seal Installation
Switch Handle
Removal And Installation
Troubleshooting (Ahc)
Chart
Wiring Schematics
With Advanced Hand Control Options