Bobcat 763, 763H G-Series Skid-Steer Loader Service Manual – 6900977 (2-06)

(S/N: 512250001 & Above) – (S/N: 512450001 & Above) – (S/N: 512620001 & Above)
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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 – G Series
(S/N: 512250001 & Above)
(S/N: 512450001 & Above)
(S/N: 512620001 & Above)

TABLE OF 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
SERVICE MANUAL REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6900977 (2-06)
Total Pages : 752

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 LOCATION
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Installing Lift Arm Support Device
Removing The Lift Arm Support Device
OPERATOR CAB
Description
Raising The Operator Cab
Lowering The Operator Cab
Emergency Exit
TRANSPORTING THE BOBCAT LOADER
Procedure
TOWING THE LOADER
Procedure
REMOTE START
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Checking
Replacing Filter Element(s)
ENGINE COOLING SYSTEM
Cleaning The Cooling System
Checking The Coolant Level
Replacing The Coolant
FUEL SYSTEM
Fuel Specifications
Filling the Fuel Tank
Fuel Filter
Removing Air From The Fuel System
Checking Engine Oil
Oil Chart
Replacing Oil And Filter
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Replacing Hydraulic/Hydrostatic Filter
Replacing Hydrostatic Motor Case Drain Filter(s)
Replacing Hydraulic Fluid
Breather Cap
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
Removing The Oil
FAN GEARBOX
Checking And Maintaining
BOB-TACH
Inspection And Maintenance
LUBRICATION OF THE BOBCAT LOADER
Procedure
Pivot Pins
TIRE MAINTENANCE
Wheel Nuts
Rotating
Mounting
SPARK ARRESTOR MUFFLER
Servicing

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Tighten Procedures
Troubleshooting Chart
CYLINDER (LIFT)
Checking
Removal And Installation
Identification
Disassembly
Assembly
CYLINDER (TILT)
Checking
Removal And Installation
Rod End Pivot Pin Bushing And Seal Replacement
Identification
Disassembly
Assembly
CYLINDER (POWER BOB-TACH)
Checking
Removal And Installation
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Checking
Adjustment
Removal And Installation
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
Removal And Installation (S/N 512262999 & Below)
Removal And Installation (S/N 512263000 & Above)
BICS™ Valve, Removal And Installation
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation
BICS™ Valve, Check Valve Removal And Installation
BICS™ Valve, Lock Valve Removal And Installation
BICS™ Valve, Solenoid Removal And Installation
BICS™ Valve, Solenoid Testing
Identification Chart
Load Check Valve
Main Relief Valve
Port Relief Valve
Anti-Cavitation Valve/Port Relief Valve
Anti-Cavitation Valve
Rubber Boot
Lift And Tilt Lock Block Removal And Installation
Lift Spool And Detent
Tilt Spool Removal And Installation
Auxiliary Spool Removal And Installation
Auxiliary Electric Solenoid
Port-Auxiliary Section
Cleaning And Inspection
HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)
Description
Removal And Installation (S/N 512262999 & Below)
Removal And Installation (S/N 512263000 & Above)
Actuator Removal And Installation
BICS™ Valve, Removal And Installation
BICS™ Valve, Lift Arm By-Pass Orifice Removal and Installation
BICS™ Valve, Check Valve Removal and Installation
BICS™ Valve, Lock Valve Removal and Installation
BICS™ Valve, Solenoid Removal and Installation
BICS™ Valve, Solenoid Testing
Identification Chart (AHC)
Identification Chart (ACS)
Lift Base End Restrictor
Load Check Valve
Main Relief Valve
Port Relief Valve
Anti-Cavitation Valve/Port Relief Valve
Anti-Cavitation Valve
Lift Spool Removal And Installation
Tilt Spool Removal And Installation
Lift And Tilt Spool Disassembly And Assembly
Auxiliary Spool Removal And Installation
Auxiliary Electric Solenoid
Port-Auxiliary Section
Cleaning And Inspection
LIFT ARM BY-PASS CONTROL VALVE
Inspecting
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP (ALUMINUM)
Checking The Output Of The Hydraulic Pump
Removal And Installation
Parts Identification
Disassembly And Assembly
Inspection
HYDRAULIC PUMP (ALUMINUM HI-FLOW)
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC PUMP (CAST IRON)
Check The Output Of The Hydraulic Pump Without Power Bob-Tach
Check The Output Of The Hydraulic Pump With Power Bob-Tach.
Removal And Installation
Identification
Disassembly And Assembly
HYDRAULIC/HYDROSTATIC FILTER
Housing Removal And Installation
HYDRAULIC FLUID RESERVOIR
Fluid Removal
Removal And Installation (S/N 512264899 & Below)
Removal And Installation (S/N 512264900 & Above)
BUCKET POSITION VALVE
Solenoid Removal And Installation
Solenoid Testing
Removal And Installation
Disassembly And Assembly
SELECT VALVE
Checking The High Flow Pump Relief Valve
Removal And Installation
Disassembly And Assembly
Solenoid Testing
REAR AUXILIARY DIVERTER VALVE (SINGLE SHUTTLE)
Removal And Installation
Disassembly
Inspection
Solenoid Testing
Assembly
REAR AUXILIARY DIVERTER VALVE (DUAL SHUTTLE)
Removal And Installation
Disassembly And Assembly
Solenoid Testing
Inspection
POWER BOB-TACH BLOCK (S/N 512267827 & BELOW)
Removal And Installation
Disassembly And Assembly
POWER BOB-TACH BLOCK (S/N 512267828 & ABOVE)
Removal And Installation
Disassembly And Assembly
FRONT AUXILIARY PRESSURE RELIEF BLOCK
Removal And Installation
Disassembly And Assembly
Solenoid Testing
Solenoid Inspection
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Removal and Installation
Disassembly And Assembly

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Replenishing Valve Function
HYDROSTATIC MOTOR
Removal And Installation
Parts Identification
Disassembly
Assembly
Prior to assembly:
Carrier Shaft Seal Replacement
Carrier Removal And Installation
Carrier Parts Identification
Carrier Disassembly
Carrier Assembly
CHARGE PRESSURE
Sender Removal And Installation
Checking Charge Pressure
Adjusting
HYDROSTATIC PUMP
Replenishing/High Pressure Relief Valve
Removal And Installation
Parts Identification (Right Half)
Parts Identification (Left Half)
Hydraulic Pump Removal And Installation
Pump Separation
Disassembly
Assembly
DRIVE BELT
Shield Removal And Installation
Adjusting
Drive Belt Replacement
Tensioner Pulley Removal And Installation
Tensioner Pulley Parts Identification
Tensioner Pulley Disassembly
Tensioner Pulley Assembly
OIL COOLER
Removal and Installation

DRIVE SYSTEM
DRIVE COMPONENTS
Axle Seal Removal And Installation
Axle Sprocket And Bearings Removal And Installation
Chain Removal And Installation
CHAINCASE
Checking And Adding Oil
Removing The Oil
Front Cover Removal And Installation
Center Cover Removal And Installation
Rear Cover Removal And Installation
BRAKE
Pedal Removal And Installation
Pedal Disassembly And Assembly
Disk Removal And Installation
Switch Operated Parking Brake

MAIN FRAME
SEAT BAR
Removal And Installation
Assembling Components
Compression Spring Disassembly And Assembly
OPERATOR CAB
Gas Cylinder Removal And Installation
Gas Cylinder Disassembly
Removal And Installation
OPERATOR SEAT
Removal And Installation
Seat Belt Removal And Installation
OPERATOR SEAT (SUSPENSION)
Removal And Installation
Slide Rail Removal And Installation
Cushion Removal And Installation
Back Removal And Installation
Shock Removal And Installation
BOB-TACH
Removal And Installation
Bob-Tach Lever And Wedge
Bob-Tach Stops
LIFT ARM
Removal And Installation
REAR GRILL
Gas Cylinder Removal And Installation
Removal And Installation
REAR DOOR
Removal And Installation
Door Latch And Catch Adjustment (S/N 512261535 & Below)
Door Latch Removal And Installation (S/N 512261535 & Below)
Striker Removal and Installation (S/N 512261536 & Above)
Striker Disassembly and Assembly (S/N 512261536 & Above)
Adjusting The Striker (S/N 512261536 & Above)
Latch Removal and Installation (S/N 512261536 & Above)
FUEL TANK
Removal And Installation
Fuel Level Sender
CONTROL PEDALS
Removal And Installation
Pedal Adjustment
Crossbar Linkage Removal And Installation
Lift Foot Pedal Linkage Removal And Installation
Tilt Foot Pedal Linkage Removal And Installation
CONTROL PEDALS (ACS)
Foot Sensor Removal And Installation
Foot Pedal Removal And Installation
Foot Pedal Linkage Disassembly And Assembly
CONTROL PANEL
Removal and Installation
Shock Removal And Installation
Shaft Removal And Installation
Shaft Disassembly And Assembly
Linkage Removal And Installation
Linkage Adjustment
Linkage Neutral Adjustment
CONTROL HANDLE
Control Lever Removal And Installation
Control Lever Boot
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)
Components Identification
Control Handle Unit Removal And Installation
Control Handle Removal And Installation
Control Handle Disassembly And Assembly
Control Lever Removal And Installation
Control Lever Boot
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) W/PUSH BUTTON FLOAT
Components Identification
Handle Sensor Removal And Installation
Control Handle Removal And Installation
Control Handle Disassembly And Assembly
Control Lever Removal And Installation
Control Lever Boot
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL
Components Identification
Handle Sensor Removal And Installation
Control Handle Removal and Installation
Control Handle Disassembly and Assembly
Control Lever Removal and Installation
Control Lever Boot
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL
Components Identification
Handle Sensor Removal And Installation
Control Handle Removal And Installation
Control Handle Disassembly And Assembly
Control Lever Removal And Installation
Control Lever Boot

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
763 Wiring Schematics
Troubleshooting Chart
Description
Fuse Location
Relay Switch Location
Solenoid Test
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR (55 AMP)
Adjusting The Alternator Belt
Alternator Output Test
Rectifier (Diode) Test
Alternator Regulator Test
Removal And Installation
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Rectifier Continuity (Diode) Test
Assembly
ALTERNATOR (90 AMP)
Adjusting The Alternator Belt
Alternator Identification
Charging System Check
Alternator Voltage Test
Low Voltage Test
High Voltage Test
Removal And Installation
Rectifier Continuity (Diode) Test
Alternator Regulator Test
Disassembly
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Assembly
STARTER (NIPPONDENSO)
Checking
Removal And Installation
Parts Identification
Disassembly
Inspection And Repair
No Load Test
Assembly
STARTER (VALEO)
Checking
Removal And Installation
Parts Identification
Disassembly and Assembly
Inspection And Repair
No Load Test
INSTRUMENT PANEL
Left Panel
Right Panel (Standard) (With Key Switch)
Right Panel – (Deluxe) (With Keyless Start)
Right Panel Setup Display Options (Deluxe)
Passwords
Option And Field Accessory Panels
Removal And Installation
Front Accessory Panel Removal And Installation
LIGHTS
Front Removal And Installation
Rear Removal And Installation
BOBCAT CONTROLLER
Identification Chart (S/N 512263854 & Below)
Identification Chart (S/N 512263855 & Above)
Removal And Installation
DIAGNOSTICS
Service Codes
BICS™ SYSTEM
Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
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 (AHC)
Troubleshooting Chart
Troubleshooting Guide.
SEAT BAR SENSOR
Troubleshooting Chart
Test
Removal And Installation
BICS™ Circuit Test
TRACTION LOCK
Troubleshooting Chart
Inspecting
Solenoid Removal And Installation
Guide Removal
Guide Installation
ADVANCE HAND CONTROL (AHC) SYSTEM
Components Identification
Troubleshooting Guide
Parts Identification
AHC Controller Removal And Installation
Handle Control Unit Connector
Switch Handle Removal And Installation
Actuators Disassembly And Assembly
ADVANCED HAND CONTROL (AHC) SYSTEM (W/ PUSH BUTTON FLOAT)
Components Identification
Troubleshooting Guide
Controller Connector And Wire Identification
AHC Controller Removal And Installation
Handle Sensor Removal And Installation
Handle Sensor Connector
Switch Handle Removal And Installation
Actuators Disassembly And Assembly
ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL
Components Identification
Troubleshooting Guide
Controller, Connector And Wire Identification
ACS Controller Removal And Installation
Handle Sensor Connector
Switch Handle Removal
Switch Handle Installation
Actuators Disassembly and Assembly
ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROL
Components Identification
Troubleshooting Guide
Controller, Connector And Wire Identification
ACS Controller Removal And Installation
Handle Sensor Connector
Switch Handle Removal
Switch Handle Installation
Actuators Disassembly and Assembly
Handle Lock Solenoid Removal And Installation
Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Connector
Calibration Of The ACS System
Switchable Hand/Foot Controls Calibration Procedure
Hand Controls Only Calibration Procedure
Foot Sensor Disassembly And Assembly
Foot Sensor Connector
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart

ENGINE SERVICE
TROUBLESHOOTING
Chart
ENGINE SPEED CONTROL
Removal And Installation
Disassembly
MUFFLER
Removal And Installation
AIR CLEANER
Removal And Installation
RADIATOR
Removal And Installation
COOLING FAN
Drive Tension Pulley Removal And Installation
Gearbox/Blower Housing Removal And Installation
Blower Housing Grill Removal And Installation
Blower Disassembly And Assembly
Gearbox Parts Identification
Gearbox Disassembly
Gearbox Assembly
Gearbox Checking Backlash
ENGINE COMPONENTS AND TESTING
Compression Checking
Glow Plugs Checking
Glow Plugs Removal And Installation
Fuel Shut-Off Solenoid Checking
Fuel Shut-Off Solenoid Adjusting
Fuel Shut-Off Solenoid Removal And Installation
Checking
Fuel Injection Pump Removal And Installation
Timing The Injection Pump
Fuel Injector Removal And Installation
Fuel Injector Checking
Fuel Injector Disassembly
Fuel Injector Assembly
Valve Clearance Adjustment
Rocker Arm And Shaft Checking
Valve Timing Checking
ENGINE
Removal And Installation
Engine Mount Replacement
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation
RPM SENSOR
Adjustment
RECONDITIONING THE ENGINE
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head Servicing
Cylinder Head Top Clearance
Checking The Valve Guide
Reconditioning The Valve And Valve Seat
Valve Spring
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
Fuel Camshaft 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
Checking The Cylinder Bore
Water Pump Disassembly And Assembly

HEATER
COMPONENTS
Identification
REGULAR MAINTENANCE
Filter Elements Removal And Installation
BASIC TROUBLESHOOTING
Cleaning The Heater Coil
Checking The Electrical System
Engine Coolant By-Passing The Heater Valve
Heater Valve Not Opening Or Closing
SYSTEM TROUBLESHOOTING CHART
HEATER UNIT
Removal And Installation
Disassembly And Assembly
HEATER COIL
Removal And Installation
HEATER FAN
Removal And Installation
Disassembly And Assembly
Wire Connector Removal and Installation
HEATER VALVE
Removal and Installation
Disassembly And Assembly

SPECIFICATIONS
LOADER SPECIFICATIONS
Loader Dimensions
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
Timing Gear
Thermostat
Crankshaft Re-Grind Data
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
Torque For Kubota 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
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion

SERVICE MANUAL REVISIONS
Revision No: 763/763H-1
Revision No: 763-2
Revision No: 763-3
Revision No: 763-4
Revision No: 763-5

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