‘SAFETY AND MAINTENANCE AIR CLEANER SERVICE . . 10-80-1 . Checking = 10-80-1 @ Replacing Filter Element(s) . 10-80-1 BOB-TACH . - 10-150-1 Inspection And Maintenance . » 10-150-1 ENGINE COOLING SYSTEM... 10-90-1 Checking The Coolant Level +. 10-90-2 Cleaning The Cooling System - 10-90-1 Replacing The Coolant ........ 10-90-2 ENGINE LUBRICATION SYSTEM . . - 10-110-1 Checking Engine Oil . = 10-110-1 Oil Chart...... . 10-110-4 Replacing Oil And Filter... .. 10-110-4 FAN GEARBOX. ... 10-140-1 Checking And Maintaining. + 10-140-1 FINAL DRIVE TRANSMISSION (GHAINCABE).. 10-130-1 Checking And Adding Oil. . . veces 10-1304 Removing The Oil » 10-130-1 FUEL SYSTEM... » 10-400-1 Filling the Fuel Tank » 10-100-1 Fuel Filter. . » 10-100-2 Fuel Specifications + 10-400-1 Removing Air From The Fuel System - 10-100-2 HYDRAULIC/HYDROSTATIC SYSTEM » 10-420-1 Breather Cap - 10-120-4 Checking And Adding Fluid . » 10-120-1 Replacing Hydraulic Fluid . . 10-120-3 Replacing Hydraulic/Hydrostatic Filter. - - 10-120-2 Replacing Hydrostatic Motor Case Drain Filter(s) . 10-120-2 LIFT ARM SUPPORT DEVICE ..... 10-20-4 Installing Lift Arm Support Device 7 10-20-1 Removing The Lift Arm Support Device. ...... +. 10-20-2 LIFTING AND BLOCKING THE LOADER. ... .. ve ee 10-404 Procedure ...... os - 10-10-41 Continued On Next Page 10-01 SAFETY & Ruy aie 763 Bobcat Loader ‘Service ManualSAFETY AND MAINTENANCE (CONT'D) LUBRICATION OF THE BOBCAT LOADER. + 10-160-1 Pivot Pins. - 10-160-2 Procedure » 10-1601 OPERATOR CAB » 10-30-1 Description. . 10-30-41 Emergency Exit . ‘ - 10-30-3 Lowering The Operator Cab. +. 10-30-2 Raising The Operator Cab. - 10-30-41 REMOTE START. » 10-60-1 Procedure .. «10-60-14 SERVICE SCHEDULE veces cece ences 10-704 Chart » 10-7041 SPARK ARRESTOR MUFFLER . » 10-180-1 Servicing 10-180-1 TIRE MAINTENANCE = 10-170-1 Mounting »10-470-1 Rotating... ve beens es 1470-4 Wheel Nuts o.oo ee cece cere es ete enenee 10-170-1 TOWING THE LOADER . +. 1050-1 Procedure . . ~ 10-50-1 TRANSPORTING THE BOBCAT LOADER 10-40-1 Procedure .......... 10-40-4 10-02 1763 Bobeat Loader ‘Service ManualLIFTING AND BLOCKING THE LOADER Procedure Figure 10-10-1 A WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and Instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained ‘operators and failure to follow instructions can cause Injury or death. 2008-0188 Always park the loader on a level surface. A WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. e207? 0266 10104 Figure 10-10-2 oe Put tloor jack under the rear of the loader [Figure 10-10- ah, Lift the roar of the foader and install jackstands [Figure 10-10-2} Figure 10-10-3, Pul the floor jack under the front of the loader [Figure 10- 10-3} Lift the front of the joader and put jackstands under the axle tubes [Figure 10-10-3}. NOTE: Make sure the jackstands do not touch the tires. Make sure tires clear floor or any obstacles, 763 Bobcat Loader Service ManualBobcat. - 1763 Bobcat Loader 10102 Service ManualLIFT ARM SUPPORT DEVICE Installing Lift Arm Support Device A WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm ‘support device can allow the lift arms or attachment to fall and cause injury or death. 2050-0598 4 WARNING Service lift arm support device if damaged or it parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop ‘causing injury or death. Figure 10-20-1 Put jackstands under the rear corners of the loader frame (oset) [Figure 10-20-1], Disconnect the spring from the lif arm support device retaining pin (tem t) [Figure 10-20-1]. Support the lift farm support device (tem 2) [Figure 10-20-1] with your hand and remove the retaining pin, 10-20-41 A DANGER “AVOIO DEATH + Discernecting or leoseig ary hyratfe ‘Note, ose, eg, companort 2p ‘alr can case ft as to ep ‘Keep ctf is aes wen i ars are rased less spared by an approved ars suppor Replace i damaged oe) Lower the lift arm support device on top of the itt cylinder. Hook the free end of the spring (Item 1) [Figure 1020-2] to the lift arm support device so there wit be no interference with the support device engagement, With the operator in the seat, seat belt fastened and seat bar lowered, start the engine. 763 Bobcat Loader ‘Service ManualLIFT ARM SUPPORT DEVICE (CONT’D) Installing Lift Arm Support Device (Cont'd) Figure 10-20-3 Raise the lift arms, until the lit arm support device drops ‘onto the lit cylinder rod [Figure 10-20-3]. Lower the iift arms slowly until the support device is held between the lft arm and the lift cylinder. Stop the engine, Raise the seat bar and move pedals unti! both pedals lock. Install pin (Item 1) [Figure 10-20-3} into the rear of the fit arm support davice below the cylinder rod. 10202 Removing The Lift Arm Support Device Figure 10-20-4 Remove the pin from the lift arm support device. Connect the spring {item 1} [Figure 10-20-4] from the lift aim support device fo the bracket below the lift arms, With the operator in the seat, seat belt fastened and seat bar lowered, start the engine. Raise the ift arms a small amount and the spring wil it the support device off the fit cylinder rod. Lower the lit arms. Stop the engine. Raise the seat bar and move pedals until both pedals lock. Disconnect the spring from the bracket 763 Bobcat Loader ‘Sorvice ManualLIFT ARM SUPPORT DEVICE (CONT'D) Removing The Lift Arm Support Device (Cont'd) Figure 10-20-5 Raise the support device into storage position and insert pin (item 1) [Figure 10-20-5] through ft arm support device (Vom 2} [Figure 10-20-5] and bracket. Connect spring t0 pin. Remove jackstands, 10-203 763 Bobcat Loader Service Manual763 Bobcat Loader 1020-4 Service ManualOPERATOR CAB Description ‘The Bobsat loader has an operator cab (ROPS and FOPS) as standard eguipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged. The seat belt must be worn for roll over protection. ROPS/FOPS - Roll Over Protective Structure per SAE J1040 and ISO 9471. and Faling Object Protective Structure per SAE J1043 and ISO 8449. Level 5, Level It is available. Level | ~ Protection from falling bricks, small concrete blocks, and hand tools encountered in operations such as highway maintenance, landscaping. and other construction site services. Level i - Protection trom falling trees, rocks; for machines involved in site clearing, oveshead demolition or forestry. Raising The Operator Cab Always stop the engine before raising or lowering the cab, NOTE: Make sure the seat bar is fully raised or jowered when lowering the cab. Always use the grab handles to lower the cab. Stop the loader on a level surface, Lower the lift arms. ff the lift arms must be up while raising the operator cab, install the lift arm support device. (See LIFT ARM SUPPORT DEVICE, Contents, Page 10-01.) Figure 10-30-1 Install jackstands under the rear of the loader frame {Figure 10-30-1} 1090-1 Advanced Hand Contro! and Control System WARNING \ ied Sy Unexpected oder, arm of tachment _moverent eed by cab contact wth ering ‘nvr cancerous hry doa. BEFORE RAISING OR LOWERING CAB * Stop engine A WARNING Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death. vez060-1209 Figure 10-30-2 Loosen ihe nut (both sites) at the front comers of the operator cab [Figure 10-30-2) Remove the nuts and plates [Figure 10-30-2] (both sides) 763 Bobcat Loader Service ManualOPERATOR CAB (CONT'D) Figure 10-30-4 Raising The Operator Cab (Cont'd) Figure 10-30-3 Lift on the grab handle and bottom of the operator cab slowly untii the cab is ail the way up and the laiching mechanism engages[Figure 10-30-3). o Advanced Hand Controls Only Lowering The Operator Cab Always stop the engine before raising or lowering the cab, NOTE: Make sure the seat bar is fully raised or lowered when lowering the cab. Always use the grab handles to lower the cab. Pull down on the bottom of the operator cab until it stops at the latching mechanism[Figure 10-30-4). Release the latching mechanism (Inset) [Figure 10-30-4] and pull the cab all the way down, 763 Bobeat Loader 1030-2 Service ManualOPERATOR CAB (CONT'D) Lowering The Operator Cab (Cont'd) Figure 10-30-5 install the plates and nuts [Figure 10-30-8] (Doth sides). Tighten the nuts to 40-50 f-Ibs. (64-68 Nm) torque. Emergency Exit Figure 10-30-6 The front opening on the operator cab and rear window provide exits. Rear Window (if Equipped) Pull om the tag on the top of the rear window to remove the rubber cord [Figure 10-30-6]. 10-30-3 Figure 10-30-7 Push the rear window out of tha rear of the operator cab. Exit through the rear of the operator cab [Figure 10-30- 7. Figure 10-30-8 Front Door {it Equipped) NOTE: When an Operator Cab Enclosure Kit is ‘stalled, the window of the front door can be used as an emergency exit {Figure 10-30-8}, Pull the plastic loop at the top of the window in the front door to remave the rubber cord [Figure 10-30-8], 763 Bobcat Loader Service ManualOPERATOR CAB (CONT'D) Emergency Exit (Cont'd) Figure 10-30-9 ances Figure 10-30-10 Push the window out with your foot [Figure 10-30-9] at ‘any comer of the window. Exit through the front door, 1030-8 763 Bobcat Loader Service Manual‘TRANSPORTING THE BOBCAT LOADER Procedure Figure 10-40-1 WAVE Ce) Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury. w-2nse-o195 A loade; with an empty bucket or no attachment must be loaded backward onto the transport vehicie[Figure 10- 40-4} Be sure the transport and towing vehicies are of adequate size and capacity. (See SPECIFICATION: Contents, Page SPEC-01. for weight of loader.) ‘The rear of the trailer must be blocked or supported (item 1)[Figure 10-40-1] when loading or unloading the leader to prevent the front end of the trailer from raising up. 10-401 Use the following procedure to fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops ar when going up or down slopes [Figure 10-40-2} + Lower the bucket or attachment to the floor. + Stop the engine. + Engage the parking brake. * Install chains at the front and rear loader te down positions (Inset) [Figure 10-40-2]. + Fasten each end of the chain to the transport venicte. 763 Bobcat Loader ‘Service Manual763 Bobeat Loader 1040-2 ‘Service Manual6 ‘TOWING THE LOADER ‘To prevent damage to the loaders hydrostatic system, the loader must be towed only a short distance ai slow speed. (Example: Moving the loader onto @ transport vehicle). ‘The towing chain (or cable) must be rated at 1 & 172 times the weight of the loader. (See the SPECIFICATIONS, Contents, Page SPEC-01.) + Turn the key switch to RUN (Item 4) [Figure 10-50-1] (Standard Panel) OR press the BUN/ENTER Button (Deluxe Pane. 1050-1 Figure 10-50-2 + Press the TRACTION LOCK OVERRIDE Button (item 1)[Figure 10-50-2}. ‘+ Tow the Bobcat at 2 MPH (3.2 km/hr) or fess for not more than 25 feet (7,6 meters) If the electrical system is not functioning or the engine does net run part of the brake system must be disassembled to move the loader. (See the TRACTION LOCK Removal And installation procedure, Cortents, Page 60-01.) 763 Bobeat Loader Service ManualService Manual ‘763 Bobcat Loader 10802REMOTE START Procedure A WARNING AVOID INJURY OR DEATH With the 7-pin connector plugged into the loader and Remote Start Key Switch in the OFF position, the joader can still be started from the operator panel inside the cab. Placing the key switch of the remote start tool in the run position disconnects the ‘operator panel key switch from the start circuit. if the service technician will be working the engine area it is important to remove the operator panel keys. Figure 10-60-1 Figure 10-60-2 Figure 10-60-3 The too! fisted will be need to do the following procedure: MEL1563: Romote Start Too! Kit The remote start tool (item 1) [Figure 10-60-1] is required when the operator cab is in the raised position for service and the service technician needs to turn the key switch on or start the engine. Exampie: adjusting the steering linkage. 10-601 Lift and block the loader, (See Contents, Page 10-01.) Raise the litt arms (if required by the procedure) and install an approved lift arm support device. (See Contents, Page 10-01.) Raise the operator cab (if required by the procedure) (See Contents, Page 10-01.) ‘Open the rear door of the loader. Remove the plug (Item 1) [Figure 10-60-2] or disconnect, the attachment control hamess (Item 1) [Figure 10-60-3] if connected, 763 Bobeat Loader ‘Service ManualREMOTE START (CONT'D) Procedure (Cont'd) Figure 10-60-4 Connect the remote start tool to the engine hamess connector {item 1) [Figure 10-60-4). NOTE: The key switch on the right-hand side operator panel must be in the off position or the Remote Start Kit will not operate. 4& WARNING TSE TRAGTION LOOK OVERTIDE SWITCH FOR SERVICE TRACTION LOCK IS ENGAGED WHEN LIGHT 1S OFF ORT AND BLOCK THE LOADER, SHEGR THAT WHEELS ARE CLEAR TRAGTION LOCK (S DISENGAGEO WHEN LIGHT 1S ON, 1 SEE SERVICE MANUAL FOR MORE INSTRUCTION, Figure 10-60-5 ae 2 The remote start tool (item 1) [Figure 10-60-5] has three. rocker switches. 1060-2 The traction lock switch (ttem 1) [Figure 10-60-6] is used to tum traction lock on or off. Push the switch to the override position, The switch will iluminate to indicate traction lock OVERRIDE, in this position the wheels are able to turn, ‘The maximum flowivariabie flow switch (Item 2) [Figure 10-60-6] is used 10 aclivate the auxiliary hydrauties, Pressing the switch once will activate variable fiow. Pressing the switch again wil activate maximum flow. ‘The switch will illuminate to indicate which flow rato is active. Prassing the switch a third time will turn the flow OFF, The switch is used when checking pressures and flow rate. SIN 512263234 & Below ‘The auntliary pressure release (item 3) [Figure 10-60-6) fs used to release hydraulic pressure to the front and/or rear auxiliary couplers. To release pressure; push and hold the switen for three seconds, NOTE: With the engine running; pushing and holding the pressure release switch this will cause the engine to stop in three seconds. To relieve the pressure; continue to press the switch after the engine has stopped. 763 Bobcat Loader ‘Service ManualREMOTE START (CONTD) SIN 512263235 & Above Figure 10-60-7 It your foader is equipped with the front auxiliary coupler block push the couplers towards the block and hold for five seconds to release the front auxiliary pressure. To release the rear auxiliary coupler pressure use the pressure release button (Item 3) [Figure 10-60-6] on the remote start tool. 763 Bobeat Loader 10-603, ‘Service Manual763 Boboat Loader Service ManualSERVICE SCHEDULE Chart Maintenance work must be done at regular intervals. Failure io do so will result in excessive wear and early tailures. The service schedule is a guide for correct maintenance of the Bobcat loader. FNC Ne} | sea Strand Som ania Soy Signe ard Salty ih ie a abrivieen Gina oe (Rename Fe" ie er Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct tunction alter adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. "om ts a ai wag "eer cared od soe aan [Enka ner ti it ana ie ame | ‘eden lights ond uncon sre tnt See Omid Fo Sceeatins eines [erin sre ei cone oa se ines en oo ene a ra wr edge Ba in [pace Pena comer ‘seis ite snes eth rt hove an when he taneiston warning gh comes 10-70-41 763 Bobcat Loader Service Manual763 Bobeat Loader Service Manual 3AIR CLEANER SERVICE Chee! 9 Figure 10-80-1 pov | It is important to change the air filter olement only when the Air Cieaner icon in the right panel is ON (item t) {Figure 10-80-1] and you hear three beeps from the alaem, Replace the inner fiter every third time the outer fier is replaced or as indicated on Contents, page 70-01 Figure 10-80-2 Press and hold the LIGHT Button (Item 1) [Figure 10-80- 2] for two seconds. Ui the filter efement needs replacement, the CODE [01- 17] {Air Filter Plugged) will show in the HOURMETER / CODE DISPLAY (item 2) [Figure 10-80-2] 1080-1 Replacing Filter Element(s) OUTER FILTER Remove the wing nut (tem 1) [Figure 10-80-3} and remove the dust cover. Figure 10-80-4 Remove the wing nut (Item 1) [Figure 10-80-4] from the outer fiter elornent, 763 Bobcat Loader Service ManualAIR CLEANER SERVICE (CONT'D) Replacing Filter Element(s) (Cont'd) Figure 10-80-5, Remove the outer filter element [Figure 10-80-5]. NOTE: Be sure all sealing surfaces are clean. Install the new filter element and washer. Tighten the wing nut NOTE: Be sure seating washer is in place on each ‘wing nut (Figure 10-80-4). Install the dust cover and tighten the wing nut. ‘Check the air intake hose and the air cleaner housing for damage. Make sure all connections are tight 10-802 INNER FILTER, Only replace the inner fiter eiement under the following conditions: + Replace the inner filter element every third time the cuter fitter is replaced + After the outer element has been replaced, start the engine and run at full RPM. If the HOURMETER / CODE DISPLAY shows [01-17] (Air Filter Plugged), replace the inner filter element. Remove the inner fitter wing nut (Item 1) [Figure 10-80- o 8 Figure 10-80- Remove the inner fiter [Figure 10-80-7}. Install a new fiter and tighten the wing nut. 763 Bobeat Loader ‘Service ManualENGINE COOLING SYSTEM 7 Nae NS IN Ne) Wear safety glasses to prevent eye injury when any of the following conditions exist: + When fluids are under pressure. + Flying debris or loose material is present. + Engine is running. + Tools are being used. IMPORTANT AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze. Jo much antifreeze reduces cooling system efficiency and may cause serious premature engine damage. Too little antifreeze reduces the additives which protect the Internal engine components; reduces the boiling point and freeze protection of the system. Always add a premixed solution, Adding fuil strength concentrated coolant can cause serious premature engine damage. sev28.0807 10-901 Figure 10-90-1 Chock the cooling system every day to prevent over heating, loss of performance or engine damage. Cleaning The Cooling System Open the rear door and raise the rear gril. Use air pressure or water pressure to clean the top of the oll cooler [Figure 10-90-41]. Figure 10-90-2 Raise the oil cooler. Clean the top of the radiator [Figure 40-90-2], Lower the oil cooler. Check cooling system fer leaks. Lower the rear grill and close the rear door 763 Bobeat Loader Service ManualENGINE COOLING SYSTEM (CONT'D) Checking The Coolant Level Figure 10-90-3 Open the rear door. Remove the cover from the coolant recovery tank (Item 1) [Figure 10-90-3]. Check the coolant level. The coolant level must be betwoen the MIN and MAX marks on the coolant recovery tank when the engine #s cold, Close the rear door before operating the ioader. 10-902 Replacing The Coolant IMPORTANT AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze. Yo much antifreeze reduces cooling system efficiency and may cause serious premature engine damage. Too litte antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system. Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage. 42126-0107 Figure 10-90-4 A WARNING Do not remove radiator cap when the engine is hot. You can be seriously burned. v 10-1268 ‘Open the rear door and raise the rear gril. Remove the radiator cap (Item 1) [Figure 10-90-4} 1783 Bobcat Loader Service ManualENGINE COOLING SYSTEM (CONT'D) Replacing The Coolant (Cont'd) Figure 10-90-5 Connect a hose to the engine biock drain vaive (Iter 1) {Figure 10-90-5]. Open the ¢rain valve and drain the coolant into a container. Drain coolant from recovery tank. After all the coolant is removed, ciose the drain valve and remove the hose. Recycle or dispose of used cooiant in an environmentally safe manner. Mix the coolant in a separate container. (See Contents, Page SPEC-01} NOTE: The loader is factory filled with propylene glycol coolant (purple color). DO NOT mix propylene glycol with ethylene glycol. 10-903 Add premixed coolant, 47% water and 53% propyiene glycol to the recovery tank ifthe coolant levet is low. One gallon and one pint (4.8L) of propylene glyco! mixes with one galion (3,8 L) of water is the correct mixture of coolant to provide a -94°F (-37°C) freeze protection. Use a refractomete: te check the condition of propylene glyco! in your cooling systam, Fill the radiator with the premixed coolant. instal the radiator cap. Remove the cover from the coolant recovery tank. Fill the nk Until itis at the fower marker. Run the engine until it is at operating temperature, Stop the engine. Check the coolant iavol in the recovery tank and radiator when cool. Add coolant as needed, Lower the rear gril! and close the rear door. 783 Bobcat Loader Service Manual763 Bobcat Loader 10-904 Service ManualFUEL SYSTEM Fuel Specifications Use only clean, high quality diese! fuel, Grade No. 2 or Grade No. 1 ‘The following is one suggosted blending guideline which shoukt prevent fue! gelling during catd temperatures: Temp. F* (C*) No.2 No.1 io5% ons 50% 50% Below -20° (-29°) 0% 100% Contact your fuel supplier for local recommendations. Filling the Fuel Tank A WARNING Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire. A WARNING Always clean up spilled fuel or oll. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. w.2t09-1265 10-1004 Figure 10-100-1 Remove the fue! fil cap (ftom 1) [Figure 10-100-1). Figure 10-100-2 Use a clean, approved safety container to add fuel of the correct specifications. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING! [Figure 10-100-2) Install and tighten the fuel fill cap (Item 1) [Figure 10- 100-1], 783 Bobeat Loader ‘Service ManualFUEL SYSTEM (CONTD) Fuel Fitter Figure 10-100-3 ‘Open the sear door. (See Contents Page 10-01) for the service Interval tor removing water from. of replacing the fuel titer. Loosen the drain (item 1) [Figure 10-100-3] at the bottom of the filter element to remove water from the fiter move the filter element (Nem 2) [Figure 10-100-3} Clean the area around the fitter housing. Put clean oll on the seat of the new filter element. Install the tue! fier, and hand tighten remove the alr from the fuat system. See Removing Air From The Fuel System on page 10-100-2 Removing Air From The Fuel System A WARNING Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a plece of cardboard or wood to find feaks. Do not use your bare hand. Wear safety goggles. If tluld enters skin or eyes, get immediate medical attention from a physician familiar with this injury. wiz0720406 After replacing the filter element or when the fuel tank has run cut of fuel, the alr must be removed from the fue! system before starting the engine. 30-100-2 Figure 10-100-4 Open the vent (item 1) [Figure 10-100-4] on the fue! fier housing. Close the vent (item 1) [Figure 10-100-4] cn the fuel fiter housing. Open the vent (Item 3) [Figure 10-100-4] on the fue! injection pump. ‘Squeeze the hand pump (priming bulb) (em 2) [Figure 10-100-4] until the pump feels solid Tighten the vent plug (Item 9) [Figure 10-100-4), Start the engine, ft may be necessary to open the vent plug (item 3) [Figure 10-100-4} briefly while the engine is running. Close the vent when the engine runs smoothly. ° 763 Bobeat Loader ‘Service Manual@ ENGINE LUBRICATION SYSTEM Checking Engine O11 Figure 10-110-1 ‘Check the engine oll level every day before starting the engine for the work shift, Open the rear door and remove the dipstick (Item 1) [Figure 10-110-1). Keep the oil level between the marks on the dipstick, Use a good quality motor oi! that meets API Service Ciassitication of CD or better (See Oli Chart on page 10- 110-1.) Install the dipstick and close the rear door. 10-1104 Ol Chart RECOMMENDED SAE VISCOSITY NUMBER ¢_ {LUBRICATION ols FoR DIESEL ENGINE CRARKCASE) F “ATED, BEFORE NEXT Oil. CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION CD, CF-4, G4) “Can be used ONLY when avaitable with appropriate diese! rating Replacing Oil And Filter Figure 10-110-2, (See Contents, Page 10-01) for the service interval for replacing the engine oll and fiter. Fun the engine unti it is at operating temperature. Stop the engine. Open the rear door. Remove the drain plug (Item 1) [Figure 10-110-2}. Drain the oil into a container and dispose of used oil in an environmentally safe manner. 763 Bobcat Loader Service ManualENGINE LUBRICATION SYSTEM (CONT'D) Replacing Oil And Filter (Cont’é) A WARNING Always clean up spilled fuof or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil Failure to use care around combustibles can cause ‘explosion or fire which can result in injury or death. Figure 10-110-3 Remove the oil fiter (em 1) [Figure 10-110-3], Clean the filter housing surtace. Put clean off on the new of filter gasket Install the iter and hand tighten, Install and tighten the drain plug. Remove the ff cap (Item 1) [Figure 10-110-4), Put oif in the engine. (See Contents, Page SPEC-01,) [Figure 10-110-4] (See Oli Chart on page 10-110-1.) Start the engine and tet it run for several minutes, Stop the engine and check for leaks at the oil fiter. Remove the dipstick and check the oil level. Figure 10-110-5 Add oll as needed if it is not at the top mark (item 1) [Figure 10-110-5] on the dipstick. Install the dipstick and ciose the rear door 783 Bobcat Loader 10-1102 Service ManualHYDRAULIC/HYDROSTATIC SYSTEM Figure 10-120-2 Checking And Adding Fluid Figure 10-120-1 Figure 10-120-3, Use only recommended fluid in the hydraulic. system, (See Contents, Page SPEC-01,) Stop the loader on a level surface, Lower the lift arms and tit the Bob-Tach fully back. Stop the engine. Remove the dipstick (tem 1) (Figure 10-120-1] and check the fluid evel. Remove the fill cap (Iter 2) [Figure 10-120-1] 0 ‘Add the fluid as needed to bring the level to the top mark on the dipstick (Item 1) [Figure 10-120-2). Remove the screen and clean with solvent as needed {Figure 10-120-3} Install the fil cap. 10-1201 763 Bobeat Loader Service ManualHYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Replacing Hydraulic/Hydrostatic Filter Figure 10-120-4 {See Contents intervals.) Page 10-01 for the correct service ‘Open the rear door. Remove the fitter element (Item 4) [Figure 10-120-4] Clean the surlace of the fitter housing where the seal contacts the housing, Put clean olf on the seat of the new fiter element Insta and hand tighten the fitter element. Close the rear door before operating the loader. Check fluid level. 10-120-2 Replacing Hydrostatic Motor Case Drain Filter(s) (See Contents Page 10: for the service interval} Raise the operator cab. (See Contents Page 10-01.) Drain the hydraulic thud re 20-01.) rvoit. (See Contents Page Figure 10-120-5, Disconnect the hose (item 1) {Figure 10-120-5] from the case drain liter (em 2) [Figure 10-120-6} located on the reservolr, Use a plug and cap on the filter hose and case drain hose to prevent leakage. Disconnect the hoses {Item 1) [Figure 10-120-6} from the vase drain fiter iocated on the ieft drive motor, Use a plug and cap on the filter and case drain hose to pravent leakage. Remove and replace both hydrostatic motor case drain fiters (em 2) [Figure 10-120-5] & [Figure 10-120-6]. 763 Bobeat Loader Service ManualHYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Replacing Hydrostatic Motor Case Drain Filter(s) (Cont'd) A WARNING Hydraulic fluid escaping under pressure can have sufficient force to enter a porson’s body by penetrating the skin. This can cause serious injury and possible death if proper medical treatment by a physician familiar with this injury is not received immediately. 145. Always clean up spilled fuel or oil. Keop heat, flames, sparks or lighted tobacco away from fuel and oil Failure to use care around combustibles can cause ‘explosion or fire which can result in injury or death, w2100-1285 Replacing Hydraulic Fluid (See Contents Page 10-01, for the service interval.) ‘The fluid must be repiaced if i becomes contaminated or after major repairs. Ifthe fluid Is replaced, the hydrostatic fitter and both case drain fiters must be replaced. Figure 10-120-7 Remove the reservoir fil cap (Item 1) [Figure 10-120-7) Pump fluid from reservoir, 10-120-3 Raise the operator cab. (See contents, page 10-01.) Replace the hydraulicchydrostatic filter element. (See Replacing Hydraulic/Hydrostatic Filter on page 10-120- 2) Repiace both hydrostatic motor case drain filters. (See Replacing Hydrostatic Motor Case Drain Filter(s} on page 10-120-2) Add the correct fiuid to the reservoir until the fluid level is between the marks an the dipstick, DO NOT till above the top mark on the dipstick, A WARNING Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possible death if proper medical treatment by a physician familiar with this injury is not received immediately. werasce90 Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and ol Failure to use care around combustibles can cause explosion or fire which can result in injury or death, w2103-1285 Lower the operator cab (See Contents Page 10-01.) Start the engine and operate the foader hydraulic controls. Stop the engine and check for leaks. Check the fluid level in the reservoir and add as needed, 763 Bobcat Loader Service ManualHYDRAULIC/HYDROSTATIC SYSTEM (CONT'D) Breather Cap Figure 10-120-8 Clean the fiter (tem 1) [Figure 10-120-8] in the breather cap. NOTE: Be sure the rubber gasket (Item 2) is installed See the Contents Paye 10-01, for the correct service on the cap. interval Install the breather eap, Flemove the breather cap (item 1) {Figure 10-120-8} 3 763 Bobeat Loader 10-120-4 ‘Service ManualFINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Oil Figure 10-130-1 The chaincase coniains the final drive sprockets and chains and uses the same type of oil as the hydraulic! hydrostatic system. (See Contents Page SPEC-01,) To check the chaincase oil ievel, use the following procedure: Drive the loader on a ievel surface. Stop the engine. Remove the piug (item 1) [Figure 10-190-1} trom the front of the chaincase housing Hf oil can be reached with the tip of the your finger through the hole the oil level is corres Hf the level is low, add oil through the check plug hole until the oil flows from the hoie. install and tighten the plug. 10-1304 Removing The Oit Figure 10-130-2 To drain the oii from the chaincase, remove the cover (item 1) [Figure 10-130-2} which is installed over the drain plug at the rear of the chainease. instattation: Tighten the cover bolts to 10-20 ft-lbs. (24: 27 Nm) torque. Figure 10-130-3 Remove the drain plug (item 1) [Figure 10-130-3] and drain the oil into a container. NOTE: When Installing the drain plug into the chaincase, always use a NEW drain plug gasket, 763 Bobcat Loader Service Manualane Bobcat. 763 Bobcat Loader 10-130-2 Service ManualFAN GEARBOX Checking And Maintaining Figure 10-140-1 (Seen Contents Page 10-01 for the correct service interval.) Raise the operator cab. (See Contents Page 10-01) Remove the plug (Item 1) [Figure 10-140-1] to check the lubricant level If the levet is low, add SAE 90W gear lubricant through the check plug hole unt! lubricant flows from the hole, Install and tighten the plug Lower the operator cab. (See Contents Page 10-01.) 763 Bobeat Loader 10-140-1 Service Manual@ * Bohcat 763 Bobcat Loader 10-140-2 ‘Service ManualBOB-TACH Inspection And Maintenance Figure 10-150-1 Move the Bob-Tach levers to engage the wedges [Figure 40-150-1]. The levers and weddgas must move freely. The wedges must extend through the holes in the attachment mounting frame (Iter 1) [Figure 10-150-1). A WARNING Bob-Tach wedges must extend through the holes in attachment. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death. we2102-0897 Figure 10-150-2 Rene 104504 Figure 10-150-3 | ee Bob-Tach / nee Wedge Must enna | Lower Edge Of Hole en |_In The Attachment ow ‘The spring loaded wedga (Item 1)[Figure 10-150-1] must contact the lower edge of the hole in the attachment (liom 4) [Figure 10-150-2] and [Figure 10-180-3}. fhe wedge does not contact the lower edge of the hole [Figure 10-150-2] and [Figure 10-150-9]._ the attachment will be loose and can come off the Bob-Tach. Figure 10-150-4 the mounting frame on the attachment and the Bob-Tach, linkages and wedges for excessive wear or damage [Figure 10-150-4]. Replace any parts that are damaged, bent, or missing. Keep al fasteners tight. Look for cracked welds, Contact your Bobcat dealer for repair or replacement parts. Lubricate the wedges. (See the SERVICE SCHEDULE, and LUBRICATION OF THE BOBCAT LOADER, Contents, Page 10-01.) 783 Bobeat Loader Service Manual8 ro Bohcat 763 Bobeat Loader 10-180-2 Service ManualLUBRICATION OF THE BOBCAT LOADER Figure 10-160-3 Procedure Figure 10-160-1 S.Litt Arm Pivat Pin (Both Sides) [Figure 10-160-3]. Figure 10-160-4 Lubricate the loader as specified in the SERVICE SCHEDULE, Contents, Page 10-01 for the best performance of the loader. Record the operating hours each time you lubricate the Bobcat loader, Always use a good quailty lithium based multi-purpose grease. Apply lubricant until extra grease shows. Lubricate the following locations on the loader: 1. Rod End Lift Cylinder (Both Sides) [Figure 10-160-1} Figure 10-160-2 4 Base End Tit Cylinder [Figure 10-160-4}. 2.Base End Lift Cylinder (Both Sides) [Figure 10-160- é@ 2], 763 Bobcat Loader 10-1604 Service ManualLUBRICATION OF THE BOBCAT LOADER (CONT'D) Procedure (Cont'd) Figure 10-160-5, 5.Rod End Tilt Cylinder [Figure 10-160-5), Figure 10-1606 6.Bob-Tach Pivot Pin (Both Sides) [Figure 10-160-6}, 7.Bob-Tach Wedge (Both Sides) [Figure 10-160-6} 10-160-2 8. 260 Hours: Steering Lever Shait (2) [Figure 10- 160-7] Pivot Pins Figure 10-160-8 ‘All litt arm and cylinder pivots have a large pin held in position with a retainer bolt and lock nut (item 1) [Figure 10-160-8), Check that the lock nuts are tightened to 18-20 ft-fbs. (24-27 Nm) torque. 763 Bobcat Loader Service ManualTIRE MAINTENANCE, Wheel Nuts Figure 10-170-1 (See Contents Page 10-01) for the service interval to check the wheel nuts. The correct torque Is 105-118 Ibs. (142-156 Nm) torque [Figure 10-170-1] Rotating Figure 10-170-2 Check the tires regularly for wear, damage and pressure, {See Contents Page SPEC-01 for the correct tire pressure.) Rear tires usually wear faster than front tires. To keep tire wear even, mave the front tires to the rear and rear tires to the front [Figure 10-170-2} 104704 {tis important to keep the same size tires on each side of the loader. If different sizes are used, each tire will be turning at a diferent rate and cause excessive wear. The tread bars of af the tires must face the same direction. Recommended tire pressure must be maintained to avoid excessive tire Wear and joss of stabilily and handling capability. Check for the correct pressure belore ‘operating the loader. Mounting Tiras are to be repaired only by an authorized person using the proper procedures and safety equipment, ‘Tires and sims must always be checked for correct size before mounting. Check rim and tire bead for damage. ‘The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire, Avoid excessive pressure which can rupture the tire and cause serious injury or death. During inflation of the tite, check the tie pressure frequently to avoid over inflation. Hees a Inflate tires to the MAXIMUM pressure shown on the sidewall of the tire. DO NOT mix brands of tires used on the same loader. 2087-0784 A WARNING Do not inflate tires above specified pressure. Failure to use correct tire mounting procedure can cause an explosion which can resutt in injury or death. we2078-12 763 Bobeat Loader ‘Service Manualx Bobcat. 763 Bobcat Loader 10-1702 Service ManualSPARK ARRESTOR MUFFLER Servicing Figure 10-180-1 Do not operate the loader with a defective exhaust system, (See the SERVICE SCHEDULE, Contents, Page 10-01,) for service interval for cloaning the spark arrestar muffler. IMPORTANT This loader is factory equipped with a U.S.0.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor mutfler must be serviced by dumping the spark chamber every 100 hours of operation. If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC. ‘Make reference to local laws and regulations for spark arrestor requirements. 202e. Stop the engine. Open the rear door and raise the rear gril, Remove the plug (tem 1} [Figure 10-180-1] from the bottom of the muffler. 10-180-4 7A ENN) When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death. W.2008-0284 Stan the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood aver the outlet of the muffler. This will force contaminants out through the clean out hole. Stop the engine. Install and tighten the plug. Lower the rear gill and close the rear door. A WARNING When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning. W. 2080-126 A WARNING Stop engine and allow the muffler to coo! before cleaning the spark chamber. Wear safety goggles. Failure to obey can cause serious injury. A WARNING Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death. wronne-120 763 Bobeat Loader Service ManualBobcat. t0-190-2 76aBobcat Loader ‘Service Manual