BOBCAT 773 SKID STEER LOADER Service Repair Manual Europe Only SN 509616001-509634999

Service Manual (773 S/N 509635001 & Above) (773 Europe Only S/N 509616001–509634999)

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM) 6900092 (6–97)

Printed in U.S.A.

© Bobcat Company 1997

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s 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 W-2003-0903 instructions can cause injury or death.

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

CORRECT

CORRECT

B-10731a

B-13573

B-13561

Never service the Bobcat SkidSteer Loader without instructions.

WRONG

B-13574

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

WRONG

WRONG

B-15232

B-15281

Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device.

Replace it if damaged.

Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged.

Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

WRONG

WRONG

B-13576

B-13577 B-16102

B-6589 B-16102

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust loader with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Never fill fuel tank with engine running, while smoking or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used.

Use eye protection approved for type of welding.

Keep rear door closed except for service. Close and latch door before operating the loader.

Lead-acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact.

Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer.

MSW03-0805

ALPHABETICAL INDEX ACTUATOR VOLTAGE TEST . . . . . . . . . . . . . . . . . . 10–1 AHC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 AHC/PWM CONTROLLER . . . . . . . . . . . . . . . . . . . . 10–1 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . 1–1 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 AXLE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 AXLE, SPROCKET AND BEARINGS . . . . . . . . . . . . 4–1 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 BICS™ SYSTEM CONTROLLER . . . . . . . . . . . . . . . . 8–1 BICS™ VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1, 10–1 BLOWER HOUSING/FAN GEARBOX . . . . . . . . . . . 7–1 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . 8–1, 10–1 BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1 BOSS® DIAGNOSTIC TOOL . . . . . . . . . . . . . . . . . . . 8–1 BOSS® INSTRUMENT PANEL . . . . . . . . . . . . . . . . . 8–1 CHAINCASE COVERS . . . . . . . . . . . . . . . . . . . . . . . . 4–1 CHAINCASE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/PUSH BUTTON FLOAT) . 10–1 CONTROL INTERLOCK LINKAGE . . . . . . . . . . . . . . 2–1 CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 CRANKSHAFT AND BEARINGS . . . . . . . . . . . . . . . . 7–1 CRANKSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 DECIMAL & MILLIMETER EQUIVALENTS . . . . . . .

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE BELT HOUSING . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL/HYDRAULIC CONTROLS REFERENCE . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM INFORMATION . . . . . . . . .

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COMPRESSION . . . . . . . . . . . . . . . . . . . . . .

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . .

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . .

ENGINE MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . .

9–1 1–1 3–1 4–1 8–1 6–1 7–1 7–1 1–1 1–1 7–1 9–1 7–1

FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 7–1 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . 1–1 FIXED DRIVE BELT TENSIONER PULLEY . . . . . . . 3–1 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 FRONT LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 FUEL CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 FUEL INJECTION NOZZLES . . . . . . . . . . . . . . . . . . . 7–1 FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . 7–1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 HANDLE CONTROL UNIT TEST . . . . . . . . . . . . . . . 10–1 HYDRAULIC CONNECTION SPECIFICATIONS . . 9–1 HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . 10–1 HYDRAULIC CYLINDER IDENTIFICATION . . . . . . . 2–1 HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDRAULIC FILTER HOUSING . . . . . . . . . . . . . . . . 2–1 HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . 2–1 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 9–1 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . 1–1 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . 2–1 HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . 3–1 HYDROSTATIC MOTOR 30 SERIES . . . . . . . . . . . . 3–1 HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 HYDROSTATIC SYSTEM INFORMATION . . . . . . . . 3–1 Revised June 01

IDLER GEAR AND CAMSHAFT . . . . . . . . . . . . . . . . . . 7–1 LIFT ARM LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . .

LIFT CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFT LOCK BY–PASS VALVE . . . . . . . . . . . . . . . . . . . .

LIFTING AND BLOCKING THE LOADER . . . . . . . . .

LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . .

LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .

LUBRICATION OF THE BOBCAT LOADER . . . . . . .

5–1 5–1 1–1 2–1 2–1 1–1 1–1 9–1 1–1

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 MONITOR SERVICE CODES . . . . . . . . . . . . . . . . . . . . 8–1 MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1 OPERATOR CAB GAS CYLINDER . . . . . . . . . . . . . . . 5–1 OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 OPERATION SENSING SYSTEM UNIT . . . . . . . . . . . 8–1 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARKING BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . .

PISTON AND CONNECTING ROD . . . . . . . . . . . . . . .

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–1 4–1 7–1 1–1

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RELAY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE START SWITCH . . . . . . . . . . . . . . . . . . . . . .

ROCKER ARM AND SHAFT . . . . . . . . . . . . . . . . . . . . .

RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–1 5–1 5–1 5–1 6–1 1–1 7–1 8–1

SEAT BAR (W/COMPRESSION SPRINGS) . . . . . . . 5–1 SEAT BAR (W/GAS CYLINDER) . . . . . . . . . . . . . . . . . 5–1 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . 1–1 SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SEAT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SENDER AND SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . 1–1 SPRING LOADED DRIVE BELT TENSIONER PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 STANDARD INSTRUMENT PANEL . . . . . . . . . . . . . . . 6–1 STANDARD TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . 1–1 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 SWITCH HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 TILT LOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TIMING GEARCASE COVER . . . . . . . . . . . . . . . . . . . . 7–1 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TORQUE SPECIFICATIONS FOR LOADER . . . . . . . 9–1 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 TRACTION LOCK GUIDES . . . . . . . . . . . . . . . . . . . . . . 4–1 TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . . 1–1 TROUBLESHOOTING . . . . . . . 2–1, 3–1, 6–1, 7–1, 10–1 TROUBLESHOOTING THE BOSS® & L.C.D. DISPLAY . . . . . . . . . . . . . . . . 8–1 U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . . 9–1 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 VALVE, VALVE SEAT AND GUIDE . . . . . . . . . . . . . . . 7–1 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SYSTEMS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 ADVANCED HAND CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

HYDROSTATIC SYSTEM

DRIVE SYSTEM

MAIN FRAME

ELECTRICAL SYSTEM

ENGINE SERVICE

SYSTEMS ANALYSIS

SPECIFICATIONS

ADVANCED HAND CONTROL SYSTEM

Revised Jan. 99 i

773 BICS Loader Service Manual

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.

A general inspection of the following items must be made after the loader has had service or repair: 9. The parking brake function correctly.

1. Check that the ROPS/FOPS (Including sidescreens) is in good condition and is not modified.

must

2. Check that ROPS mounting hardware is tightened and is Melroe approved.

10. Enclosure door latches must open and close freely.

3. The seat belt must be correctly installed, functional and in good condition.

11. Bob–Tach wedges and linkages must function correctly and be in good condition.

4. The seat bar and pedal interlocks must be correctly adjusted, clean and lubricated.

12. Safety treads must in good condition.

5. Check lift arm support device, replace if damaged.

13. Check for correct function of indicator lamps (Optional on some models).

6. Machine signs must be legible and in the correct location.

14. Check hydraulic fluid level, engine oil level and fuel supply.

WARNING

7. Steering levers and foot pedals must return to neutral.

15. Inspect for fuel, oil or hydraulic fluid leaks.

8. Check for correct function of the work lights.

16. Lubricate the loader.

Revised Jan. 99

ii

773 BICS Loader Service Manual

17. Check the condition of the battery and cables.

18. Inspect the air cleaner for damage or leaks. Check the condition of the element.

19. Check the electrical charging system.

20. Check tires for wear and pressure.

21. Inspect for loose or broken parts or connections.

22. Operate the loader and check all functions.

23. Check for any field modification not completed.

24. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer.

Recommend to the owner that all necessary corrections be made before the machine is returned to service.

Revised Jan. 99

iii

773 BICS Loader Service Manual

SAFETY INSTRUCTIONS

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.

W–2003–0199

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

• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.

• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine maintenance

and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.

• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.

• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the

operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.

• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.

• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and repair work.

• The Skid–Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.

• The Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and correct service procedures for Bobcat Skid–Steer loaders.

• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

This notice identifies procedures which must be followed to avoid damage to the machine.

I–2019–0284

W–2044–1285

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

SIO5–0299

Revised June 01

v

773 BICS Loader Service Manual

FIRE PREVENTION The loader has several components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase the fire hazard. The loader must be cleaned as often as necessary to avoid this accumulation. Flammable debris in the engine compartment is a fire hazard when the loader is parked with a hot engine.

The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot.

• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

• Do not use ether or starting fluids on this engine. It has glow plugs. These starting aids can cause explosion and injure you or bystanders.

• Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.

• • • •

Stop the engine and let it cool before adding fuel. No smoking!

Use the procedure in the Operation & Maintenance Manual for connecting the battery.

Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler.

Know where fire extinguishers and first aid kits are located and how to use them.

A fire extinguisher is available from your Bobcat dealer. The fire extinguisher can be installed in the location shown [A].

A

SI06–0301

P–10650

vi

773 BICS Loader Service Manual

SERIAL NUMBER LOCATIONS

A

Always use the serial number of the loader when requesting service information or when ordering parts.

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

LOADER SERIAL NUMBER The loader serial number plate is located on the inside of the left upright, above the grill [A].

Explanation of loader Serial Number: XXXX

N–15176

XXXXX Production Sequence (Series)

B

Model/Engine Version The four digit Model/Engine Combination module number identifies the model number and engine combination.

The five digit Production Sequence Number identifies the order which the loader is produced.

ENGINE SERIAL NUMBER The serial number (Item 1) [B] is located on the engine block between engine oil fill and the injection pump.

P–04314

DELIVERY REPORT

C

The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. The form contents must be explained to the owner. Make sure it is filled out completely [C].

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773 BICS Loader Service Manual

BOBCAT LOADER IDENTIFICATION 773ServiceManual#6900092–ContentsSection

FRONT LIGHTS (OPTIONAL)

OPERATOR SEAT

GRAB HANDLES

STEERING LEVERS

REAR AUXILIARY QUICK COUPLERS (OPTIONAL)

SEAT BELT TILT CYLINDER

FRONT AUXILIARY QUICK COUPLERS (OPTIONAL)

BUCKET SAFETY TREAD BUCKET STEPS

OPERATOR CAB (ROPS & FOPS)

REAR WINDOW (OPTIONAL)

SEAT BAR LIFT ARM LINK

LIFT ARM

REAR GRILL

LIFT CYLINDER LIFT ARM SUPPORT DEVICE

TAIL LIGHTS (OPTIONAL) REAR LIGHTS (OPTIONAL)

REAR DOOR STABILIZER ROD

TIRES*

B–13544 B–13545

* TIRES – The Bobcat loader is factory equipped with heavy duty flotation tires. See 773 Series Equipment for available optional tires.

BUCKET – Several different buckets and other attachments are available for the Bobcat loader.

ROPS, FOPS – Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level II is available. The Bobcat loader is base–equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level). viii

773 BICS Loader Service Manual

PREVENTIVE MAINTENANCE Page Number

PREVENTIVE MAINTENANCE

AIR CLEANER SERVICE Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 ALTERNATOR BELT Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22 BOB–TACH Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–36 DRIVE BELT Adjusting The Drive Belt Equipped With The Fixed Drive Idler . . . . . . . 1–29 Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler 1–31 Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–32 ENGINE COOLING SYSTEM Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20 Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20 Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 ENGINE LUBRICATION SYSTEM Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 FAN GEARBOX Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22 FINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28 Removing Oil From The Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28 FUEL SYSTEM Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–16 1–16 1–16 1–17

HYDRAULIC/HYDROSTATIC SYSTEM Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–25 1–23 1–23 1–24

LIFT ARM SUPPORT DEVICE Installing Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Removing Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 LIFTING AND BLOCKING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 LIFTING THE LOADER Single Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 LUBRICATION OF THE BOBCAT LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–33 Continued On Next Page Revised Jan. 99

–1–1–

773 BICS Loader Service Manual

PREVENTIVE MAINTENANCE (Cont’d) Page Number OPERATOR CAB Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–8 1–10 1–9 1–8

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–35 REMOTE START SWITCH Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–37 SEAT BAR RESTRAINT SYSTEM (Advanced Hand Controls) Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 SEAT BAR RESTRAINT SYSTEM (Foot Pedals) Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 SEAT BAR RESTRAINT SYSTEM (Mechanical Hand Controls) Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 SPARK ARRESTOR MUFFLER Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 TIRE MAINTENANCE Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27 TOWING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 TRANSPORTING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

Revised Jan. 99

–1–2–

773 BICS Loader Service Manual

SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader.

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.

W–2003–0199

ITEM Engine Oil Engine Air Filter and Air System Engine Cooling System Tires Seat Belt, Seat Bar, Foot Pedal or Hand Control Interlocks Safety Signs and Safety Tread Indicators & Lights (Opt.) Operator Cab Lift Arms, Cyl., Bob–Tach Pivot Pins and Wedges Fuel Filter Bobcat Interlock Control System (BICSTM) Hydraulic Fluid, Hoses and Tubelines Final Drive Trans.(Chaincase) Foot Pedals, Hand Controls, and Steering Levers Wheel Nuts Parking Brake Spark Arrestor Muffler Battery Steering Shaft Engine/Hydros. Drive Belt Fan Drive Gearbox Alternator Belt Engine Oil and Filter Fuel Filter Hydraulic Reservoir Breather Cap Hydraulic Reservoir Final Drive Trans.(Chaincase) Hydraulic/Hydrostatic Filter Case Drain Filters Bobcat Interlock Control System (BICSTM)

*

SERVICE REQUIRED

8–10 50 100 250 500 1000

Check the oil level and add oil as needed.

Check condition indicator or display panel. Service only when required. Check for leaks and damaged components.

Clean debris from oil cooler, radiator and grill. Check coolant level in recovery tank (engine cold). Add coolant as needed.

Check for damaged tires and correct air pressure.

Check the condition of seat belt. Check the seat bar, and foot pedal interlocks or hand control interlocks. Clean dirt and debris from moving parts.

Check for damaged signs (decals) and safety tread. Replace any signs or safety treads that are damaged or worn.

Check for correct operation of all indicators & lights.

Check the fastening bolts, washers & nuts. Check the condition of cab.

Lubricate with multi–purpose lithium based grease.

Remove the trapped water.

Check BICSTM functions. Clean dirt, debris or objects from under and behind seat and around brake pedal as required.

Check fluid level and add as needed. Check for damage and leaks. Repair or replace as needed.

Check oil level.

Check for correct operation. Repair or adjust as needed.

Check for loose wheel nuts and tighten to 105–115 ft.–lbs.

(142–156 Nm) torque.

Check operation.

Clean the spark chamber.

Check cables, connections and electrolyte level. Add distilled water as needed Grease two fittings. * Check for wear or damage. Adjust as needed.

Check gear lube level. Add as needed.

Check belt tension and adjust as needed.

Replace oil and filter. Use CD or better grade oil and Melroe filter.

Replace the filter element.

Replace the reservoir breather cap.

Replace the fluid.

Replace the fluid.

Replace the filter element.

Replace the filters.

Check lift arm bypass control

Check wheel nut torque every 8 hours for the first 24 hours.

Replace filter element after the first 50 hours and when the transmission warning light comes ON. Or every 12 months.

Inspect the new belt after first 50 hours.

First oil and filter change must occur at 50 hours; 250 hours thereafter.

Revised June 01

–1–3–

773 BICS Loader Service Manual

A

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 [A].

W–2003–0199 LIFTING AND BLOCKING THE LOADER Procedure

B–07023

Always park the loader on a level surface.

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.

W–2017–0286

B

Put the floor jack under the rear of the loader [B].

Lift the rear of the loader and install jackstands [B].

P–03869

Put the floor jack under the front the loader [C].

C

Lift the front of the loader and put jackstands under the axle tubes [C].

NOTE: Make sure the jackstands do not touch the tires.

P–03868

Revised June 01

–1–4–

773 BICS Loader Service Manual

TRANSPORTING THE BOBCAT LOADER

A

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–2058–0494

SUPPORT

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A].

P–10643

B

Be sure the transport and towing vehicles are of adequate size and capacity (See SPECIFICATIONS Page 9–1, for weight of loader.).

The rear of the trailer must be blocked or supported [A] when loading or unloading the loader to prevent the front end of the trailer from raising up.

Use the following procedure to fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up or down slopes [B].

• Lower the bucket or attachment to the floor.

P–05077

• Stop the engine.

P–10638

• Engage the parking brake.

• Install chains at the front and rear loader tie down positions (Inset) [B].

• Fasten each end of the chain to the transport vehicle.

TOWING THE LOADER To prevent damage to the loaders hydrostatic system, the loader must be towed only a short distance at slow speed.

(Example: Moving the loader onto a transport vehicle).

The towing chain (or cable) must be rated at 1 & 1/2 times the weight of the loader. (See SPECIFICATIONS Page 9–1.)

• Turn the key switch to ON and press the traction lock override button.

• Tow the Bobcat at 2 MPH (3,2 km/hr) or less for not more than 25 feet (7,6 meters).

6707867

P–10646

If the electrical system is not functioning part of the brake system must be disassembled to move the loader. (See TRACTION LOCK Removal and Installation procedure Page 8–1.)

Revised Jan. 99

–1–5–

773 BICS Loader Service Manual

LIFTING THE LOADER

A

Single Point Lift

AVOID INJURY OR DEATH • Before lifting, check fasteners on single point lift and operator cab.

• Assemble front cab fasteners as shown in this manual.

• Never allow riders in the cab or bystanders

MC–01822

within 15 feet (5 meters) while lifting the machine.

W–2007–0497

The loader can also be lifted with the single point lift which is available as a kit from your Bobcat loader dealer.

Install the kit and lift as shown [A].

The single point lift, supplied by Bobcat Company is designed to lift and support the Bobcat loader without affecting roll over and falling object protection features of the operator cab.

STOPPING THE BOBCAT LOADER When the steering levers are moved to the neutral position, the hydrostatic transmission will act as a service brake and stop the loader.

Revised June 01

–1–6–

773 BICS Loader Service Manual

LIFT ARM SUPPORT DEVICE 1.

A

1

P–10589

B

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.

W–2059–0598

1 2 P–10592

Installing Lift Arm Support Device Put jackstands under the rear corners of the loader.

Remove the lift arm support device (Item 1) [A] from storage position.

P–10594

The operator must be in the operator’s seat, with the seat belt fastened and seat bar lowered, until the lift arm support device is installed.

C

Start the engine, and raise the lift arms all the way up.

Have a second person install the lift arm support device (Item 1) [B] over the rod of one of the lift cylinders.

The lift arm support device must be tight against the cylinder rod. The tabs of the lift arm support device must be under the cylinder as shown (Item 2) [B].

Lower the lift arms slowly until the stop is held between the lift arms and lift cylinder [C].

P–10593

Removing Lift Arm Support Device The operator must be in the operator’s seat, with the seat belt fastened and seat bar lowered, until the lift arm support device is removed and the lift arms are lowered all the way.

Start the engine, raise the lift arms all the way up.

Have a second person remove the lift arm support device.

Service lift arm support device if damaged or if parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death.

Return the lift arm support device to storage position and secure with clamping knobs.

Remove the jackstands.

Revised Jan. 99

W–2271–1197

–1–7–

773 BICS Loader Service Manual

OPERATOR CAB

A

Description The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment 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 J104 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level ll is available.

Level l – Protection from falling bricks, small concrete blocks and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services.

P–00660

B

Level ll – Protection from falling trees, rocks; for machines involved in site clearing, overhead demolition or forestry.

Emergency Exit The front opening on the operator cab and rear window provide exits.

Rear Window Pull on the tag on the top of the rear window to remove the rubber cord [A].

P–10598

C

Push the rear window out of the rear of the operator cab.

Exit through the rear of the operator cab [B].

Front Door NOTE: When an Operator Cab Enclosure Kit is installed, the window of the front door can be used as an emergency exit. [C] Pull the plastic loop at the top of the window in the front door to remove the rubber cord [C].

P–09216

D

Push the window out with your foot [D].

Exit through the front door.

P–09217

Revised Jan. 99

–1–8–

773 BICS Loader Service Manual

OPERATOR CAB (Cont’d) Raising The Operator Cab

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat Company.

Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

W–2069–1299

AVOID INJURY OR DEATH

Stop the loader on a level surface. Lower the lift arms.

Stop the engine. If the lift arms must be up while raising the operator cab, install an approved lift arm support device. (See Page 1–7.)

When operator cab is equipped with a cab enclosure kit (front door, side windows and top window) and other accessories, the cab will not stay in the fully raised position. Use a chain hoist to secure cab in fully raised position or lower cab until it rests against the cab latch on the gas spring.

W–2156–0594

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.

W–2059–0598

Use care when raising or lowering the operator cab to prevent damaging the shaft of the lift arm by–pass control.

I–2070–0596

If equipped with with mechanical hand controls: Disconnect the control linkage joint from the bottom hole (work position) and move to the TOP hole on the control handle (both sides) [A].

A

Both control handles must be in the vertical position so there will be no cab interference with the steering levers when the operator cab is raised or lowered.

Before the cab or the lift arms are raised for service, jackstands must be put under the rear corners of the frame. Failure to use jackstands can allow the machine to tip backward causing injury or death.

P–03470

B

W–2014–0895

AVOID INJURY OR DEATH Accidental movement of the loader, the lift arms or the attachment can occur if the lift or tilt control handles are not positioned correctly before lifting or lowering the cab.

Move control linkage to top hole in handles as shown, so cab does not hit handles when being lifted or lowered.

W–2157–0594

Loosen and remove the nut and plate (both sides) from the front corner of the operator cab [B].

Revised June 01

P–01518

–1–9–

P–01528

773 BICS Loader Service Manual

OPERATOR CAB (Cont’d)

A

Raising The Operator Cab (Cont’d) Lift on the grab handle and bottom of the operator cab slowly until the cab latching mechanism engages and the cab is all the way up [A].

Lowering The Operator Cab NOTE: Make sure the seat bar is fully raised or lowered when lowering the cab. Use the grab handles to lower the cab.

P–10599

Pull down on the bottom of the operator cab until it stops at the latching mechanism (Inset) [A]. Release the latching mechanism (Inset) [A] and pull the cab all the way down.

P–10596

Install the plate and nut (both sides) [B].

B

Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque.

P–01518

If equipped with mechanical hand controls move the control linkage from the TOP hole to the BOTTOM hole (work position) on the control handle (both sides) [C].

C

P–03561

Revised Jan. 99

–1–10–

773 BICS Loader Service Manual

SEAT BAR RESTRAINT SYSTEM (Foot Pedals)

A

Description 2.

The seat bar restraint system has a pivoting, spring assist seat bar with arm rests and has spring loaded interlocks for the lift and tilt functions.

Clean (Both Sides)

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls.

When the seat bar is up, the lift and tilt control functions are locked when returned to the NEUTRAL POSITION. P–10361

Seat Bar Inspection Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Loaders without seat sensors press the green PRESS TO OPERATE Button. Operate each foot pedal to check both the lift and tilt functions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground.

AVOID INJURY OR DEATH Never operate loader without pedal lock shield 6705474 on both interlocks. Shields prevent feet from unlocking interlocks when leaving loader seat.

Raise the seat bar. Try to move each foot pedal. Pedals must be firmly locked in neutral position. There must be no motion of the lift arms or tilt (bucket) when the pedals are pushed.

W–2162–1194

Pull the seat bar down. Loaders without seat sensors press the green PRESS TO OPERATE Button. Lower the lift arms. Operate the lift pedal. While the lift arms are going up, raise the seat bar and the lift arms should stop.

Lower the seat bar. Loaders without seat sensors press the green PRESS TO OPERATE Button. Lower the lift arms and put the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the foot pedals to be sure that the pedals are firmly locked in the neutral position. Unbuckle the seat belt.

B

Seat Bar Maintenance Interlock Shield

See the SERVICE SCHEDULE Page 1–3 and on the loader for correct service interval.

Clean any debris or dirt from the moving parts [A] & [B].

Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).

Clean (Both Sides)

If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust pedal control linkage. Replace parts that are worn or damaged. Use only genuine Bobcat replacement parts.

P–10569

Revised Jan. 99

–1–11–

773 BICS Loader Service Manual

SEAT BAR RESTRAINT SYSTEM (Mechanical Hand Controls)

A Clean (Both Sides)

Description 3.

The seat bar restraint system has a pivoting, spring assist seat bar with arm rests and has spring loaded interlocks for the lift and tilt control functions.

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

The interlocks require the operator to lower the seat bar in order to operate the hand controls.

When the seat bar is up, the lift and tilt control functions are locked when returned to the NEUTRAL POSITION.

P–10361

Seat Bar Inspection Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Loaders without seat sensors press the green PRESS TO OPERATE Button. Start the engine. Operate each hand control to check both the lift and tilt functions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground.

AVOID INJURY OR DEATH Never operate loader without interlock shield 6705474 on both interlocks. Shields prevent foot from unlocking interlocks when leaving loader seat.

W–2158–0594

Raise the seat bar. Try to move each hand control. The controls must be firmly locked in neutral position. There must be no motion of the lift arms or tilt (bucket) when the controls are moved.

Pull the seat bar down. Loaders without seat sensors press the green PRESS TO OPERATE Button. Lower the lift arms. Operate the lift control. While the lift arms are going up, raise the seat bar and the lift arms should stop.

B

Lower the seat bar. Lower the lift arms. Loaders without seat sensors press the green PRESS TO OPERATE Button and put the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the hand controls to be sure that the controls are firmly locked in the neutral position. Unbuckle the seat belt.

Interlock Shield Clean (Both Sides)

Seat Bar Maintenance See the SERVICE SCHEDULE Page 1–3 for correct service interval.

Clean any debris or dirt from the moving parts [A] & [B].

Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).

P–01640

If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust hand control linkage. Replace parts that are worn or damaged. Use only genuine Bobcat replacement parts.

AVOID INJURY OR DEATH The Seat Bar System must lock the lift and tilt foot pedals or hand controls in neutral when the Seat Bar is up. Service the system if controls do not lock correctly.

W–2263–0597

Revised Jan. 99

–1–12–

773 BICS Loader Service Manual

SEAT BAR RESTRAINT SYSTEM (Advanced Hand Controls)

A

Description The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests.

1

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

When the seat bar is down and the green PRESS TO OPERATE Button is activated, the lift, tilt, and traction drive functions can be operated.

P–13721

When the seat bar is up, the lift, tilt, and traction drive functions are deactivated.

B

Seat Bar Inspection 4.

Sit in the operator’s seat. Turn the key ON, lower the seat bar and press the green PRESS TO OPERATE Button.

Both lights on the left handle should be ON.

Clean (Both Sides)

Move each hand control back and forth. You should hear the zip–zip sound of the lift and tilt actuators moving the control valve spools (under the seat).

Raise the seat bar fully. Both lights on the left handle should be OFF. Move each hand control back and forth. There must be no zip–zip sound of the lift or tilt actuators. If either actuator makes a sound while the seat bar is raised, contact your dealer for service.

P–10361

Seat Bar Maintenance See the SERVICE SCHEDULE Page 1–3 for correct service interval.

Clean any debris or dirt from the moving parts [B].

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar.

• (Advanced Hand Controls) Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.

The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate.

If the seat bar system does not function correctly replace parts that are worn or damaged. Use only genuine Bobcat replacement parts.

W–2321–0698

Revised Jan. 99

–1–13–

773 BICS Loader Service Manual

AIR CLEANER SERVICE

A

Replacing Filter Element

1

Without BOSS® – Condition Indicator: Replace the large (outer) filter element only when the red ring shows in the window of the condition indicator (Item 1) [A].

2

NOTE: Before replacing the filter element, push the button on the condition indicator (Item 2) [A].

Start the engine. If the red ring does not show, do not replace the filter element.

Replace the inner filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter has been replaced.

P–10308

With BOSS®: It is important to change the air filter element only when the service codes (on the BOSS® option display panel) shows the symbols [AF.2] [B].

B

MC–02320

Open the rear door.

C

Remove the dust cover wing nut (Item 1) [C].

Remove the dust cover (Item 2) [C].

2

1

P–10313

Remove the wing nut (Item 1) [D] from the large air filter element.

D

1

P–10314

Revised Jan. 99

–1–14–

773 BICS Loader Service Manual

AIR CLEANER SERVICE (Cont’d)

A

Replacing Filter Element (Cont’d) Remove the large filter element [A].

NOTE: Be sure all sealing surfaces are free of dirt and debris.

Install the new filter element and washer and tighten the wing nut.

NOTE: Be sure sealing washer is in place on each wing nut [B].

P–10312

Install the dust cover and tighten the wing nut.

B

Check the air intake hose for damage. Check the air cleaner housing for damage. Check to make sure all connections are tight.

Only replace the inner filter element under the following conditions: •

Replace the inner filter element every third time the outer filter is replaced.

•

Press the button to remove the red ring in the condition indicator after the outer filter element has been replaced. Start the engine and run at full RPM. If the red ring shows again, replace the inner filter element.

•

BOSS Only: If the service codes show symbols AF.2 during full engine speed, replace the inner filter element only after the outer filter element has been changed.

1

P–10310

C

Remove the inner filter wing nut (Item 1) [B].

Remove the inner filter [C].

Install a new filter and tighten the wing nut.

Close the rear door before operating the loader.

P–10309

Revised Jan. 99

–1–15–

773 BICS Loader Service Manual

FUEL SYSTEM

A

Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1.

1

The following is one suggested blending guideline which should prevent fuel gelling problems: Temp. F° (C°)

No. 2

No.1

+15°(9°) Down to –20° (–29°) Below –20° (29°)

100% 50% 0%

0% 50% 100%

Contact your fuel supplier for local recommendations.

P–10601

Filling the Fuel Tank

B

WRONG

Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can cause an explosion or fire.

W–2063–0887

Remove the fuel fill cap (Item 1) [A].

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! [B].

B–13579

C

Install and tighten the fuel fill cap (Item 1) [A].

Fuel Filter

2 Always clean up spilled fuel 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.

1

W–2103–1285

P–10315

See the SERVICE SCHEDULE, Page 1–3, for the service interval when to remove the water from the fuel filter and when to replace the fuel filter.

Loosen the drain (Item 1) [C] at the bottom of the filter element to drain water from the filter.

See the SERVICE SCHEDULE, Page 1–3, for the service interval when to replace the fuel filter.

Remove the filter element (Item 2) [C].

Clean the area around the filter housing. Put oil on the seal of the new filter element. Install the fuel filter, and hand tighten.

Remove the air from the fuel system. (See Page 1–17.)

Revised Jan. 99

–1–16–

773 BICS Loader Service Manual

FUEL SYSTEM (Cont’d)

A

Removing Air From The Fuel System 5.

After replacing the fuel filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine.

3

2

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 piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

1

P–10571

W–2072–0496

Open the vent (Item 1) [A] on the fuel filter housing.

Operate the hand pump (priming bulb) (Item 2) [A] until fuel flows from the vent with no air bubbles.

Close the vent (Item 1) [A] on the fuel filter housing.

Open the vent (Item 3) [A] on the fuel injection pump.

Operate the hand pump (priming bulb) (Item 2) [A] until the pump feels solid.

Tighten the vent plug (Item 3) [A].

Start the engine.

It may be necessary to open the vent plug (Item 3) [A] briefly until the engine runs smoothly.

Revised Jan. 99

–1–17–

773 BICS Loader Service Manual

ENGINE LUBRICATION SYSTEM

A

Checking Engine Oil Check the engine oil level every day.

1

Before starting the engine for the work shift, open the rear door. Remove the dipstick (Item 1) [A].

Keep the oil level between the marks on the dipstick.

Use a good quality motor oil that meets API Service Classification of CD. (See Oil Chart below.)

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)

C° –40

–34

–29

–23

–18

–13

–7

–1

+4

+10

+15

+21

+27

+32

+38

P–10574

+43 +49

SAE 40W or 20W–50

B

SAE 10W–30 SAE 15W–40 SAE 30W

* SAE 5W–30 SAE 20W–20

1

SAE 10W SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

P–10576 –40 –30

–20

–10

0

+10

+20

+30

+40

+50

+60

+70

+80

+90 +100 +110 +120

F°

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION CD, CF4, CG4 )

* Can be used ONLY when available with appropriate diesel rating.

Replacing Oil And Filter See the SERVICE SCHEDULE Page 1–3 for the service interval for replacing the engine oil and filter.

Run the engine until it is at operating temperature. Stop the engine.

Open the rear door. Remove the drain plug (Item 1) [B].

Drain the oil into a container and dispose of used oil in an environmentally safe manner.

Revised June 01

–1–18–

773 BICS Loader Service Manual

ENGINE LUBRICATION SYSTEM (Cont’d)

A

Replacing Oil And Filter (Cont’d) Remove the oil filter (Item 1) [A].

Clean the filter housing surface. Put clean oil on the new oil filter gasket. Install the filter and hand tighten.

1

Install and tighten the drain plug.

NOTE: Photo’s may appear procedure is the same.

different

but the

P–10576

Remove the filler cap (Item 1) [B] from the oil fill tube.

B

Put 7.5 qts. (7,1 L) of oil in the engine. (See Oil Chart Page 1–18.)

1

P–10572

C

Start the engine and let it run for several minutes. Stop the engine. Check for leaks at the oil filter and check the oil level. Add oil as needed if it is not at the top mark (Item 1) [C] on the dipstick.

1

Always clean up spilled fuel 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.

P–01575

W–2103–1285

Revised Jan. 99

–1–19–

773 BICS Loader Service Manual

ENGINE COOLING SYSTEM

A

Check the cooling system every day to prevent over–heating, loss of performance or engine damage.

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.

P–10607

B

W–2019–1285

Cleaning The Cooling System Open the rear door and raise the rear grill.

Use air pressure or water pressure to clean the top of the oil cooler [A].

Raise the oil cooler and clean the top of the radiator [B].

Check cooling system for leaks.

Lower the rear grill and close the rear door.

P–10608

Checking The Coolant Level Open the rear door.

C

Check the coolant level in the coolant recovery tank (Item 1) [C].

The coolant recovery tank must be 1/3 full.

Close the rear door before operating the loader.

1

AVOID ENGINE DAMAGE

P–10572

Always use the correct ratio of water to antifreeze.

Too 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 full strength concentrated coolant can cause serious premature engine damage.

I–2124–0497

Revised Jan. 99

–1–20–

773 BICS Loader Service Manual

ENGINE COOLING SYSTEM (Cont’d)

A

Replacing The Coolant

1

Do not remove radiator cap when the engine is hot. You can be seriously burned.

W–2070–1285

Open the rear door. Open the rear grill.

P–03964

Remove the radiator cap (Item 1) [A].

B

Connect a hose to the engine block drain valve (Item 1) [B]. Open the drain valve and drain the coolant into a container.

1

After all the coolant is removed, close the drain valve.

Mix the coolant in a separate container. (See SPECIFICATIONS for correct capacity, Page 9–1.)

NOTE: The loader is factory filled with propylene glycol coolant. (Purple Color) DO NOT mix propylene glycol with ethylene glycol.

Add premixed coolant, 47% water and 53% propylene glycol to the recovery tank if the coolant level is low.

P–10311

One gallon and one pint of propylene glycol mixed with one gallon of water is the correct mixture of coolant to provide a –34°F (–37°C) freeze protection.

Use a refractometer to check the ratio of propylene glycol and water in your cooling system.

Fill the radiator with the premixed coolant. Install the radiator cap.

AVOID ENGINE DAMAGE

Fill the coolant recovery tank 1/3 full.

Always use the correct ratio of water to antifreeze.

Run the engine until it is at operating temperature. Stop the engine. Check the coolant level in the recovery tank when cool. Add coolant to the recovery tank as needed.

Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.

Lower the rear grill and close the rear door.

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 full strength concentrated coolant can cause serious premature engine damage.

I–2124–0497

Revised Jan. 99

–1–21–

773 BICS Loader Service Manual

ALTERNATOR BELT

A

Adjustment

2

Stop the engine.

Raise the operator cab. (See Page 1–9.)

Loosen the alternator mounting bolt (Item 1) [A].

Loosen the adjustment bolt (Item 2) [A].

Move the alternator until the belt has 5/16 inch (8,0 mm) movement at the middle of the belt span with 15 lbs. (66 N) of force.

1 P–10323

Tighten the adjustment bolt and mounting bolt.

Lower the operator cab.

B

FAN GEARBOX See the SERVICE SCHEDULE Page 1–3 for the correct service interval.

Checking And Maintaining Gear Lube Level

Raise the operator cab. (See Page 1–9.)

1

Remove the plug (Item 1) [C] to check the lubricant level.

If the level is low, add SAE 90W gear lube through the check plug hole until the lubricant flows from the hole.

P–03975

Install and tighten the plug.

Lower the operator cab. (See Page 1–10.)

Revised Jan. 99

–1–22–

773 BICS Loader Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM

A

Checking And Adding Fluid Use only recommended fluid in the hydraulic system.

(See SPECIFICATIONS Page 9–1.)

2

Stop the loader on a level surface, Lower the lift arms and tilt the Bob–Tach fully back.

1

Stop the engine.

Remove the dipstick (Item 1) [A].

P–10597

B

The fluid level must be between the marks on the dipstick [B].

If fluid is needed, remove the fill cap (Item 2) [A].

P–10303

C

Clean the hydraulic reservoir fill screen [C].

Add the fluid as needed to bring the level to the top mark on the dipstick [B].

Install the fill cap.

P–10600

Replacing Hydraulic/Hydrostatic Filter 6.

See the SERVICE SCHEDULE Page 1–3 for the correct service interval.

D

Open the rear door.

Remove the filter element (Item 1) [D].

1

Clean the surface of the filter housing where the element seal contacts the housing.

Put clean oil on the rubber seal of the filter element.

Install and hand tighten the filter element.

P–10318

Close the rear door before operating the loader.

Revised Jan. 99

–1–23–

773 BICS Loader Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Replacing Hydraulic Fluid See the SERVICE SCHEDULE Page 1–3, for the service interval.

1 CD–12250

The fluid must also be replaced if it becomes contaminated or after major repairs.

Remove the reservoir fill cap (Item 1) [A].

NOTE: Be sure the rubber gasket is installed on the fill cap [A].

Raise the operator cab. (See Raising The Operator Cab Page 1–9.)

P–10597

Disconnect the hose (Item 1) [B] from the case drain filter located on the reservoir. Use a plug and cap on the filter and case drain hose to prevent leakage.

B

Disconnect the hose (Item 1) [C] from the case drain filter located on the left drive motor. Use a plug and cap on the filter and case drain hose to prevent leakage.

2

Remove the case drain filters (Item 2) [B] & [C] and drain the fluid into a container.

Replace the hydraulic/hydrostatic filter element. (See Page 1–23.)

Replace both hydrostatic motor case drain filters (Item 2) [B] & [C].

1

When all the fluid is removed from the reservoir, reconnect the hose to case drain filter on the reservoir.

P–10603

C

Add the correct fluid to the reservoir until the fluid level is between the marks on the dipstick. DO NOT fill above the top mark on the dipstick.

2

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin and cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately.

1 P–10602

W–2145–0290

Always clean up spilled fuel 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.

W–2103–1285

Lower the operator cab.

Start the engine and operate the loader hydraulic controls. Stop the engine and check for leaks.

Check the fluid level in the reservoir and add as needed.

Revised Jan. 99

–1–24–

773 BICS Loader Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

773ServiceManual#6900092–PreventativeMaintenanceSectionPart1of2

Breather Cap See the SERVICE SCHEDULE Page 1–3, for the correct service interval.

1

Raise the operator cab (See Raising The Operator Cab Page 1–9.)

Remove the breather cap (Item 1) [A].

P–10604

NOTE: Be sure the rubber gasket (Item 1) [B] is installed on the fill cap.

B

Clean the filter (Item 2) [B] in the breather cap.

2

Be sure the baffle washer (Item 3) [B] is installed in the hydraulic reservoir.

Replace the breather cap at regular intervals. (See the SERVICE SCHEDULE Page 1–3.)

1 3

Lower the operator cab.

P–10605

Revised Jan. 99

–1–25–

773 BICS Loader Service Manual

SPARK ARRESTOR MUFFLER

A

Cleaning Procedure See the SERVICE SCHEDULE Page 1–3 for service interval for cleaning the spark arrestor muffler.

Do not operate the loader with a defective exhaust system.

1

P–10322

This loader is factory equipped with a U.S.D.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 muffler 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.

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–2050–1285

Make reference to local laws and regulations for spark arrestor requirements.

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety glasses or goggles. Failure to obey can cause serious injury.

I–2022–0595

W–2011–1285

Stop the engine. Open the rear door and rear grill.

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.

Remove the plug (Item 1) [A] from the bottom of the muffler.

Start the engine and run for about ten seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler.

W–2068–1285

This will force contaminants out through the cleanout hole.

Stop the engine. Install and tighten the plug. Lower the rear grill and close the rear door.

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–2006–0284

Revised Jan. 99

–1–26–

773 BICS Loader Service Manual

TIRE MAINTENANCE

A

Wheel Nuts See the SERVICE SCHEDULE Page 1–3 for the service interval to check the wheel nuts. The correct torque is 105–115 ft.–lbs. (142–156 Nm) torque [A].

Tire Rotation Check the tires regularly for wear, damage and pressure.

(See SPECIFICATIONS Page 9–1 for the correct tire pressure.)

Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [B].

P–10628

B

It is 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 different speed and cause excessive wear.

The tread bars of all the tires must face the same direction.

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for the correct pressure before operating the loader.

Tire Mounting Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage.

B–09976

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 tire, check the tire pressure frequently to avoid over inflation.

Do not inflate tires above specified pressure.

Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.

W–2078–1285

Inflate tires to the MAXIMUM pressure shown on the sidewall of the tire. DO NOT mix brands of tires used on the same loader.

I–2057–0794

Revised Jan. 99

–1–27–

773 BICS Loader Service Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

A

Checking And Adding Oil The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic/hydrostatic system. (See SPECIFICATIONS Section Page 9–1.)

1

To check the chaincase oil level, use the following procedure: Drive the loader on a level surface. Stop the engine.

Remove the plug (Item 1) [A] from the front of the chaincase housing.

P–03870

If oil can be reached with the tip of the your finger through the hole the oil level is correct.

B

If the level is low, add oil through the check plug hole until the oil flows from the hole. Install and tighten the plug.

Removing Oil From The Chaincase To drain the oil from the chaincase, remove the cover (Item 1) [B] which is installed over the drain plug at the rear of the chaincase.

1

Installation: Tighten the cover bolts to 10–20 ft.–lbs.

(24–27 Nm) torque.

P–01616

C

Remove the drain plug (Item 1) [C] and drain the oil into a container.

NOTE: When installing the drain plug into the chaincase, always use a NEW drain plug gasket.

1

P–01619

Revised June 01

–1–28–

773 BICS Loader Service Manual

DRIVE BELT

A

Adjusting The Drive Belt Equipped With The Fixed Drive Idler The tools listed will be needed to do the following procedure: MEL1405 – Bar MEL1406 – Spring Scale

1

See the SERVICE SCHEDULE Page 1–3 for the service interval.

To adjust the drive belt between the engine flywheel and the hydrostatic pump pulley, use the following procedure:

P–03967

Stop the engine. Open the rear door.

B

Disconnect the negative (–) battery cable.

Remove the belt shield holddown clips (Item 1) [A].

Remove the belt shield [B].

P–03969

Use the correct tools to adjust the idler tensioner and the drive belt.

C

MEL1405 – Belt Tension Bar MEL1406 – Spring Scale The pulley tensioner is located between the flywheel and pump pulley.

Loosen the bolt (Item 1) [C] at the pulley tensioner.

P–04232

1

Use the end of the belt tensioning tool (MEL1405) to move the tension pulley down (Inset) [C].

Tighten the bolt (Item 1) [C] at the pulley tension bracket to 25–28 ft.–lbs. (34–38 Nm) torque..

P–04070

Install the Belt Tension Bar (MEL1405) on the drive belt [D].

D

The pin (Item 1) [D] must be pulled tight against the engine drive pulley.

Make a mark on the cast flange just below the tool handle (Item 2) [D].

2

1 Revised Jan. 99

–1–29–

P–04227

773 BICS Loader Service Manual

DRIVE BELT (Cont’d)

A

Adjusting The Drive Belt Equipped With The Fixed Drive Idler (Cont’d) Install the spring scale (MEL1406) on the tool handle. The line of pull on the spring scale must be at a right angle or perpendicular to the tool handle as shown [A].

NEW BELT: A new belt is one with a 1/2 hour or less of operating time. With 15 lbs. (67 N) of force the tool should move 1.250 inch (32 mm) (the width of the tool handle).

NOTE: When a NEW belt is installed, run the engine for approximately 5 minutes. Then the belt tension must be checked and adjusted to 15 lbs. (67 N) spring scale force.

P–01660

USED BELT: With 12 lbs. (53 N) of force, the tool should move 1.250 inch (32 mm) (the width of the tool handle), if not, readjust pulley tensioner.

NOTE: The belt tension should be adjusted if a tension check results in a reading of 8 lbs. (36 N) of force or less.

Revised Jan. 99

–1–30–

773 BICS Loader Service Manual

DRIVE BELT (Cont’d)

A

Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler To adjust the drive belt between the flywheel and the hydrostatic pump pulley, use the following procedure: Stop the engine. Open the rear door.

1

Disconnect the negative (–) battery cable.

Remove the belt shield holddown clips (Item 1) [A].

P–03967

B

Remove the belt shield [B].

The pulley tensioner is located between the flywheel and pump pulley.

P–03969

C

Loosen the bolt (Item 1) [C] on the spring loaded drive idler.

NOTE: The pointer (Item 2) [C] will be at the 1 o’clock position when the idler is not under spring tension.

1

2

P–08760

D

Using the Belt Tensioner Bar (MEL1405) or a pry bar push the idler assembly against the belt, the pointer (Item 1) [D] will be at the 3 o’clock position when the idler stop is bottomed out.

1

P–08762

–1–31–

773 BICS Loader Service Manual

DRIVE BELT (Cont’d)

A

Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler (Cont’d) Raise the idler assembly slightly so that the pulley is operating on spring tension and not against the stop.

Tighten the mounting bolt (Item 1) [A] to 25–28 ft.–lbs.

(34–38 Nm) torque.

1

NOTE: Do not set the idler against the travel stop in the 3 o’clock position.

Run the engine for a few minutes.

P–08761

Stop the engine and recheck the pointer position.

Readjust if necessary.

B

After the idler has been in service, readjust when the pointer reaches the 1 o’clock position.

Install the belt shield using the fasteners.

Reconnect the negative (–) battery cable.

Close the rear door.

Drive Belt Replacement Stop the engine. Open the rear door.

P–03969

Raise the operator cab. (See Page 1–9.)

Remove the negative (–) cable from the battery. The battery may be removed for additional working clearance.

(See Page 6–1.)

C

1

2

Remove the belt shield fasteners. Remove the belt shield [B].

Remove the fan drive belt (Item 1) [C].

The belt tensioner is located between the flywheel and pump pulley. Loosen and remove the bolt (Item 2) [C] from the belt tensioner.

Remove the belt tensioner assembly.

Remove the drive belt from the pump pulley and flywheel.

Remove the drive belt from the loader [D].

P–08760

D

Install the new drive belt. Install the belt tensioner assembly.

Install the fan drive belt.

Adjust the drive belt. (See Page 1–29 or 31.)

Reinstall previously removed components and connect the negative (–) cable to the battery.

P–04064

–1–32–

773 BICS Loader Service Manual

LUBRICATION OF THE BOBCAT LOADER 7.

Lubricate the loader as specified in the SERVICE SCHEDULE, Page 1–3, for the best performance of the loader.

A 1

Record the operating hours each time you lubricate the Bobcat loader.

Always use a good quality lithium based multi–purpose grease when you lubricate the loader. Apply lubricant until extra grease shows.

Lubricate the following locations on the loader: 1. Stabilizer Rod – Front (Both Sides) [A]

P–10619

B

2. Stabilizer Rod – Rear (Both Sides) [B].

3 3. Lift Cylinder Rod End (Both Sides) [B].

4. Lift Cylinder Base End (Both Sides) [B].

2

4 P–10640

C

P–10620

5

5. Tilt Cylinder Base End [C].

P–10622

Revised Jan. 99

–1–33–

773 BICS Loader Service Manual

LUBRICATION OF THE BOBCAT LOADER (Cont’d)

A

6. Tilt Cylinder Rod End. [A].

6 P–10625

B

7. Bob–Tach Wedge (Both Sides) [B].

7

P–10626

C

8. Bob–Tach Pivot Pin (Both Sides) [C].

8 P–10635

D

9. Lift Arm Pivot Pin (Both Sides) [D].

9

10. Lift Arm Link Pivot Pin (Both Sides) [D].

10

P–10621

Revised Jan. 99

–1–34–

773 BICS Loader Service Manual

LUBRICATION OF THE BOBCAT LOADER (Cont’d)

A

11. 250 Hours: Steering Lever Shaft (2) [A].

11

P–01533

PIVOT PINS

B

1

All lift arm and cylinder pivots have a large pin held in position with a retainer bolt and lock nut (Item 1) [B].

Check that the lock nuts are tightened to 18–20 ft.–lbs.

(24–27 Nm) torque.

P–10620

Revised Jan. 99

–1–35–

773 BICS Loader Service Manual

BOB–TACH

A

Inspection and Maintenance Move the Bob–Tach levers to engage the wedges [A].

The levers and wedges must move freely.

1

The wedges must extend through the holes in the attachment mounting frame (Item 1) [A].

N–17022

N–17027

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.

B

W–2102–0588

The spring loaded wedge (Item 1) [A] must contact the lower edge of the hole in the attachment (Item 1) [B] and [C].

If the wedge does not contact the lower edge of the hole [B] and [C], the attachment will be loose and can come off the Bob–Tach.

1

N–17023

C

Bob–Tach Wedge

Wedge Must Contact Lower Edge Of Hole In The Attachment B–15177

Inspect the mounting frame on the attachment and the Bob–Tach, linkages and wedges for excessive wear or damage [D]. Replace any parts that are damaged, bent, or missing. Keep all fasteners tight.

D

Look for cracked welds. Contact your Bobcat dealer for repair or replacement parts.

Lubricate the wedges (See SERVICE SCHEDULE, Page 1–3 and LUBRICATION OF THE BOBCAT LOADER, Page 1–33).

TS–01062

Revised June 01

–1–36–

773 BICS Loader Service Manual

REMOTE START SWITCH

A

Procedure The tool listed will be needed to do the following procedure: MEL1429 – Remote Start Switch

1 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.

P–10115

B

W–2017–0286

The Remote Start Switch (Item 1) [A] is required when the operator cab is in the raised position for service and the service technician needs to start the engine. The operator cab wire harness connectors must be separated from the engine wiring harness connector under the cab.

The remote start switch is required when the service technician is adjusting the steering linkage and checking the hydraulic/hydrostatic system.

1

Lift and block the loader. (See Page 1–4.)

P–10114

Raise the lift arms and install an approved lift arm support device. (See Page 1–7.)

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.

W–2059–0598 Raise the operator cab. (See Page 1–9.)

Connect the remote start switch to these connectors (Item 1) [B].

Revised Jan. 99

–1–37–

773 BICS Loader Service Manual

REMOTE START SWITCH (Cont’d)

A

773ServiceManual#6900092–PreventativeMaintenanceSectionPart2of2

Procedure (Cont’d)

1

Put the traction lock override switch (Item 1) [A] in the ON position so the traction function is locked. The wheels are not able to turn.

Turn the key to the right and start the engine.

P–04713

Move the traction lock override switch (Item 1) [B] to the OFF position so the traction function is unlocked. The wheels are now able to turn.

B 1

The auxiliary mode switch (Item 2) [B] is used to turn the front auxiliary quick couplers ON and OFF during relief pressure and flow tests.

2 P–04714

Added Jan. 99

–1–38–

773 BICS Loader Service Manual

HYDRAULIC SYSTEM Page Number BICS™ VALVE (S/N 509640660 & Above, S/N 509616542 & Above) BICS Valve Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23

HYDRAULIC SYSTEM

Check Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27 Lift Arm By–Pass Orifice Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–26 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–21 Lock Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–20 CONTROL INTERLOCK LINKAGE (Pedal or Mechanical Hand) Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–87 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–86 CONTROL PEDALS Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–85 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–85 CONTROL VALVE (S/N 509640659 & Below, S/N 509616541 & Below) Anti–Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification And Installation Of Spool Seal . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tilt Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–63 2–71 2–70 2–61 2–60 2–73 2–72 2–65 2–61 2–62 2–62 2–57 2–64 2–69

Continued On Next Page Revised Jan. 99

–2–5–

773 BICS Loader Service Manual

HYDRAULIC SYSTEM (Cont’d) Page Number CONTROL VALVE (S/N 509640660 & Above, S/N 509616542 & Above) Anti–Cavitation Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–52 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–35 Auxiliary Electric Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–45 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–43 Auxiliary Spool Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42 Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–44 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31 Lift Base End Restrictor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32 Lift Spool And Detent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–49 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–37 Load Check Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–54 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32 Main Relief Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–54 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–33 Port–Auxiliary Section Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–45 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–44 Port Relief Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–53 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–34 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–28 Rubber Boot Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–51 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–36 Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–56 Tilt Spool And Centering Spring Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–47 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–40 Continued On Next Page Revised May 98

–2–6–

773 BICS Loader Service Manual

HYDRAULIC SYSTEM (Cont’d)

Page Number HYDRAULIC CYLINDER IDENTIFICATION Lift Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10 Tilt Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 HYDRAULIC CYLINDERS Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 HYDRAULIC FILTER HOUSING Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–83 HYDRAULIC FLUID RESERVOIR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–84 HYDRAULIC PUMP Checking The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . .

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–78 2–80 2–82 2–82 2–76

HYDRAULIC SYSTEM INFORMATION Tightening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 LIFT CYLINDER(S) Checking The Lift Cylinder(s) For Internal Leakage . . . . . . . . . . . . . . . . 2–7 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 LIFT LOCK BY–PASS VALVE Disassembly And Assembly (S/N 509640660 & Above, S/N 509616542 & Above) . . . . . . . . . . . . .

Disassembly And Assembly (S/N 509640659 & Below, S/N 509616541 & Below) . . . . . . . . . . . . . .

Removal And Installation (S/N 509640660 & Above, S/N 509616542 & Above) . . . . . . . . . . . . .

Removal And Installation (S/N 509640659 & Below, S/N 509616541 & Below) . . . . . . . . . . . . . .

2–89 2–91 2–88 2–90

MAIN RELIEF VALVE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–75 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–74 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–75 TILT CYLINDER Checking The Tilt Cylinder For Internal Leakage . . . . . . . . . . . . . . . . . . 2–8 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 Rod End Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 TILT LOCK VALVE Disassembly And Assembly (S/N 509640659 & Below, S/N 509616541 & Below) . . . . . . . . . . . . . . 2–94 Removal And Installation (S/N 509640659 & Below, S/N 509616541 & Below) . . . . . . . . . . . . . . 2–92 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 9) UNLESS OTHERWISE SPECIFIED. Revised Jan. 99

–2–7–

773 BICS Loader Service Manual

HYDRAULIC SYSTEM INFORMATION

Revised June 01

773 BICS Loader Service Manual

HYDRAULIC SYSTEM INFORMATION (Cont’d)

Revised June 01

773 BICS Loader Service Manual

HYDRAULIC SYSTEM INFORMATION (Cont’d)

Revised June 01

773 BICS Loader Service Manual

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