PDF Service Manual Bobcat 773 Loader - 4 MB

Keep your Bobcat 773 loader running at its best with this complete factory service manual.
This guide provides detailed, step-by-step instructions for all repair and maintenance tasks.
It covers the engine, hydraulic system, hydrostatic drive, and more, offering the specifications and troubleshooting information needed for accurate and efficient service.
This is the same manual used by dealership technicians, making it an indispensable resource for any owner or mechanic.
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--- Page 1 ---
Service
                                                                               Manual


                                                                                                                            Dealer Copy -- Not for Resale
                                                                            (773฀S/N฀509635001฀&฀Above)
                                                                         (773฀Europe฀Only฀S/N฀509616001–509634999)


Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Bobcat Company or the products of
either.

    EQUIPPED฀WITH
  BOBCAT฀INTERLOCK
CONTROL฀SYSTEM฀(BICS TM)
6900092฀฀(6–12)                                                                 Printed฀in฀U.S.A.          Bobcat฀Company฀1997
   1 of 556

--- Page 3 ---
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฀Bobca
  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                  This฀ notice฀identifies฀procedures
          manuals฀are฀for฀your฀safety.฀Failure฀to               which฀ must฀be฀followed฀to฀avoid
          obey฀ warnings฀can฀cause฀injury฀or                    damage฀to฀the฀machine.
          death.                                                                             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

                                                                                                           773฀BICS฀Loader
Revised฀June฀01                                             v                                               Service฀Manual

--- Page 4 ---
LIFT฀ARM฀SUPPORT฀DEVICE
1.                                                                   A


                                                                                                   1


                                                                                                                 P–10589


   Never฀work฀on฀a฀machine฀with฀the฀lift฀arms฀up
   unless฀the฀lift฀arms฀are฀secured฀by฀an฀approved
                                                                     B
   lift฀ arm฀ support฀ device.฀Failure฀to฀use฀an
   approved฀lift฀arm฀support฀device฀can฀allow฀the                                            1
   lift฀arms฀or฀attachment฀to฀fall฀and฀cause฀injury
   or฀death.                              W–2059–0598
                                                                                                       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
Return฀the฀lift฀arm฀support฀device฀to฀storage฀position฀and           parts฀ are฀missing.฀Using฀a฀damaged฀lift฀arm
secure฀with฀clamping฀knobs.                                          support฀ or฀with฀missing฀parts฀can฀cause฀lift
                                                                     arms฀to฀drop฀causing฀injury฀or฀death.
Remove฀the฀jackstands.                                                                                     W–2271–1197


                                                                                                       773฀BICS฀Loader
Revised฀Jan.฀99                                              –1–7–                                      Service฀Manual

--- Page 5 ---
FUEL฀SYSTEM฀(Cont’d)
Removing฀Air฀From฀The฀Fuel฀System
                                                                      A
5.
After฀replacing฀the฀fuel฀filter฀element฀or฀when฀the฀fuel฀
                                                      tank                    3
has฀run฀out฀of฀fuel,฀the฀air฀must฀be฀removed฀from฀the฀fuel
system฀before฀starting฀the฀engine.


                                                                          2          1


  Diesel฀ fuel฀or฀hydraulic฀fluid฀under฀pressure
  can฀ penetrate฀skin฀or฀eyes,฀causing฀serious                                            P–10571
  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.
                                           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.


                                                                                  773฀BICS฀Loader
Revised฀Jan.฀99                                              –1–17–                Service฀Manual

--- Page 6 ---
TIRE฀MAINTENANCE
Wheel฀Nuts
                                                                         A
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.฀T
                                                 o฀keep฀tire
wear฀even,฀move฀the฀front฀tires฀to฀the฀rear฀and฀rear฀tires                           P–10628
to฀the฀front฀[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
                                                                         B
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                              B–09976
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฀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


                                                                             773฀BICS฀Loader
Revised฀Jan.฀99                                                 –1–27–        Service฀Manual

--- Page 7 ---
REMOTE฀START฀SWITCH
Procedure
                                                                       A
The฀ tool฀listed฀will฀be฀needed฀to฀do฀the฀        following
procedure:
MEL1429฀–฀Remote฀Start฀Switch


                                                                           1


  Put฀jackstands฀under฀the฀front฀axles฀and฀rear                                        P–10115
  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

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                        1
technician฀is฀adjusting฀the฀steering฀linkage฀and฀checking
the฀hydraulic/hydrostatic฀system.
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].


                                                                               773฀BICS฀Loader
Revised฀Jan.฀99                                               –1–37–            Service฀Manual

--- Page 11 ---
BICS฀ VALVE฀ (S/N฀509640660฀&฀Above,฀S/N
509616542฀&฀Above)฀(Cont’d)                                           A           2
Installation
Install฀the฀four฀large฀O–rings฀(Item฀1)฀ [A]฀and฀the฀small
O–ring฀(Item฀2)฀[A]฀on฀the฀top฀of฀the฀control฀valve.
                                                                              1       1


                                                                                              P–08950


Install฀the฀BICS฀valve฀on฀the฀control฀valve฀[B].                     B


                                                                                              P–08949


Install฀the฀six฀mounting฀bolts฀[C].                                   C   4           5
The฀chart฀below฀lists฀the฀correct฀torque฀specifications฀and
tightening฀sequence฀when฀reinstalling฀the฀BICS ฀valve                    2
assembly฀to฀the฀control฀valve.฀Thoroughly฀clean฀and฀dry                                   1
bolts฀and฀threads฀in฀valve.฀Use฀liquid฀adhesive฀LOCTITE
#242฀or฀equivalent.                                                       6               3

    Step               Torque              Sequence
      1           110–130฀in.–lbs.
                  (12,4–14,7฀Nm)
      2           190–210฀in.–lbs.
                  (21,5–23,7฀Nm)         1,฀2,฀3,฀4,฀5฀&฀6                                    P–08948

     3*           190–210฀in.–lbs.
                  (21,5–23,7฀Nm)

*Torque฀ must฀be฀190–210฀in.–lbs.฀(21,5–23,7฀Nm)฀for
every฀bolt฀or฀repeat฀step฀3.


                                                                                  773฀BICS฀Loader
                                                             –2–27–                Service฀Manual

--- Page 12 ---
CONTROL฀ VALVE฀ (S/N฀509640660฀&฀Above,฀            S/N
509616542฀&฀Above)฀(Cont’d)                                          A
Lift฀Spool฀And฀Detent
Disassembly
Remove฀the฀snap฀ring฀(Item฀1)฀ [A]฀and฀washer฀(Item฀2)
[A].


                                                                                         2

                                                                                         1
                                                                                                     P–08982

Remove฀the฀two฀bolts฀(Item฀1)฀[B]฀from฀the฀detent฀bonnet.
Remove฀the฀bonnet.
                                                                     B


                                                                             1
   The฀ detent฀assembly฀has฀small฀springs฀and
   balls.฀ Do฀not฀lose฀these฀parts฀during
   disassembly฀and฀assembly.                                                             1
                                           I–2012–0284
                                                                                                     P–08983


Wrap฀a฀shop฀towel฀around฀the฀detent฀assembly.฀This฀will
prevent฀the฀detent฀balls฀and฀spring฀from฀being฀lost฀when
                                                                     C
the฀detent฀sleeve฀is฀removed฀[C].


                                                                                                     P–08984

Remove฀the฀detent฀sleeve฀(Item฀1)฀[D],฀detent฀balls฀(Item
2)฀[D]฀and฀spring฀(Item฀3)฀[D].                                      D


                                                                                 2
                                                                         1


                                                                                     3   2
                                                                                                     P–08985

                                                                                             773฀BICS฀Loader
                                                            –2–37–                            Service฀Manual

--- Page 13 ---
CONTROL฀ VALVE฀ (S/N฀509640660฀&฀Above,฀                 S/N
509616542฀&฀Above)฀(Cont’d)                                             A
Auxiliary฀Spool฀(Cont’d)
Assembly฀(Cont’d)
Install฀the฀auxiliary฀spool฀covers฀(Item฀1)฀[A]฀&฀[B].
Install฀the฀two฀bolts฀(Item฀2)฀[A]฀&฀[B].
Tighten฀ the฀ bolts฀ to฀90–100฀in.–lbs.฀(10,2–1 1,3฀ Nm)                        2
torque.
                                                                                    1
                                                                                            2
                                                                                                                P–11000


                                                                        B


                                                                                2

                                                                                    1
                                                                                            2
                                                                                                                P–11001

Tilt฀Spool฀And฀Centering฀Spring
Assembly
                                                                        C                       5
                                                                                        6           4          3
Slide฀a฀new฀spool฀seal฀(Item฀1)฀[C]฀on฀the฀spool.

NOTE: The฀spool฀seal฀must฀be฀installed฀with฀the฀lip
      face฀toward฀the฀valve฀body.฀The฀lip฀face฀has
      the฀largest฀outside฀diameter.                                         1
                                                                        2
Install฀ the฀bushing฀(Item฀2)฀ [C],฀ washer฀(Item฀3)฀ [C],
spring฀(Item฀4)฀[C],฀collar฀(Item฀5)฀[C],฀and฀adapter฀(Item
6)฀[C].


                                                                                                                P–08999


Clamp฀the฀activating฀end฀of฀the฀tilt฀spool฀in฀a฀vise.                   D
                                                                                                1
Install฀the฀centering฀spring฀bolt฀(Item฀1)฀[D].
Tighten฀the฀bolt฀to฀90–100฀in.–lbs.฀(10,2–1
                                          1,3฀Nm)฀torque.


                                                                                                                P–08998

                                                                                                        773฀BICS฀Loader
                                                               –2–47–                                    Service฀Manual

--- Page 14 ---
CONTROL฀ VALVE฀ (S/N฀509640659฀&฀Below              ,฀ S/N
509616541฀&฀Below)                                                    A
Removal฀And฀Installation


                                                                                             1


Raise฀the฀lift฀arms฀and฀install฀an฀approved฀lift฀arm฀support
device.฀(See฀Page฀1–1.)                                                                            P–04105


                                                                      B       2


   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
                                                                          1
Stop฀the฀engine.฀Move฀the฀hydraulic฀controls฀to฀release
the฀hydraulic฀pressure.฀Raise฀the฀seat฀bar.
                                                                                                   P–04099
Raise฀the฀operator฀cab.฀(See฀Page฀1–1.)
Control฀panel฀removal฀is฀optional.฀(See฀Page฀3–1.)                    C               1


  When฀ repairing฀hydrostatic฀and฀hydraulic
  systems,฀ clean฀the฀work฀area฀before
  disassembly฀ and฀keep฀all฀parts฀clean.฀Always
  use฀ caps฀and฀plugs฀on฀hoses,฀tubelines฀and
  ports฀to฀keep฀dirt฀out.฀Dirt฀can฀quickly฀damage
  the฀system.
                                            I–2003–0888                                            P–04104

Thoroughly฀clean฀the฀control฀valve฀area.
Loosen฀or฀remove฀the฀tubeline฀clamp฀(Item฀1)฀[A].
                                                                      D
                                                                                  1
Disconnect฀the฀drain฀hoses฀(Item฀1)฀ [B]฀from฀the฀main
control฀valve.
Disconnect฀the฀electric฀solenoid฀connectors฀(Item฀2)฀[B].

Disconnect฀ the฀outlet฀tubeline฀(Item฀1)฀   [C]฀ from฀the
control฀valve.

Disconnect฀both฀tubelines฀(Item฀1)฀[D]฀from฀the฀auxiliary
section฀of฀the฀control฀valve.                                                                      P–04100

                                                                                          773฀BICS฀Loader
Revised฀Jan.฀99                                              –2–57–                        Service฀Manual

--- Page 15 ---
CONTROL฀ VALVE฀ (S/N฀509640659฀&฀Below          ,฀ S/N
509616541฀&฀Below)฀(Cont’d)                                       A
Lift฀Spool฀Detent฀(Cont’d)
Remove฀the฀spool,฀centering฀spring,฀back–up฀washer฀
                                                 and
spool฀seal฀assembly฀from฀the฀control฀valve฀[A].


                                                                            CD–10816

Put฀the฀linkage฀end฀of฀the฀spool฀in฀a฀vise.

NOTE: BE฀ CAREFUL฀when฀removing฀the฀detent
                                                                  B
      adapter,฀because฀there฀is฀spring฀pressure.
Loosen฀the฀detent฀adapter฀[B].


                                                                            CD–10817

Remove฀the฀detent฀adapter,฀end฀cap฀and฀centering฀spring
[C].
                                                                  C


                                                                            CD–10818


Remove฀the฀back–up฀washer฀and฀spool฀seal฀[D].
                                                                  D


                                                                            CD–10819

                                                                      773฀BICS฀Loader
Revised฀Jan.฀99                                          –2–67–        Service฀Manual

--- Page 16 ---
HYDRAULIC฀PUMP฀(Cont’d)
                                                                      A
Removal฀And฀Installation฀(Cont’d)
Remove฀ the฀ two฀ mounting฀bolts฀(Item฀1)฀ [A]฀ from฀the
hydraulic฀pump฀with฀a฀5/16฀inch฀allen฀wrench.

NOTE: The฀allen฀wrench฀will฀need฀to฀be฀modified฀for
      the฀procedure.                                                          1
Installation: Tighten฀the฀mounting฀bolts฀to฀27–37฀in.–lbs.
(37–50฀Nm)฀torque.
Remove฀the฀hydraulic฀pump฀from฀the฀hydrostatic฀pump.

                                                                                          P–04133


Remove฀the฀coupler฀(Item฀1)฀[B]฀from฀the฀hydraulic฀pump
shaft.
                                                                      B
Remove฀the฀large฀O–ring฀(Item฀2)฀[B].
                                                                          1
Installation: Use฀ a฀new฀O–ring฀when฀installing฀the
hydraulic฀pump.


   Always฀clean฀up฀spilled฀fuel฀or฀oil.฀Keep฀heat,                    2
                                                                                          P–04283
   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


See฀ Page฀2–80฀for฀the฀proper฀        Disassembly and
Assembly฀procedures.


                                                                                  773฀BICS฀Loader
Revised฀Jan฀99                                               –2–77–                Service฀Manual

--- Page 17 ---
CONTROL฀ INTERLOCK฀ LINKAGE฀(Pedal฀or
Mechanical฀Hand)฀(Cont’d)                                              A
Adjustment


                                                                               3


           AVOID฀INJURY฀OR฀DEATH                                       2
  Adjust฀locking฀tabs฀on฀control฀linkage฀so฀that
  lift฀and฀tilt฀control฀pedals฀or฀(Mechanical฀Hand                         1
  controls)฀are฀locked฀in฀neutral฀when฀the฀seat
  bar฀is฀up.                                                                               P–04052
                                            W–2104–0199


Check฀the฀interlock฀linkages฀(Item฀1)฀[A]฀so฀they฀are฀free
                                                                       B
and฀lock฀both฀controls฀(pedal฀or฀mechanical฀hand)฀when
in฀neutral,฀(shown฀with฀interlock฀shield฀removed).
Check฀to฀ensure฀the฀locking฀tab฀(Item฀2)฀[A]฀is฀centered
in฀the฀slot฀(Item฀1)฀[A].
                                            [A]฀and฀bolts.
If฀not,฀loosen฀the฀tab฀mounting฀nuts฀(Item฀3)฀
Center฀the฀tab฀in฀the฀slot.
Installation: Tighten฀the฀mounting฀nuts฀and฀bolts฀to฀25
ft.–lbs.฀(34฀Nm)฀torque.
With฀the฀controls฀in฀neutral฀the฀locking฀tabs฀must฀fit฀into
the฀ slot฀of฀the฀interlocks฀as฀shown฀ [B],฀ when฀adjusted                                  P–04051
properly.


                                                                                   773฀BICS฀Loader
Revised฀Jan.฀99                                               –2–87–                Service฀Manual

--- Page 18 ---
TROUBLESHOOTING
Chart
The฀ following฀troubleshooting฀chart฀is฀provided฀for
assistance฀in฀locating฀and฀correcting฀problems฀which฀are
most฀ common.฀Many฀of฀the฀recommended฀procedures
must฀be฀done฀by฀authorized฀Bobcat฀Service฀Personnel            Check฀ for฀correct฀function฀ after฀ adjustments,
only.                                                          repairs฀ or฀service.฀Failure฀to฀make฀correct
                                                               repairs฀ or฀adjustments฀can฀cause฀injury฀or
                                                               death.
                                                                                                    W–2004–1285


                                        PROBLEM                                               CAUSE

 No฀drive฀on฀one฀side,฀in฀one฀direction.                                               1,฀2
 No฀drive฀on฀one฀side฀in฀both฀directions.                                              2,฀3,฀4,฀5

 The฀loader฀does฀not฀move฀in฀a฀straight฀line.                                          2,฀3,฀5,฀6,฀7

 The฀hydrostatic฀system฀is฀overheating.                                                8,฀9,฀10,฀11
 Service฀code฀HP฀2฀appears.฀(Warnings,฀low฀charge฀pressure.)                           8,฀11,฀12,฀13


                                       KEY฀TO฀CORRECT฀THE฀CAUSE

                ฀฀1.    The฀hydrostatic฀pump฀replenishing฀valves฀not฀seating.
                ฀฀2.    The฀steering฀linkage฀needs฀adjustment.

                ฀฀3.    The฀hydrostatic฀pump฀has฀damage.

                ฀฀4.    The฀final฀drive฀chains฀are฀broken.
                ฀฀5.    The฀hydrostatic฀motor฀has฀damage.

                ฀฀6.    The฀tires฀do฀not฀have฀the฀correct฀tire฀pressure.

                ฀฀7.    The฀tires฀are฀not฀the฀same฀size.
                ฀฀8.    The฀hydrostatic฀fluid฀is฀not฀at฀the฀correct฀level.

                ฀฀9.    The฀oil฀cooler฀has฀a฀restriction.
                10.     The฀temperature฀sending฀switch฀is฀not฀operating฀correctly.

                11.     The฀loader฀is฀not฀being฀operated฀at฀the฀correct฀RPM.

                12.     The฀hydraulic฀charge฀pressure฀sender฀is฀defective.
                13.     Pump฀is฀defective฀or฀worn฀hydrostatics.


                                                                                                773฀BICS฀Loader
                                                       –3–3–                                     Service฀Manual

--- Page 19 ---
STEERING฀LINKAGE฀(Cont’d)
Steering฀Neutral฀Adjustment฀(Cont’d)
                                                                        A
Adjust฀the฀right฀hand฀centering฀block฀[A].
Move฀the฀right฀hand฀steering฀lever฀until฀the฀tires฀do฀not
turn฀(neutral฀position).
Move฀ the฀right฀hand฀centering฀block฀to฀the฀left฀until฀it
contacts฀both฀pintle฀cams฀and฀the฀steering฀lever฀is฀still฀in
the฀neutral฀position฀[A].
Tighten฀the฀bolts฀to฀25–28฀ft.–lbs.฀(34–38฀Nm)฀torque.
Test฀both฀levers฀by฀moving฀them฀backward฀and฀forward
and฀ letting฀them฀return฀to฀neutral฀by฀ the฀ return฀ spring                                     P–03732
force.
If฀the฀levers฀do฀not฀return฀to฀neutral฀and฀the฀tires฀do฀not
come฀ to฀ a฀ complete฀stop,฀repeat฀the฀adjustment
                                                                        B
procedure฀again.                                                                    1
Stop฀the฀engine.


Tighten฀the฀two฀bolts฀(Item฀1)฀[B]฀to฀11–13฀ft.–lbs.฀(15–17
Nm)฀ torque,฀ then฀tighten฀the฀two฀nuts฀(Item฀2)฀ [B]฀ to
21–25฀ft.–lbs.฀(28–33฀Nm)฀torque.

                                                                                2
                                                                                4       3

                                                                                                P–03726


Tighten฀the฀two฀bolts฀to฀11–13฀ft.–lbs.฀(15–17฀Nm)฀torque,
then฀tighten฀the฀two฀nuts฀to฀21–25฀ft.–lbs.฀(28–33฀Nm)                  C
torque฀at฀the฀steering฀cross฀shaft฀(Items฀1฀&฀2)฀ [C].
Remove฀the฀service฀shield.฀Install฀the฀fan฀drive฀belt.
Install฀both฀access฀covers.

                                                                            1

                                                                        2


                                                                                                P–04069


                                                                                        773฀BICS฀Loader
Revised฀May฀98                                                 –3–13–                    Service฀Manual

--- Page 20 ---
HYDROSTATIC฀MOTOR฀30฀SERIES
Parts฀Identification฀–฀(S/N฀509639899฀&฀Above฀&฀S/N฀509616505฀&฀Above)


                                  3

                                        10
                                                 11
                                                           9
                                                                   8
                                                                               13


                              4

                                            3                                                     16

                                                       5

                                                                                         14

                                                                                     6
                                                                        15
                                                                                     3
                                                                                                       7
                        21
                             22                                   6
                                  20
                                       17
                                            19                                                     43
                                                  18
                                                       19
                                                               17 20
                                                                         1


                                                                                              3


                                                             2524 26
                                                      12                             2
                                                           23
                                                                                                                   D–03431

              Ref.   Description                                        Ref.        Description
              ฀฀1.   HOUSING                                            15.         SHAFT,฀drive
              ฀฀2.   O–RING                                             16.         BOLT
              ฀฀3    SEAL,฀square                                       17.         SPRING
              ฀฀4.   VALVE,฀plate                                       18.         PISTON
              ฀฀5.   GEROLER                                            19.         POPPET
              ฀฀6.   BALL                                               20.         SLEEVE
              ฀฀7.   PLATE,฀balance                                     21.         PLUG
              ฀฀8.   RING,฀back–up                                      22.         O–RING
              ฀฀9.   SEAL                                               23.         O–RING
              10.    RING,฀back–up                                      24.         SPRING
              11.    O–RING                                             25.         SHIM
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