DRIVE SYSTEM BGAKE er eee eee ae boon = 40-10-4 Disk Removal And Installation... peters eee 4010-3 Pedal Disassembly And Assembly .. ... Roonpna Gd Pedal Removal And Installation........... 40-10-1 Switch Operated Parking Brake. ce 4010-4 CHAINCASE.... bee eect eevee etna ee ess 40-804 Checking And Adding Oil... soG0 cs 40-8041 Center Cover Removal And Installation. .............. 40-30-8 Front Cover Removal And Installation ae 40-30-2 Rear Cover Removal And Installation ...... =. 40-30-46 Removing The Oi! . = 40-30-1 DRIVE COMPONENTS. . 40-20-41 ‘Axle Seal Removal And Installation. - 40-20-14 ‘Axle Sprocket And Bearings Removal And installation... 40-20-8 Chain Removal And Installation. ..... . - 40-20-8 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD. TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED. 4001 763 Bobcat Loader ‘Service Manual\ e- ® 763 Bobcat Loader 40-02 ‘Service ManualBRAKE Figure 40-10-2 Pedal Removal And Installation >, SIN 512257998 & Below a’ SIN 512450999 & Below Figure 1 Remove the fuse mount bracket (item 1)[Figure 40-10-2) from the front of the control panel Disconnect the electrical connector from the parking NRO brake pedal sensor. The connector is iocated behind the - control panel Raise the loader operator cab. (See Contents, Page 10- _Flemove the parking brake assembly from the loader. 01) Reverse the removal procedure to install the parking Remove the two mounting bolts (item 1) [Figure 1] from brake assembly in the loader. the brake pedal mounting bracket instalistion: Tighten the mounting bolts to 25-28 ft-1os. (84-38 Nem} torque. 763 Bobcat Loador 40-104 Sorvice ManualBRAKE (CONT'D) Pedal Disassembly And Assembly Figure 40-10-3, Loosen and remove the mounting bol (Item 1) and nut from the spring mounting bracket (Item 2} [Figure 40-10- 3} Remove the brake peda spring (tem 3) from the tension spring mounting bracket (Item 2) and from the brake peda! mounting brackat {ler 4) [Figure 40-10-3). Remove the two mounting bolts, washers and nuts (item 5) [Figure 40-10-3] from the brake pedal senscr. Remove the hamess mounting clamp (ttem 1) {Figure 40-10-4} trom the pedal mounting. bracket (tem 4) {Figure 40-10-5} Remove the sensor hamess from the pedal mounting bracket, Remove the pedal mounting bolt (item 6) [Figure 40-10- 3], plastic spacers and bushing nut trom the brake pedal Remove the pedal from the pedal mounting bracket. Photo [Figure 40-10-4] shows the parking brake disassembled to identiy the existing parts in the brake assembly. ‘763 Bobcat Loader ‘Service ManualBRAKE (CONTD) Disk Removal And installation A DANGER ‘AVOID DEATH + Discornectng rooney Hyer {ebetine, bane, ip, compan or a par fate can ea tsa fo op. + Ke outa ts ares won i arms re {aleed unless supported by 2 approved tm suppor pice damaged se Never work on a machine with the fift 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. 1-2059-0596, Raise the loader lft arms and install an approved litt arm support device. (See Contents Page 10-01.) Raise the loader operator cab. (See Contents Page 10: 01) Disconnect and remove the engine speed control, (See Contents Page 70-01.) Remove the contrat pane! from the loader, (See Contents Page 50-01.) Remove the canter chainease cover. (See Contents Page 40-01.) Remove the front chaincase cover. (See Contents Page 40-01.) Remove the traction loci assembly. (See Contents Page 60-01.) 40-10-3, Figure 40-10-5 ee ‘The parking brake discs (Item 1) [Figure 40-10-5] are Jocated beneath the center chainease cover. Figure 40-10-6 ae Inspect the traction tock guides (Item 1) [Figure 49-10-6} and the brake disc tor damage or wear and replace as. necessary. 763 Bobcat Loader Service ManualBRAKE (CONT'D) Disk Removal And Installation (Cont'd) Figure 40-107 ‘A snap ting pliers with 90° tips are necessary for remaving the parking brake disc. Remove the snap ring (Item 1) [Figure 40-10-7] from the end of the sprocket on the hydrostatic motor cartier Figure 40-10-86 Slide the disc (Item 2) [Figure 40-10-7] off the sprocket (iter 1) [Figure 40-10-8} and remove the disc through the front chaincase cover. Roverse the removal procedure {o instail the disc in the loader, See the traction lock inspection procedure, Contents Page 60-01 40-104 ‘Switch Operated Parking Brake SIN 512258000 & Above SIN 512451000 & Above Figure 40-10-9 Peasees ‘The parking brake switch in the front pane! (tem 1) [Figure 40-10-9} replaced the pedal parking brake. (See Contents, Page 60-01 Instrument Pane! For Front Accessory Panel Removal.) 763 Bobcat Loader Service Manuala DRIVE COMPONENTS ‘Axle Seal Removal And installation Figure 40-20-1 ‘The tools listed are needed for the following procedure: Axle Hub Puller Tool MEL1299 - Seal Driver Tool MEL1242 - Power Ram (may be used if desired) To loosen the axle hub mounting bok (Item 1) [Figure 40- 20-1], use the following procedure: Before fifting and blocking the loader, loosen the hub mounting bolt (Item 1) {Figure 40-20-1]. NOTE: If the axle and bearings are being replaced, also loosen the sprocket mounting bolt inside the chaincase before lifting and blocking the loader. See Axle Sprocket And Bearings Removal And Installation on page 40-20-3. Lift and biock the loader. (See Contents, Page 10-01.) Remove the front tre/wheol assembly. Installation: Tighten the whee! mounting nuts to 105-118 ft-lbs. (142-156 Nm) torque, Remove the hub mounting bolt (Item 1) [Figure 40-20-1] and washer from the axle, Installation: Tighten the hub mounting bolt te §75-625 ft-lbs. (780-848 Nm) torque, Remove two of the wheel mounting studs (tem 2) [Figure 40-20-1]. 40-2041 Use a wheel mounting nut on each stud and remove the two studs with a hammer, Installation: Support the flange of the axle hub and install the two studs with a hammer, A hydraulic press can also be used to instal the studs. Figure 40-20-2 Install the puiler toot (tem 1) [Figure 40-20-2] on the: axle hub. A driver too! (item 2) [Figure 40-20-2] can be used tor centering the threaded rod of the puller. A WARNING NEVER STAND IN-LINE OF THE HUB WHEN REMOVING A HUB FROM AN AXLE. The hub has a tapered fit on the axle ond and can come off the axle with great force and cause serious injury. werieecoas Use a wrench with the puller and remove the axle bub: from the axle tube. A spacer and a power ram can be used between the axle and the tool if available, instead of the wrench, threaded rod and driver tool 783 Bobcat Loader Service ManualDRIVE COMPONENTS (CONT'D) Axle Seal Removal And Installation (Cont'd) Figure 40-20-3 Remove the key (item 1) [Figure 40-20-3] from the axle. Figure 40-20-4 Dri a small hole in the axle seat. Install a slide hammer (Item 1) [Figure 40-20-4) with a screw tip end in the axie seal Remove the axle seal Figure 40-205, Installation: MEL1399 seal driver tool Is necessary lor the following procedure: Clean the seat arva and inspect the shatt tor wear. NOTE: If the shaft is damaged or worn, an axle repair sleeve kit is available from Melroe Parts Sales in Chicago. Place tho new axle seal over the axle and into the axie tube. Install MEL1999 seal driver too! over the axle and put against tne axle seal [Figure 40-20-5}. Hit the seal driver tool with @ hammer until the too! is flush with the edge of the axle tube [Figure 40-20-5] Reverse removal procedure to install the axle hub and wheel assembly. 763 Bobcat Loader Service ManualDRIVE COMPONENTS (CONT’D) Axle Sprocket And Bearings Removal And installation Figure 40-20-6 ‘The tools listed are needed for the following procedure: MEL1242 - Power Ram MEL12028 - Axle Bearing Service Set NOTE: The procedure shown is for removing the front axle, bearings and sprocket. This procedure can also be used for the rear axle, bearings and sprocket. (See Contents, Page 40-01 for rear chaincase cover removal.) WANTING) ‘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 58-05 Raise the lift arms and install an approved lift arm suppor’ device. (See Contents Page 10-01.) Lift and block the loader. (See Contents Page 10-01.) Raise the operator cab. (See Contents Page 10:01.) Remove the control panel. (See Contents Page 50-01), Remove the brake pedal (Item 1) [Figure 40-20-6}. (iso equipped.) Remove the eight front cover mounting bolts (Item 2} and the front cover (item 3) (Figure 40-20-6] from tho chaincase. Figure 40-20-7 Loosen the axie sprocket mounting bolt (item 1) (Figure 40-20-7], Remove the fluid from the chaincase. (See Contents, Page 40-01) Flomove the axle hub. (See Contents, Page 10-01.) Remove the sprocket mounting bolt (Item 1) [Figure 40- 20-7) Installation: Tighten the sprocket mounting bolt to 220- 245 ft-lbs. (298-332 Nm) torque. 763 Bobest Loader Service ManualDRIVE COMPONENTS (CONT'D) Axie Sprocket And Bearings Removal And Installation (Contd) Figure 40-208 Install the MEL1242 power ram (Item 1} [Figure 40-20-8) belwaen the two sprockets. Pula spacer between the power ram and axle, Push the le Gut to the end of the power ram stroke. Add anather spacer and push the axle again. Repeat this proceduce until the axle is free from the sprocket and inner bearing. Figure 40-209 Remove the drive chain from the spr et (item 1) [Figure 40-20-9] and remove the sprocket from the chaincase. Romove the inner bearing (Item 2) [Figure 40-20-9] and remove the axle Irom the axle tube. (See Contents Page 40-01 for outer bearing removal from the axle.) Installation: Pack both axle bearings with grease before installing them, 40-204 Figure 40-20-10 A bearing puller (Itern 1) (Figure 40-20-10] is needed for ‘the following procedure: Put the axie/outer bearing assembly in the bearing puller as shown and put in the hydraulic press[Figure 40-20- 10] Be sure the bearing puller makes good contact with the inner race of the bearing and press the bearing off the ‘mounting surface of the axte. Figure 40-20-11, Be sure to hold onto the axle during removal as it will slide freely along the axle shaft aftor cemoval from the bearing mounting surface and until the bearing contacts the spline on the shaft. Prass the splined end of the axle free from the bearing [Figure 40-20-11}. ‘763 Bobeat Loader Service ManualDRIVE COMPONENTS (CONT'D) Axle Sprocket And Bearings Removal And installation (Cont'd) Figure 40-20-12 Installation: A piece of round tubing (Item 1) [Figure 40- 20-12] is needed to install the bearing on the axle shaft. The tubing needs to measure approximately 0.500 inch (12,7 mm} to 1.0 inch (25.4 mm) in length. The inside diameter of the tubing should not be under 2.100 inches (63,3 mm) and the outside diameter should not be over 2.400 inches (60 mm), ‘A bearing puller (Item 2) [Figure 40-20-12] is also needed to install the bearing on the axle. Put the tubing {Item 1) on the bearing puller (item 2) [Figure 40-20-12} Putthe bearing (Item 3) [Figure 40-20-12] on the tube as shown. Put the spline end of the axle shaft (item 4) [Figure 40- 20-12] in the bearing and press the bearing onto the axle. Be sure fo hold onto the axle during installation, as it will slide freely along the axle shaft after the spiine end has passed through the bearing and until it reaches the bearing mounting surface on the axle. 40-20-5 When the bearing reaches the bearing mounting surface, cantinue the installation until the bearing is fully seated [Figure 40-20-13} Figure 40-20-14 Use the tools provided in the MEL1202B Axle Bearing Service Set for bearing cup removal and installation. A slide hammer is also necessary for this procedure. Use the long rod and bearing cup too! to remove the inner bearing cup [Figure 40-20-14]. Hit the tong rod with a hammer to remove the bearing cup from the axle tube [Figure 40-20-14}. 763 Bobcat Loader Service ManualDRIVE COMPONENTS (CONT'D) Axle Sprocket And Bearings Removal And Installation (Cont'd) Figure 40-20-15, To remove the outer bearing cup, place the bearing cup tool (tem 1} {Figure 40-20-15] on the slide hammer Leave the bearing cup too! loose until the tool is instalted inside the lube [Figure 40-20-18}. = ating cup tool is inside the axle tube, pull the tool against the bearing cup and tighten the nut (item 2) [Figure 40-20-15} on the tool. Figure 40-20-16 Use the slide hammer and remove the bearing cup from the axle tube [Figure 40-20-16) 40-206 Figure 40-20-17 Use the bearing cup installation tools (Hlere 1} [Figure 40- 20-17] and (Item 1) [Figure 40-20-18] and the long threaded rod (Item 2) [Figure 40-20-18] iror the service set to install the inner and outer bearing cups, Put the inner bearing cup in the axie tube (tom 2) {Figure 40-20-17] Put the instalation too! (Item 1) [Figure 40-20-17] in the axle tube. Install the long threaded rod (ltem 2) [Figure 40-20-18] into the axle tube and through the installation tool (Item 1) [Figure 40-20-17} ‘Secure the tool to the threaded rod with a nut (item 3) {Figure 40-20-17}. 763 Bobeat Loader Sorvice ManualDRIVE COMPONENTS (CONT'D) Axle Sprocket And Bearings Removal And Installation (Cont'd) Figure 40-20-18 Put the installation tool (item 4) [Figure 40-20-18] in the axle tube with the threaded rod through the hole in the tool ‘Secure the too! to the threaded rod with a nut [Figure 40- 20-18]. © tac ne insta nut (hem 9) (gure 40-20-17) with @ wren and tight the otade ut ae shown ho tPigue 0-208) Tighten the nut unti the bearing cup is seated. Figure 40-20-19 tall the cuter beating cup, use the short rod and the bearing cup tool used for removing the bearing cups Put the bearing cup tool on the short rod Put the bearing cup in the axle tube and put the tool into the tube over the bearing cup [Figure 40-20-19} Hit the short rod with a hammer until the bearing cup is sealed inside the axle tube. 783 Bobcat Loader Service ManualDRIVE COMPONENTS (CONT'D) Chain Removal And installation A WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. We 2089-0508 Raise the isader lit arms anc install an approved lift arm support device. (See Contents Page 10-01.) Lift and block the loader. (See Contents Page 10-01.) Raise the loader operator cab. (See Contents Page 10- ony Drain the fivid trom the chaincase. (See Contents Page 40-01} Remove the engine speed control. (See Contents Page 70-01) Remove the contol panel. (See Contents Page 60-01.) Remove the traction tock assembly, (See Contents Page 60-01.) Remove the center chaincase cover. (See Contents Page 40-01.) Remove the front Contents Page 40: (er rear) chaincase cover. (See Remove the front (or rear) axle and sprocket, (See Contents Page 40-01.) 40-20-68 Figure 40-20-20 Remove the parking brake disc (item 1) [Figure 40-20- 20]. (See Contents Page 40-01.) Remove the six carrier mounting bolts (ltem 2) [Figure 40-20-20] from inside the chaincase. Installation: Tighten the motor cartier mounting bolts to 125-140 H-lbs. (170-190 Nin) torque. Figure 40-20-21 Tip the end of the sprocket on the motor carrier toward the rear of the loader and remove the rear from the sprocket NOTE: It may be necessary to tie the front drive chain up as shown in photo [Figure 40-20-21], so the carrier/motor assembly can be moved enough to free the rear drive chain (Item 1) [Figure 40- 20-21] from the sprocket. Remove the front drive chain from the chainease. 763 Bobeat Londer Service ManualDRIVE COMPONENTS (CONT'D) ‘Chain Removal And Installation (Cont'd) FFL cl = The too! listed is eeded for the following procedure: MEL1037 - Chain Link Too! Installation: if a new chain is installed, a connector tink must be used to connect the chain together. Use MEL1037 Chain Link Too! and #80 chain adapter. ‘Secure the tool and place the connector link in the too! as shown [Figure 40-20-22}, ‘Turn the threaded rod of the too! and press the connector link together on the chain (Figure 40-20-22). Tighton the threaded rad of the chain link too! to 130 ft.bs, (176 Nm) torque. 7 Na NINE} DO NOT exceed the recommended torque of 130 ft.- Ibs. (176 Nm). The too! may fail under too much torque. Put cloth around the tool to protect yourself from flying debris. we2299-0096 763 Bobcat Loader ‘Service Manual= Bolicat. - os ® 763 Bobcat Loader 40-20-10 Service ManualCHAINCASE ‘Checking And Adding Oil Figure 40-30-1 ‘The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic’ hydrostatic system. (See Contents Page SPEC-01,) To check the chaincase oil evel, use the following procedure’ Drive the loader on a level surlace. Stop the engine. Remove the plug (Item 1) [Figure 40-30-1] from the front of the chaincase housing, {foil can be reached with the tip of the your finger through the hole the oil level is correct. If the level is low, add oif through the check plug hole until the oll flows from the hole, Install and tighten the plug. 40-30-1 Flemoving The Oil Figure 40-30-2 Jo drain the olf from the chainease, remove the cover (item 1) [Figure 40-20-2) which is installed over the drain plug at the rear of the chaincase. Installation: Tighten the cover bolts to 10-20 ft-bs, (24- 27 Nin) torque. igure 40-30-3 Remove the drain plug (item 1) {Figure 40-30-3} and Grain the oil into a container. NOTE: When installing the drain plug into the chaincase, always use a NEW drain plug gasket. 763 Bobcat Loader Service ManualCHAINCASE (CONT'D) Front Cover Removal And installation ‘AVOID DEATH + Disconnctig or laesning ay bya label, bos, ting, component or apart falar can cause cms to dep. Keep ot af hie area when a ae ‘aisod unless seppovted by an aperoted tam suppor Replace damaged sx 02 A WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the jift arms or attachment to fall and cause injury or death. 2059-0500 Raise the loader lt arms and install an approved lit arr support device. (See Contents Page 10-01.) Raise the loader operator cab. (See Contonts Page 10: Figure 40-30-4 Remove the mounting bolts {Item 1) [Figure 40-30-4] from the parking brake. 40-20-2 Figure 40-30-5, Remove the eight front chaincase cover mounting bolts (item 1) [Figure 40-30-5] & [Figure 40-30-6). Installation: Tighten the mounting bolts to 25:28 ft-lbs. (34-38 Nm) torque. Remove the front chaincase cover (tem 2) (Figure 40- 80-6] from the loader. Installation: The tront chaincase cover (item 2) [Figure 40-30-6] has a gasket installed between the cover and the chaincase as shown in photo [Figure 40-30-6). install new gasket if necessary 763 Bobcat Loader Service ManualCHAINCASE (CONT) Center Cover Removal And Installation ‘AVOID DEATH + isconnocing a foooning any hts ‘ben, hose ting, cmpona o apart fale can cause ams lo op. + Keep out of hs area when tit arms are ‘asad utes suppared by an approves am support Replace damaged gx WAT NGI ct 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. we2056- 98 Raise the loader lit arms and install an approved lit arm suppor davice, (See Contents Page 10-01.) Rai 01.) the loader operator cab. (See Contents Page 10- Disconnect and remove the engine speed control from the control panel. (See Contents Page 70-01.) Remove the contro! the loader (See Contents, Page 50-01.) panel from Figure 40-30-7 Disconnect the iift control cross bar (Item 1) [Figure 40- 30-7} from the lit pedal linkage. Disconnect the tilt control cross bar (them 2) [Figure 40 30-7] from the lift sp00! on the main controt vaive. Figure 40-30-8 EARLIER Disconnect the electrical connector (Item 3) [Figure 40- 30-7} & [Figure 40-30-8) from the parking brake pedal sense. Remove the center chaincase cover mounting bolts (item 4) [Figure 40-30-8), Installation: Tighten the mounting bolts to 25-28 ft-lbs. (84-38 Nm) torque. Remove the center chaincase cover and gasket. Installation: Repiace gasket hofore installation. 783 Bobcat Loader Service ManualCHAINCASE (CONT'D) Rear Cover Removal And installation A DANGER ‘AVOIO DEATH + Disconnetng ar oosering ary iyrc Inbal, hos, iting, camponcnt ora part fate can caus if aes to cop. + Kesp ct of his anaheim ‘aisod unless suppated by an approved ian suppat, Replace danaged get 7 AEGAN) Never work on a machine with the lift arms up untess the lift arms are secured by an approved lift arm ‘support device. Fallure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. 2080-0508 Rise the loader lit arms and install an approved fift arm support device. (See Contents Page 10-01.) Rise tho foader operator cab. (See Contents Page 10- ot) Mack and disconnect the front steering linkage bars from the rear linkage bars. (See the CONTROL PANEL, Contents Page 80-01 for correct procedure.) Move the linkage bars to allow adequate space to remove the rear chaincase cover. Remove the front auxiliary bleed block. (If so equipped.) {See Contents Page 20-01.) Remove the rear auxiliary diverter block. (i so equipped.) (See Contents Page 20:01.) 40-308 Figure 40-30-9 Ie 3 Remove the eight rear chaincase cover mounting bolts {ter 1) [Figure 40-20-9}, 25-28 ft-lbs. Installation: Tighten the mounting bolts, (84-38 Nm) torque. Remove the rear chaincase cover (item 2) [Figure 40- 30-9] from the loader, Figure 40-30-10 i Installation: The tear chaincase cover (Item 2) [Figure 40-30-9] has a gasket (item 1) [Figure 40-30-10) installed between the cover and the chainoase. instalt a new gasket, 1783 Bobcat Loader Service Manual