773 6900092 SM 6-97

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
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING 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-2003-0903
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 Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
B-13574 B-15232 B-15281

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-13576 B-13577 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
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 IDLER GEAR AND CAMSHAFT . . . . . . . . . . . . . . . . . . 7–1
AHC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
AHC/PWM CONTROLLER . . . . . . . . . . . . . . . . . . . . 10–1 LIFT ARM LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . 1–1 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . 1–1
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 LIFT CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 LIFT LOCK BY–PASS VALVE . . . . . . . . . . . . . . . . . . . . 2–1
AXLE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 LIFTING AND BLOCKING THE LOADER . . . . . . . . . 1–1
AXLE, SPROCKET AND BEARINGS . . . . . . . . . . . . 4–1 LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 9–1
BICS™ SYSTEM CONTROLLER . . . . . . . . . . . . . . . . 8–1 LUBRICATION OF THE BOBCAT LOADER . . . . . . . 1–1
BICS™ VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1, 10–1
BLOWER HOUSING/FAN GEARBOX . . . . . . . . . . . 7–1 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
BOBCAT INTERLOCK MONITOR SERVICE CODES . . . . . . . . . . . . . . . . . . . . 8–1
CONTROL SYSTEM (BICS™) . . . . . . . . . . . . 8–1, 10–1 MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1
BOSS® DIAGNOSTIC TOOL . . . . . . . . . . . . . . . . . . . 8–1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
BOSS® INSTRUMENT PANEL . . . . . . . . . . . . . . . . . 8–1 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1
CHAINCASE COVERS . . . . . . . . . . . . . . . . . . . . . . . . 4–1 OPERATOR CAB GAS CYLINDER . . . . . . . . . . . . . . . 5–1
CHAINCASE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
CONTROL HANDLE (ADVANCED HAND OPERATION SENSING SYSTEM UNIT . . . . . . . . . . . 8–1
CONTROL) (AHC) . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
CONTROL HANDLE (ADVANCED HAND PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
CONTROL) (AHC) (W/PUSH BUTTON FLOAT) . 10–1 PARKING BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . 4–1
CONTROL INTERLOCK LINKAGE . . . . . . . . . . . . . . 2–1 PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . 7–1
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
CRANKSHAFT AND BEARINGS . . . . . . . . . . . . . . . . 7–1 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
CRANKSHAFT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
CYLINDER BORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 REAR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
RELAY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
DECIMAL & MILLIMETER EQUIVALENTS . . . . . . . 9–1 REMOTE START SWITCH . . . . . . . . . . . . . . . . . . . . . . 1–1
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 ROCKER ARM AND SHAFT . . . . . . . . . . . . . . . . . . . . . 7–1
DRIVE BELT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . 3–1 RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
SEAT BAR (W/COMPRESSION SPRINGS) . . . . . . . 5–1
ELECTRICAL/HYDRAULIC SEAT BAR (W/GAS CYLINDER) . . . . . . . . . . . . . . . . . 5–1
CONTROLS REFERENCE . . . . . . . . . . . . . . . . . . . . 8–1 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . 1–1
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . 6–1 SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SEAT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
ENGINE COMPRESSION . . . . . . . . . . . . . . . . . . . . . . 7–1 SENDER AND SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 8–1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . 1–1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . 1–1 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
ENGINE MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . 1–1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 9–1 SPRING LOADED DRIVE BELT
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . 7–1 TENSIONER PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
STANDARD INSTRUMENT PANEL . . . . . . . . . . . . . . . 6–1
FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 7–1 STANDARD TORQUE SPECIFICATIONS
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . 1–1 FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
FIXED DRIVE BELT TENSIONER PULLEY . . . . . . . 3–1 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . 1–1
FRONT LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
FUEL CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SWITCH HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1
FUEL INJECTION NOZZLES . . . . . . . . . . . . . . . . . . . 7–1
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . 7–1 TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TILT LOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
TIMING GEARCASE COVER . . . . . . . . . . . . . . . . . . . . 7–1
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
HANDLE CONTROL UNIT TEST . . . . . . . . . . . . . . . 10–1 TORQUE SPECIFICATIONS FOR LOADER . . . . . . . 9–1
HYDRAULIC CONNECTION SPECIFICATIONS . . 9–1 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . 1–1
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . 10–1 TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
HYDRAULIC CYLINDER IDENTIFICATION . . . . . . . 2–1 TRACTION LOCK GUIDES . . . . . . . . . . . . . . . . . . . . . . 4–1
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . 2–1 TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . . 1–1
HYDRAULIC FILTER HOUSING . . . . . . . . . . . . . . . . 2–1 TROUBLESHOOTING . . . . . . . 2–1, 3–1, 6–1, 7–1, 10–1
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . 2–1 TROUBLESHOOTING
HYDRAULIC/HYDROSTATIC THE BOSS® & L.C.D. DISPLAY . . . . . . . . . . . . . . . . 8–1
FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 9–1
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . 1–1 U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . . 9–1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . 2–1 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . 3–1 VALVE, VALVE SEAT AND GUIDE . . . . . . . . . . . . . . . 7–1
HYDROSTATIC MOTOR 30 SERIES . . . . . . . . . . . . 3–1
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . 3–1
Revised June 01
CONTENTS
PREVENTIVE
MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii HYDRAULIC
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 HYDROSTATIC
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 SYSTEM
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
SYSTEMS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
ADVANCED HAND CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 DRIVE
SYSTEM
CALIFORNIA
PROPOSITION 65 WARNING MAIN
Diesel engine exhaust and some of its FRAME
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.
ELECTRICAL
SYSTEM
ENGINE
SERVICE
SYSTEMS
ANALYSIS
SPECIFICATIONS
ADVANCED
HAND CONTROL
SYSTEM
Revised Jan. 99 773 BICS Loader

i 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:
1. Check that the ROPS/FOPS 9. The parking brake must

(Including sidescreens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Melroe approved.
3. The seat belt must be correctly 11. Bob–Tach wedges and

installed, functional and in linkages must function
good condition. correctly and be in good
condition.
4. The seat bar and pedal 12. Safety treads must in good
interlocks must be correctly condition.
adjusted, clean and lubricated.
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).
6. Machine signs must be legible WARNING 14. Check hydraulic fluid level,
and in the correct location. engine oil level and fuel supply.
7. Steering levers and foot pedals 15. Inspect for fuel, oil or hydraulic
must return to neutral. fluid leaks.
8. Check for correct function of 16. Lubricate the loader.

the work lights.
773 BICS Loader

Revised Jan. 99 ii 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.
773 BICS Loader

Revised Jan. 99 iii 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 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
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].
SI06–0301
P–10650
773 BICS Loader

vi Service Manual
SERIAL NUMBER LOCATIONS
Always use the serial number of the loader when
A
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 XXXXX N–15176
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].
773 BICS Loader

vii 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
BUCKET
(OPTIONAL)
SAFETY TREAD
BUCKET STEPS
OPERATOR CAB
(ROPS & FOPS)
REAR WINDOW
(OPTIONAL)
SEAT BAR
LIFT ARM LINK
LIFT ARM
REAR GRILL LIFT CYLINDER
TAIL LIGHTS LIFT ARM

(OPTIONAL) SUPPORT DEVICE
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).
773 BICS Loader
viii Service Manual
PREVENTIVE MAINTENANCE
PREVENTIVE
Page MAINTENANCE
Number
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
HYDRAULIC/HYDROSTATIC SYSTEM
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–25
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
773 BICS Loader

Revised Jan. 99 –1–1– Service Manual
PREVENTIVE MAINTENANCE (Cont’d)
Page
Number
OPERATOR CAB
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 RESTRAINT SYSTEM (Mechanical Hand Controls)

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
773 BICS Loader

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 SERVICE REQUIRED 8–10 50 100 250 500 1000

Engine Oil Check the oil level and add oil as needed.
Engine Air Filter Check condition indicator or display panel. Service only when
and Air System required. Check for leaks and damaged components.
Engine Cooling System Clean debris from oil cooler, radiator and grill. Check coolant level
in recovery tank (engine cold). Add coolant as needed.
Tires Check for damaged tires and correct air pressure.
Seat Belt, Seat Bar, Foot Check the condition of seat belt. Check the seat bar, and foot pedal
Pedal or Hand Control interlocks or hand control interlocks. Clean dirt and debris from
Interlocks moving parts.
Safety Signs and Safety Check for damaged signs (decals) and safety tread. Replace any
Tread signs or safety treads that are damaged or worn.
Indicators & Lights (Opt.) Check for correct operation of all indicators & lights.
Operator Cab Check the fastening bolts, washers & nuts. Check the condition of
cab.
Lift Arms, Cyl., Bob–Tach Lubricate with multi–purpose lithium based grease.
Pivot Pins and Wedges
Fuel Filter Remove the trapped water.
Bobcat Interlock Control Check BICSTM functions. Clean dirt, debris or objects from under
System (BICSTM) and behind seat and around brake pedal as required.
Hydraulic Fluid, Hoses and Check fluid level and add as needed. Check for damage and
Tubelines leaks. Repair or replace as needed.
Final Drive Trans.(Chaincase) Check oil level.
Foot Pedals, Hand Controls, Check for correct operation. Repair or adjust as needed.
and Steering Levers
Wheel Nuts Check for loose wheel nuts and tighten to 105–115 ft.–lbs.
(142–156 Nm) torque.
Parking Brake Check operation.
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water
as needed
Steering Shaft Grease two fittings.
Engine/Hydros. Drive Belt * Check for wear or damage. Adjust as needed.
Fan Drive Gearbox Check gear lube level. Add as needed.
Alternator Belt Check belt tension and adjust as needed.
Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Melroe filter.
Fuel Filter Replace the filter element.
Hydraulic Reservoir Replace the reservoir breather cap.
Breather Cap
Hydraulic Reservoir Replace the fluid.
Final Drive Trans.(Chaincase) Replace the fluid.
Hydraulic/Hydrostatic Filter Replace the filter element.
Case Drain Filters Replace the filters.
Bobcat Interlock Control Check lift arm bypass control
System (BICSTM)
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.
773 BICS Loader
Revised June 01 –1–3– 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
773 BICS Loader

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 P–10643
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [A].
Be sure the transport and towing vehicles are of adequate
size and capacity (See SPECIFICATIONS Page 9–1, for
B
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 P–10638
• Stop the engine.
• 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
6707867 P–10646
more than 25 feet (7,6 meters).
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.)
773 BICS Loader

LIFTING THE LOADER
Single Point Lift A
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.
773 BICS Loader

LIFT ARM SUPPORT DEVICE
1. A
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

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 P–00660
highway maintenance, landscaping, and other
construction site services.
Level ll – Protection from falling trees, rocks; for
B
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
Push the rear window out of the rear of the operator cab. C
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
Push the window out with your foot [D]. D

Exit through the front door.
P–09217
773 BICS Loader

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

Stop the engine. If the lift arms must be up while raising When operator cab is equipped with a cab
the operator cab, install an approved lift arm support enclosure kit (front door, side windows and top
device. (See Page 1–7.) 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

approved lift arm support device can allow the
lift arms or attachment to fall and cause injury Use care when raising or lowering the operator
or death. W–2059–0598 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 P–03470
can allow the machine to tip backward causing
injury or death.
W–2014–0895
B
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]. P–01518 P–01528
773 BICS Loader

Raising The Operator Cab (Cont’d)
A
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 P–10599

lowered when lowering the cab. Use the grab
handles to lower the cab.
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].

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

SEAT BAR RESTRAINT SYSTEM (Foot Pedals)
Description
A
2. Clean
The seat bar restraint system has a pivoting, spring assist (Both Sides)
seat bar with arm rests and has spring loaded interlocks
for the lift and tilt 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 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
Raise the seat bar. Try to move each foot pedal. Pedals Never operate loader without pedal lock shield
6705474 on both interlocks. Shields prevent feet
must be firmly locked in neutral position. There must be from unlocking interlocks when leaving loader
no motion of the lift arms or tilt (bucket) when the pedals seat.
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
B
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.
Seat Bar Maintenance

See the SERVICE SCHEDULE Page 1–3 and on the Interlock
loader for correct service interval. Shield
Clean any debris or dirt from the moving parts [A] & [B].
Inspect the linkage bolts and nuts for tightness. The Clean
correct torque is 25–28 ft.–lbs. (34–38 Nm). (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
773 BICS Loader

SEAT BAR RESTRAINT SYSTEM (Mechanical
Hand Controls) A
Description Clean
3. (Both Sides)
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 AVOID INJURY OR DEATH
ground.
Never operate loader without interlock shield
Raise the seat bar. Try to move each hand control. The 6705474 on both interlocks. Shields prevent
controls must be firmly locked in neutral position. There foot from unlocking interlocks when leaving
must be no motion of the lift arms or tilt (bucket) when the loader seat. W–2158–0594
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.
Lower the seat bar. Lower the lift arms. Loaders without B
seat sensors press the green PRESS TO OPERATE Interlock
Button and put the bucket flat on the ground. Stop the Shield
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. Clean
(Both Sides)
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.

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
773 BICS Loader

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.
When the seat bar is up, the lift, tilt, and traction drive P–13721
functions are deactivated.
Seat Bar Inspection
4.
B
Sit in the operator’s seat. Turn the key ON, lower the seat Clean
bar and press the green PRESS TO OPERATE Button. (Both Sides)
Both lights on the left handle should be ON.
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, P–10361
contact your dealer for service.
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:
If the seat bar system does not function correctly replace • Lower the lift arms, put the attachment flat on
parts that are worn or damaged. Use only genuine Bobcat the ground.
replacement parts. • 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.
W–2321–0698
773 BICS Loader

AIR CLEANER SERVICE
Replacing Filter Element
A 1
Without BOSS® – Condition Indicator: Replace the large
(outer) filter element only when the red ring shows in the 2
window of the condition indicator (Item 1) [A].
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® B
option display panel) shows the symbols [AF.2] [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
P–10313
Remove the wing nut (Item 1) [D] from the large air filter
element. D
P–10314
773 BICS Loader

AIR CLEANER SERVICE (Cont’d)
Replacing Filter Element (Cont’d)
A
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.
Check the air intake hose for damage. Check the air
cleaner housing for damage. Check to make sure all
B
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 1
been replaced. Start the engine and run at full RPM.
If the red ring shows again, replace the inner filter
element.
P–10310
• 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.
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
773 BICS Loader

FUEL SYSTEM
Fuel Specifications
A
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°) 100% 0%
Down to –20° (–29°) 50% 50%
Below –20° (29°) 0% 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
B–13579
free movement of air and no open flames or sparks. NO
SMOKING! [B].
Install and tighten the fuel fill cap (Item 1) [A]. C
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.)
773 BICS Loader
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

ENGINE LUBRICATION SYSTEM
Checking Engine Oil
A
Check the engine oil level every day.
Before starting the engine for the work shift, open the rear 1
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

C° (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
–40 –34 –29 –23 –18 –13 –7 –1 +4 +10 +15 +21 +27 +32 +38 +43 +49 P–10574
SAE 40W or 20W–50
SAE 10W–30
B
SAE 15W–40
SAE 30W
* SAE 5W–30
SAE 20W–20
SAE 10W 1
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.
773 BICS Loader

ENGINE LUBRICATION SYSTEM (Cont’d)
Replacing Oil And Filter (Cont’d)
A
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 different but the

procedure is the same.
P–10576
Remove the filler cap (Item 1) [B] from the oil fill tube.
Put 7.5 qts. (7,1 L) of oil in the engine. (See Oil Chart Page
B
1–18.)
1
P–10572
Start the engine and let it run for several minutes. Stop the
engine. Check for leaks at the oil filter and check the oil
C
level. Add oil as needed if it is not at the top mark (Item
1) [C] on the dipstick.

combustibles can cause explosion or fire P–01575
which can result in injury or death.
W–2103–1285
773 BICS Loader

ENGINE COOLING SYSTEM
Check the cooling system every day to prevent
A
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. P–10607
• Engine is running.
• Tools are being used.
W–2019–1285
B
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.
AVOID ENGINE DAMAGE P–10572

Always use the correct ratio of water to anti-
freeze.
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 compo-
nents; reduces the boiling point and freeze
protection of the system.
Always add a premixed solution. Adding full
strength concentrated coolant can cause seri-
ous premature engine damage.
I–2124–0497
773 BICS Loader

ENGINE COOLING SYSTEM (Cont’d)
Replacing The Coolant
A
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].
Connect a hose to the engine block drain valve (Item 1)
[B]. Open the drain valve and drain the coolant into a
B
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
Always use the correct ratio of water to anti-
Fill the coolant recovery tank 1/3 full. freeze.
Run the engine until it is at operating temperature. Stop Too much antifreeze reduces cooling system
the engine. Check the coolant level in the recovery tank efficiency and may cause serious premature
when cool. Add coolant to the recovery tank as needed. engine damage.
Lower the rear grill and close the rear door. Too little antifreeze reduces the additives
which protect the internal engine compo-
nents; reduces the boiling point and freeze
protection of the system.
Always add a premixed solution. Adding full
strength concentrated coolant can cause seri-
ous premature engine damage.
I–2124–0497
773 BICS Loader

ALTERNATOR BELT
Adjustment
A
Stop the engine. 2
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
Tighten the adjustment bolt and mounting bolt. P–10323
Lower the operator cab.

B
FAN GEARBOX
See the SERVICE SCHEDULE Page 1–3 for the correct
service interval.
Checking And Maintaining
Gear Lube 1
Level
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.)
773 BICS Loader

HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
A
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
The fluid level must be between the marks on the dipstick

[B].
B
If fluid is needed, remove the fill cap (Item 2) [A].
P–10303
Clean the hydraulic reservoir fill screen [C].

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. D
See the SERVICE SCHEDULE Page 1–3 for the correct
service interval.
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
773 BICS Loader
HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)
Replacing Hydraulic Fluid
A
See the SERVICE SCHEDULE Page 1–3, for the service
interval. 1
The fluid must also be replaced if it becomes CD–12250

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.
Remove the case drain filters (Item 2) [B] & [C] and drain 2
the fluid into a container.
Replace the hydraulic/hydrostatic filter element. (See
Page 1–23.)
Replace both hydrostatic motor case drain filters (Item 2) 1
[B] & [C].
When all the fluid is removed from the reservoir, P–10603
reconnect the hose to case drain filter on the reservoir.
Add the correct fluid to the reservoir until the fluid level is
between the marks on the dipstick. DO NOT fill above the
C
top mark on the dipstick.
Hydraulic fluid escaping under pressure can

have sufficient force to enter a person’s body 1
by penetrating the skin and cause serious
injury and possibly death if proper medical
treatment by a physician familiar with this P–10602
injury is not received immediately.
W–2145–0290
W–2103–1285

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.
773 BICS Loader

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)
773ServiceManual#6900092–PreventativeMaintenanceSectionPart1of2
Breather Cap
A
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
Lower the operator cab. 3
P–10605
773 BICS Loader

SPARK ARRESTOR MUFFLER
Cleaning Procedure
A
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.
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 When an engine is running in an enclosed area,
equipped with a spark arrestor attached to the fresh air must be added to avoid concentration
exhaust system and maintained in working of exhaust fumes. If the engine is stationary,
order. Failure to do so will be in violation of vent the exhaust outside. Exhaust fumes
California State Law, Section 4442 PRC. 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
I–2022–0595 cleaning the spark chamber. Wear safety
glasses or goggles. Failure to obey can cause
serious injury.
W–2011–1285
Stop the engine. Open the rear door and rear grill.
Never use machine in atmosphere with
Remove the plug (Item 1) [A] from the bottom of the explosive dust or gases or where exhaust can
muffler. contact flammable material. Failure to obey
warnings can cause injury or death.
Start the engine and run for about ten seconds while a W–2068–1285
second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler.
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
773 BICS Loader

TIRE MAINTENANCE
Wheel Nuts
A
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 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

FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
A
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.
If the level is low, add oil through the check plug hole until
B
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 1
rear of the chaincase.
Installation: Tighten the cover bolts to 10–20 ft.–lbs.
P–01616
Remove the drain plug (Item 1) [C] and drain the oil into
a container. C
NOTE: When installing the drain plug into the
chaincase, always use a NEW drain plug
gasket.
P–01619
773 BICS Loader

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
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.
Disconnect the negative (–) battery cable. B
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.
1 P–04232
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
P–04227
773 BICS Loader

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 P–01660
lbs. (67 N) spring scale force.
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.
773 BICS Loader

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:
1
Disconnect the negative (–) battery cable.
Remove the belt shield holddown clips (Item 1) [A].
P–03967
Remove the belt shield [B]. B

The pulley tensioner is located between the flywheel and
pump pulley.
P–03969
Loosen the bolt (Item 1) [C] on the spring loaded drive

idler.
C
NOTE: The pointer (Item 2) [C] will be at the 1 o’clock 1
position when the idler is not under spring
tension.
P–08760
Using the Belt Tensioner Bar (MEL1405) or a pry bar push D

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.
P–08762
773 BICS Loader

–1–31– Service Manual
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.
After the idler has been in service, readjust when the
B
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

Raise the operator cab. (See Page 1–9.) P–03969
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. P–08760
Remove the drive belt from the loader [D].
Install the new drive belt. Install the belt tensioner
assembly.
D
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
773 BICS Loader

LUBRICATION OF THE BOBCAT LOADER
7. A
Lubricate the loader as specified in the SERVICE
SCHEDULE, Page 1–3, for the best performance of the
loader.
Record the operating hours each time you lubricate the 1
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
2. Stabilizer Rod – Rear (Both Sides) [B]. B

3
3. Lift Cylinder Rod End (Both Sides) [B].
4. Lift Cylinder Base End (Both Sides) [B].
4
P–10640 P–10620
C 5
5. Tilt Cylinder Base End [C].
P–10622
773 BICS Loader

LUBRICATION OF THE BOBCAT LOADER (Cont’d)
A
6. Tilt Cylinder Rod End. [A].
6
P–10625
7. Bob–Tach Wedge (Both Sides) [B].

B 7
P–10626
8. Bob–Tach Pivot Pin (Both Sides) [C]. C
P–10635
D 9
9. Lift Arm Pivot Pin (Both Sides) [D].
10. Lift Arm Link Pivot Pin (Both Sides) [D].
10
P–10621
773 BICS Loader

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.
P–10620
773 BICS Loader

BOB–TACH
Inspection and Maintenance
A
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 B
injury or death.
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,
D
or missing. Keep all fasteners tight.
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
773 BICS Loader

REMOTE START SWITCH
Procedure
A
The tool listed will be needed to do the following
procedure:
MEL1429 – Remote Start Switch
Put jackstands under the front axles and rear P–10115

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.)

or death. W–2059–0598

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

REMOTE START SWITCH (Cont’d)
773ServiceManual#6900092–PreventativeMaintenanceSectionPart2of2
Procedure (Cont’d)
A
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
773 BICS Loader

Added Jan. 99 –1–38– Service Manual
HYDRAULIC SYSTEM
Page
Number
BICS™ VALVE (S/N 509640660 & Above, S/N 509616542 & Above)
BICS Valve Solenoid HYDRAULIC
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–24 SYSTEM
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–23
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
CONTROL VALVE
(S/N 509640659 & Below, S/N 509616541 & Below)
Anti–Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–63
Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–71
Auxiliary Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–70
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–61
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–60
Identification And Installation Of Spool Seal . . . . . . . . . . . . . . . . . . . . . . . 2–73
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–72
Lift Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–65
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–61
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–62
Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–62
Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–64
Tilt Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–69
773 BICS Loader

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
Rubber Boot
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–36
Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–56
Tilt Spool And Centering Spring
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–47
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–40
773 BICS Loader

Revised May 98 –2–6– Service Manual
HYDRAULIC SYSTEM (Cont’d)
Page
HYDRAULIC CYLINDER IDENTIFICATION Number
Lift Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
Tilt Cylinder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
HYDRAULIC CYLINDERS
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
HYDRAULIC FILTER HOUSING
HYDRAULIC FLUID RESERVOIR
HYDRAULIC PUMP
Checking The Output Of The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . 2–78
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–82
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–82
HYDRAULIC SYSTEM INFORMATION
Tightening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
LIFT CYLINDER(S)
Checking The Lift Cylinder(s) For Internal Leakage . . . . . . . . . . . . . . . . 2–7
LIFT LOCK BY–PASS VALVE
Disassembly And Assembly
(S/N 509640660 & Above, S/N 509616542 & Above) . . . . . . . . . . . . . 2–89
(S/N 509640659 & Below, S/N 509616541 & Below) . . . . . . . . . . . . . . 2–91
Removal And Installation
(S/N 509640660 & Above, S/N 509616542 & Above) . . . . . . . . . . . . . 2–88
(S/N 509640659 & Below, S/N 509616541 & Below) . . . . . . . . . . . . . . 2–90
MAIN RELIEF VALVE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–75
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–74
TILT CYLINDER
Checking The Tilt Cylinder For Internal Leakage . . . . . . . . . . . . . . . . . . 2–8
Rod End Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
TILT LOCK VALVE
(S/N 509640659 & Below, S/N 509616541 & Below) . . . . . . . . . . . . . . 2–94
(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.
773 BICS Loader
773 BICS Loader

Revised June 01 Service Manual
HYDRAULIC SYSTEM INFORMATION (Cont’d)
773 BICS Loader

HYDRAULIC SYSTEM INFORMATION (Cont’d)
773 BICS Loader

TROUBLESHOOTING
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
only. Check for correct function after adjustments,
repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W–2004–1285
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8

The transmission warning light comes ON when hydraulics are
operating. 1, 3
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7

Lift arms go up slowly at full engine RPM. 1, 3, 4, 6, 7, 8, 9
The lift arms or Bob–Tach will move when the pedal is in neutral position. 4
The lift arms come down with the pedal in the neutral position. 4, 9, 10, 11
By–pass valve stuck. 12
By–pass valve stem bent or broke. 13
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.

5. Relief Valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid. (See Section 9.)

8. Using the loader for more than its rated capacity.
9. Internal leak in the lift cylinder(s).

10. External leak from the lift cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.

13. Replace manual spool cartridge.
773 BICS Loader
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
Tightening Procedures
For tightening torques for hydraulic fittings,
tubelines etc., See Section 9. – Hydraulic Connection
Specifications.
773 BICS Loader

LIFT CYLINDER(S)
Checking The Lift Cylinder(s) For Internal Leakage
A
Lower the lift arms. Stop the engine. Pull up on the lift arm 2
bypass control and move the lift pedal to release the
hydraulic pressure. Raise the seat bar.
NOTE: Fuses may need to be moved for clearance. 1
3
Check only one cylinder at a time. Disconnect the tubeline

(Item 1) [A] from the lift cylinder rod end port.
Lift the tubeline up for clearance. Disconnect the hose
(Item 1) [B] from the lift cylinder base end port (Item 2)
[B]. N–00819
Install a plug in the hose (Item 1) [B] and tighten.

Reconnect the tubeline (Item 2) [A] to the lift cylinder rod
B
end port. Engage the parking brake. Lower the seat bar.
Start the engine and push the top (toe) of the lift pedal.
If there is any leakage from the base end cylinder port
(Item 2) [B], remove the lift cylinder for repair. Repeat the
2
procedure to check the other lift cylinder.

Stop the engine. Pull up on the lift arm by–pass control 1
and move the lift pedal to release the hydraulic pressure.
N–00820
Disconnect the two hoses (Item 1) [B] from the lift
cylinder.
Remove the retainer bolt (Item 2) [A] & [C] and nut from C
the pivot pin.
Installation: Tighten the retainer bolt and nut to 18–20 2
ft.–lbs. (24–27 Nm) torque.
Remove the pivot pin (Item 3) [A] & (Item 1) [C] from the
cylinder.
Slide the lift cylinder forward and remove it from the
loader.
N–15187
Reverse the removal procedure to install the lift cylinder.
Always clean up spilled fuel or oil. Keep heat, Diesel fuel or hydraulic fluid under pressure
flames, sparks or lighted tobacco away from can penetrate skin or eyes, causing serious
fuel and oil. Failure to use care around injury or death. Fluid leaks under pressure may
combustibles can cause explosion or fire not be visible. Use a piece of cardboard or wood
which can result in injury or death. to find leaks. Do not use your bare hand. Wear
W–2103–1285 safety goggles. If fluid enters skin or eyes, get
W–2072–0496
773 BICS Loader

TILT CYLINDER
Checking The Tilt Cylinder For Internal Leakage
A
Remove the attachment. Roll the Bob–Tach fully back.
Stop the engine. Raise the seat bar. 2
1
can penetrate skin or eyes, causing serious
injury or death. Fluid leaks under pressure may P–01187
immediate medical attention from a physician B
W–2072–0496
Disconnect the hose (Item 1) [A] which goes to the base

end of the tilt cylinder.
Put a plug in the hose and tighten.
Install a test hose between cylinder and a drain pan.
Engage the parking brake. Lower the seat bar. Start the
engine and push the bottom (heel) of the tilt pedal. If there
is leakage from the open port, remove the tilt cylinder for P–00843
repair.
Removal And Installation C

Remove the attachment. Roll the Bob–Tach forward and
lower the lift arms [B].
Place the Bob–Tach flat on a pallet to allow the tilt cylinder
base end pin enough clearance to be removed.
1
Stop the engine. Move the tilt pedal to release the
Disconnect both hydraulic hoses (Items 1 & 2) [A].

Remove the retainer nut (Item 1) [C] from the rod end
P–03907
pivot pin.
Installation: Tighten the retainer nut to 18–20 ft.–lbs.
(24–27 Nm) torque. D
1
Remove the grease fitting from the rod end pivot pin (Item
1) [D].
Remove the rod end pivot pin.
P–03904
773 BICS Loader

TILT CYLINDER (Cont’d)
A
Removal And Installation (Cont’d)
Remove the retainer nut (Item 1) [A] and bolt from the
base end pivot pin.
Installation: Tighten the retainer nut and bolt to 18–20
ft.–lbs. (24–27 Nm) torque. 1
N–00847
combustibles can cause explosion or fire B
W–2103–1285
Remove the base end pivot pin (Item 1) [B].

1
Remove the tilt cylinder from the loader.
N–00845
Rod End Seal Replacement

Remove the old seal (both sides) from the rod end of the
C
tilt cylinder.
Apply a light coat of grease on the new seals (Item 1) [C].
Install the new seals with the lip facing in [C].
P–03911
Use two pieces of shim stock (light cardboard), install the

rod end of the tilt cylinder into the Bob–Tach [D].
D
Be careful not to damage the new seals during
installation.
Reverse the removal procedure to install the tilt cylinder.
P–03910
773 BICS Loader

HYDRAULIC CYLINDER IDENTIFICATION
Lift Cylinder Components
1. Case 9. O–ring
2. Piston 10. O–ring
3. Head 11. Washer
4. Rod 12. Seal
5. Spacer 13. Seal
6. O–ring 14. Plug
7. Nut 15. O–ring
8. Ring 16. Tube
2
4
7
14
15
6
13
16
12
1
14 3
15
11
10
TS–01097
773 BICS Loader

HYDRAULIC CYLINDER IDENTIFICATION (Cont’d)
Tilt Cylinder Components
1. Case 10. O–ring

2. Piston 11. Seal
3. Head 12. Seal
4. Rod 13. Bushing
5. Nut 14. Tube
6. Seal 15. O–ring
7. O–ring 16. Plug
8. O–ring 17. Clamp
9. Washer 18. Nut
MC–01688
14
15
16
17
3
5
18
2 11
12
6
4
8
MC–01688 13
10 13
TS–01127
773 BICS Loader

HYDRAULIC CYLINDERS
A
Disassembly
Tools necessary for the disassembly/assembly
procedures:
MEL1074 – O–ring Seal Hook
MEL1075 – Adjustable Gland Nut Wrench
MEL1396 – Seal Installation Tool
MEL1033 – Rod Seal Installation Tool
Piston Ring Compressor
NOTE: The drawings may not show the cylinder

exactly as it appears, but the procedure is
correct for all cylinders.
B–07000
See the Service Manual for your model loader to find the
correct information for removing and installing the
cylinder. B
Put the base end of the hydraulic cylinder in a drain pan.
Move the rod in and out to remove the fluid from the
cylinder. Move the rod slowly so the fluid will go directly
into the drain pan.
Put the base end of the cylinder in a vise.
Use the adjustable gland nut wrench to loosen the head
[A].
Remove the rod assembly from the cylinder case [B].

Remove the cylinder case from the vise. B–07001
Put the rod end in the vise.

C
Remove the nut from the piston end of the rod [C].
B–07002
Pull the piston off the rod (Item 1) [D].

D
Pull the head (Item 2) [D] off the rod. 2
B–07003
773 BICS Loader

HYDRAULIC CYLINDERS (Cont’d)
Disassembly (Cont’d)
A
If the head has a seal, remove the seal from the head [A].
B–07004
Remove the O–ring and back–up washer from the head

[B]. B
B–07199
Remove the wiper seal [C].

C
B–07005
Remove the oil seal from the head [D].

D
B–07006
773 BICS Loader

A
Remove the piston seal from the piston [A].
B–03689
Remove the O–ring from the piston [B].

Wash the cylinder parts in solvent and air dry them.
B
While servicing the cylinder do not damage the parts.
Inspect for nicks, scratches or otherwise damaged or
bent parts before assembling the cylinder. Replace parts
that appear damaged in any way. The cylinder may not
function correctly if there is damage to any of the parts.
Destroy all the O–rings and seals and replace them with
NEW O–rings and seals.
B–03703
Assembly
Install the O–ring on the piston [C]. C
B–12812
NOTE: Do not overstretch the seal.

D
Install the seal on the tool and stretch it until it fits the
piston [D].
Allow the O–ring to stretch for 30 seconds before
removing it from the tool.
B–12809
773 BICS Loader

Assembly (Cont’d)
A
Install the seal on the piston [A].
B–12813
Use a ring compressor to compress the seal to the correct

size [B]. B
Leave the piston in the ring compressor for three minutes.
B–12811
Install the oil seal on the rod seal tool [C].

C
NOTE: The O–ring side of the oil seal goes toward
the inside of the cylinder.
B–03702
Install the oil seal in the head [D].

D
B–03671
773 BICS Loader

Assembly (Cont’d)
A
Install the wiper seal with the lip toward the outside of the
head [A].
B–03682
Install the back–up washer on the head [B] & [C].

B
B–07008
B–07200
Install the O–ring next to the back–up ring [D].

D
B–07007
773 BICS Loader

Assembly (Cont’d)
A
If a seal was removed from the head use the following
procedure to install a new one.
NOTE: Do not overstretch the seal.
Install the seal on the tool and stretch it until it fits the
piston [A].
Allow the O–ring to stretch for 30 seconds before
removing it from the tool.
NOTE: Do not turn (roll) the seal as you install it.
Damage to the seal may result. B–12809
Use a ring compressor to compress the seal to the correct

size [B]. Leave the tool over the seal for five minutes. B
B–14305
Install the head on the rod [C].
C
B–07011
Install the piston on the rod [D].
B–07198
773 BICS Loader

Assembly (Cont’d)
A
Clean and dry the cylinder rod threads.
For the tilt cylinder only:
Apply grease to the shoulder of the rod shaft where the
piston makes contact [A]. Do not get grease on the
threads.
For lift and tilt cylinders:
Gease Shoulder
Install the piston (with the chamfered side to the cylinder And Piston
rod shoulder) and the nut.
P–10452
Tighten the lift cylinder nut (with 0.750 inch thread
diameter) to 180 ft.–lbs. (244 Nm) torque.
For tilt cylinder only:
B
Grease the piston where the nut contacts the piston. Do
not get grease on the threads.
Tighten the nut (with 1.125 inch thread diameter) to 100
ft.–lbs. (136 Nm) torque.
Mark the end of the shaft and nut [B]. Tighten the nut an
additional 135 degrees or 2–1/4 flats [B].
For lift and tilt cylinders:
Remove the rod from the vise.
P–10450 P–10456
Install the cylinder case in the vise.
Put oil on the seal surface of the cylinder case [C]. C
B–07013
Put oil on the teflon seal on the piston [D]. D
B–07012
773 BICS Loader

Assembly (Cont’d)
A
Install the rod assembly in the cylinder case [A].
B–07001
Put oil on the seals on the head [B].

Put oil on the threads of the head.
B
B–07014
Use the adjustable gland nut wrench to tighten the head

[C].
C
B–07000
Replace the seal on the rod end (if so equipped) if it shows

signs of wear or damage[D].
D
B–07015
773 BICS Loader

BICS™ VALVE (S/N 509640660 & Above, S/N
509616542 & Above) A 1 1
Removal
Remove the BICS™/control valve. (See Page 2–28.) 1
Loosen and remove the six mounting bolts (Item 1) [A].
1 1
P–08948
Remove the BICS™ valve assembly from the top of the
control valve [B].
B
P–08949
Remove the four large O–rings (Item 1) [C] and the small
O–ring (Item 2) [C] from the top of the control valve.
C 2
1 1
P–08950
773 BICS Loader

509616542 & Above) (Cont’d) A
Disassembly
Remove the fitting (Item 1) [A] from the valve.
1
P–08951
Using a flat blade screw driver, remove the lift arm

by–pass orifice (Item 1) [B] & [C].
B
Orifice size is 0.078 inch.
P–08952
P–08953
Check Valve
D
Disassembly
Remove the check valve (Item 1) [D].
P–08954
773 BICS Loader

509616542 & Above) (Cont’d) A
Check Valve (Cont’d)
2
Remove the O–rings (Item 1) [A] and back–up ring (Item

2) [A].
P–08955
Clean and inspect the screen (Item 1) [B] on the end of

the valve.
B
1
P–08956
Lock Valve C
Disassembly
Remove the lock valves (Item 1) [C] from the BICS™
valve.
P–08957
Remove the O–rings (Item 1) [D] and back–up rings (Item

2) [D] from both the tilt and lift lock valves. D
2 2 2
1 1
P–08958
773 BICS Loader

509616542 & Above) (Cont’d) A 1
BICS™ Valve Solenoid

Disassembly
Remove the mounting nut (Item 1) [A] from the solenoid
cartridge.
Remove the solenoid (Item 2) [A].
2
NOTE: The solenoid resistance value is (8–10
ohms).
P–08959
Remove the O–rings (Item 1) [B] from both ends of the

solenoid. B
1 1
P–08960
Remove the solenoid cartridge (Item 1) [C].

C 1
P–08961
Remove the O–rings (Item 1) [D] and back–up rings (Item

2) [D] from the solenoid cartridge. D
2
P–08962
773 BICS Loader

509616542 & Above) (Cont’d) A
BICS™ Valve Solenoid (Cont’d) 3 2
Assembly
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and replace any showing
excessive wear.
NOTE: The screen (Item 3) [A] may be cleaned with
solvent. If it is torn or worn it needs to be 1
replaced.
Use only new O–rings and apply oil to all O–rings and
back–up rings before installation. P–08962
Install new O–rings (Item 1) [A] and new back–up rings

(Item 2) [A] on the solenoid cartridge.
B 1
Install the solenoid cartridge (Item 1) [B].

Tighten the cartridge (Item 1) [B] to 20 ft.–lbs. (27 Nm )
torque.
P–08961
Install new O–rings (Item 1) [C] on both ends of the

solenoid. C
1 1
P–08960
Install the solenoid (Item 1) [D] on the cartridge.

Install the mounting nut (Item 2) [D] on the cartridge.
D 2
Tighten the mounting nut to 53 in.–lbs. (6 Nm) torque.
NOTE: Do not over torque the mount nut or the

solenoid may not function correctly.
1
P–08959
773 BICS Loader

509616542 & Above) (Cont’d)
773ServiceManual#6900092–HydraulicSystemSectionPart1of4
A
Lock Valve
2 2 2
Assembly
Install new O–rings (Item 1) [A] and back–up rings (Item
2) [A] on the tilt and lift lock valves.
1 1
P–08958
Install the lock valves (Item 1) [B]. Tighten the lock valves
to 25 ft.–lbs. (34 Nm) torque.
B
P–08957
Check Valve C
Assembly
3
Install new O–rings (Item 1) [C] and back–up ring (Item 2
2) [C] on the check valve.
Check valve (Item 3) [C] has a rating of 5–10 PSI.
P–08955
Install the check valve (Item 1) [D].

D
Tighten the valve to 20 ft.–lbs. (27 Nm) torque.
P–08954
773 BICS Loader

509616542 & Above) (Cont’d) A
Assembly
Install the lift arm by–pass orifice (Item 1) [A] & [B] in the
valve.
Orifice size is 0.078 inch.
P–08953
P–08952
Install the fitting (Item 1) [C] on the valve. C
1
P–08951
773 BICS Loader

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

CONTROL VALVE (S/N 509640660 & Above, S/N
509616542 & Above) (Cont’d) A 1
Removal And Installation 1
3
4
3
3 2
Raise the lift arms and install an approved lift arm support N–15066

unless the lift arms are secured by an approved 1
or death. W–2059–0598
Stop the engine. Use the lift lock valve knob to release the N–15065
C
Remove the steering control panel. (See Page 3–1.)
1
Clean area around the control valve.
Mark all tubelines for correct installation.
Disconnect the wire harness connectors (Item 1) [A] from
the auxiliary solenoid connectors.
Disconnect the wire harness connector (Item 2) [A] from
the BICS™ valve solenoid connector.
Installation: Install a never modify sta–strap around the
connector (Item 2) [A].
N–15064
Disconnect the drain hoses (Item 3) [A] from the main
control valve.
Disconnect the hose (Item 4) [A] from the lift arm by–pass D
control valve.
Disconnect the outlet tubeline (Item 1) [B] from the

control valve. 1
Disconnect both tubelines (Item 1) [C] from the auxiliary

section of the control valve.
Disconnect the tilt tubelines (Item 1) [D]. 1
N–15063
773 BICS Loader

509616542 & Above) (Cont’d) A
Disconnect the lift tubelines (Item 1) [A].
N–15062
Remove the clevis pin (Item 1) [B] from the tilt spool
linkage.
B
Remove the clevis pin (Item 2) [B] from the lift spool 1
linkage.
NOTE: The lift lock valve has been removed for

clarity purpose only.
N–15061
773 BICS Loader

509616542 & Above) (Cont’d) A
Remove the right rear tire. 1
Locate the rectangular access cover (Item 1) [A] on the
right side of the loader frame.
P–04109
Loosen one mounting bolt and remove the other

mounting bolt from the access cover [B]. B
Rotate the cover to expose the access slot in the loader
[B].
P–04108
Disconnect the inlet hose from the control valve through

the access slot [C].
C
Remove the two control valve mounting bolts & nuts.
Remove the control valve from the loader.
Installation: Tighten the mounting bolt & nut to 18–20
Reverse the removal procedure to install the control
valve.
P–04110
773 BICS Loader

509616542 & Above) (Cont’d) A H3 H2
H1
Identification Chart
Item 773 Loader C4
B3 A3 D3
A1 Lift Cylinder Base End/Restrictor G3
.134–141 (3,40–3,58 mm) C3
G2 B2 A2 E2 D2
A2 Tilt Cylinder Base End
F2 C2
A3 Auxiliary Hydraulics G1 B1 A1 E1 D1
F1 C1
B1 Lift Cylinder Rod End
MR
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics
MC–02229
C1 Load Check Valve/Lift Function
C2 Load Check Valve/Tilt Function
C3 Plug/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Spring
E1 Port Relief Valve
E2 Anti–Cavitation Valve
Port Relief/Anti–Cavitation Valve
(If Equipped)
F1 Anti–Cavitation/Port Relief (optional) Valve
F2 Plug
Port Relief (If Equipped)
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Spring
H1 Auxiliary Electric Solenoid
H2 Plug or Auxiliary Port Relief (Optional)
MR Main Relief Valve
773 BICS Loader

509616542 & Above) (Cont’d) A 2
Disassembly
Remove the BICS valve assembly from the control valve.
(See Page 2–20.)
Mark each anti–cavitation valve, port relief valve, plug, 1 1
spool and related parts for ease of assembly.
Bolt the control valve to a work bench for ease of
disassembly and assembly.
Remove the four large O–rings (Item 1) [A] and the small
O–ring (Item 2) [A] from the top of the control valve.
P–08950
Remove the end caps (Item 1) [B] from the base end of
the lift and tilt sections. B
1 1
P–08963

Disassembly
C 1
Remove the restrictor (Item 1) [C] from the lift section

base end port.
P–08964
Load Check Valve

D
Disassembly
Remove the load check plugs (Item 1) [D] from the lift and
tilt valve sections.
P–08965
773 BICS Loader

509616542 & Above) (Cont’d) A
Load Check Valve (Cont’d)
Remove the spring (Item 1) [A] and poppet (Item 2) [A]

from the lift and tilt valve sections.
Remove the O–ring (Item 3) [A] from the plug.
3 1 2
P–08966
Remove the plug (Item 1) [B]. B
P–08967
Remove the O–ring (Item 1) [C] from the plug (Item 2) [C]. C
2
Main Relief Valve P–11342
Disassembly
Remove the main relief valve (Item 1) [D]. D
P–08969
773 BICS Loader

509616542 & Above) (Cont’d) A
Main Relief Valve (Cont’d)
Remove the glid ring (Item 1) [A] & [B] from the main relief 1
valve.
P–08970
Remove the O–rings (Item 2) [B] and back–up ring (Item

3) [B] from the main relief valve. B 2
3 1
B–6764
3 1
2 2
P–08971
Port Relief Valve

Disassembly
C
Remove the port relief valve (Item 1) [C].
P–08972
Remove the O–rings (Item 1) [D] and back–up ring (Item

2) [D] from the port relief valve. D 1
2
1 E–01509
2
1
P–08973
773 BICS Loader

509616542 & Above) (Cont’d) A
Disassembly
Remove the anti–cavitation valve (Item 1) [A] from the
control valve tilt section.
1
NOTE: The anti–cavitation valve (Item 1) [A] is
standard on the control valve. The available
3500 PSI anti–cavitation/port relief looks like
a port relief valve. (See Page 2–34.)
P–08974
Remove the anti–cavitation valve (Item 1) [B] from the

control valve lift section. B
P–08975
Remove the O–rings (Item 1) [C] and back–up ring (Item

2) [C] from the anti–cavitation valves. C 1
2
E–01509
1
P–08976
Remove the plug (Item 1) [D] from the tilt section.

D
NOTE: On later models only this port may contain an
available 3500 PSI port relief valve for the rod 1
end of the tilt section.
P–08977
773 BICS Loader

509616542 & Above) (Cont’d) A 2
Anti–Cavitation Valve (Cont’d)

Disassembly (Cont’d) 1
E–01509
Remove the O–rings (Item 1) [A] and back–up ring (Item
2) [A] from the plug. 2
1
P–08978
Rubber Boot
Disassembly
B
Remove the two bolts (Item 1) [B] from the rubber boot
retainer on the lift spool. 1
P–08979
Remove the rubber boot (Item 1) [C] and retainer (Item

2) [C] from the lift spool. C
1
P–08980
Remove the bushing (Item 1) [D] and O–ring (Item 2) [D].

D
P–08981
773 BICS Loader

509616542 & Above) (Cont’d) A
Lift Spool And Detent
Disassembly
Remove the snap ring (Item 1) [A] and washer (Item 2)
[A].
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

509616542 & Above) (Cont’d) A
Lift Spool And Detent (Cont’d)
Remove the spool assembly from the control valve [A].
P–08986
Remove the spool seal (Item 1) [B] from the control valve.
B
P–08987
Clamp the linkage end of the spool in a vise. C

NOTE: Use care when removing the detent adapter
as it is under spring pressure. 1
Loosen the detent adapter (Item 1) [C].
P–08988
Remove the detent adapter (Item 1) [D], collar (Item 2)

[D], spring (Item 3) [D] and washer (Item 4) [D]. D 1
2
P–08989
773 BICS Loader

509616542 & Above) (Cont’d) A
1
Remove the bushing (Item 1) [A] and seal (Item 2) [A]
from the spool.
2
P–08990
Wrap a shop towel around the detent adapter and collar.

This will prevent the detent balls and spring from being
lost when the detent adapter is removed from the collar.
B
2
Remove the detent adapter (Item 1) [B], detent balls
(Item 2) [B] and spring (Item 3) [B] from the collar (Item 3
4) [B].
1 4
2
P–08991
Remove the stud from the end of the spool [C]. C

Removal of the plastic plug:
Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
tap drill.
Turn a 6–32 tap into the plug. Pull the tap and plug out of
the spool. Be careful, do not break the tap.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE LOCTITE ON THE STUD

THREADS. CD–15048
Installation: Slide the O–ring over the nipple on the

plastic plug. Install the plastic plug in the spool. Install the
stud so that the end is about 0.600 inch (15,2 mm) from
D O–ring
the spool [D].
Plastic Plug
0.600’’
(15,2 mm)
B–14712
773 BICS Loader

509616542 & Above) (Cont’d) A
Disassembly
Remove the two bolts (Item 1) [A] from the rubber boot
retainer on the tilt spool.
1
P–08992
Remove the rubber boot (Item 1) [B] and retainer (Item

2) [B] from the tilt spool. B
1 2
P–08993
Remove the bushing (Item 1) [C] and O–ring (Item 2) [C].

C
2
1
P–08994
Remove the two end cap bolts (Item 1) [D] and the end
cap (Item 2) [D].
D
2
1
P–08995
773 BICS Loader

509616542 & Above) (Cont’d) A
Tilt Spool And Centering Spring (Cont’d)
Remove the spool assembly [A].
P–08996
Remove the spool seal (Item 1) [B] from the actuating end
of the spool. B
1
P–08997
Clamp the actuating end of the spool in a vise.
NOTE: Use care when removing the centering

C
spring bolt as it is under spring pressure. 1
Remove the centering spring bolt (Item 1) [C] & [D].
P–08998
Remove the adapter (Item 2) [D], collar (Item 3) [D],

spring (Item 4) [D] and washer (Item 5) [D].
D 3
2 4 5
1
Remove the bushing (Item 6) [D] and seal (Item 7) [D]
from the spool.
7
6
P–08999
773 BICS Loader

509616542 & Above) (Cont’d) A
Auxiliary Spool
Disassembly
Remove the two bolts (Item 1) [A] & [B] from both
auxiliary spool covers.
Remove both of the auxiliary spool covers (Item 2) [A] & 1
[B].
2
1
P–11000
2
1
P–11001
Remove the O–ring (Item 1) [C] & [D], spring (Item 2) [C]
& [D] and spring seat (Item 3) [C] & [D].
C
3
1
2
P–11002
Remove the auxiliary spool (Item 4) [D].

D
3
1 2
P–11003
773 BICS Loader

509616542 & Above) (Cont’d) A
Disassembly
Remove the nut (Item 1) [A] from both solenoids.
1 1
P–11004
Remove the end plate (Item 1) [B] and housing (Item 2)

[B]. B
P–11005
Remove the coil (Item 1) [C] and end plate (Item 2) [C].
C
Remove the solenoid valve (Item 3) [C].
2
1
3
P–11008
Remove the O–rings (Item 1) [D] from the solenoid

valves.
D
P–11006
773 BICS Loader

509616542 & Above) (Cont’d) A
Port–Auxiliary Section
Disassembly
Remove the plug (Item 1) [A] or optional port relief valve
from the control valve.
NOTE: Optional port relief (Item 1) [A] is either 2500

PSI or 3000 PSI depending on the option
used. 1
P–11007
Remove the O–rings (Item 1) [B] & [C] and back–up ring
(Item 2) [B] & [C] from the plug. B Plug
Cleaning And Inspection 2

Clean all components with clean solvent and dry with
compressed air.
Check the spools for wear or scratches.
Check that the spools are not loose in their bore.
Check that the centering springs are not broken. 1 1
Check that the load check valve seats are not worn. P–08968
Check the load check poppets for damage.

Check the rubber boots and retainers. C Port Relief (Optional)
Replace the parts as needed.
Use new O–rings and back–up rings.
1
Apply oil to all new O–rings and back–up rings before 2
installation.
1
P–08973
773 BICS Loader

509616542 & Above) (Cont’d) A
Port–Auxiliary Section (Cont’d)
Assembly 2
Install new O–rings (Item 1) [A] and back–up ring (Item

2) [A] on the plug.
P–08968
Install the plug (Item 1) [B] in the control valve. B

Tighten the plug to 35–40 ft.–lbs. (47–54 Nm) torque.
P–11007

Assembly
C
Install new O–rings (Item 1) [C] on both of the solenoid
valves.
P–11006
Install the solenoid valve (Item 1) [D] in the control valve.

D
Tighten the valve to 8–12 ft.–lbs. (11–16 Nm) torque.
Install the end plate (Item 2) [D] and coil (Item 3) [A].
2
3
1
P–11008
773 BICS Loader

509616542 & Above) (Cont’d) A
Auxiliary Electric Solenoid (Cont’d)
Assembly (Cont’d)
1
Install the housing (Item 1) [A] and the end plate (Item 2)
[A].
2
P–11005
Install the nut (Item 1) [B] on the solenoid valve. B

Tighten the nut to 9–12 in.–lbs. (1,02–1,36 Nm) torque.
1 1
P–11004
Auxiliary Spool
Assembly C
Install the auxiliary spool (Item 1) [C] & [D] in the control
valve.
Install the spring seats (Item 2) [C] & [D] and springs
(Item 3) [C] & [D]. 1
4
Install the O–rings (Item 4) [C] & [D] in the spool covers
(Item 5) [C] & [D].
2
3
5
P–11002
1
4
2
3
5
P–11003
773 BICS Loader

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. (10,2–11,3 Nm) 2
torque.
1
2
P–11000
1
2
P–11001

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. (10,2–11,3 Nm) torque.
P–08998
773 BICS Loader

509616542 & Above) (Cont’d) A
Assembly (Cont’d)
Install the spool seal (Item 1) [A] in the spool bore.
NOTE: The spool seal must be installed with the lip

face toward the valve body. The lip face has
the largest outside diameter.
P–08997
Install the spool assembly [B].

B
P–08996
Install the end cap (Item 1) [C] and the two retaining bolts
(Item 2) [C]. C
Tighten the bolts to 90–100 in.–lbs. (10,2–11,3 Nm)
torque.
1 2
P–08995
Install the O–ring (Item 1) [D] on the bushing (Item 2) [D]. D

Install the bushing (Item 2) [D] over the actuating end of
the tilt spool.
P–08994
773 BICS Loader

509616542 & Above) (Cont’d) A
Assembly (Cont’d)
2
Install the rubber boot (Item 1) [A] and retainer (Item 2)
[A] over the actuating end of the tilt spool.
3
NOTE: Make sure the rubber boot sits in the sealing
surface of the spool.
Install the two bolts (Item 3) [A] on the rubber boot 1 3
retainer.
Tighten the bolts to 90–100 in.–lbs. (10,2–11,3 Nm) P–08992
torque.
Lift Spool And Detent B
Assembly
Clamp the actuating end of the lift spool in a vise.
Install the spool seal (Item 1) [B] and bushing (Item 2) [B].
2
P–08990
Apply grease on all the detent component surfaces before

assembly [C]. C
Install the detent adapter (Item 1) [C] & [D], detent balls
(Item 2) [C] and spring (Item 3) [C] in the collar (Item 4) 2 4
1
[C] & [D] using the detent installation tool (MEL1278).
2
P–11009
4
P–11010
773 BICS Loader

509616542 & Above) (Cont’d)
A
Lift Spool And Detent (Cont’d) 3
Assembly (Cont’d)
Install the washer (Item 1) [A], spring (Item 2) [A] and 2
collar/detent adapter assembly (Item 3) [A].
1
P–08989
Tighten the detent adapter (Item 1) [B] to 90–100 in.–lbs.

(10,2–11,3 Nm) torque.
B
1
P–08988
Install the detent sleeve (Item 1) [C], detent balls and

spring in the detent adapter (Item 2) [C] using the detent
C 1
installation tool (MEL1278).
P–11011
Install the lift spool assembly in the spool bore [D].

D
P–11012
773 BICS Loader

509616542 & Above) (Cont’d) A
Assembly (Cont’d)
Install the detent bonnet (Item 1) [A] and two bolts (Item
2) [A].
2
torque.
1 2
P–08983
Install the washer (Item 1) [B] and snap ring (Item 2) [B].
B
2
P–08982
Rubber Boot
Assembly
C
Install the O–ring (Item 1) [C] and bushing (Item 2) [C].
P–08981
Install the rubber boot (Item 1) [D] and retainer (Item 2)

[D].
D
NOTE: Make sure the rubber boot sits in the sealing
surface of the spool.
1
P–08980
773 BICS Loader

509616542 & Above) (Cont’d) A
Rubber Boot (Cont’d)
Assembly (Cont’d) 1
Install the two bolts (Item 1) [A].
torque.
1
P–08979
Assembly
B 2
Install new O–rings (Item 1) [B] and back–up ring (Item

2) [B] on the plug. 1
E–01509
1
P–08978
Install the plug (Item 1) [C] in the tilt section of the control
valve. C
Tighten to 35–40 ft.–lbs. (47–54 Nm) torque.
1
NOTE: On later models only this port may contain an

available 3500 PSI port relief valve for the rod
end of the tilt section
P–08977
Install new O–rings (Item 1) [D] and back–up ring (Item

2) [D] on both anti–cavitation valves. D 1
2
E–01509
1
P–08976
773 BICS Loader

509616542 & Above) (Cont’d) A
Assembly (Cont’d) 1
Install the anti–cavitation valve (Item 1) [A] on the control
valve lift section.
P–08975
Install the anti–cavitation valve (Item 1) [B] on the control

valve tilt section.
B
1
NOTE: This port may contain an available 3500 PSI

anti–cavitation/port relief valve for the base
end of the tilt section.
P–08974
Port Relief Valve

Assembly
C 2
Install new O–rings (Item 1) [C] and back–up ring (Item

2) [C] on the port relief valve.
1 1
E–01509
2
1
P–08973
Install the port relief valve (Item 1) [D]. D

P–08972
773 BICS Loader

509616542 & Above) (Cont’d) A 3
Main Relief Valve
Assembly
2 1
B–06764
Install new O–rings (Item 3) [A] and back–up ring (Item
2) [A] on the main relief valve. 2
1
Install the glid ring (Item 1) [A] & [B] over the O–ring.
3
P–08971
1
P–08970
Install the main relief valve (Item 1) [C]. C

1
P–08969
Load Check Valve

D
Assembly 2
Install a new O–ring (Item 1) [D] on the plug (Item 2) [D].
P–11342
773 BICS Loader

509616542 & Above) (Cont’d) A
Load Check Valve (Cont’d)
Assembly (Cont’d)
Install the plug (Item 1) [A].
1
Tighten the plug (Item 1) [A] to 35–40 ft.–lbs. (47–54 Nm)
torque.
P–08967
Install a new O–ring (Item 1) [B] on both of the load check

plugs.
B
Install the poppet (Item 2) [B], spring (Item 3) [B] and load
check plug (Item 4) [B] in the lift and tilt sections.
Tighten the plugs to 35–40 ft.–lbs. (47–54 Nm) torque.
1
3
2
P–08966
Install the restrictor (Item 1) [C] in the lift section base end
port.
C
NOTE: There are two restrictor sizes. 0.134 inch
(3,40 mm) and 0.141 inch (3,58 mm).
P–08964
Install the end caps (Item 1) [D] on the base end of the lift
and tilt sections. D
Install the BICS™ valve on the control valve. (See Page
2–27.)
1 1
P–11013
773 BICS Loader

509616542 & Above) (Cont’d) A
Spool Seal Installation
To install new spool seals when the centering spring (tilt
spool) or the detent assembly (lift spool) are not removed
from the spool, use the following procedure:
Check the seal surface area in the control valve for rust,
corrosion, scratches, etc. Correct any irregularities
before continuing.
Oil and install the new spool seal (Item 1) [A] in the spool 1
bore.
P–08987
Put plastic material (example: Plastic food wrap) on the

valve spool [B].
B
Put clean oil on the spool seal. Install the spool seal (Item
1) [B] on the spool. Be careful not to damage the seal on
the sharp edges.
NOTE: The seal must be installed with the lip face 1
toward the valve body. The lip face has the
largest outside diameter.
Remove the plastic material.
CD–15080
Install the spool into the control valve, by slowly turning

the spool while pushing the spool through the spool bore
and spool seal [C].
C
Be careful not to damage the spool seal.
P–11012
Install the O–ring (Item 1) [D] and bushing (Item 2) [D].

Continue assembling the control valve.
D
P–08981
773 BICS Loader

CONTROL VALVE (S/N 509640659 & Below, S/N
509616541 & Below) A
device. (See Page 1–1.) P–04105
B 2

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
Control panel removal is optional. (See Page 3–1.) C 1

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

509616541 & Below) (Cont’d) A
Disconnect the tubeline (Item 1) [A] from the rear port of
the tilt section of the control valve. 1
Disconnect the tubeline (Item 2) [A] from the rear port of
the lift section of the control valve.
P–04102
Disconnect the tubeline (Item 1) [B] from the front port of

the tilt section of the control valve. B
1
P–04107
Disconnect the tubeline (Item 2) [C] from the front port of

the lift section of the control valve.
C
1
P–04111
Remove the clevis pin (Item 1) [D] from the tilt spool
linkage. D
1
Remove the clevis pin (Item 2) [D] from the lift spool
linkage.
NOTE: The lift lock valve has been removed for

clarity purpose only.
2
P–04097
773 BICS Loader

509616541 & Below) (Cont’d) A
right side of the loader frame.
P–04109
Loosen one mounting bolt and remove the other

mounting bolt from the access cover [B]. B
[B].
P–04108

the access slot [C]. C
Remove the two control valve mounting bolts & nuts.
valve.
P–04110
773 BICS Loader

A 773 SERIES
509616541 & Below) (Cont’d)
E1
Identification Chart MR
F1
Item 773 Series
D1 G1
A1 Lift Cylinder Base End Restrictor F2
E2 G2
A2 Tilt Cylinder Base End
D2
A3 Auxiliary Hydraulics
D3 G3
B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics
H1 H2 H3
MC–01423
C2 Load Check Valve/Tilt Function
C3 Plug/Auxiliary Function
D1 Lift Spool Detent
D2 Centering Spring Tilt Spool
D3 Auxiliary Spool
E1 Port Relief
E2 Anti–Cav. Valve
Port Relief/Anti–cavitation Valve
(If Equipped)
F1 Anti–Cav. Valve
F2 Port Relief (If Equipped)
G1 Lift Spool
G2 Tilt Spool
G3 Auxiliary Spool
H2 Plug or Port Relief (Optional)
MR Main Relief Valve
773 BICS Loader

509616541& Below) (Cont’d) A
The anti–cavitation valve, port relief valves and plugs are
at different locations in the control valve. (Refer to Page
2–62 CONTROL VALVE Identification Chart for the
correct location of the parts for each Model control valve.)
NOTE: THE PHOTO’S MAY NOT SHOW THE EXACT
LOCATION FOR THE PART BEING
REMOVED OR INSTALLED ON THE
CONTROL VALVE, BUT THE PROCEDURE IS
THE SAME.
CD–10793

the system.
I–2003–0888
Mark each valve section and spool so that the parts will
be returned to its original bore during assemble. CD–10794
Use bolts to fasten the control valve to a work bench for

easier disassemble and assemble.
C
Load Check Valve
Loosen the load check plug (C port).[A]. (See CONTROL
VALVE Identification Chart, Page 2–60.)
Assemble: Always use new O–ring. Tighten the plug to
35–40 ft.–lbs. (47–54 Nm) torque.
Remove the load check plug [B].
Remove the spring and poppet [C].

CD–10795
773 BICS Loader

509616541 & Below) (Cont’d) A
Main Relief Valve
Loosen the main relief valve [A].
Assemble: Always use new O–rings and back–up
washers. Tighten to 35–40 ft.–lbs. (47–54 Nm) torque.
CD–10796
Remove the main relief valve [B].

B
CD–10797
Remove the O–ring and back–up washers from the main

relief valve [C].
C 1 2 3 4 5
E–01509
1. Relief Valve
2. Back–up Washer
3. O–ring
4. O–ring
5. Back–up Washer
CD–10798
Port Relief Valve

Loosen the port relief valve [D]. D
NOTE: The port relief valve can be located on either
side of the control valve (E or F ports). (See
CONTROL VALVE Identification Chart Page
2–60.)
CD–10799
773 BICS Loader

509616541 & Below) (Cont’d) A
Port Relief Valve (Cont’d)
Remove the port relief valve [A]. 1
CD–10800
Remove the O–rings and back–up washer from the port

relief valve [B].
B 1 2
3 4
NOTE: The port (Item 1) [A] may contain an available

E–01509
3500 PSI anti–cavitation/port relief valve for
the base end of the tilt section. 1. Relief Valve
2. O–ring
3. Back–up Washer
4. O–ring
CD–10801
Loosen the anti–cavitation valve [C].
C
NOTE: The anti–cavitation valve can be located on

either side of the control valve (E or F ports).
(See CONTROL VALVE Identification Chart
Page 2–60.)
CD–10802
Remove the anti–cavitation valve from the control valve

[D]. D
NOTE: This port (Item 1) [D] may contain an available 1
3500 PSI port relief valve for the rod end of the
tilt section.
CD–10803
773 BICS Loader

CONTROL VALVE (S/N 509640659 & Below, S/N 2
1
509616541 & Below) (Cont’d) A 3 4
Remove the O–rings and back–up washer from the
anti–cavitation valve [A].
E–01509
1. Anti–Cavitation Valve
2. O–ring
3. Back–up Washer
4. O–ring
CD–10804
Rubber Boot B
Loosen the two bolts on the rubber boot retainer [B].
Assemble: Tighten the bolts to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.
CD–10805
Remove the bolts [C].

C
CD–10806
Remove the rubber boot and retainer [D].

D
CD–10807
773 BICS Loader

509616541 & Below) (Cont’d) A
Rubber Boot (Cont’d)
Remove the back–up washer [A].
CD–10808
After the spool is removed, use a O–ring pick and remove

the spool seal from the spool bore [B]. B
NOTE: See Page 2–73 for spool seal identification
and installation.
CD–10809
Lift Spool Detent

C
procedure:
MEL1278 – Detent Tool
Remove the snap ring with a screwdriver [C].
CD–10810
Remove the snap ring and washer [D].

D
CD–10811
773 BICS Loader

509616541 & Below) (Cont’d) A
Lift Spool Detent (Cont’d)
Remove the bolts from the detent cap [A].
Assemble: Tighten the bolts to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.
CD–10812
Remove the detent cap [B].

B
The detent assembly has small springs and

balls. Do not lose these parts during
I–2012–0284
CD–10813
Put a rag around the detent sleeve [C]

C
CD–10814
Remove the detent sleeve, detent balls and spring [D].

D
CD–10815
773 BICS Loader

509616541 & Below) (Cont’d) A
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

509616541 & Below) (Cont’d) A
Lift Spool Only: Remove the stud from the end of the
spool [A].
Removal of the plastic plug:
a. Make a center point in the plug using a 3/16 inch drill.
b. Drill a hole all the way through the plug using a 7/64
inch tap drill.
c. Turn a 6–32 tap into the plug. Pull the tap and plug
out of the spool. BE CAREFUL, do not break the tap. CD–10820
d. Clean all the debris from the inside of the spool bore.
B
Assemble: Install the new plastic plug. Install the stud
and leave about 0.600 inch (15,2 mm) sticking out [B].
NOTE: DO NOT USE LOCTITE ON THE STUD
THREADS.
Plastic
Plug 0.600’’
(15,2 mm)
B–09973
NOTE: Put grease on all detent components

surfaces before assembly. C
Install the detent balls and spring into the detent adapter.
Hold the detent balls in position with the tool and install the
detent adapter into the end cap [C].
CD–10821
Install the spool seal, back–up washer, centering spring,

end cap/detent adapter on the valve spool. Tighten the
detent adapter to 90–100 in.–lbs. (10,2–11,3 Nm) torque.
D
Install the detent balls and spring [D].
CD–10822
773 BICS Loader

509616541 & Below) (Cont’d) A
Hold the detent balls and spring in position with the tool
[A].
CD–10823
Install the detent sleeve over the balls and into position
[B]. B
CD–10824
Tilt Centering Spring

Remove the end cap bolt [C]. C
Assemble: Tighten the screws to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.
CD–10825
Remove the end cap [D].

D
CD–10826
773 BICS Loader

509616541 & Below) (Cont’d) A
Tilt Centering Spring (Cont’d)
Remove the spool, centering spring, back–up washer and
spool seal [A].
Assemble: If the centering spring bolt is removed, tighten
to 90–100 in.–lbs. (10,2–11,3 Nm) torque. Put grease on
all the centering spring component parts. Always use new
spool seal.
CD–10827
Auxiliary Spool B
Remove the end plate bolt [B].
Assemble: Tighten the bolt to 90–100 in.–lbs. (10,2–11,3
Nm) torque.
CD–10828
Remove the end plate, O–ring and spring [C].

C
Remove the end plate, O–ring and spring from the other
side.
CD–10829
Remove the washer (both sides) [D].

D
CD–10830
773 BICS Loader

509616541 & Below) (Cont’d) A
Auxiliary Spool (Cont’d)
Remove the auxiliary section spool from the control valve
[A].
CD–10831
Auxiliary Electric Solenoid B

Remove the nut from the end of the solenoid [B].
Assemble: Tighten the nut to 9–12 in.–lbs. (1,02–1,36
Nm) torque.
CD–10832
Remove the solenoid coil and end plate [C].

C
CD–10833
Loosen the electric solenoid valve [D].

D
Assemble: Tighten the electric solenoid valve to 96–144
in.–lbs. (10,8–16 Nm) torque.
CD–10834
773 BICS Loader

509616541 & Below) (Cont’d) A
Auxiliary Electric Solenoid (Cont’d)
Remove the electric solenoid valve from the control valve
[A].
NOTE: Always use new O–rings and back–up

washers when assembling.
CD–10835
Remove the plug from the control valve (H port) [B]. (See
CONTROL VALVE Identification Chart, Page 2–60.) B
Replace the O–ring.
CD–10836
Depending on the application of the auxiliaries, the control

valve may be equipped with a port relief valve (H port,)
[C]. (See CONTROL VALVE Identification Chart, Page
C
2–60.)
Remove the port relief valve and replace the O–rings and
back–up washers. (See Page 2–62.)
Inspection
Check the spools for wear or scratches.
Check that the centering springs are not broken.
Check that the load check valve seats are not worn. CD–10837
Check the load check poppets for damage.

Check the rubber boots and retainers that they are not
worn or damaged.
Replace the parts as needed.
773 BICS Loader

509616541 & Below) (Cont’d) A LIP FACE
TOWARD
Identification And Installation Of Spool Seal VALVE BODY
1. Uses only lip seal.
2. Check the seal surface area for rust, corrosion, CUT AWAY SIDE VIEW
scratches, etc. Correct any irregularities before OF VALVE BODY 1
continuing.
MC–01699
3. Put clean oil on the valve spool. Install the lip seal
over the valve spool. Be Careful not to damage the
lip seal on the valve spool edges.
NOTE: An alternate method is to protect the lip seal
by putting plastic material (Example:
Discarded microfiche card) over the spool to
protect the seal.
4. Install spool into the valve bore. 2

NOTE: Lubricate with grease between the seal and
retainer before installation (both ends).
5. Slide the linkage end lip seal over the rubber boot 0.145’’ (3,7 mm)
groove. Be Careful not to damage the seal.
6. Install the seal retainer.

45°
7. Continue with assembling the control valve.
LATEST PRODUCTION MC–01606
CD–15080
INSTALLING LIP
SEAL ON VALVE
SPOOL INSTALLING LIP SEAL
RETAINER
CD–15081
773 BICS Loader

MAIN RELIEF VALVE
Checking
A
procedure:
MEL10003 – Hydraulic Tester
MEL10006 – Hydraulic Test Kit
2
Turn the key switch to the OFF position, as the engine
stops running, turn the key switch all the way to the left to 1
release the hydraulic pressure at the front auxiliary quick
couplers.
P–04343
Connect the IN port (Item 1) [A] of the hydraulic tester to
the bottom (female) quick coupler on the loader.
Connect the OUT port (Item 2) [A] of the hydraulic tester
B
to the top (male) quick coupler on the loader.
2
1
The hydraulic tester must be in the fully open
position before you start the engine.
I–2024–0284 3
P–03272
Put jackstands under the front axles and rear 1

the machine to fall or move and cause injury or Right
death. Steering
W–2017–0286 Lever
Control
(Optional)
Start the engine and run at low idle RPM. Push the mode
switch (Item 1) [B] twice (on the instrument panel) to
engage the front auxiliary hydraulics detent, the lights
(Items 2 & 3) [B] will come ON. P–02152
Push the button (Item 1) [C] for fluid flow to the quick
couplers.
Watch the flow meter on the hydraulic tester to make sure
the flow is correct. Increase the engine speed to full RPM.
There should be 15 GPM (56 L/min.) free flow. Turn the
restrictor control, on the tester, until the main relief valve When the engine is running during service, the
opens. The correct pressure for the main relief is 3000 steering levers must be in neutral and the
PSI (20600 kPa). parking brake engaged. Failure to do so can
W–2006–0284
Push the button (Item 1) [C] to disengage the detent
position to the front quick couplers.
If the relief valve pressure is not correct, stop the engine.
Adjust (See Page 2–75) or replace the main relief valve.
(See Page 2–62.)
773 BICS Loader
MAIN RELEIF VALVE (Cont’d)
Adjustment
A
If the pressure is not correct, adjust the main relief valve. O–ring
Remove the end cap (Item 1) [A].
Turn the adjusting screw in or out until the pressure is
correct.
1
NOTE: If the correct pressure can not be reached,
replace the main relief valve. Check the
pressure setting of the new relief valve.
Back–up
Removal and Installation B–06764

Clean the area around the control valve. Loosen and
B
remove the main relief valve (Item 1) [B].
Remove the O–rings and back–up washers [A].
Clean the main relief valve in clean solvent. Use air 1
pressure to dry the valve.
Install new O–rings and back–up washers. Install the
main relief valve (Item 1) [B] and tighten. Check the
pressure again. (See Page 2–74.)
Installation: Tighten the main relief valve to 35–40
P–04178

the system.
I–2003–0888
NOTE: The control panel and lift lock valve have

been removed for clarity only. They do not
need to the removed for this main relief valve
removal and installation procedure.
NOTE: The valves may appear to be different, but the

773 BICS Loader

HYDRAULIC PUMP
A
1
P–11779

or death. W–2059–0598 1
Stop the engine. Move the hydraulic controls to release

the hydraulic pressure.
N–00809
Raise the seat bar.
Lift and block the rear of the loader. (See Page 1–1.) C
1
Remove the tilt lock valve. (See Page 8–1.) (Earlier
models only.) 2
Disconnect the case drain hose (Item 1) [A] from the main
control valve.

Drain the hydraulic fluid (using the case drain hose) from 4 3
the reservoir into a clean container.
P–04136
Disconnect the hydraulic pump inlet hose (Item 1) [B]
from the reservoir and drain as much fluid from the hose
as possible. Reconnect the hose to the reservoir.
Disconnect the inlet hose (Item 1) [C] from the hydraulic
pump (Item 2) [C].
Disconnect the hose (Item 3) [C] (which is routed to the
tilt lock valve), from the side of the hydraulic pump outlet
fitting on earlier machines only. When repairing hydrostatic and hydraulic
NOTE: Also disconnect the pilot pressure hose (not systems, clean the work area before
shown) from the pump outlet fitting if the disassembly and keep all parts clean. Always
loader has optional rear auxiliary hydraulics. use caps and plugs on hoses, tubelines and
the system. I–2003–0888
Disconnect the hydraulic pump outlet hose (Item 4) [C]
from the outlet fitting.
773 BICS Loader

Revised Jan 99 –2–76– Service Manual
HYDRAULIC PUMP (Cont’d)
A
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.
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
W–2103–1285
See Page 2–80 for the proper Disassembly and

Assembly procedures.
773 BICS Loader

Revised Jan 99 –2–77– Service Manual
Checking The Output Of The Hydraulic Pump
A
procedure:
MEL 1429 – Remote Start Switch
MEL10003 – Hydraulic Tester 1
MEL10006 – Hydraulic Test Kit
NOTE: *Relief pressure must be per specification
before the test is done.
N–15482
Put jackstands under the front axles and rear B

the machine to fall or move and cause injury or 1
death. W–2017–0286

device. (See Page 1–1.) 2

or death. W–2059–0598
Rasie the operator cab. (See Page 1–1.)

Connect the remote start switch. (See Page 1–1.)
NOTE: Photos may appear different but the

Disconnect the OUTLET hose (Item 1) [A] from the N–15776
pump.
Connect the INLET hose (Item 1) [B] from the tester to the
OUTLET fitting (Item 1) [C] of the pump. Connect the
C
OUTLET hose (Item 2) [B] from the tester to the hose 1
(Item 2) [C] which was disconnected from the pump.
The hydraulic tester must be in the fully open

position before you start the engine.
I–2024–0284
P–04351
773 BICS Loader

Check The Output Of The Hydraulic Pump (Cont’d)
A EXAMPLE: TESTER
CONNECTION
Reservoir
Sample tester connection shown [A].
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.
Warm the fluid to 140°F. (60°C.) by turning the restrictor
control (Item 1) [A] on the tester to about 1000 PSI (6895 Hydraulic Pump
kPa). DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (GPM) at full Out In
RPM. Hydraulic Control
Valve
Push the mode switch (on the remote start switch) to
engage the front auxiliary hydraulics, the light will come
ON. Push the button (on the right steering lever) for fluid 1
flow to the quick coupler (fluid pressure will go over main
relief). Record the highest pressure (PSI) and flow BH–00196
(GPM). The high pressure flow must be at least 80% of
free flow.
HIGH PRESSURE FLOW (GPM)

%= X 100
FREE FLOW (GPM)
A low percentage may indicate a failed pump.
*Refer to SPECIFICATIONS Section 9–1 for system
relief pressure and full RPM.
773 BICS Loader

A

the system. CD–10735
I–2003–0888
Mark the pump sections for correct assembly.

B
Loosen the pump bolts [A].
Assemble: Tighten the bolts to 25 ft.–lbs. (34 Nm)
torque.
Remove the pump housing bolts [B].
CD–10736
Remove the end housing [C].

C
CD–10737
Remove the O–rings and seals from the end housing [D].
D
CD–10738
773 BICS Loader

A
Disassembly And Assembly (Cont’d)
Remove the mounting flange end housing [A].
Remove the O–ring and seal from the end housing.
CD–10739
Remove the bearing housing [B]. B
CD–10740
Remove the drive gear [C]. C
CD–10741
Remove the idler gear [D].

D
CD–10742
773 BICS Loader

A
Remove the other end bearing housing [A].
NOTE: Always use new O–rings and seals when

assembling the hydraulic pump.
CD–10743
Inspection
B
Wash all parts in clean solvent and use air pressure to dry
them.
Make a visual inspection of all the parts. If parts are visibly
worn or damaged, pump replacement is necessary.
Check the gear [B]. If excessive wear is visible on the
journals, side or face of the gears they must be replaced.
If the splines are worn, replace the drive gear.
Check the bushings in the housing [B]. Replace the
bushings as needed.
CD–10744
Identification
MODEL: 773 1. BOLT

2. WASHER
3. END HOUSING
4. O–RING SEAL
5. SEAL
6. RING
7. BODY
8. BEARING HOUSING
9. DRIVE GEAR
1 10. IDLER GEAR
2 3 11. DOWEL
4 12. END HOUSING
5 13. O–RING
6 7
8
10
8 6
5
12 13
11 2
TS–01022
773 BICS Loader

HYDRAULIC FILTER HOUSING
A
4
2 1

ports to keep dirt out. Dirt can quickly damage 3
the system. P–11784
I–2003–0888
B
Stop the engine and open the rear door.
Remove the muffler. (See Page 7–1.)
Disconnect the wires from the charge pressure sender
(Item 1) [A] from the filter housing.
Disconnect the temperature sender connector (Item 2) 1

[A] from the filter housing.
Disconnect the oil cooler tubeline (Item 3) [A] from the N–15399
filter housing.
Remove the two mounting bolts (Item 4) [A] from the filter
housing mounting bracket.
C
Installation: Tighten the mounting bolts to 25 ft.–lbs. (34 1

Nm) torque.
Disconnect the hose (Item 1) [B] from the filter housing
outlet.
Disconnect the wire (Item 1) [C] from the differential

pressure switch on the filter housing.
Remove the hydraulic filter housing and filter.
P–04207
Reverse the removal procedure to install the filter housing
and filter.
773 BICS Loader

HYDRAULIC FLUID RESERVOIR
A

lift arm support device. Failure to use an N–00808
or death. W–2059–0598
B
Hydraulic fluid reservoir is located behind the operator 1
cab mounted on the loader frame (Item 1) [A].
Disconnect the case drain hose (Item 1) [B] from main

control valve.
Place the end of hose in a clean container and drain the
fluid from the reservoir. P–11779
Disconnect the fuel fill hose (Item 1) [C], fuel tank C

breather hose (Item 2) [C]. 2
Disconnect the hydraulic pump inlet hose (Item 3) [C]
from the reservoir.
4
Disconnect the tubeline (Item 4) [C] from the reservoir 1
which comes from the tilt lock valve.
N–00809
Remove the right side mounting bolt (Item 1) [D] and plate D
from the mounting strap.
Installation: Tighten the bolt to 16–20 ft.–lbs. (22–27
Nm) torque.
Remove the hydraulic reservoir from the loader.
Reverse removal procedure to install the hydraulic fluid
reservoir. 1
Refer to the loader specification section for the correct
hydraulic fluid capacity.
P–04067
773 BICS Loader

CONTROL PEDALS
A
Remove the bolt (Item 1) [A] and nut from the pedal 1
linkage.
Installation: Tighten the bolt and nut to 21–25 ft.–lbs.
Check the rubber bushing in the pedal for wear and
replace as needed.
P–04059
Remove the two mounting bolts (Item 1) [B] from the

pedal mounting bracket. B
Remove the pedal assembly from the loader. 1
Pedal Adjustment
After installing the pedal, adjust the pedal so that there is
clearance under the rear of the pedal. The valve spool
must travel full stroke without the pedal hitting the floor
panel.
P–04061

Adjust locking tabs on control linkage so that
lift and tilt control pedals or (Mechanical Hand
Controls) are locked in neutral when the seat
bar is up.
W–2104–0199
NOTE: See Page 2–87 for correct procedure to

adjust the pedal interlock linkage.
773 BICS Loader

CONTROL INTERLOCK LINKAGE (Pedal or
Mechanical Hand) A
Remove the lock nuts (Item 1) [A] from the interlock
shield (Item 2) [A].
2 1
Installation: Tighten the lock nuts to 25–28 ft.–lbs.
Remove the interlock shield (Item 2) [A] from the
interlock.
P–04048
Remove the lock nuts and plastic washers (Item 1) [B]

from the interlock bolts.
B
Installation: Tighten the interlock nut to 84–96 in.–lbs.
2
(9,5–10,8 Nm) torque.
Remove the spring (Item 1) [D] from under the interlock
block (Item 2) [B].
Remove the interlock.
1
P–04046
Remove the plastic washers (Item 1) [C] which are C

located between the interlock and the fender.
Installation: During installation be sure to keep the

interlock pressed against the loader frame so the plastic
washers (Item 2) [D] do not fall off the collar of each lock
nut. If the washer does not sit properly over the collar on
the lock nut, it will become wedged between the fender 1
and the lock nut.
After installation, inspect the seat bar operation. (See
Page 1–1.)
P–04050
D 1
2
P–04049
773 BICS Loader

CONTROL INTERLOCK LINKAGE (Pedal or
Mechanical Hand) (Cont’d) A
Adjustment
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].
If not, loosen the tab mounting nuts (Item 3) [A] and bolts.
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

Removal And Installation (S/N 509640660 & Above
A 2
S/N 509616542 & Above)
3 4
Raise the loader lift arms and install an approved lift arm
support device. (See Page 1–1.) N–15060
B
1

or death. W–2059–0598
1
N–15067

the system. I–2003–0888
Install jackstands under the rear corners of the loader.

Raise the loader operator cab. (See Page 1–1.)
Drain the hydraulic fluid reservoir. (See Page 2–84.)
The lift lock by–pass valve (Item 1) [A] is located under
the right side of the control panel.
Remove the engine speed control. (See Page 7–1.) This
procedure is optional.
If you choose not to remove the engine speed control and
control panel, the lift arm by–pass control knob (Item 2)
[A] will need to be removed from the control panel.
Hold the by–pass control knob (Item 2) [A] and loosen the
jam nut (Item 3) [A] on the by–pass valve shaft.
Remove the by–pass control knob and jam nut from the
valve shaft.
Remove the rubber washer (Item 4) [A].
Disconnect the two hoses (Item 1) [B] from the lift lock
by–pass valve (Item 1) [A].
773 BICS Loader
LIFT LOCK BY–PASS VALVE (Cont’d)
A
Removal And Installation (S/N 509640660 & Above
S/N 509616542 & Above) (Cont’d)
Remove the two mounting bolts and nuts (Item 1) [A] from
the lift lock by–pass valve.
Installation: Tighten the two mounting bolts and nuts to
180–200 in.–lbs. (21–23 Nm) torque.
Refer to Page 8–1 for lift arm by–pass control inspection 1
procedure.
Reverse the removal procedure to install the lift lock
by–pass valve in the loader.
N–15068
Disassembly And Assembly (S/N 509640660 & Above

S/N 509616542 & Above)
B
Remove the by–pass valve (Item 1) [B] from the valve
block. Inspect the by–pass valve for damage and replace
if necessary.
1
Installation: Tighten the valve to 33–37 ft.–lbs. (45–50
Nm) torque.
Inspect the hydraulic fittings on the valve block for
damage and replace if necessary.
N–00927
773 BICS Loader

Removal And Installation (S/N 509640659 & Below,
A
S/N 509616541 & Below)
support device. (See Page 1–1.) P–03992
B
1
lift arm support device. Failure to use an 2
or death. W–2059–0598
P–03991
When repairing hydrostatic and hydraulic C

disassembly and keep all parts clean. Always 1
the system.
I–2003–0888
Install jackstands under the rear corners of the loader.

Drain the hydraulic fluid reservoir. (See Page 2–84.)
The lift lock by–pass valve (Item 1) [A] is located under
the right side of the control panel. P–04095
Remove the engine speed control. (See Page 7–1.) This

procedure is optional.
Control panel removal is optional. (See Page 3–1.)
If you choose not to remove the engine speed control and
control panel, the lift arm by–pass control knob (Item 1)
[B] will need to be removed from the control panel.
Hold the by–pass control knob (Item 1) [B] and loosen the
jam nut (Item 2) [B] on the by–pass valve shaft.
Remove the by–pass control knob and jam nut from the
valve shaft.
Remove the rubber washer (Item 3) [B].
Disconnect the five tubelines from the lift lock by–pass
valve (Item 1) [C].
773 BICS Loader
LIFT LOCK BY–PASS VALVE (Cont’d)
A
S/N 509616541 & Below) (Cont’d)
Remove the two mounting bolts and nuts (Item 1) [A] from 1
the lift lock by–pass valve.
Installation: Tighten the two mounting bolts and nuts to
180–200 in.–lbs. (21–23 Nm) torque.
1
Refer to Page 8–1 for lift arm by–pass control inspection
procedure.
P–04093
Remove and replace the by–pass valve mounting bracket

(Item 1) [B] if necessary. B 1
Reverse the removal procedure to install the lift lock
by–pass valve in the loader.

fuel and oil. Failure to use care around P–04094
W–2103–1285
C
Disassembly And Assembly (S/N 509640659 &
Below, S/N 509616541 & Below) 1
Remove the by–pass valve (Item 1) [C] from the valve
block. Inspect the by–pass valve for damage and replace
if necessary.
Remove the check valve (Item 2) [C] from the valve block.
Inspect the check valve for damage and replace if
necessary.
2
Inspect the hydraulic fittings on the valve block for
damage and replace if necessary. P–04096
773 BICS Loader

TILT LOCK VALVE
A
S/N 509616541 & Below) 3
Place jackstands under the rear corners of the loader.
Raise the loader lift arms and install an approved lift arm P–03993
support device (See Page 1–1).
B
1

or death. W–2059–0598 3
Drain the hydraulic fluid reservoir. (See Page 2–84.) P–04106
The tilt lock valve (Item 1) [A] is located on the right side
of the loader frame below the fuel fill hose (Item 2) [A]. C
Loosen the hose clamp (Item 3) [A] and disconnect the
fuel fill hose (Item 2) [A]. Position the hose out of the way
of the tilt lock valve.
Disconnect the P2 port tubeline (Item 1) [B] and the B1

port tubeline (Item 2) [B] from the tilt lock valve.
P–04103
Do not modify the electrical wiring connected
to the tilt lock valve solenoid. Service work for
the tilt lock valve should be performed by a
qualified technician. Use only genuine
Bobcat/Ingersoll–Rand parts if repair to the
BICS™is necessary. W–2166–0100
Remove the Do Not Modify sta–strap (P/N 6665527) from When repairing hydrostatic and hydraulic
the electric solenoid connector (Item 3) [B]. systems, clean the work area before
Installation: Install a new Do Not Modify sta–strap (P/N use caps and plugs on hoses, tubelines and
6665527) on the electric solenoid connector (Item 3) [B]. ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
Disconnect the X port tubeline (Item 1) [C] from the tilt
lock valve.
773 BICS Loader
TILT LOCK VALVE (Cont’d)
A
S/N 509616541 & Below) (Cont’d)
Disconnect the P1 port tubeline (Item 1) [A] from the tee
fitting located on the bottom of the tilt lock valve. Use a
tubeline wrench to remove the tubeline.
Remove the tilt lock valve mounting bolt (Item 2) [A], 3
spacer (Item 3) [A] and nut.
2
1
P–04112
Disconnect the PP port hose (Item 1) [B] from the tilt lock
valve. B
P–04113
Disconnect the PT port hose (Item 1) [C] from the tee

fitting on the bottom of the tilt lock valve. C
Remove the tilt lock valve from the loader.
Installation: Connect the PT port hose (Item 1) [C] to the

tee fitting as shown. Before connecting the PT port
tubeline (Item 1) [D], place the tilt lock valve in its normal 1
mounting position to check the routing of the PT port hose
(Item 1) [C]. Tighten the hose when the routing is correct. P–04116
Replace the tilt lock valve in its normal mounting position

and install the PT tubeline (Item 1) [D]. Use a tubeline
wrench to install the tubeline. D

which can result in injury or death. 1
W–2103–1285
P–04117
773 BICS Loader

TILT LOCK VALVE (Cont’d)
A
Disassembly And Assembly (S/N 509640659 &
Below, S/N 509616541 & Below)
Remove the solenoid mounting nut (Item 1) [A], solenoid
(Item 2) [A] and solenoid valve (Item 3) [A] from the tilt
lock valve.
3 1
P–04115
Remove the check valve (Item 1) [B] from the lift lock
valve.
B
Assembly: Tighten the solenoid mounting nut to 80–90
in.–lbs. (9–10 Nm) torque.
Inspect the solenoid valve, check valve and hydraulic
fittings for damage or wear. Replace if necessary.
Refer to Page 8–1 for lift arm by–pass control inspection
procedure.
1
P–04114
773 BICS Loader

HYDROSTATIC SYSTEM
Page
Number
CONTROL PANEL
Rubber Boot Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
Steering Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
Steering Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 3–6
Steering Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Steering Shock Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
HYDROSTATIC
DRIVE BELT HOUSING SYSTEM
FIXED DRIVE BELT TENSIONER PULLEY

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–62
Checking Pulley End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–66
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–60
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–59
HYDROSTATIC MOTOR 30 SERIES
Assembly – (S/N 509639899 & Above &
S/N 509616505 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29
Disassembly – (S/N 509639899 & Above &
S/N 509616505 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24
Parts Identification – (S/N 509639899 & Above &
S/N 509616505 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
HYDROSTATIC DRIVE MOTOR

Disassembly and Assembly – (S/N 509639898 & Below &
S/N 509616504 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
Parts Identification – (S/N 509639898 & Below &
S/N 509616504 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
Inspection – (S/N 509639898 & Below &
S/N 509616504 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14
Timing the Hydrostatic Motor – (S/N 509639898 & Below &
S/N 509616504 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22
HYDROSTATIC PUMP
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–48
Swashplate Pre–Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–50
HYDROSTATIC SYSTEM INFORMATION

Checking Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
OIL COOLER
773 BICS Loader

HYDROSTATIC SYSTEM
Page
Number
SPRING LOADED DRIVE BELT TENSIONER PULLEY
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–56
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–55
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–54
STEERING LINKAGE
Steering Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10
Steering Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

773 BICS Loader

TROUBLESHOOTING
Chart
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
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
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

HYDROSTATIC SYSTEM INFORMATION
A CHARGE OIL

ports to keep dirt out. Dirt can quickly damage Valve Moves for Charge
the system. FUNCTION 1 Oil Replacement
I–2003–0888
Replenishing Valve Function

The functions of the replenishing valves are:
1. To give replacement fluid to the low pressure side
of the hydrostatic circuit. Replacement fluid is
needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling;
Function 1 [A].
2. To keep high pressure fluid out of the low pressure
side of the hydrostatic circuitry; Function 2 [A].
Valve Stays on Seat to
Hold High Pressure for Drive
Checking Charge Pressure FUNCTION 2
Lift and block the loader. (See Page 1–1.) B–02804
B
2
Put jackstands under the front axles and rear 1

death.
W–2017–0286
Open the rear door.

N–00973
Disconnect the wires (Item 1) [B] from the charge
pressure sender.
Remove the charge pressure sender (Item 2) [B] from C
fitting.
Install a gauge (Item 1) [C] as shown.
Start the engine. 1
The gauge must read as follows:
200 PSI (1379 kPa) with approximately 120° F (49° C)
fluid.
If the charge pressure is not correct remove the charge
relief valve at the pump. (See Page 3–40.)
Check the poppet and spring for wear or damage. N–00973
773 BICS Loader

CONTROL PANEL
A 2
Removal and Installation
P–04188
B
2 2
lift arm support device. Failure to use an 1 1
or death. W–2059–0598

Remove the engine speed control. (See Page 7–1.)
NOTE: Photo’s may appear different but the P–04074

Loosen the jam nut (Item 1) [A] from the by–pass control
knob (Item 2) [A].
C
Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [A]. 1
Disconnect the control harness connectors (Item 4) [A]
from the right side steering lever.
NOTE: If the loader is equipped with rear auxiliary
hydraulics, also disconnect the electrical
connectors from the left side steering lever.
Scribe a mark across the top of the steering linkage bars
(Item 1) [B] which are connected to the steering shaft on 1
the control panel. P–04073
Remove the four steering linkage mounting bolts (Item 2)

[B].
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to
25–28 ft.–lbs. (34–38 Nm) torque.
Remove the four control panel mounting bolts (Item 1) [C]
from both sides of the control panel.
Installation: Tighten the control panel mounting bolts to corners of the frame before running the engine
25–28 ft.–lbs. (34–38 Nm) torque. for service. Failure to use jackstands can allow
Remove the control panel from the loader. death.
W–2017–0286
panel.
773 BICS Loader

CONTROL PANEL (Cont’d)
Steering Shock Removal And Installation
A
Remove the mounting nut (Item 1) [A] from the end of the
shock connected to the steering linkage.
Remove the mounting nut (Item 2) [A] from the other end 3
of the shock connected to the bracket on the control
panel.
Installation: Tighten the mounting bolts to 25–28 ft.–lbs.
2 1
Steering Shaft Removal And Installation
P–04069
NOTE: The steering shaft can be removed without
removing the control panel from the loader.
Photo [B] shows the control panel removed
for clarity purpose only.
B
2
Remove the steering linkage mounting bolts (Item 3) [A].
Remove the steering shock mounting nuts (Item 2) [A].
Remove the steering shaft pivot bolt (Item 1) [B] from 1

both sides of the control panel.
Installation: Tighten the pivot bolts to 180–200 in.–lbs.
(21–23 Nm) torque. P–04146
Remove the steering shaft from the control panel.

C
Steering Shaft Disassembly And Assembly
Disassemble the right and left steering shafts from the
cross shaft assembly [C]. 1
Assembly: Install new nylon bushings (Item 1) [C] as

needed when assembling the steering shaft. Be sure to 1
apply grease on the cross shaft before installing the right
and left steering shaft.
1
P–04154
To remove the steering shaft mounting bracket (Item 2)

[B], remove the three mounting bolts (Item 1) [D] from the D
front of the control panel.
Remove the steering shaft mounting bracket.
1
P–04193
773 BICS Loader

CONTROL PANEL (Cont’d)
A
Steering Lever Removal And Installation
Disconnect the electrical connectors from the steering
lever [A]. 2
Remove the nuts from the two U–bolts (Item 1) [A] used
to mount the steering lever.
Remove the U–bolts from the steering lever mount.
Remove the steering lever (Item 2) [A] by sliding the lever 1
P–04188
through the rubber boot (Item 1) [B] on the front of the
control panel.
Installation: Tighten the u–bolts so the lever can not be
moved either right or left when seated in the operator
B
seat. Be sure the steering lever does not interfere with the
operator cab when lowering or raising the cab.
3
Rubber Boot Replacement
2
To replace the rubber boot (Item 1) [B] on the control
panel, remove the steering lever (See above procedure).
1
Drill out the four rivets (Item 2) [B] located on the flange
of the rubber boot and remove the old boot.
Install the new boot and reinstall the steering lever.
P–04193
773 BICS Loader

STEERING LINKAGE
A
Remove the nut (Item 1) [A] from the end of the centering
spring shoulder bolt (Item 2) [A].
Remove the shoulder bolt/spring assembly.
Installation: Tighten the centering spring shoulder bolt
and a NEW lock nut to 25–28 ft.–lbs. (34–38 Nm) torque.
2
1
P–03729
Slide the plate (Item 1) [B] to the right and remove it from
the two guide pins (Item 2) [B]. B
NOTE: The two guide bushings (Item 3) [B] will be 1
loose and can fall out of the plate (Item 1) [B] 2
as soon as it is removed from the guide pins
(Item 2) [B].
3 2
P–03736
C EARLY MODELS
5 6
4
1
The centering plate/centering spring assembly consists
of the following parts; shoulder bolt (Item 1), [C], shoulder
bushings (Item 2) [C], spring (Item 3) [C], lock nut (Item
4) [C], centering plate (Item 5) [C] and guide bushings
(Item 6) [C].
Earlier Models: 2
2 3
When servicing early model machines, order and install P–03735
new parts to include a bolt (Item 1) [D], washer (Item 2)
[D], spacer tube (Item 3) [D], nut (Item 4) [D] and
bushings (Item 5) [D], See parts manual for correct part
numbers. D LATER MODELS
4
2
1
3
N–16758
773 BICS Loader

STEERING LINKAGE (Cont’d)
A
1 2
If the surface of any of the four pintle cams (Item 1) [A] 3
are worn, loosen the bolt (Item 2) [A] and rotate the cams
1/4 turn.
Tighten the bolts to 45–50 ft.–lbs. (62–68 Nm) torque.
2
NOTE: When replacing the old style pintle levers 1
(Item 3) [A], wear cams (Item 1) [A] and cam
bolts (Item 2) [A]; order and install the latest
style parts. See the parts manual for correct
part numbers. P–03733
Remove the nut (Item 1) [B] from the torsion B

bushing/linkage bar. The bolts is threaded into the linkage
bar, remove the bolt from underneath the pintle lever.
1
Nm) torque, then tighten the nut to 21–25 ft.–lbs. (28–33
Nm) torque.
P–03733
Remove the linkage bar (Item 1) [C] and remove the

torson bushing (Item 2) [C].
C
2
Remove the nuts (Item 1) [D] from both shock absorber

ball joint ends.
Remove the shock absorbers. 1
Installation: Tighten the nuts to 25–28 ft.–lbs. (34–38
Nm) torque.
P–03734
Remove the nuts (Item 2) [D] from the linkage bar
mounting bolt. The bolts (Item 3) [D] are threaded into the
linkage bars, remove the bolts (Item 3) [D].
D 1
The torsion bushings can now be removed from the

steering bell cranks.
3 1
Installation: Tighten the bolts to 11–13 ft.–lbs. (21–25 2
Nm) torque, then tighten the nuts to 21–25 ft.–lbs. (28–33
Nm) torque.
The linkage and the centering plate must be readjusted 1
for neutral after the components have been reassembled.
See Page 3–12 for the neutral adjustment procedure.
P–04069
773 BICS Loader

A
Steering Linkage Adjustment
2
2
or death. W–2059–0598 P–04069
device. (See Page 1–1.) B
1

for service. Failure to use jackstands can allow 2
death. 4 3
W–2017–0286
P–03726
Raise the operator cab. (See Page 1–1.) C
Connect the remote start switch (MEL1429). (See Page
1–1.)
Pre–load tension in the torsion bushings must be
removed before adjusting the steering linkage.
Loosen the nut (Item 1) [A] 3 to 4 turns, then loosen the
bolt (Item 2) [A]. The bolt (Item 2) [A] is threaded into the
linkage bar (Item 3) [A]. The bolt (Item 2) [A] must be 3
loosened enough to allow the torsion bushing to turn
freely between the steering bellcrank and the linkage bar. 1 2
Loosen the nut (Item 1) [B] 3 to 4 turns, then loosen the
bolt (Item 2) [B]. The bolt (Item 2) [B] is threaded into the P–03724
linkage bar (Item 3) [B]. The bolt (Item 2) [B] must be
loosened enough to allow the torsion bushing to turn
freely between the pintle arm and the linkage bar. D
Move the right side steering lever to the rear and install
a 3/8 inch (10 mm) thick spacer (Item 1) [C] between the
pintle arm cam (Item 2) [C] and the centering block (Item
3) [C].
Move the right side steering lever forward and install a
15/16 inch (24 mm) thick spacer (Item 1) [D] between the 2
center plate (Item 2) [D] and the mounting plate (Item 3)
[D].
This will allow the pintle arms to move freely while
adjusting the steering linkage for full forward travel speed. 1
3
Remove the 3/8 inch (10 mm) thick spacer (Item 1) [C]. P–03723
773 BICS Loader

Steering Linkage Adjustment (Cont’d)
A 4
Before adjusting the linkage, check that the pintle arm 2
mounting bolt (Item 1) [A] is tight, 25–28 ft.–lbs. (34–38
Nm) torque and that there is no play between the pintle
arm (Item 2) [A] and the square pump shaft (Item 3) [A]. 1
Also check that the cam mounting bolts (Item 4) [A] are
tight, 45–50 ft.–lbs. (62–68 Nm) torque.
3
P–03730
Loosen the two bolts and nuts (Item 1) [B] on each

steering linkage bar. B
P–03727
Move the left hand steering lever to the full forward

position (until the lever hits the stop), then pull forward on
the left hand rear linkage bar until the pintle arm is rotated C
to the front as far as possible [C]. Use a locking plier and
clamp the two linkage bars together.
Tighten the nuts and bolts to 25–28 ft.–lbs. (34–38 Nm)
torque.
Check the lever movement to make sure that the pintle
arm and the steering lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the procedure for the right hand side linkage.
After both sides of the linkage have been adjusted, the
feel of both levers at full stroke should be the same. P–03728
Readjust the linkage if necessary.
Remove the spacer (Item 1) [D]. D
1
3
P–03723
773 BICS Loader

A
Steering Neutral Adjustment
1
The following tool listed will be needed to do the follwoing
procedure:
MEL1429A – Remote Start Switch
Connect the remote start switch to the engine harness.
(See Page 1–1.)
2
4 3
P–03726

corners of the frame before running the engine B
the machine to fall or move and cause injury or 2 1
2
death. 1
W–2017–0286
Loosen the nut (Item 1) [A] a couple of turns, then loosen

the bolt (Item 2) [A]. The bolt (Item 2) [A] is threaded into
the linkage bars (Items 3 & 4) [A].
The bolt (Item 2) [A] must be loose enough to allow the
torsion bushing to turn freely between the pintle arm and
the linkage bar.
P–03731
Loosen the four bolts (Item 1) [B] holding the two
centering blocks. Move the right hand centering block to
the right as far as possible.
C
NOTE: Bolt holes (Item 2) [B] are slotted for pintle
arm centering adjustment.
Adjust the left hand centering block first [C].

Start the engine and run at high RPM.
Move the traction lock override switch (Item 1) [D] to the
OFF position so the traction function is unlocked. The
wheels are now able to turn.
Move the left hand steering lever until the tires do not turn
(neutral position). P–03725
Move the left hand centering block to the left until it

contacts both pintle cams and the steering lever is still in
the neutral position [C].
D
1
NOTE: If the centering blocks are worn, they can be

removed and rotated 180 degrees and
reinstalled. If the cams are worn, they can be
loosened and rotated 90 degrees and
reinstalled.
P–04714
773 BICS Loader

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].
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.
P–04069
773 BICS Loader

HYDROSTATIC DRIVE MOTOR
A
device. (See Page 1–1.) P–04142
B
1

or death. W–2059–0598

fuel and oil. Failure to use care around 2
combustibles can cause explosion or fire P–04145
W–2103–1285
C
Remove the front and rear wheel/tire assemblies. (See
Page 1–1.)
Remove the control panel. (See Page 3–5.) 1
Remove the four motor cover mounting bolts (Item 1) [A].
Mark the two hoses (Item 1) [B] before disconnecting
them from the hydrostatic drive motor for correct
installation.
P–04148
NOTE: Photo may appear different, but the
D
Remove the two hoses (Item 1) [B] from the drive motor.
Remove the drain hose (Item 2) [B] from the drive motor.
Remove the four drive motor mounting bolts (Item 1) [C].
Installation: Tighten the drive motor mounting bolts to
90–100 ft.–lbs. (122–136 Nm) torque.
Remove the drive motor from the access hole in the
loader frame [D].
Reverse the removal procedure to install the hydrostatic
drive motor.
P–04141
773 BICS Loader

HYDROSTATIC DRIVE MOTOR (Cont’d)
Parts Identification – (S/N 509639898 & Below & S/N 509616504 & Below)
10
11
4
9
12
5 3
6
3 5
1 7
13
4
2
14
15 15
21 20
19 8
22
14
23 16
17
18 24
24 25
22
27 24
26
28 24
29
D–01443
Ref. Description Ref. Description

1. PLUG 16. O–RING
2. O–RING 17. SEAL, outer
3. SHUTTLE 18. SEAL, inner
4. SPRING 19. PLATE, balancing
5. POPPET 20. VALVE
6. PLUG 21. PLATE, valve
7. O–RING 22. O–RING
8. HOUSING 23. SHAFT
9. PISTON 24. O–RING
10. PLUG 25. GEROLER
11. O–RING 26. SHAFT
12. BOLT 27. FLANGE
13. BOLT 28. SEAL
14. SPRING 29. BUSHING, bronze
15. O–RING
773 BICS Loader

A
THE ILLUSTRATIONS MAY NOT EXACTLY SHOW
THE SAME MOTOR YOU ARE WORKING ON, BUT
THE PROCEDURE IS THE SAME.
Disassembly And Assembly (S/N 509639898 & Below
& S/N 509616504 & Below)
When repairing hydrostatic and hydraulic B–08695

ports to keep dirt out. Dirt can quickly damage B
the system.
I–2003–0888
Put a mark across the sections of the motor for correct

assembly.
Remove the four bolts from the motor [A].
Assembly: Tighten the bolts as follows:
50 ft.–lbs. (68 Nm) torque.
Lift the valve housing straight up [B]. If done carefully, the B–08692
springs and balanced plate will stay on the valve.
NOTE: See Page 3–20 for the correct installation of

the housing and the balance plate.
C
Remove the O–rings.

Remove the plug at the shuttle valve [C].
Assembly: Tighten the plug to 200 in.–lbs. (22,6 Nm)
torque.
B–08748
Remove the spring and shuttle [D].

D
B–08742
773 BICS Loader

Disassembly And Assembly) (S/N 509636898 &
A
Below & s/N 509616504 & Below) (Cont’d)
Remove the shuttle valve spool [A].
B–08741
Use a punch, through the housing and remove the

poppet, spring, O–ring and plug from the other side [B].
B
B–08696
Assembly: Make sure all parts are cleaned and check for
wear. Assembly as shown [C]. C
D–01526
Remove the balance plate [D].

D
B–08731
773 BICS Loader

A
& S/N 509616504 & Below) (Cont’d)
Remove the inner seal from the balance plate [A].
Assembly: Put grease on the seal and install as shown
[A]. Balance
Plate Outer
Outer Seal
Seal
Pin B–08733
Inner Seal Pin B–03046
Remove the outer seal from the balance plate [B]. B

Assembly: Put grease on the seal and install as shown
[B].
NOTE: When assembling the motor, See Page 3–22

for the timing of the motor when installing
the valve, valve drive and geroler.
Balance Outer
Outer Plate Seal
Seal
Pin B–08732
Inner Seal Pin B–03046
Remove the valve [C].

C
B–08738
Remove the valve plate [D].
D
B–08730
773 BICS Loader

A
& S/N 509616504 & Below) (Cont’d)
Remove the valve drive [A].
B–08729
Remove the geroler [B].

B
Make sure to keep the rollers in the geroler.
B–08739
Remove the drive shaft [C]. C
B–08736
Remove the O–rings from the housing [D].

D
B–08730
773 BICS Loader

A
& S/N 509616504 & Below ) (Cont’d)
Remove the O–rings inside the bore of the mounting
flange [A].
B–04636
The bushing is a guide to center the motor on the

gearcase. If the bushing needs replacing, use the
following procedure:
B
Drill several holes in the bushing [B].
B–09469
Use a chisel and hammer, remove the bushing from the

mounting flange [C].
C
Use a hydraulic press to install the new bushing.
B–09470
Assembly: When installing the balance plate in the end

housing, put your finger through the hole and hold it in
position until the housing and balance plate is in position D
[D].
NOTE: Always use new O–rings, gaskets and seals

when assembling the hydrostatic motor.
B–08690
773 BICS Loader

Inspection (S/N 509639898 & Below & S/N 509616504
A
& Below)
Clean all the parts in solvent and use air pressure to dry
them. DO NOT use cloth or paper because small pieces
of material can get into the system and cause damage.
Before the motor is assembled, check the following items:
Check the geroler rollers and rotor for wear and scratches B–06392
[A].
NOTE: Put all the rollers back in their original

position.
B–06394
Check the valve plate for scratches [B]. B
B–06390
B–06391
Check the balance plate for scratches [C].

Check the valve drive and the main drive for wear.
C
B–06389
Check the end plate surface for scratches [D]. D
B–06388
773 BICS Loader

Timing the Hydrostatic Motor (S/N 509639898 &
A Rotate Valve Clockwise
1/2 Tooth to Engage Spline
Below & S/N 509616504 & Below)
Anyone of 6 Ports
The timing of the motor controls the direction of rotation Open to Outside of Valve 4
of the drive shaft of the motor. The timing parts are as
follows: Largest Opening
1. Geroler (Item 1) [A]. Valve
2. Valve Drive (Item 2) [A].
3. Valve Plate (Item 3) [A].
4. Valve (Item 4) [A].

Case Drain
Find the largest opening between the geroler star and the Hole (2)
geroler ring and mark the outside of the geroler ring at that
point [A]. Valve Plate
Align the two drain holes and the three pressure holes in 2
the geroler ring with the same holes in the mounting
flange and install the geroler assembly. 3
Valve Drive
Install new O–rings. 1
Pressure
Install the valve drive [A]. Relief Hole (3)
Align the drain hole in the valve plate with the drain hole Geroler
in the geroler. Install the valve plate with the O–ring Ring
Geroler
toward the geroler. Make sure the slot opening of the Star
valve plate is in alignment with the largest opening of the C–02384
geroler.
Install the valve plate.
Install the valve on the valve plate. Make alignment with
one of the side openings with the mark on the geroler.
Turn the valve clockwise a small amount until the teeth on
the valve drive engage.
Continue with the rest of the assembly procedure.
773 BICS Loader

HYDROSTATIC MOTOR 30 SERIES
Parts Identification – (S/N 509639899 & Above & S/N 509616505 & Above)
10
11
9
8
13
3 16
14
6
15
3
7
21
22 6
20
17
19 43
18
19
17 20
1
2524 26
12 2
23
D–03431

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
12. PLUG 26. POPPET
13. FLANGE, mounting
14. SEAL, face
773 BICS Loader

HYDROSTATIC MOTOR 30 SERIES (Cont’d)
A
Disassembly (S/N 509639899 & Above & S/N
509616505 & Above)

ports to keep dirt out. Dirt can quickly damage N–00621
the system.
I–2003–0888
B
Drain the oil from the motor.
1
Seal all open ports and clean the motor with solvent.
Put a mark across the sections of the motor for correct
assembly [A].
Remove the nine bolts (Item 1) [B] from the motor.
N–00622
Lift and remove the mounting flange (Item 1) [C] from the
motor. C 1
NOTE: Do not scratch or damage the surfaces of the
motor sections. Always put them on a soft
surface.
N–00623
Turn the mounting flange over and remove the O–ring

(Item 1) [D] and back–up ring (Item 2) [D]. D 1
2
N–00624
773 BICS Loader

773ServiceManual#6900092–HydrostaticSystemSectionPart1of3
A
509616505 & Above) (Cont’d) 1
Turn the mounting flange backover and remove the seal

(Item 1) [A] from the mounting flange.
N–00625
Remove the balancing plate (Item 1) [B] from the gerolor

assembly.
B
1
N–00626
Remove the main drive (Item 1) [C] from the gerolor

assembly. C 1
N–00627
Remove the two check balls (Item 1) [D] from the gerolor.
NOTE: Care should be taken not to misplace the D

check balls.
N–00628
773 BICS Loader

A
509616505 & Above) (Cont’d)
Remove the square cut seal (Item 1) [A] from the gerolor.
N–00629
Remove the gerolor assembly (Item 1) [B]. B 1

NOTE: Care should be taken to keep the gerolor
assembly together.
NOTE: If rollers are removed, put them back in their
original bore.
N–00630
Carefully turn the gerolor assembly over and remove the

square cut seal (Item 1) [C]. C
N–00631
Remove the valve plate (Item 1) [D] from the end cap.
D 1
N–00632
773 BICS Loader

HYDRAOSTATIC MOTOR 30 SERIES (Cont’d)
A 1
509616505 & Above) (Cont’d) 2
Remove the square cut seal (Item 1) [A] and small O–ring
(Item 2) [A] from the end cap.
N–00633
Remove the spring seat (Item 1) [B] and spring (Item 2)

B 1
[B].
2
N–00634
Remove the poppet and shuttle valve (Item 1) [C].

C 1
N–00635
D
Turn the end cover over and remove the shuttle valve plug
from the end cover [D].
N–00636
773 BICS Loader

A 2
509616505 & Above) (Cont’d) 1
3
Remove the spring seat (Item 1) [A], spring (Item 2) [A]
and poppet (Item 3) [A].
N–00637
Remove the low pressure relief valve plug from the side
of the end cover [B]. B
N–00639
Remove the spring (Item 1) [C] and poppet (Item 2)

[C]from the end cover (Item 3) [C]. C
3
NOTE: The relief pressure is factory set and must
not be changed. Shims may or may not have
been used at the factory for setting the 2
pressure. If shims are present, make sure
they are reinstalled during assembly. 1
N–00640
The low pressure relief valve is made up of the poppet

(Item 1) [D], the spring (Item 2) [D] and the plug assembly D 3
(Item 3) [D].
2
1
N–00641
773 BICS Loader

A 2
Assembly (S/N 509639899 & Above & S/N 509616505
& Above) 1

ports to keep dirt out. Dirt can quickly damage N–00642
the system.
I–2003–0888
Prior to assembly:
B
Clean all parts with solvent and dry with compressed air.
Put grease on O–rings.
Lubricate parts with oil.
Install the poppet (Item 1) [A] and spring (Item 2) [A] in
the low pressure relief port in the end cover.
Install the new O–ring on the plug and tighten to 300

in.–lbs. (34 Nm) torque [B].
N–00643
Install the poppet (Item 1) [C], the spring (Item 2) [C] and
the spring seat (Item 3) [C] in the end cover. C 3 2
NOTE: The tapered end of the poppet must face

towards the shuttle valve.
N–00644
Install a new O–ring on the plug [D] and tighten to 260

in.–lbs. (41 Nm) torque.
D
NOTE: Always use new O–rings and seals when
assembling the motor. Put a small amount of
grease on all the O–rings and seals for easier
installation.
N–00646
773 BICS Loader

A 4
& Above) (Cont’d) 2
Install the shuttle valve (Item 1) [A], poppet (Item 2) [A], 1

spring (Item 3) [A] and spring seat (Item 4) [A] in the port 3
hole in the end cap.
NOTE: The tapered end of the poppet must face
towards the shuttle valve.
N–00647
Install the square cut seal (Item 1) [B] and small O–ring
(Item 2) [B] in the end cover. B 1
N–00648
Mark the case drain port location on the outside of the end
cover for ease of assembly [C]. C
N–00649
Align the case drain ports in the valve plate with the case
drain port in the end cover [D]. D
N–00650
773 BICS Loader

A 1
& Above) (Cont’d)
Install the large square cut seal (Item 1) [A] in gerolor
assembly.
N–00651
Mark the case drain port location on the outside edge of

the valve plate as shown [B]. B
N–00652
Install the gerolor assembly (Item 1) [C] by aligning the

case drain hole with the case drain hole in the valve plate.
C 1
N–00653
Install the square cut seal (Item 1) [D] in the gerolor outer
ring. D 1
N–00654
773 BICS Loader

A
& Above) (Cont’d)
Install the two check balls (Item 1) [A] in their bores in the
gerotor.
N–00655
1
Install the main drive (Item 1) [B] in the gerolor (as
shown).
B
NOTE: Whenever the main drive is not symmetrical,
the smallest end of the main drive must be
installed into the gerolors.
N–00656
Mark the case drain hole on the outer ring of the gerolor
(as shown) [C]. C
N–00657
Align the case drain holes and install the balancing plate
(Item 1) [D] on the gerolor assembly. D
1
N–00658
773 BICS Loader

A
& Above) (Cont’d)
Install the seal (Item 1) [A] (as shown). 1
N–00659
Install the square cut seal (Item 1) [B], seal (Item 2) [B],
back–up seal (Item 3) [B], seal (Item 4) [B] and back–up
B 1
ring (Item 5) [B] in the mounting flange.
2
3
4
5
N–00660
Mark the case drain holes on the side of the balancing

plate [C]. C
N–00661
Align the case drain port (Item 1) [D] in the mounting

flange with the case drain port in the balancing plate (as D
shown). 1
N–00662
773 BICS Loader

A
& Above) (Cont’d) 1
Align the two case drain port (Item 1) [A] and install the
mounting flange on the balancing plate.
Be careful not to displace the seals and back–up rings.
N–00663
Install the nine bolts into the motor. Make sure all the parts
are in correct alignment [B].
B
N–00664
1. Tighten the bolts to 45–55 ft.–lbs. (61–75 Nm)

torque as shown in figure [C].
C
2. Tighten the bolts to 55–65 ft.–lbs. (75 –88 Nm)
torque as shown in figure [C].
NOTE: To prevent damage to the balance plate,

never lift or support the motor by the center
shaft.
MC–02230
773 BICS Loader

HYDROSTATIC PUMP
A

use caps and plugs on hoses, tubelines and 2
the system. P–04279
I–2003–0888
Remove the engine/hydrostatic pump assembly from the

loader. (See Page 7–1.)
B
Remove the steering linkage (Item 1) [A] from the
hydrostatic pump. (See Page 3–8.)
Remove the hydrostatic pump mounting bolt (Item 2) [A]
and washer(s).
NOTE: Washers can be added or removed from the

mounting bolt to adjust the pump drive belt
alignment.
Installation: Tighten the mounting bolt to 65–70 ft.–lbs. 1
(88–95 Nm) torque. P–04275
Remove the hydraulic pump (Item 1) [B] from the

hydrostatic pump. (See Page 2–1.)
C
Loosen the drive belt tensioner (Item 1) [C] and remove
the drive belt.
Remove the hydrostatic pump drive pulley mounting nut
(Item 2) [C] and washer.
Installation: Tighten the pump pulley mounting nut to
175–200 ft.–lbs. (237–271 Nm) torque.
P–04236
Install a puller on the hydrostatic pump drive pulley and

remove the pulley from the pump shaft [D]. D
P–04235
773 BICS Loader

HYDROSTATIC PUMP (Cont’d)
A
Installation: Install the key in the hydrostatic pump shaft
(Item 1) [A] before installing the pump drive pulley.
1
2
P–04238
Hold the nut (Item 1) [B] on the two hydrostatic pump

mounting bolts (Item 2) [A]. B
Remove the two hydrostatic pump mounting bolts (Item
2) [A] from the pump and drive belt housing.
Installation: Tighten the pump mounting bolts to 65–70
1
P–04277
W–2103–1285
Reverse the removal procedure to install the hydrostatic

pump assembly.
773 BICS Loader

Identification 1
MODEL: 773 2
4 3
7 5
9 6
13
11 8
10 18
17
16
14
15
23 17
25 21 18
15
27 28 14
22 21 20 16
24 29 19
26 21 12
30 25
23 13
33 22
31 28 26
32 24 9
36 38
37
34
35
35
34
39
36
38
22
9 10 24 40
26 41
27
16 42
14
15 23 43 45
11 25 44
17 51
45 32
20
21 26
46 24
18 49
30
16 25
1
17 47 48 23
52 1815 29 22
14 50
5 6
12
9
D–01929
D–01979
773 BICS Loader

Identification (Cont’d)
MODEL: 773

1. SNAP RING 28. PLUG
2. ADAPTER 29. BOLT
3. SEAL 30. RELIEF/REPLENISHING VALVE
4. O–RING 31. END CAP
5. SNAP RING 32. BEARING
6. BEARING 33. BOLT
7. KEY 34. SWASHPLATE
8. SHAFT 35. THRUST PLATE
9. BOLT 36. BLOCK ASSY.
10. COVER 37. VALVE PLATE
11. SEAL 38. PIN
12. COVER 39. VALVE PLAT
13. PLUG 40. PLUG
14. QUAD RING 41. O–RING
15. SPACER 42. SHIMS
16. SHIMS (not used on later pumps) 43. SPRING
17. RACE 44. CHARGE RELIEF
18. BEARING 45. PLUG
19. HOUSING 46. O–RING
20. GASKET 47. O–RING
21. PIN 48. END CAP
22. PLUG 49. O–RING
23. O–RING 50. COUPLING
24. O–RING 51. HOUSING
25. SPRING 52. SHAFT
26. SNAP RING
27. REPLENISHING VALVE (S/N 509641106
& Below, S/N 509616589 & Below)
RELIEF/REPLENISHING VALVE (S/N 509641107
& Above, S/N 509616590 & Above)
773 BICS Loader

A

the system. CD–10745
I–2003–0888
NOTE: Photo’s may be different but the procedure is

the same for all models.
B
NOTE: Keep the two pump sections separate during
Loosen the charge relief valve plug [A].
Assemble: Always use a new O–ring. Tighten the plug to
30–50 ft.–lbs. (41–68 Nm) torque.
Remove the plug, spring and poppet [B].

CD–10746
There are several different thickness of the shims (Item

1) [C] and are used to adjust the charge pressure. C
NOTE: 0.010 inch (0,254 mm) is 8 PSI (55.16 kPa)
increase in pressure.
N–00961
Loosen the replenishing valve plug [D].

Assemble: Always use a new O–ring. Tighten the plug to
D
30–50 ft.–lbs. (41–68 Nm) torque.
NOTE: S/N 509641107 & Above and S/N 509616590 &
Above now use relief/replenishing valves
(Item 1) [D]. The relief valve limits the
pressure in the motor drive circuit when
operating in reverse. 1
NOTE: The relief valve on the top of the pump is for

the reverse circuit, the bottom relief valve on
the pump is for the forward circuit and is set
at 5000 PSI. CD–10748
773 BICS Loader

HYDROSTATIC PUMP (Cont’d) 3
A 1. Plug
2. Spring
Remove the plug, spring and poppet from the pump end 3. Relief Valve
cap (both pumps) [A]. 1 2 B–14078
NOTE: S/N 509641106 & Below and S/N 509616589 &

Below use replenishing valves only.
Loosen the high pressure replenishing/relief valve plug CD–10751

[B].
Assembly: Always use a new O–ring. Tighten the plug to
30–50 ft.–lbs. (41–68 Nm) torque. B
Remove the plug, spring and high pressure replenishing
relief valve from the pump end cap (both pumps) [A].
NOTE: The high pressure relief valves are factory set

and should not be tampered with except for
replacing the complete valve.
Assembly: If the high pressure relief valve and spring are
held in the plug with a retaining ring. Remove and discard
this retaining ring before assembly (per pump
manufacturer’s request). If you have difficulty installing,
use petroleum jelly to hold parts together.
CD–10750
Loosen the four bolts which fasten the two pumps

together [C].
C
CD–10752
773 BICS Loader

A
Assemble: Tighten the four bolts to 35–45 ft.–lbs. (47–61
Nm) torque [A].
CD–10753
Separate the two pumps [B].

B
CD–10754
Remove the pump coupler [C].

C
CD–10755
Remove the large O–ring [D].

D
CD–10756
773 BICS Loader

A
Remove the two small O–rings (Items 1 & 2) [A].
2
1
CD–10757
Remove the four bolts from the pump housing end cap
[B]. B
CD–10758
Assemble: Tighten the bolts to 35–45 ft.–lbs. (47–61

Nm) torque [C].
C
CD–10759
Remove the pump housing end cap. Remove the valve

plate from the end cap [D]. D
Check the brass valve plate on both sides for damage &
replace if worn or damaged.
CD–10760
773 BICS Loader

A
Assemble: Make sure the valve plate notch is located
over the dowel and the feathering groove is correct for the
pump rotation [A].
CD–10761
Put your hand over the rotating group and turn the pump
housing over and let the rotating group slide into your
hand [B].
B
CD–10762
Remove the key from the drive shaft [C].

C
CD–10763
Remove the snap ring [D].

D
Assemble: If a beveled snap ring is used, install the snap
ring with its beveled side out.
CD–10764
773 BICS Loader

A
Remove the seal carrier and O–ring [A].
CD–10765
Remove the drive shaft [B].

B
CD–10766
On the other pump, the shaft is held in position by a snap

ring at the bearing. There is no seal carrier on this pump
[C]. C
CD–10767
Remove the trunnion cover bolts [D].

D
CD–10768
773 BICS Loader

A
Assemble: Tighten the trunnion cover bolts to 18–22
ft.–lbs. (24–30 Nm) torque [A].
CD–10769
Remove the trunnion cover, lip seal and O–ring [B].

B
Assemble: Wrap the end of the swashplate control shaft
with thin plastic to prevent damage to the lip seal.
NOTE: If there are shims installed, do not alter the
thickness when installing the trunnion cover.
CD–12458
Remove the bearing spacer [C].

C
NOTE: On later hydrostatic pumps spacers are not
used.
CD–12459
Remove the bearing shims [D].

D
NOTE: On later hydrostatic pumps shims are not
used.
CD–12460
773 BICS Loader

A
Remove the bearing cup [A].
CD–12462
Remove the tapered roller bearing [B]. B

NOTE: If the housing, swashplate or bearings are
not replaced, the original shims will be used
again. If any of the parts are replaced, See
Swashplate Pre–load Page 3–50 to determine
the proper shim thickness.
CD–12463
Remove the bolts from the plain trunnion cover [C].

Assemble: Tighten the bolts to 18–22 ft.–lbs. (24–30
C
Nm) torque.
CD–10772
Remove the O–ring and bearing spacer [D]. D
CD–12464
773 BICS Loader

A
Remove the bearing spacer shims [A].
NOTE: Machines S/N 509641107 & Above and S/N

509616590 & Above do not use shims.
CD–12465
Remove the swashplate from the pump housing [B].

B
CD–12466
Remove the wear plate [C].

C
Inspection
Clean all the parts in clean solvent and use air pressure
to dry them. DO NOT use cloth or paper towels because
small pieces of material can get into the system and
cause damage.
Check the wear plate for scratches [C].
CD–10775
Check the end of the rotating block for wear and

scratches [D]. D
Check the valve brass plate on both sides for wear or
damage. Replace if necessary.
CD–10776
773 BICS Loader

Inspection (Cont’d)
A
NOTE: DO NOT use sandpaper or a file to remove
scratches.
Check each piston in its bore. The piston must move
freely [A].
Check each piston shoe for wear or scratches.
CD–10777
Inspect the spherical washer for wear or damage [B].

B
CD–10778
Check the pins for wear and all are the same length [C].
If there is any defect in the rotating group, the complete
C
unit must be replaced.
Check the shaft splines for damage.
Replace the defective parts as needed.
CD–10779
Support the seal carrier, use the correct size driver tool to
remove and install the seal [D].
D
CD–10780
773 BICS Loader

Inspection (Cont’d)
A
Support the trunnion cover, use the correct size driver tool
to remove and install the lip seal [A].
CD–10781
Check the bearing in the pump housing end cap. If the

bearing is worn, use the correct size driver tool to remove
and install the bearing [B].
B
Swashplate Pre–Load
Install the bearing spacer and cup into the housing with
no shims (both sides).
Install the trunnion covers. Install the bolts and tighten to
18–22 ft.–lbs. (24–30 Nm) torque.
Install the magnetic base dial indicator as shown [C].
Move the swashplate back and forth by hand.
Add shims, under the bearing spacers, to provide CD–10782
0.002–0.004 inch (0,05–0,10 mm) pre–load on the
bearings.
EXAMPLE: If the dial indicator reads 0.040 inch (10,2 C
mm) end play. Shim thickness of 0.042–0.044 inch
(10,7–11,2 mm) should be installed between the bearing
spacers and cups. See Parts Microfiche for correct shim
thickness.
Remove the trunnion cover. Remove the bearing
spacers.
Install the correct amount of shims. Locate the shims so
that there is no more than 0.008 inch (0,20 mm) difference
in shim thickness from one side to the other. Install the
bearing spacers and trunnion covers.
NOTE: When the correct amount of shims are CD–12461
installed, apply a torque of 5–20 in.–lbs.
(0,6–2,3 Nm) to the swashplate shaft to move
the swashplate.
NOTE: Later model pumps, shims are not used, the
swash plate pre–load test procedure and
bearing clearance is the same.
Color or Shim & Value
Green – 0.003 inch (0,076 mm)
Blue – 0.005 inch (0,127 mm)
Brown – 0.010 inch (0,25 mm)
Yellow – 0.020 inch (0,51 mm)
773 BICS Loader

DRIVE BELT HOUSING
A
Remove the engine/hydrostatic pump assembly from the 1
Remove the three drive belt shield mounting clips (Item
1) [A]. 1
Remove the belt shield (Item 2) [A] from the belt shield
housing.
P–04230
Loosen the drive belt tensioner bolt (Item 1) [B] from the
housing and remove the drive belt. B
Nm) torque.
1
Adjust the drive belt. (See Page 1–1.)
P–04223
Remove the eight flywheel mounting bolts (Item 1) [C]

and remove the engine flywheel.
C
Installation: Apply engine oil to the threads and seats
before tightening. Tighten the mounting bolts to 72–80
P–04234
Remove the four mounting bolts (Item 1) [D] which fasten

the housing on the engine. D
3
2
Remove the bolt (Item 2) [D] which fasten the two drain
hoses to the housing.
Remove the starter (Item 3) [D] from the drive belt
housing. (See Page 6–1.) 1
P–04233
773 BICS Loader

DRIVE BELT HOUSING (Cont’d)
A
Remove the hydrostatic pump drive pulley mounting nut
(Item 1) [A] and washer.
Installation: Tighten the mounting nut to 175–200
P–04236
Install a puller on the drive pulley and remove the pulley

from the hydrostatic pump shaft [B]. B
Installation: Install the pulley key in the shaft before
installing the drive pulley.
P–04235
Remove the two mounting bolts (Item 1) [C] from the drive
belt housing which mount the hydrostatic pump to the
C
housing.
Remove the drive belt tensioner (Item 2) [C] from the
drive belt housing. (See Page 3–53 & 3–58.)
1
2
P–04238
Remove the mounting bolt (Item 1) [D] from engine
coolant tubeline mounting bracket which is attached to
the belt shield housing.
D 2
Installation: Tighten the mounting bolt to 25–28 ft. lbs.
Remove the blower fan drive belt tensioner assembly
(Item 2) [D] from the housing.
Remove the drive belt housing.
Reverse the removal procedure to install the drive belt
housing.
1
P–04231
773 BICS Loader

A
Remove the drive belt shield fastener (Item 1) [A].
P–03967
Remove the belt shield [B].

B
P–03969
Loosen and remove the tensioner pulley mounting bolt

(Item 1) [C].
C 1
Nm) torque.
Remove the belt tensioner pulley from the housing.
Installation: Refer to Page 1–1 in the PREVENTIVE
MAINTENANCE section to adjust the drive belt correctly.
tensioner.
P–08760
773 BICS Loader

SPRING LOADED DRIVE BELT TENSIONER PULLEY (Cont’d)
Identification
1. Cover
2. Bolt 1
3. Washer
4. Pins
5. Washer
6. Spring
7. Snap Ring
8. Snap Ring 2
9. Bearing
10. Dust Shield
11. Pulley
12. Bushing
13. Hub 11
14. Washer 3
15. Seal
16. Arrow Indicator Plate
17. Locating Pin 12
18. Spring 4
19. Shaft
20. Bracket
5
NOTE: Drive idler parts are not

available individually. Consult 13
parts catalog for available 6
sub–assemblies.
5 14
15
7
8
16
17
9
18
10
19
20
E–02296
773 BICS Loader

(Cont’d) A
Disassembly
1
NOTE: There are two different types of spring loaded
drive idlers that have been used. The earlier
version is no longer available and new parts
will need to be ordered. Later in this
procedure these components are shown.
Remove the grease cover (Item 1) [A].
P–08858
Remove the bolt (Item 1) [B], the flat washer (Item 2) [B],
the retainer washer (Item 3) [B], the spring washer (Item
4) [B] and the second retainer washer (Item 3) [B] from
B
the pulley assembly (Item 5) [B]. 5
2 3
1 4
P–08859
Remove the two pins (Item 1) [C] from the hub assembly
(Item 2) [C] only if they have been damaged. C
Remove the bracket assembly (Item 3) [C] by tapping on
the shaft (Item 4) [C] with a plastic hammer.
3 1
P–08861
Remove the spring (Item 1) [D] from the bracket (Item 2)

[D].
D
P–08862
773 BICS Loader

(Cont’d) A
Assembly
Install the spring (Item 1) [A] on the pulley (Item 2) [A] as
shown.
1
P–08871
Install the shaft from the bracket assembly (Item 1) [B]

into the pulley assembly (Item 2) [B] and align the spring
B
(Item 3) [B] over the alignment pin on the bracket.
2
3
P–08872
Turn the pulley assembly over and install the two pins
(Item 1) [C] into the hub. C
P–08873
Install a punch as shown and turn clockwise while D

applying down pressure on the pulley.
Turn until the pulley snaps down into place; this procedure
winds the spring and retains the end of the spring in
proper location [D].
P–08874
773 BICS Loader

(Cont’d) A
Assembly (Cont’d)
Install the first retainer washer (Item 1) [A] and spring 2
washer (Item 2) [A] over the roll pins.
P–08875
Install the second retainer washer (Item 1) [B], the

washer (Item 2) [B] and the bolt (Item 3) [B]. Tighten the
bolt to 28–32 ft.–lbs. (38–45 Nm) torque.
B
3
Fill the grease cap 1/4 full (approximately 1/2–3/4 oz.) of
grease.
2
1
P–08876
Press the grease cap (Item 1) [C] onto the pulley

assembly (Item 2) [C]. Press on the outer formed edge of C
the grease cap.
NOTE: When pressing the grease cap onto the

pulley assembly, do not press down on the
arrow indicator plate. Support the hub
assembly so that it contacts only the hub and
not the arrow indicator plate. 2
P–08877
773 BICS Loader

FIXED DRIVE BELT TENSIONER PULLEY
A
1
Remove the three drive belt shield mounting clips (Item
1) [A] and remove the drive belt shield from the housing.
NOTE: Engine is removed for photo clarity.

1
P–04230
Loosen and remove the tensioner pulley

mounting/adjusting bolt (Item 1) [B]. B
Nm) torque.
1
Remove the belt tensioner pulley from the housing.
Installation: Refer to Page 1–1 in the PREVENTIVE
MAINTENANCE section to adjust the drive belt correctly.
tensioner.
P–04223
773 BICS Loader

FIXED DRIVE BELT TENSIONER PULLEY (Cont’d)
Identification
1. Bracket
2. Washer
3. Bolt
4. Pulley
5. Bearing
6. Washer
7. Bolt
8. Cover
5
6 7 8
2 3
E–02269
773 BICS Loader

A
Disassembly
NOTE: Be careful, the pulley hub is full of oil.
Remove the cap [A].
CD–12634
Remove the bolt and washer [B].

B
CD–12635
Install a long bolt into the shaft [C].

C
CD–12636
Remove the idler pulley and bearing from the shaft using
a press [D]. D
CD–12637
773 BICS Loader

A
Install a bearing puller behind the seal and wear sleeve
[A].
CD–12638
PHOTO CLARITY ONLY: If the bearing puller is installed

behind the bearing, seal and wear sleeve, the wear sleeve
will also be removed [B].
B
CD–12639
Remove the bearing, seal and wear sleeve using the

press [C]. C
CD–12640
773 BICS Loader

A
Assembly
NOTE: The bearings, cups and spacers are a

matched set and must be replaced as a unit.
If the spacer is replaced, compress the new spacer and
install into the pulley [A].
CD–12641
Use a driver tool (1–5/16 inch diameter) and push the

spacer into the machined groove [B]. B
CD–12642
Install the bearing cup using the driver tool [C] (both
sides). C
NOTE: The seal side of the pulley hub has the larger
I.D. diameter.
CD–12643
Install the taper roller bearing to the pulley (seal side) [D].
D
CD–12644
773 BICS Loader

Assembly (Cont’d)
A
Put sealant (P/N 6633538) around the diameter of the
shaft where the wear sleeve is installed on the shaft [A].
CD–12645
Put grease (P/N 6599719) on the seal lips (Item 1) [B].

Make sure the grease is between the outside and inside
lips and all the way around the seal.
B
MC–01648
Press the seal into the pulley hub larger diameter using
a press [C].
C
NOTE: The wear sleeve and the seal must be
replaced as a unit.
DO NOT damage the seal lips with the sharp edge of the
wear sleeve. Install the wear sleeve into the seal.
CD–12646
Use a spacer tube which goes over the shaft and pushes
on the inside diameter of the taper bearing, install the D
pulley, seal and wear sleeve onto the shaft [D].
CD–12647
773 BICS Loader

Assembly (Cont’d)
A
Install the small bearing spacer [A].
CD–12648
Install the taper roller bearing pushing on the I.D. of the

bearing [B]. B
CD–12649
Put LOCTITE (P/N 6540410) on the bolt threads [C].

C
CD–12650
Install the bolt and washer into the shaft [D].

D
CD–12651
773 BICS Loader

Assembly (Cont’d)
A
Tighten the bolt to 25–28 ft.–lbs. (43–38 Nm) torque [A].
CD–12652
Use only 15W/50 synthetic oil (example: Mobil One) for

Measure Oil
the bearings. Use the cap and add oil until it is at the 0.500
inch (12,7 mm) mark on the scale, which should be 0.75
B Level in the
oz. (20 C.C.) of oil [B]. Center of the Cap
0.75 oz.
(20 C.C.)
Capacity
0.500’’ (12,7 mm)
MC–01648
Add the oil slowly, at one location of the bearing which will
allow the trapped air to escape from the other side [C].
C OIL LEVEL
NOTE: Oil capacity is very critical, do not add any
more and/or any less oil to the idler pulley.
MC–01648
Check the cap sealing edge to make sure it is not

damaged. Replace the cap as needed. D
Make sure the sealing edge on the hub bore and cap
sealing edge is clean and free of oil, put a bead of sealant
(P/N 6633538) on the cap [D].
Install the cap.
CD–12653
773 BICS Loader

Checking Pulley End Play

A
Install the pulley/mounting bracket assembly in to vise.
Install a dial indicator on the pulley hub [A].
CD–12655
Move the pulley by hand, back and forth. The correct end
play is 0.005–0.013 inch (0,13–0,33 mm) [B].
B
If the end play is not correct, there is no adjustment
replace the hub, pulley and/or bearings.
OIL COOLER
Removal and Installation
CD–12656

the system.
I–2003–0888
2
Open the rear door of the loader. 1 3
Raise the rear grill. N–00831
Disconnect the inlet and outlet hoses (Items 1 & 2) [C]

from the oil cooler (Item 3) [C].
Lift up the oil cooler and remove the cooler from the
loader.
Reverse the removal procedure to install the oil cooler.
773 BICS Loader

DRIVE SYSTEM
Page
Number
AXLE SEAL
AXLE, SPROCKET AND BEARINGS
CHAINCASE COVERS
Center Chaincase Cover Removal And Installation . . . . . . . . . . . . . . . . 4–9
Front Chaincase Cover Removal And Installation . . . . . . . . . . . . . . . . . . 4–10
Rear Chaincase Cover Removal And Installation . . . . . . . . . . . . . . . . . . 4–10
CHAINCASE FLUID
Removing Oil From The Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
DRIVE
DRIVE CHAIN SYSTEM
MOTOR CARRIER
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–14
Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11
PARKING BRAKE
PARKING BRAKE DISC

TRACTION LOCK GUIDES
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5

773 BICS Loader

PARKING BRAKE
A
2
brake pedal mounting bracket.
P–03989
Remove the cover (Item 1) [B] from the front of the control
panel. B
Disconnect the electrical connector from the parking
brake pedal sensor (Item 2) [A]. The connector is located
behind the control panel.
Remove the parking brake assembly from the loader.
Reverse the removal procedure to install the parking 1
brake assembly in the loader.
P–04073

C 5
Loosen and remove the mounting bolt (Item 1) [C] and nut
from the spring mounting bracket (Item 2) [C]. 6
Remove the brake pedal spring (Item 3) from the tension
spring mounting bracket (Item 2) [C] and from the brake
pedal mounting bracket (Item 4) [C].
Remove the two mounting bolts, washers and nuts (Item 1
5) [C] from the brake pedal sensor. 4
Remove the harness mounting clamp (Item 1) [D] from
the pedal mounting bracket (Item 4) [C].
2
Remove the sensor harness from the pedal mounting 3
P–04189
bracket.
Remove the pedal mounting bolt (Item 6) [C], plastic
spacers and bushing nut from the brake pedal. D
1
Remove the pedal from the pedal mounting bracket.
Photo [D] shows the parking brake disassembled to

identify the existing parts in the brake assembly.
P–04156
773 BICS Loader

PARKING BRAKE DISC
A 2
Raise the loader lift arms and install an approved lift arm 1 3
support device. (See Page 1–1.)
4
Never work on a machine with the lift arms up 1
P–04137
or death. W–2059–0598
B
Disconnect and remove the engine speed control. (See
Page 7–1.)
Remove the control panel from the loader. (See Page
3–1.)
Remove the center chaincase cover. (See Page 4–9.)
Remove the front chaincase cover. (See Page 4–10.)
Remove the traction lock assembly. (See Page 8–1.)
P–04163
The parking brake discs (Item 1) [A] are located beneath
the center chaincase cover (Item 2) [A].
Inspect the traction lock guides (Item 3) [A] and the brake
C
disc guides (Item 4) [A] for damage or wear and replace 1
as necessary. (See Page 4–5.)
NOTE: Brake disc guides (Item 4) [A] are used only
on earlier machines.
A snap ring pliers with 90° tips are necessary for removing
the parking brake disc.
Use the snap ring pliers and remove the snap ring from
the end of the sprocket on the hydrostatic motor carrier
[B].
P–04166
NOTE: Later machines use a snap ring on both sides

of each brake disc [B].
Slide the brake disc (Item 1) [C] off the sprocket and
remove the brake disc through the front chaincase cover.
Reverse the removal procedure to install the parking
brake disc in the loader.
Refer to Page 8–1 for the traction lock inspection
procedure.
773 BICS Loader
TRACTION LOCK GUIDES
A 1
The part number listed will be needed to do the following 3
procedure: 3
P/N 6633583 – Polyurethane

Disassembly
2 2
3 3
1
P–11328

B
lift arms or attachment to fall and cause injury 2 1
or death. W–2059–0598

Disconnect and remove the engine speed control. (See
Page 7–1.)
3–1.)
P–11331
C
1
Do not modify the electrical wiring connected
to the traction lock solenoid or any part of the
traction lock system. The traction lock
provides the locking function of the parking
brake. Service work on the traction lock system
should only be performed by a qualified 1
technician. Use only genuine Bobcat parts if
repair is necessary.
W–2165–0100
P–11330

After the center chaincase cover is removed from the D 1
machine locate the traction lock guides (Item 1) [A] & [B].
To remove the brake disc guides (Item 2) [A] remove the 3
four bolts (Item 3) [A] older models only.
NOTE: Bolt (Item 2) [B] is on the rear of the chaincase
cover, notice the direction of the groove (Item
1) [B] in the traction lock guides.
To remove the traction lock guides remove the four bolts
(Item 1) [C].
Thoroughly clean the polyurethane from the chaincase 2

cover (Item 1) [D], bolts (Item 2) [D] and traction lock
guides (Item 3) [D] and dry. P–11332
773 BICS Loader

TRACTION LOCK GUIDES (Cont’d)
Assembly
A
Apply a bead of polyurethane (P/N 6633583) on the
traction lock guides and bolts [A].
P–11333
Install the electric solenoid/bracket assembly (Item 1) [B]

to the center chaincase cover (Item 2) [B].
B
NOTE: Bolt (Item 3) [B] & [C] represents the rear of
the chaincase cover. 2
Install and tighten the two bolts (Item 4) [B].
3
4 4
P–11334
Install the traction lock guides (Item 1) [C] to the INCORRECT CORRECT
chaincase cover (Item 2) [C] using the four bolts C 1
(removed earlier).
Do not tighten at this time. 2
P–11336 P–11335
Install the traction wedge assembly (Item 1) [D] into the

solenoid and traction lock guides (Item 2) [D]. D
After the bolts have been tightened recheck to make sure 1
the shaft assembly is moving freely in the guides.
Remove the wedge assembly (Item 1) [D].
NOTE: The wedge assembly must slide freely in the

grooves of the guides. Tighten the four guide
bolts to 90–100 ft.–lbs. (123–135 Nm) torque. 2
P–11337
773 BICS Loader

TRACTION LOCK GUIDES (Cont’d)
A 2 1
Assembly (Cont’d)
Remove the two bolts (Item 1) [A] and remove the electric
solenoid (Item 2) [A] from the center chaincase cover. 1
P–11334
Install the chaincase cover (Item 1) [B] using the ten

mounting bolts (Item 2) [B]. B
NOTE: Thoroughly clean and dry the bolts and apply

LOCTITE #242.
1
2
P–11339
Install the wedge assembly (Item 1) [C] into the grooves

in the traction lock guides making sure that there is no C
binding.
Install the gasket (Item 2) [C].
Install the solenoid mounting bracket assembly (Item 1)
[D] on the chaincase cover using the two bolts (Item 2) [D] 1
2
and tighten to 25–28 ft.–lbs. (34–38 Nm) torque.
NOTE: Be sure the solenoid mounting bracket is

installed in the same position. The solenoid
mounting surface has a slight angle which
tips the top of the solenoid toward the rear of
the loader when installed correctly.
P–11340
Install a new DO NOT MODIFY sta–strap (Item 3) [D]

(P/N 6665527) on the electric solenoid connector. D 3
Install the control panel. (See Page 3–1.)
Install the engine speed control. (See Page 7–1.)
Lower operator cab. (See Page 1–1.)
2
Perform the BICS™ inspection procedure. (See Page
8–1.)
1
2
P–11341
773 BICS Loader

CHAINCASE FLUID
A
Removing Oil From The Chaincase
To drain the oil from the chaincase, remove the cover
(Item 1) [A] which is installed over the drain plug at the
rear of the chaincase.
Installation: tighten the cover mounting bolts to 190–200
in–lbs (21,5–27 Nm) torque.
1
P–01616
Remove the drain plug (Item 1) [B] and drain the oil into
a container.
B
Check the drain plug gasket and replace if necessary.
P–01619
773 BICS Loader

CHAINCASE COVERS
Center Chaincase Cover Removal And Installation
A
P–04098
support device. (See Page 1–1.) B

or death. W–2059–0598
P–04132

Disconnect and remove the engine speed control from
C
the control panel. (See Page 7–1.) 2
3–1.)
Disconnect the lift control cross bar (Item 1) [A] from the
lift pedal linkage.
Disconnect the lift control cross bar (Item 1) [A] from the
lift spool on the main control valve.
1
Disconnect the electrical connector (Item 1) [B] from the
parking brake pedal sensor. P–04101
Remove the two mounting bolts (Item 1) [C] from the

traction lock assembly (Item 2) [C] on the center
D
chaincase cover. (See Page 8–1.)
Installation: Tighten the mounting bolts for the traction
lock assembly to 25–28 ft.–lbs. (34–38 Nm) torque.
Remove the traction lock assembly (Item 2) [C] from the
chaincase cover. (See Page 8–1.) 1
Remove the ten chaincase cover mounting bolts (Item 1)

[D].
Installation: Tighten the cover mounting bolts to 25–28
ft.–lbs. (34–38 Nm) torque. P–04140
773 BICS Loader

CHAINCASE COVERS (Cont’d)
Center Chaincase Cover Removal And Installation
A
(Cont’d)
Remove the center chaincase cover from the loader [A].
P–04137
Installation: The chaincase cover has a gasket (Item 1)

[B] installed between the cover and the chaincase. Install
a new gasket if necessary.
B
Reverse the removal procedure to install the chaincase
cover.
Front Chaincase Cover Removal And Installation

Remove parking brake. (See Page 4–3.)
P–04152
Remove the eight front chaincase cover mounting bolts
(Item 1) [C].
Installation: Tighten the mounting bolts to 25–28 ft.–lbs. C
Remove the front chaincase cover (Item 2) [C] from the
loader.
Installation: The front chaincase cover (Item 2) [C] has
1
a gasket installed between the cover and the chaincase
as shown in photo [B]. Install new gasket if necessary.
Rear Chaincase Cover Removal And Installation
2
Disconnect the front steering linkage bars from the rear
linkage bars. (Refer to CONTROL PANEL Page 3–1 for
correct procedure.)
P–04144
Move the linkage bars to allow adequate space to remove
the rear chaincase cover.
Remove the eight rear chaincase cover mounting bolts
D
(Item 1) [D].
1
Remove the rear chaincase cover (Item 2) [D] from the
loader.
Installation: The rear chaincase cover (Item 2) [D] has
a gasket installed between the cover and the chaincase
as shown in photo [B]. Install a new gasket if necessary.
(Refer to STEERING LINKAGE Adjustment Page 3–1 to 2
adjust neutral if necessary.)
P–04155
773 BICS Loader

MOTOR CARRIER
Shaft Seal Replacement
A
The tool listed is necessary for the following procedure:
MEL1420 – Carrier Seal Tool
Remove the hydrostatic motor. (See Page 3–1.)
P–04153
• When fluids are under pressure. B
• Flying debris or loose material is present.
W–2019–1285
The motor carrier seal (Item 1) [A] is located on the

outside of the motor carrier shaft.
Drill a .125 inch (3 mm) hole in the motor carrier seal [B].
P–04456
Use a slide hammer to remove the seal from the motor

carrier shaft [C]. C
P–04455
Installation: Install a new seal over the motor carrier

shaft [D]. D
P–04454
773 BICS Loader

MOTOR CARRIER (Cont’d)
Shaft Seal Replacement (Cont’d)
A
Installation: Install MEL1420 Carrier Seal Tool over the
carrier seal [A].
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [A].
P–04150
Photo [B] shows the motor carrier seal correctly installed.

NOTE: Before reinstalling the hydrostatic motor, B
check the plug (Item 1) [B] located in the
center of the carrier shaft for tightness. If the
plug becomes loosened, case drain
lubrication oil from the hydrostatic motor
can leak into the chaincase.
P–04149
773 BICS Loader

A 2

or death. W–2059–0598
P–04152
B
Drain the fluid from the chaincase. (See Page 4–8.)
1
Remove the engine speed control. (See Page 7–1.)
Remove the control panel. (See Page 3–1.)
Remove the lift lock valve. (See Page 2–1.)
P–04167
Remove the front chaincase cover. (See Page 4–10.)
C
Remove the front axle and sprocket. (See Page 4–19.)
1
Remove the hydrostatic motor. (See Page 3–1.)
Remove the parking brake disc (Item 1) [A]. (See Page
4–4.)
Remove the six motor carrier mounting bolts (Item 2) [A]
from the inside of the chaincase.
Installation: Tighten the motor carrier mounting bolts to
125–140 ft.–lbs. (170–190 Nm) torque.
For ease of removal, fasten the front drive chain
(previously removed) to the chaincase as shown [B]. P–04165
Tip the end of the sprocket toward the rear of the loader
and remove the rear drive chain (Item 1) [B] from the
sprocket.
D
1
Slide the motor carrier out of the chaincase [C].
Installation: Check the motor carrier gasket (Item 1) [C]
for wear or damage and replace if necessary.
Use one of the motor carrier mounting bolts (Item 1) [D]

and install partially into one mounting hole on the carrier.
Fasten a chain hoist to the bolt on the motor carrier and
remove the carrier from the loader.
Reverse the removal procedure to install the motor P–04168
carrier.
773 BICS Loader
Disassembly
A 3.000’’ O.D. Diameter
(76,2 mm)
It is necessary to locate or fabricate a press tool for this

procedure. Refer to photo [A] for the correct dimensions 2.530’’ I.D. Diameter
of the tool needed. (64,26 mm)
A hydraulic press, slide hammer with puller end and snap

ring pliers are also recommended for this procedure. 7.000’’
Length
Remove the motor carrier shaft seal. (See Page 4–11.) (177,8 mm)
MC–02102
Remove the snap ring (Item 1) [B] from the motor carrier
shaft using the snap ring pliers. B
1
P–04372
Put the motor carrier in the hydraulic press as shown [C].

Use 2–1/4 inch driver tool and press the sprocket shaft C
out of the motor carrier housing [C].
NOTE: The outer bearing will now be free from the
sprocket shaft.
P–04176
Remove the housing from the press and install a bearing

puller (Item 1) [D] on the sprocket shaft. D
Put the assembly in the hydraulic press. Use the same
tool driver and remove the bearing (Item 2) [D] from the
shaft. 2
1
P–04365
773 BICS Loader

A 2
Fasten the carrier motor housing to the work surface

securely with the inner bearing race (Item 1) [A] facing up.
Install the slide hammer with puller end (Item 2) [A] on the 1
bottom side of the bearing race.
Remove the bearing race from the carrier housing [A].
P–04373
Put the motor carrier housing in the hydraulic press as

shown [B].
B
Use a 3–7/8 inch driver tool and press the outer bearing
race from the housing.
Check all parts for wear and damage. Replace the
bearing race when new bearings are to be installed.
P–04370
Assembly
C
Put the motor carrier housing in the press as shown [C].
Use 4–5/16 inch driver tool and press the new inner
bearing race into the motor carrier housing [C].
Press the bearing race in until it is fully seated in the
carrier housing.
P–04369
Turn the motor carrier housing over as shown [D].

D
Use 4–5/16 inch driver tool and press the new outer
bearing race into the motor carrier housing [D].
Press the bearing race in until it is fully seated in the
carrier housing.
P–04368
773 BICS Loader

Assembly (Cont’d)
A
Use the fabricated press tool (Item 1) [A] and 3.0 inch
driver tool, install the new inner bearing (Item 2) [A] on the
sprocket shaft as shown.
Remove the press and drive tools from the sprocket shaft.
P–04366
Put the motor carrier housing (Item 1) [B] over the
sprocket shaft as shown.
Put the outer bearing over the end of the sprocket shaft B
and press the bearing on with the press tool and driver
tool [B].
Remove the press and driver tools from the sprocket
shaft.
P–04371
773 BICS Loader

Assembly (Cont’d)
A
Put the snap ring (Item 1) [A] over the end of the sprocket
shaft.
NOTE: Use the snap ring pliers to spread the snap
ring so it will fit over the sprocket shaft.
Using the press and driver tools, press the snap ring (Item 1
1) [A] over the sprocket.
Press the snap ring on until it snaps into the groove on the
shaft.
P–04374
Put a new shaft seal (Item 1) [B] on the sprocket shaft.

B
P–04376
Use MEL1420 Carrier Seal Tool (Item 1) [C] and install

the shaft seal. C
Hit the tool with a hammer until the seal is fully seated on
the carrier shaft [C].
Refer to SHAFT SEAL REPLACEMENT Page 4–11 for
complete shaft seal installation procedure.
P–04375
773 BICS Loader

Assembly (Cont’d)
A
Check the end paly of the motor carrier as follows:
Use a rubber mallet [A], tap down on the cluster shaft.
N–15088
Install a dial indicator as shown in Photo [B]. B

Use a pry bar (Item 1) [B] to lift the carrier shaft and read
the end play on the dial indicator.
The carrier shaft must turn freely with end play not to
exceed 0.007 inch (0,17 mm).
N–15087
773 BICS Loader

AXLE SEAL
A
The tools listed are needed for the following procedure:
2
Axle Hub Puller Tool
MEL1399 – Seal Driver Tool
MEL1242 – Power Ram (may be used if desired)
1
To loosen the axle hub mounting bolt (Item 1) [A], use the
following procedure:
Before lifting and blocking the loader, loosen the hub
mounting bolt (Item 1) [A]. 2
NOTE: If the axle and bearings are being replaced, P–04157
also loosen the sprocket mounting bolt
inside the chaincase before lifting and
blocking the loader. (See Page 4–21.) B
Remove the front tire/wheel assembly.
2
Installation: Tighten the wheel mounting nuts to
105–115 ft.–lbs. (142–156 Nm) torque.
Remove the hub mounting bolt (Item 1) [A] and washer
from the axle.
Installation: Tighten the bolt to the following
specifications:
2.0 inch bolt length . . . . . 600 ft.–lbs. (814 Nm) torque. 1
2.25 inch bolt length . . . 800 ft.–lbs. (1085 Nm) torque P–04159
Remove two of the wheel mounting studs (Item 2) [A].

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 install the studs.
Install the puller tool (Item 1) [B] on the axle hub.
A driver tool (Item 2) [B] can be used for centering the
threaded rod of the puller.
NEVER STAND IN–LINE OF THE HUB WHEN

REMOVING A HUB FROM AN AXLE. The hub
has a tapered fit on the axle end and can come
off the axle with great force and cause serious
injury.
W–2186–0395
Use a wrench with the puller and remove the axle hub
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.
773 BICS Loader

AXLE SEAL (Cont’d)
A
Remove the key (Item 1) [A] from the axle.
1
P–04161
Drill a small hole in the axle seal. B

Install a slide hammer (Item 1) [B] with a screw tip end in
the axle seal.
Remove the axle seal.
P–04181
Installation: MEL1399 seal driver tool is necessary for

the following procedure: C
Clean the seal area and inspect the shaft for wear.
NOTE: If the shaft is damaged or worn, an axle repair
sleeve kit is available from Melroe Parts Sales
in Chicago.
Place the new axle seal over the axle and into the axle
tube.
Install MEL1399 seal driver tool over the axle and put
against the axle seal [C].
Hit the seal driver tool with a hammer until the tool is flush
with the edge of the axle tube [C]. P–04160
Reverse removal procedure to install the axle hub and

wheel assembly.
773 BICS Loader

AXLE, SPROCKET AND BEARINGS
A
The tools listed are needed for the following procedure:
MEL1242 – Power Ram
MEL1202B – 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 Page 4–10 for 1
rear chaincase cover removal.)
2
Use jackstands to support the rear of the loader. (The
loader wheels should remain on the ground.) P–04144

or death. W–2059–0598
1
Remove the control panel. (See Page 3–1),

Remove the parking brake mounting bolts. (See Pge C
4–3.)
Remove the eight front cover mounting bolts (Item 1) [A]
and the front cover (Item 2) [A] from the chaincase.
Loosen the axle sprocket mounting bolt (Item 1) [B].
Remove the fluid from the chaincase. (See Page 4–8.)
Remove the axle hub. (See Page 4–19.)
Remove the sprocket mounting bolt (Item 1) [B].
1
Installation: Tighten the sprocket mounting bolt to P–04158
220–245 ft.–lbs. (298–332 Nm) torque.
Install the MEL1242 power ram (Item 1) [C] between the
two sprockets. D
Put a spacer between the power ram and axle. Push the
axle out to the end of the power ram stroke. Add another
spacer and push the axle again. Repeat this procedure
until the axle is free from the sprocket and inner bearing.
Remove the drive chain from the sprocket (Item 1) [D]

and remove the sprocket from the chaincase.
Remove the inner bearing (Item 2) [D] and remove the
axle from the axle tube. (See Page 4–23 for outer bearing
removal from the axle.) 2
Installation: Pack both axle bearings with grease before 1
installing them. P–04162
773 BICS Loader

AXLE, BEARINGS AND SPROCKET (Cont’d)
A
A bearing puller (Item 1) [A] is needed for the following 1
procedure:
Put the axle/outer bearing assembly in the bearing puller
as shown and put in the hydraulic press [A].
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 axle.
Be sure to hold onto the axle during removal as it will slide
freely along the axle shaft after removal from the bearing
mounting surface and until the bearing contacts the spline P–04170
on the shaft.
Press the splined end of the axle free from the bearing
[B].
B
P–04171
Installation: A piece of round tubing (Item 1) [C] is

needed to install the bearing on the axle shaft. The tubing
needs to measure approximately 0.500 inch (12,7 mm) to C
1.0 inch (25,4 mm) in length. The inside diameter of the 4
tubing should not be under 2.100 inches (53,3 mm) and 3
the outside diameter should not be over 2.400 inches (60
mm),
A bearing puller (Item 2) [C] is also needed to install the 1
bearing on the axle.
Put the tubing (Item 1) [C] on the bearing puller (Item 2)
[C].
2
Put the bearing (Item 3) [C] on the tube as shown.
Put the spline end of the axle shaft (Item 4) [C] in the P–04169
bearing and press the bearing onto the axle.
Be sure to hold onto the axle during installation, as it will
slide freely along the axle shaft after the spline end has D
passed through the bearing and until it reaches the
bearing mounting surface on the axle.
When the bearing reaches the bearing mounting surface,

continue the installation until the bearing is fully seated
[D].
P–04175
773 BICS Loader

AXLE, BEARINGS AND SPROCKET (Cont’d)
A
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 tool to remove the inner
bearing cup [A].
Hit the long rod with a hammer to remove the bearing cup
from the axle tube [A].
P–04172
To remove the outer bearing cup, place the bearing cup

tool (Item 1) [B] on the slide hammer. B
Leave the bearing cup tool loose until the tool is installed
inside the tube [B].
After the bearing cup tool is inside the axle tube, pull the
tool against the bearing cup and tighten the nut (Item 2)
[B] on the tool.
1
P–04179
Use the slide hammer and remove the bearing cup from
the axle tube [C].
C
P–04180
773 BICS Loader

AXLE, BEARING AND SPROCKET (Cont’d)
A
1
Use the bearing cup installation tools (Item 1) [A] and 2
(Item 1) [B] and the long threaded rod (Item 2) [B] from
the service set to install the inner and outer bearing cups.
Put the inner bearing cup in the axle tube (Item 2) [A].
Put the installation tool (Item 1) [A] in the axle tube.
3
Install the long threaded rod (Item 2) [B] into the axle tube
and through the installation tool (Item 1) [A].
Secure the tool to the threaded rod with a nut (Item 3) [A].
P–04174
Put the installation tool (Item 1) [B] in the axle tube with
the threaded rod through the hole in the tool.
Secure the tool to the threaded rod with a nut [B].
B 1
Hold the inside nut (Item 3) [A] with a wrench and tighten
the outside nut as shown in photo [B].
Tighten the nut until the bearing cup is seated.
2
P–04164
To install the outer bearing cup, use the short rod and the
bearing cup tool used for removing the bearing cups. C
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 [C].
Hit the short rod with a hammer until the bearing cup is
seated inside the axle tube.
P–04173
773 BICS Loader

DRIVE CHAIN
A 2
1
or death. W–2059–0598
P–04152
Lift and block the loader. (See Page 1–1.) B
Drain the fluid from the chaincase. (See Page 4–8.)
Remove the engine speed control. (See Page 7–1.) 1
Remove the control panel. (See Page 3–1.)
Remove the front (or rear) chaincase cover. (See Page
4–10.) P–04167
Remove the front (or rear) axle and sprocket. (See Page
4–21.)
Remove the parking brake disc (Item 1) [A]. (See Page
C
4–4.)
Remove the six carrier mounting bolts (Item 2) [A] from
inside the chaincase.
Installation: Tighten the motor carrier mounting bolts to
125–140 ft.–lbs. (170–190 Nm) torque.
Tip the end of the sprocket on the motor carrier toward the
rear of the loader and remove the rear drive chain from the
sprocket.
NOTE: It may be necessary to tie the front drive
chain up as shown in photo [B], so the
carrier/motor assembly can be moved B–13504
enough to free the rear drive chain (Item 1) [B]
from the sprocket.
Remove the front drive chain from the chaincase.
The tool listed is needed for the following procedure:
MEL1037 – Chain Link Tool
Installation: If a new chain is installed, a connector link
must be used to connect the chain together.
DO NOT exceed the recommended torque of
Use MEL1037 Chain Link Tool and #80 chain adapter. 130 ft.–lbs. (176 Nm.) The tool may fail under too
much torque. Put cloth around the tool to
Secure the tool and place the connector link in the tool as protect yourself from flying debris.
shown [C]. W–2233–0296
Turn the threaded rod of the tool and press the connector
link together on the chain [C]. Tighten the threaded rod of
the chain link tool to 130 ft.–lbs. (176 Nm) torque.
773 BICS Loader
MAIN FRAME
Page
Number
BOB–TACH
Bob–Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–19
Bob–Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18
FUEL TANK
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–26
LIFT ARM LINK
LIFT ARMS
OPERATOR CAB
OPERATOR CAB GAS CYLINDER MAIN
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12 FRAME
OPERATOR SEAT
REAR DOOR
Bumper Removal And Installation (2 piece door) . . . . . . . . . . . . . . . . . . 5–29
Door Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–29
Door Latch And Catch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–30
Hood Removal And Installation (2 piece door) . . . . . . . . . . . . . . . . . . . . 5–29
Removal And Installation (2 piece door) . . . . . . . . . . . . . . . . . . . . . . . . . . 5–27
Removal And Installation (1 piece door) . . . . . . . . . . . . . . . . . . . . . . . . . . 5–28
REAR GRILL
REAR LIGHTS
SEAT BAR (W/COMPRESSION SPRINGS)

Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . 5–10
SEAT BAR (W/GAS CYLINDER)

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5
Compressing The Gas Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6

773 BICS Loader

SEAT BAR (W/GAS CYLINDER)
A
The tool listed is needed for the following procedure:
MEL1426 – Gas Spring Retainer Tool 2
Lower the operator seat bar.

Install the gas spring retainer tool on the gas cylinder
(Item 1) [A].
P–03978
Install the end of the tool that is bent at a 90° angle in the
clevis of the cylinder as shown [B]. B
Install the curved end of the tool on the base end of the
gas cylinder.
Secure the tool to the gas cylinder with a hose clamp 1
(Item 2) [A].
Remove the cotter pin (Item 1) [B] from the clevis pin.
P–03248
Remove the clevis pin (Item 1) [C] from the gas cylinder.
C
1
Use a 17/32 inch tappet wrench (Item 1) [D] to hold the

ball joint on the gas cylinder.
Remove the mounting nut from the ball joint [D].
Installation: Be careful not to overtighten the mounting P–03979
nut on the ball joint.
Remove the gas cylinder from the seat bar.
D
Cylinder contains high pressure gas. Do not

open. Opening cylinder can release rod and
W–2113–0288 1
Replace the gas cylinder if it malfunctions.

P–03249
773 BICS Loader

SEAT BAR (W/GAS CYLINDER) (Cont’d)
A
Disconnect the seat bar sensor connector (Item 1) [A].
P–04702
Remove the seat bar mounting bolt (Item 1) [B] (both

sides). B
Installation: Tighten the seat bar mounting bolts to
25–28 ft.–lbs. (34–38 Nm) torque.
Remove the seat bar sensor mounting bolt (Item 2) [B] 1
and nut.
Installation: Tighten the sensor mounting bolt to 80–90
in.–lbs. (9–10 Nm) torque.
Remove the sensor assembly from the magnetic bushing
on the seat bar.
2
P–03246
Installation: Be sure the two tabs on the pivot bushing

are located in the slot on the cab as shown (Item1) [C].
C
P–03247
Pull both ends of the seat bar which are mounted to the
operator cab, back from the mounting positions on the D
operator cab [D].
Remove the magnetic bushing mounting bolt, washer,
magnetic bushing, plastic bushing and pivot bushing from
the seat bar [D]. (Refer to Page 8–1 for correct assembly
procedure of the seat bar sensor assembly.)
Remove the mounting bolt, gas cylinder mounting
bracket, plastic bushing and pivot bushing from the seat
bar [D]. (Refer to Page 5–5 for correct assembly
procedure of the gas cylinder mounting assembly.)
P–03982 P–03983
773 BICS Loader

A
To remove the seat bar from the operator cab, the seat bar
needs to be put in the correct location.
Use the squares in the right side of the operator cab side
screen to locate the seat bar correct [A].
Put the padded corner of the seat bar five squares back
from the front of the operator cab side screen and four
squares up from the bottom of the screen [A].
P–03984
The arm of the seat bar (Item 1) [B] should also be located
outside of the operator cab, just below the bottom edge
of the cab.
B
Grab both ends of the seat bar as shown and pull the left
side of the seat bar out of the operator cab until the seat
bar is free [B].
Remove the seat bar from the operator cab.
Reverse removal procedure to install the seat bar.
See the following assembly procedure when installing the
seat bar.
1
P–04065
Assembly C
Assemble the parts as shown for the left side of the seat
bar pivot assembly [C]: 7 6 3 2 1
Mounting Bolt (Item 1)
Washer (Item 2)
Keyed Plastic Bushing (Item 3)
Magnetic Bushing Assembly (Item 4)
Sensor Bracket (Item 5)
Pivot Bushing (Item 6) Left Side
8 5 4 of Seat Bar
Mounting Bolt (Item 7) 9
Sensor Mounting Bolt (Item 8)
Sensor Mounting Nut (Item 9) P–03284
773 BICS Loader

A 3 2 1
Assembly (Cont’d)
Assemble the parts as shown for the right side of the seat
bar pivot assembly [A]:
Pivot Bushing (Item 2)
Gas Spring Mounting Bracket (Item 4) 5
Mounting Bolt (Item 5) Right Side
4 of Seat Bar
Install the right side pivot assembly as shown. Tighten the
mounting bolt (Item 1) [B] to 180–200 in.–lbs. (21–23 Nm)
torque.
P–03289
NOTE: Be sure the bend in the gas spring bracket
faces in toward the operator when installing
the gas spring bracket. Slide the bracket all
the way forward so the front edge of the B 1
bracket fits tightly against the operator cab.
Compressing The Gas Cylinder

To compress the seat bar gas spring, it is necessary to
use the gas spring retainer tool MEL1426.
Use the following procedure to compress the gas spring.
P–03319

C
W–2113–0288
Open the rear door of the loader and install the gas spring
(Item 1 [C] – ball stud end) in the hole located in the loader
frame.
NOTE: Install the ball stud threads up through the

hole and install a nut (Item 2) [C] on the ball
2 3
stud.
1
Put the clevis end of the gas cylinder on the edge of the
rear door as shown and install a vise grip (Item 3) [C] on
the bottom edge of the door to keep the gas cylinder from P–03285
sliding along the edge.
Pull the door in and compress the gas cylinder [D]. D
Install the retainer tool (Item 1) [D] with the 90° bend in 1
the clevis of the rod end of the gas cylinder. Install the
curved end of the tool around the base end of the gas
spring.
Install the clamp (Item 2) [D] around the gas cylinder to
hold the retainer tool in place. Remove the nut and
remove the gas spring from the rear door.
P–03288
773 BICS Loader

SEAT BAR (W/COMPRESSION SPRINGS)
A
Lower the seat bar (Item 1) [A] so the compression
springs (Item 2) [A] will be in a down position.
1
2 2
P–09543
Loosen the adjustment lock nut (Item 1) [B] (both sides). B
P–09542
Turn the bolt (Item 1) [C] into the clevis five turns (both
sides).
C
Installation: When properly adjusted the clearance
distance between the bolt head (Item 1) [C] and the seat 1
bar tab (Item 2) [C] is 1/16 inch (1,58 mm). 2
Tighten the adjustment lock nut (Item 3) [C] to the clevis.
Repeat above installation procedure for other side. 3
1/16inch
NOTE: This adjustment must be made with the seat (1.58mm)
bar locked down in operating position.
P–09542
Remove the retaining pin (Item 1) [D] and clevis pin (both
sides). D
P–09541
773 BICS Loader

SEAT BAR (W/COMPRESSION SPRINGS) (Cont’d)
A
Disconnect the wiring harness connector (Item 1) [A] (left
side). 1
Remove the seat bar mounting bolt (Item 2) [A] (both

sides).
2
Remove the sensor mounting bolt (Item 3) [A] (left side).
3
P–09548
Installation: Make sure the two tabs (Item 1) [B] are

located in the slot on the operator cab. B
P–09547
Installation: Tighten the mounting bolt and nut (Item 1)

[C] to 180 – 200 in.–lbs. (21 – 23 Nm) torque. C
P–09554
To protect the paint on the operator cab from getting

scratched, install cardboard (Item 1) [D] on the right side. D 1
2
Wrap tape around the left pivot end (Item 2) [D] of the seat
bar.
Wrap tape around the cab grab handle (Item 3) [D] and
the front edge of the cab (Item 4) [D].
3
4
P–09546
773 BICS Loader

A 3 2
Position the seat bar in the recess on the left side of the
cab (Item 1) [A]. Position the left side pivot end of the seat 1
bar between the cab and the grab handle (Item 2) [A].
Lift straight up on the right side (Item 3) [A] of the seat bar.
P–09549
Continue to lift on the right side of the seat bar and allow
the left side of the seat bar to rotate between the cab and
B
1
the grab handle (Item 1) [B].
P–09552
Lift the right side of the seat bar until it clears the right side
screen of the cab [C]. C
P–09553
Remove the left side of the seat bar pivot from between
the cab and grab handle and remove the seat bar from the D
cab [D].
Reverse the above procedure to install the seat bar into
the operator cab.
P–09950
773 BICS Loader

A 6
3
1
Assembling Components
4
Assemble the parts as shown for the left side of the seat
bar pivot assembly [A]:
Washer (Item 2)
Magnetic Bushing Assembly (Item 4) 2
Sensor Mounting Nut (Item 5)
Sensor Bracket (Item 6)
Sensor Mounting Bolt (Item 7) 8
9 5
Pivot Bushing (Item 8) 7
P–09555
Assemble the parts as shown for the right side of the seat
bar pivot assembly [B]: B 3
2
Mounting Bolt (Item 1) 1
Pivot Bushing (Item 2)
Mounting Bracket (Item 3)
Washer (Item 5)
6 5 4
P–09551
Compression Spring Disassembly And Assembly

Loosen the lock nut (Item 1) [C] and turn the bolt (Item 2)
C
[C] out of the clevis.
Assembly: Adjust the compression spring as shown on
Page 5–7 Fig. [B]. 2
P–09542
Disassemble and assemble the seat bar compression

spring and parts as shown in Fig. [D]: D 2
1
Pin (Item 1)
Retaining Pin (Item 2)
Clevis (Item 3)
Lock Nut (Item 4)
Washer (Item 5) 3
Spring (Item 6)
Bushing (Item 7) 4
Bolt (Item 8)
5
8
6
7
P–09586
773 BICS Loader

OPERATOR CAB GAS CYLINDER
A

W–2113–0288
N–00834
Remove the operator cab stop (Item 1) (both sides) [A].
NOTE: If the operator cab is equipped with a rear

window, the rear grill and rear grill mounts B
must be removed to prevent window
damage. See Page 5–24.
Raise the operator cab See Page 1–1, to release the
tension on the gas cylinder (Item 1) [B].
Install a hoist to the cab to prevent the cab from falling
forward [B].
N–00822
Remove the bolts (Item 1) [C] from the gas cylinder

mounting bracket.
C
N–00825
773 BICS Loader

OPERATOR CAB GAS CYLINDER (Cont’d)
A
Move the mounting bracket forward to relieve any

remaining tension on the gas cylinder [A].
N–00823
Remove the retainer pin (Item 1) [B] from the top pivot
pin. B 1
Remove the pivot pin and bushing from the gas cylinder.
Remove the gas cylinder.
NOTE: Lift arms are raised for photo clarity.
N–00841

C
Remove the clevis (Item 1) [C] and washer (Item 2) [C]
from the end of the gas cylinder.
Remove the gas cylinder from the outer housing.
2
1
P–01008
Assembly: Install a replacement cylinder inside the

cylinder housing. D
Apply a small amount of LOCTITE on the threads of the
cylinder rod [D].
Reinstall the washer and clevis on the cylinder rod.
P–01006
773 BICS Loader

OPERATOR CAB
A
Remove the cab nut and holddown plate (Item 1) [A] (both
sides). 1
Installation: Tighten the nut to 40–50 ft.–lbs. (54–68 Nm)
torque.
P–01518 P–01528
Disconnect the wiring harness connectors (Item 1) [B].

Remove bolt (Item 2) [B] and ground wire.
B
2
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab
gas cylinders. If the operator cab is tilted
forward without the gas cylinders operational,
the cab will fall and could cause injury or death. N–00824
W–2245–0796
C
Remove both gas cylinders. (See Page 5–11.)
Use the hoist connected to the operator cab grab handles
to lower or (raise) the operator cab when the gas cylinders
are disconnected [C].
N–00822
773 BICS Loader

A
Remove the rear mounting bolt (Item 1) [A] (both sides)
and nut from the operator cab.
Installation: Tighten the pivot bolt and nut to 25–35
1
N–00828
Connect the slings (Items 1 & 2) [B] to a chain hoist.

Remove the operator cab from the loader [B].
B
2
N–00821
773 BICS Loader

OPERATOR SEAT
A
Use the following procedure to remove the operator seat
from the operator cab: 2
2
Raise the operator cab. (See Page 1–1.) 1
Locate the operator seat sensor (Item 1) [A] on the
bottom of the seat pan.
Disconnect the seat sensor connector and remove the 2
seat sensor assembly. (See Page 8–1.)
Remove the three seat mounting nuts (Item 2) [A] and
washers from the operator seat mounting studs. N–00959
Lower the operator cab and remove the operator seat

from the cab. B 5 5
Remove the spring (Item 1) [B], the two steel strips (Item
2) [B] (one strip on each side of the seat), the two foam 3
3
covers (Item 3) [B] (if equipped) and the two spacers
(Item 4) [B]. 2
Installation: Use duct tape (Item 5) [B] to hold the ends
of the spring and steel strips to secure parts for seat
1
installation. 4 4
5 5
N–00457
Remove the bushing (Item 1) [C] from the right rear seat
rail stud. C
Installation: The bushing (Item 1) [C] should be
centered in the seat spring slot [C]. Tighten the bushing 2
to 105–130 in.–lbs. (11,9–14,6 Nm) torque.
1
NOTE: The bushing (Item 1) [C] has precoated
adhesive patch locking material. If adhesive
is not present use liquid adhesive LOCTITE
#242 blue on threaded area of both ends of
bushing.
N–00459
Installation: Make sure the seat spring (Item 1) [D] is Operator

installed with the bend of the seat spring in the position D Seat
shown.
Inspect the seat adjustment track.
Remove the mounting bolt from each end of the track and Seat Seat
replace the adjustment track if necessary. 1 Spring
Sensor
Reverse the removal procedure to install the operator
seat. Seat Rail
Cover
Check for correct seat sensor operation. (See BICS™
inspection procedure in your Operation & Maintenance
Manual.)
MC–02043
773 BICS Loader

BOB–TACH
A
Tilt the Bob–Tach forward, so it is parallel to the floor. Put
blocks (Item 1) [A] approximately 3.0 inches thick under
each side of the Bob–Tach. Lower the Bob–Tach onto the
blocks [A].
1
N–00807
Remove the retainer nut (Item 1) [B] from the pivot pin.
Installation: Tighten the retainer bolt to 18–20 ft.–lbs.
B
P–04601
Remove the grease fitting from the pivot pin [C].

Remove the rod end pivot pin (Item 1) [C]. C
P–03915
Remove the tilt cylinder rod end.

Remove the seals (Item 1) [D]. D
P–03911
773 BICS Loader

BOB–TACH (Cont’d)
A
Installation: Use two pieces of shim stock (light
cardboard), install the rod end of the tilt cylinder into the
Bob–Tach [A].
Be careful not to damage the seals during installation.
NOTE: Removal procedure is shown for the right
side. Left side procedure is the same.
P–03910
Remove the grease fitting (Item 1) [B] from the Bob–Tach

frame for the pivot pin (both sides) [C]. B
NOTE: The pivot pin fitting must be removed to
prevent the pivot pin from being locked in the
Bob–Tach frame.
Loosen the bolt (Item 2) [B] at the Bob–Tach pivot pin.

1
2
Installation: Tighten the bolt to 175–190 ft.–lbs.
Strike the head of the bolt (Item 2) [B] to push the pivot
pin into the Bob–Tach frame.
Remove the bolt (Item 2) [B]. P–03913
Use a punch to push the pivot pin all the way into the
Bob–Tach frame.
C
Installation: A longer bolt is necessary to install through
lift arms into the pivot pin, to pull the pivot pin into the lift
arms.
NOTE: Use tapered ream MEL1233 to clean the
tapered hole in the lift arms. The tapered hole
must be clean and free of debris to provide a
good contact surface for the pivot pin. 1
Slowly back the loader away to remove the Bob–Tach
frame [C].
Remove the seal dust cup (Item 1) [C].
P–03908
Remove the rubber seal [D]. D
P–03909
773 BICS Loader

A
Install the Bob–Tach mounting bolt (Item 1) [A] into the
pivot pin (Item 2) [A]. Remove the pivot pin from the
Bob–Tach frame.
Check for wear and damage. Replace the pivot pins as
needed.
3
Installation: Push the pivot pin (Item 2) [A] into the 2
Bob–Tach frame. Position the end of the pin flush with the 1
end of the Bob–Tach bushing (Item 3) [A].
Reverse the removal procedure to install the Bob–Tach.
P–03912
Bob–Tach Lever And Wedge

Use the following procedure to remove and install the
B
Bob–Tach lever (Item 1) [B], spring and wedge.
1
P–03930
Remove the lever mounting bolt and nut (Item 1) [C],

washer (Item 2) [C] and spring (Item 3) [C]. C
torque.
3
1 2
P–03928
Remove the Bob–Tach lever (Item 1) [D].

D
P–03924
773 BICS Loader

Bob–Tach Lever And Wedge (Cont’d)
A
Use a punch and hammer, remove the roll pin (Item 1) [A] 1
from the Bob–Tach wedge and spring, bolt and clevis
assembly.
P–03925
Remove the spring, bolt and clevis assembly (Item 1) [B]. B

Remove the wedge (Item 2) [B] from the Bob–Tach
frame.
Always replace bent or broken wedges. 2
1
P–03926
If the bolt (Item 1) [C], handle pivot (Item 2) [C], spring

(Item 3) [C] or clevis (Item 4) [C] are damaged, put the C
assembly in the vise. Loosen and remove the bolt (Item
1) [C] with a 5/16 inch allen wrench.
Replace the worn or damaged parts as needed.
Reverse the removal procedure to install the Bob–Tach
Lever and Wedge. 2
1
4
3
P–03929
Bob–Tach Stops
D
Remove and replace the Bob–Tach stop (Item 1) [D]
(both sides) if worn or damaged.
NOTE: The Bob–Tach stop (Item 1) [D] must contact

the lift arm at the same time the tilt cylinder
reaches full extension. Use available shims
to adjust the Bob–Tach stop and tilt cylinder
sequence as closely as possible.
P–03914
773 BICS Loader

LIFT ARMS
A
Roll the Bob–Tach fully forward. Stop the engine.
Move the hydraulic controls to release the hydraulic
pressure.
Remove the Bob–Tach frame from the lift arms. (See 1
Page 5–16.)
Remove the tubeline clamp (Item 1) [A] under the lift arm
for clearance (both sides).
N–00829
Disconnect the hoses (Item 1) [B] (both sides). B

Install plugs into the hose ends.

N–00830
the system.
I–2003–0888
C
Remove the retainer bolt and nut (Item 1) [C] from the lift
arm pivot pin (both sides).
Installation: Tighten the retainer bolt and nut to 18–20
ft.–lbs. (24–27 Nm) torque. 1
NOTE: Grease fittings on the pivot pins should be

removed before removing the pivot pins with
a punch and hammer.
N–00811
Use a drift punch and hammer, remove the lift arm pivot
pin (both sides) [D]. D
N–00814
773 BICS Loader

LIFT ARMS (Cont’d) A
Removal And Installation (Cont’d) 2
Remove the retainer bolt and nut from the lift cylinder rod
end pivot pin (Item 1) [A] (both sides). 1
Remove the grease fitting (Item 2) [A] (both sides).
Installation: Reinstall the grease fitting (Item 2) [A] when
lift arms are reinstalled (Both sides). N–00812
Connect a nylon lift strap, chain and chain hoist to the lift
arms. (See Figure [C] for reference.)
B
Use a drift punch and hammer, remove the lift cylinder rod
end pivot pin (Item 1) [A] (both sides).
Remove the retainer bolt and nut (Item 1) [B] from the
stabilizer pivot pin (both sides).
1
Use a drift punch and hammer, remove the stabilizer pivot
pin (Item 1) [B] (both sides).
N–00813
Lift the lift arms with the chain hoist and move them away C
from the loader [C].
Reverse the removal procedure to install the lift arms on
the loader.
N–00815
773 BICS Loader

LIFT ARM LINK
A
Lower the lift arms. Stop the engine.
Disconnect the tilt cylinder hoses between the lift arm link
and the lift arms. 1
When repairing hydrostatic and hydraulic N–00811

ports to keep dirt out. Dirt can quickly damage B
the system.
I–2003–0888
Remove the retainer bolt and nut from the lift arm pivot pin
(Item 1) (both sides) [A].
ft.–lbs.(24–27 Nm) torque.
Use a drift pin and hammer, remove the lift arm pivot pin N–00814
[B] (both sides).

• When fluids are under pressure.
• Flying debris or loose material is present.
W–2019–1285
N–00816
Connect a chain and chain hoist on the lift arm link [C].
Remove the retainer bolt and nut from the lift arm link
D
pivot pin (Item 1) [D] (both sides).
N–00817
773 BICS Loader

LIFT ARM LINK (Cont’d)
A
Use a drift punch and hammer, remove the lift arm link
pivot pin (both sides) [A].
Raise the lift arm link with the chain hoist and remove it
from the loader frame.
Reverse the removal procedure to install the lift arm link
on the loader.
N–00818
773 BICS Loader

REAR GRILL
A
Remove the pivot bolt and nut (Item 1) [A] and disconnect
the gas cylinder from the rear grill.
1
NOTE: To remove and replace the gas cylinder, pry
the base end of the cylinder off of the
stationary ball joint mounted on the loader
frame.
Installation: Tighten the mounting nut to 80–90 in.–lbs.

(9–10 Nm) torque.
N–00832
Remove the cotter pin (Item 1) [B] from the pivot pin (both
sides). B
P–03892
Remove the pivot pin (Item 1) [C] (both sides).

C
P–03893
Lift the rear grill from the loader [D].

D
Reverse the removal procedure to install a new grill.
N–00835
773 BICS Loader

FUEL TANK
773ServiceManual#6900092–MainFrameSectionPart1of2
A
Remove the cover (Item 1) [A] which is installed over the
fuel drain near the rear of the chaincase.
Installation: Tighten the cover mounting bolts to
190–240 in.–lbs. (21,5–27 Nm) torque.
1
P–01616
Drain the fuel from the tank through the fuel drain (Item
1) [B].
B
Open the rear door of the loader.
P–01619
Remove the two mounting bolts (Item 1) [C] from the

battery holder.
C
Installation: Tighten the battery holder mounting bolts to
190–240 in.–lbs. (21,5–27 Nm) torque.
Remove the battery holder (Item 2) [C] from the loader. 2
P–04222
Disconnect the fuel fill hose (Item 1) [D] and the vent hose
(Item 2) [D] from the fuel tank.
D
P–04225
773 BICS Loader

FUEL TANK (Cont’d)
A
Remove the fuel inlet screen (Item 1) [A]. Clean and dry
the screen. Check the screen for damage and replace if
necessary.
P–04226
Lift the fuel tank up and remove the tank from the loader
[B]. B
Reverse the removal procedure to install the fuel tank.
P–04229
Fuel Level Sender

C
Loosen the fuel level sender (Item 1) [B] with a wrench.
Turn the fuel level sender (Item 1) [C] out and remove it
from the fuel tank. Check the fuel level sender for damage
and replace if necessary.
Installation: Tighten the fuel level sender to 50–60
in.–lbs. (5,7–6,8 Nm) torque.
1
P–04228
773 BICS Loader

REAR DOOR
Removal And Installation (Two Piece Door)
A
Attach a 1/4 inch chain to the existing holes in the rear
door as shown [A].
Use two 3/8 inch x 1–1/2 inch carriage bolts (Item 1) [A]
to secure the chain to the door.
Secure the chain to the bolts inside the rear door with a 2
washer and nut.
Using an adjustable lifting sling (Item 2) [A] will allow you
to adjust to the proper length shown.
Connect a chain hoist to the lifting sling [A].
P–11032
Disconnect the light harness connector (Item 1) [B] (if so

equipped), from the engine harness. B
Remove the top and bottom door hinge mounting bolts
(Item 2) [B] and nuts.
Installation: Tighten the mounting bolts and nuts to
25–28 ft.–lbs. (34–38 Nm) torque.
Lift the door away from the loader frame and put the door
flat on the floor.
Reverse the removal procedure to install the rear door. 1 2
P–03898
773 BICS Loader

REAR DOOR (Cont’d)
Removal And Installation (One Piece Door)
A
Remove the light assembly from the door (See Page
5–31.)
Secure the chain hooks (Item 1) [A] to the door as shown.
2
Connect a chain hoist (Item 2) [A] to the lifting chain.
Disconnect the light harness connector (Item 1) [B] (if so

equipped), from the engine harness. 1
Remove the top and bottom door hinge mounting bolts
(Item 2) [B] and nuts.
NOTE: Install the door stop (Item 3) [B] in the top

hinge as shown.
N–15410
Installation: Tighten the mounting bolts and nuts to

25–28 ft.–lbs. (34–38 Nm) torque.
B
Lift the door away from the loader frame and put the door
flat on the floor. 2
Reverse the removal procedure to install the rear door.
3
N–15860
773 BICS Loader

Hood Removal And Installation (Two Piece Door)
A 1
Remove the rear lights harness from the rear door hood
if so equipped.
Remove the five mounting bolts from the rear door hood
(Item 1) [A].
Installation: Tighten the hood mounting bolts to 25–28
Remove the hood from the rear door.
P–04143
Bumper Removal And Installation (Two Piece Door)

Remove the three rear bumper mounting bolts (Item 1)
B
[B] with a 7/32 inch allen wrench.
Installation: Tighten the mounting bolts 180–200 in.–lbs.
Remove the bumper (Item 2) [B] from the rear door.
2
1
P–04281
Door Latch Removal And Installation

C
Remove the door latch mounting bolts (Item 1) [C] from
the door latch mechanism.
(9–10 Nm) torque.
Remove the latch and handle mechanisms from the rear
door.
P–04278
773 BICS Loader

Door Latch And Catch Adjustment
A

Never service or adjust the machine when the
engine is running unless instructed to do so 1
in the manual.
W–2012–0497
P–01598
The door catch (Item 1) [A] can be adjusted side to side

for alignment with the door latch.
B
The door latch mechanism (Item 1) [B] can be adjusted
forward or backward for alignment with the door catch.
P–04278
773 BICS Loader

REAR LIGHTS
A
Rear Lights Removal and Installation (One Piece
Door)
Remove the bulb assembly (Items 1 & 2) [A] from the light
1 2
housing (Item 3) [A] by turning bulb assembly a 1/4 turn.
N–15861
Using care press the rear light and housing from the door
[B]. B
Reverse this procedure for installation.
N–15862
773 BICS Loader

ELECTRICAL SYSTEM
Page
Number
ALTERNATOR
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–13
Disassembly And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
Rectifier (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
BATTERY
Servicing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
ELECTRICAL SYSTEM INFORMATION
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4
FRONT LIGHTS
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–36 ELECTRICAL
RELAY SWITCHES SYSTEM
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–37
STANDARD INSTRUMENT PANEL
STARTER
STARTER (DELCO REMY)
Checking The Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–14
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–18
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
STARTER (DENSO)
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–20
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–19
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

773 BICS Loader

773 BICS Loader
773 BICS Loader
773 - WIRING SCHEMATIC
OPTIONS TO ATTACHMENT RIGHT HANDLE
S/N 509635001 AND ABOVE A RNG
S/N 509616001-34999 E TWO
C441
SPEED/
(PRINTED JUNE 2001) B WHT/LGN
WATER KIT
V-0112 C LGN
SKI
D YEL
CONTROL
F
TO CONTROLS
DETENT
B DGN
A RNG/WHT
D WHT
C439
E WHT/RED
PWM
C WHT/BLK
F PNK/RED
G PNK/BLK TILT
CONTROL
H PNK/DGN
TO FLOAT BUTTON
TO AHC (THIS SHEET)
C440 C630
TO LEFT HANDLE
CONTROLS
C630
(THIS SHEET)
C434
A PUR FLOAT
A PUR A SIGNAL
B
TO ATTACHMENT
A WHT
SKI
ADVANCED HAND CONTROL B DBL CONTROL
F SERIES FLOAT BUTTON TO CONTROLS

OR TO
C406
ATTACHMENT C457
HARNESS - 6727327 C406
C457
C PNK
PADDLE
or B
A
TAN
RNG
MOMENTARY
TO CONTROLS
C437
A YEL/RED LIFT
B RNG/BLK TILT
AHC DIAGNOSTIC LED
TO JUMPER (THIS SHEET)
D RED
E BLK HORN
TO LEFT HANDLE
C BRN
C631
TO CONTROLS (THIS SHEET)

TURN
D RNG D B DGN
SIGNAL
E RNG/DBL E A YEL
C BRN C G BLK/WHT
C438
C631
LIFT
B DGN B H PUR/WHT
CONTROL
A YEL A F RED/WHT
G BRN/BLK G
H BRN/DGN H LEFT HANDLE
F BRN/RED F
- +
ADVANCED HAND CONTROL

ADVANCED HAND CONTROL (WITH FLOAT BUTTON) -
F SERIES JUMPER RIGHT STEERING LEVER - 6675748 and
HARNESS - 6728741 or 6730272 LEFT STEERING LEVER - 6675747
RED = RED
RNG = ORANGE WIRES CONNECT BY LETTER
BLK = BLACK ACROSS CONNECTORS BATTERY FEED 1000-1999 RED, RED/WHT, RNG
LBL = LIGHT BLUE GROUND 2000-2999 BLK
DBL = DARK BLUE A B MONITORING 3000-3999 LBL
LGN = LIGHT GREEN HYDRAULIC 4000-4999 LGN
B A ATTACHMENT CONTROLS 5000-5999 YEL
DGN = DARK GREEN
YEL = YELLOW LIGHTS 6000-6999 PNK
PNK = PINK SOME CONNECTOR ACCESSORIES 7000-7999 WHT
BODIES NOT SHOWN ENGINE 8000-8999 TAN
WHT = WHITE
COMMUNICATION 9000-9999 PUR
BRN = BROWN FOR DRAWING CLARITY
TAN = TAN
PUR = PURPLE
GRY = GRAY
Printed in U.S.A. V-0112 (6-15-01)

TROUBLESHOOTING
Chart
assistance in locating and correcting problems. Many of
the recommended procedures must be done by
authorized Bobcat Service Personnel only. Instructions are necessary before operating or
or death. W–2003–0199
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5

Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
1. Alternator belt is loose or damaged.

2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.

5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.

8. The wiring or the solenoid is damaged.
9. Check the fuses.
773 BICS Loader

Revised Jan. 99
ELECTRICAL SYSTEM INFORMATION
Description
A
The loader has a 12 volt, negative ground alternator
charging system. The electrical system is protected by
fuses (Item 1) [A] located in the engine compartment. The 2
fuses will protect the electrical system when there is an
electrical overload. The reason for the overload must be
found before starting the engine again.
1
P–03968
Do Not use silicone base sprays and/or

sealants on harness connectors or
components. I–2123–0397
B
Fuse Location
The electrical system for loaders is protected by eight
fuses located in the fuse block (Item 1) [B]. Remove the
fuse block cover to access the fuses.
1
P–03965
The decal (Item 2 ) [A] inside the rear door specifies the
fuse sizes used in various loader circuits [C] & [D]. C
6707786
P–13771
773 BICS Loader

BATTERY
A
1
Batteries contain acid which burns eyes and

skin on contact. Wear goggles, protective
clothing and rubber gloves to keep acid off
body.
In case of acid contact, wash immediately with P–10335
water. In case of eye contact get prompt medical
attention and wash eye with clean, cool water
for at least 15 minutes.
B
If electrolyte is taken internally drink large
quantities of water or milk! DO NOT induce 1
vomiting. Get prompt medical attention.
W–2065–1296
Open the rear door.

Disconnect the negative (–) battery cable (Item 1) [A]
from the battery.
Disconnect the positive (+) cable (Item 1) [B] from the

battery.
P–10336
Remove the battery holddown clamp (Item 1) [C].

C 1
P–03880
Remove the battery from the loader [D].

D
P–03873
773 BICS Loader

BATTERY (Cont’d)
A
Installation
Always clean the terminals and cable ends when
installing a new battery [A] & [B].
When installing the battery in the loader, do not touch any
metal parts with the battery terminal posts.
Connect and tighten the battery cables. Connect the
negative (–) cable last to prevent sparks.
Install the battery holddown clamp.
P–09589
Servicing The Battery

B

skin on contact. Wear goggles, protective
body.
In case of acid contact, wash immediately with
water. In case of eye contact get prompt medical
for at least 15 minutes. P–09590
If electrolyte is taken internally drink large

quantities of water or milk! DO NOT induce
C
W–2065–1296
The battery cables must be clean and the connections

tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
water solution [C].
Clean the terminals and cable ends as shown in figure [A]

and [B].
Check the electrolyte level in the battery. Add distilled
water as needed. P–09588
Put battery saver P/N (6664458) or grease on the battery

terminals and cable ends to prevent corrosion.
773 BICS Loader

BATTERY (Cont’d)
Using A Booster Battery (Jump Starting)
A

skin on contact. Wear goggles, protective 2
body.
In case of acid contact, wash immediately with
water. In case of eye contact get prompt medical P–10644
for at least 15 minutes.
If electrolyte is taken internally drink large B
quantities of water or milk! DO NOT induce
W–2065–1296
1
Keep arcs, sparks, flames and lighted tobacco

away from batteries. When jumping from
booster battery make final connection
(negative) at engine frame.
Do not jump start or charge a frozen or damaged 2
battery. Warm battery to 60°F. (16°C.) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery.
Never lean over battery while boosting, testing P–03957
or charging.
Battery gas can explode and cause serious
injury.
W–2066–1296
If it is necessary to use a booster battery to start the

engine, BE CAREFUL! There must be one person in the Damage to the alternator can occur if:
operator’s seat and one person to connect and • Engine is operated with battery cables
disconnect the battery cables.
disconnected.
The key switch must be in the OFF position. The booster • Battery cables are connected when using a
battery to be used must be 12 volt. fast charger or when welding on the loader
(Remove both cables from the battery).
Connect the end of the first cable (Item 1) [A] to the • Extra battery cables (booster cables) are
positive (+) terminal of the booster battery. Connect the connected wrong.
other end of the same cable (Item 1) [B] to the positive I–2023–1285
terminal on the loader battery.
Connect the end of the second cable (Item 2) [A] to the
negative (–) terminal of the booster battery. Connect the
other end of the same cable (Item 2) [B] to the engine
ground cable.
Keep cables away from moving parts. Start the engine.
After the engine has started, remove the ground (–) cable
(Item 2) [B] first. Remove the cable from the positive
terminal on the loader battery.
773 BICS Loader

ALTERNATOR
A REAR VIEW OF ALTERNTOR
Test the alternator as follows:
a. Alternator Output Test
b. Rectifier (Diode) Test
c. Alternator Regulator Test
Alternator Output Test
Put jackstands under the front axles and rear MC–01813

death. B 2
W–2017–0286

Disconnect the negative (–) cable from the battery.
NOTE: The photo’s may be different but the 1
procedure is the same for all models.
Disconnect the red wire (Item 1) [B] from the alternator.
Connect that wire to the negative (–) side of the ammeter.
Connect the positive (+) side of the ammeter to the output
terminal on the alternator (Item 2) [B].
P–02284
Disconnect the fuel stop solenoid connector.
Connect the negative (–) cable to the battery.
Turn on the lights and crank the engine for 30 seconds to
C Output
Terminal
discharge the battery.
Connect the fuel stop solenoid, start the engine and run
at 2600 RPM.
The ammeter reading should be between 45–55 amps. at
2600 RPM. 1
If the reading is low, remove the bolts and pull the
regulator cover away from the alternator.
Regulator
Rectifier (Diode) Test Terminal
The alternator is removed from the loader for clarity P–01304
purposes [C].
Install the wires in their original location on the back of the
alternator.
Connect a jumper wire (Item 1) [C] to the alternator output
terminal and the regulator terminal.
Connect the battery negative (–) cable.
Start the engine and run at 2600 RPM.
If the reading is within 45–55 amps. at 2600 RPM replace
the rectifier (diode) assembly or replace the alternator.
If the reading is low, do the Alternator Regulator Test.
773 BICS Loader

ALTERNATOR (Cont’d)
A
Alternator Regulator Test
Positive
Negative
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.
P–02282
W–2050–1285
Connect the positive (+) voltmeter lead to the positive (+)

battery terminal [A].
B
Connect the negative (–) voltmeter lead to the negative
(–) battery terminal [A].
Start the engine and run at 1500–2000 RPM. Ground
Stud
The voltmeter should read between 13.9–14.7 volts.
If the reading is low stop the engine and disconnect the
battery negative (–) cable. Brush
Terminal
The alternator is removed from the loader for clarity
purposes [B]. 1
P–01364
Remove the wires from the back of the alternator.
Remove the regulator cover from the back of the
alternator.
Install the wires on the back of the alternator.
Connect a jumper wire (Item 1) [B] from the brush
terminal to the ground stud.
Connect the negative (–) battery cable and start the
engine. Run at 1500 RPM.
If the voltmeter reading is 14.5 or above replace the
regulator.
If the voltmeter reading is below 14.5, repair or replace the
alternator.
773 BICS Loader

A
1
Place jackstands under the rear corners of the loader. 3
2
4
P–03877
Damage to the alternator can occur if:

Never work on a machine with the lift arms up • Engine is operated with battery cables
unless the lift arms are secured by an approved disconnected.
lift arm support device. Failure to use an • Battery cables are connected when using a
approved lift arm support device can allow the fast charger or when welding on the loader
lift arms or attachment to fall and cause injury (Remove both cables from the battery).
or death. W–2059–0598
• Extra battery cables (booster cables) are
connected wrong.
I–2023–1285
Disconnect the red wire (Item 1) [A] from the alternator
which comes from the battery.
Disconnect the wiring harness connector (Item 2) [A]
from the alternator.
Remove the adjustment bolt (Item 3) [A] from the
mounting bracket.
Remove the alternator belt from the alternator pulley.
Remove the mounting bolt (Item 4) [A] and spacer (Item
5) [A].
Adjusting The Alternator Belt

Stop the engine.
Loosen the alternator mounting bolt (Item 4) [A].
Loosen the adjustment bolt (Item 3) [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.
Tighten the adjustment bolt and mounting bolt.
773 BICS Loader

1. Nut 9. Rectifier (Diode)
Disassembly And Inspection
A 2. Pulley 10. Case Half (Rear)
3. Fan 11. Condenser Assy.
Disassemble the alternator. (See Parts Identification 4. Bolt 12. Strap
Figure [A].) 5. Case Half (Front) 13. Regulator
6. Bearing 14. Brush
Remove the regulator cover and regulator. 7. Rotor 15. Cover
8. Stator
Remove the four bolts holding halves together.
Pry the halves apart (use a press if needed).
Use a soft jaw vise to hold rotor while removing pulley nut. 3
1 2
Remove front case half from the rotor using a plastic
hammer or press. 5
4 8
Unsolder the stator leads from the rectifier. Remove the
stator.
6 7
12
13
11 14
10
9
15 C–03312
Stator Continuity Test

B
Use an ohmmeter to test the stator.
Touch the probes to two of the bare stator wires [B].
Move one of the probes to the third wire.
The readings should be the same.
If there is no continuity, replace the stator.
P–01369
Stator Ground Test

C
Touch one probe to a bare stator lead and the other probe
to the bare metal surface of the stator [C].
There should be no continuity.
Replace the stator if there is continuity.
P–01386
773 BICS Loader

A
Rotor Continuity Test
Touch the probes to the slip rings [A].
The ohmmeter should read between 3.065–33.85 ohms.
If there is no continuity replace the rotor.
P–01365
Rotor Ground Test

Touch one probe to one of the slip rings and the other
B
probe to the rotor shaft [B].
There should be no continuity.
Replace the rotor if there is continuity.
P–01378
Rectifier Continuity (Diode) Test
NOTE: In the diode tests there should be continuity

C 1
1
in one direction only. If the diode being 1
tested shows no continuity or continuity in
both directions, replace the rectifier
assembly.
Touch the probes to the terminals (Item 1) [C] of each
diode and read the meter.
Reverse the probes to check the diode in the other
direction.
There should be continuity in one direction only.
P–01373
Touch one probe to the diode (Item 1) [D] and the other
probe to the connected heatsink and read the meter. D 1

direction.
There should be continuity in one direction only. 1
1
P–01370
773 BICS Loader

Rectifier Continuity (Diode) Test (Cont’d)
A 1
Touch one probe to the diode (Item 1) [A] and the other
1
probe to the connected heatsink and read the meter.
1
direction.
There should be continuity in one direction only.
P–01390
Assembly B
Reverse the order of disassembly.
Do not assemble the rear case half.
Place the rotor in soft jaws when tightening the shaft nut.
Tighten to 50 ft.–lbs. (68 Nm) torque [B].
Install the rear case half and the remaining parts.
P–01808
773 BICS Loader

STARTER
A
1
Remove the negative (–) and positive (+) cables from the
battery.
Remove the starter mounting bolt (Item 1) [A] and
disconnect the ground wires from the starter.
P–03879
Remove the lower mounting bolt (Item 1) [B]. Remove the

negative (–) battery cables and frame ground cable from
the starter (Item 2) [B].
B
Disconnect the engine harness power wires and positive
(+) battery cable starter solenoid terminal (Item 3), [B].
3
Disconnect the white wire (Item 4) [B] from the S terminal 4
on the starter solenoid.
Remove the mounting bolt (Item 5) [B] from the starter.
Remove the starter from the engine.
5
Installation: Tighten the three mounting bolts to 25–28
ft.–lbs. (34–38 Nm) torque. 1 2
P–03875
Reverse the removal procedure to install the starter.
STARTER (DELCO REMY)

C
Bat
Checking the Starter S
M
The key switch must be in the OFF position.
The battery must be at full charge.
Cranking
The cable connections on the battery must be clean and Motor
tight.
Connect a jumper wire between S terminal and BAT
terminal [C].
If the starter turns but does not turn the engine, the starter A–01991
drive has a defect.
Connect a jumper wire between the M terminal and the D

BAT terminal [D]. Bat
If the starter turns, the defect is in the solenoid. S
M
If the starter does not turn, the starter is defective.
Cranking
Motor
A–01992
773 BICS Loader

STARTER (DELCO REMY) (Cont’d)
Parts Identification
1. Screw
2. Solenoid
3. Bolt
4. Lever
3 5. Washer
6. Nut
2 7. Plug
4
8. Washer
9. Housing Drive
1
10. Washer
11. Bushing
12. Ring
5 13. Stop
14. Drive
15. Drive Support
6 16. Support
9 7 17. Drive Shaft
18. Washer
8 19. Washer
41 19 20. Washer
21. Screw
22. Brush
23. Frame Assy.
24. Gasket
25. Pin
10 13 17 18 20 26. Armature Support
12 14 16
15 27. Bolt
28. Spacer
29. Bearing
11
30. Armature
21 31. Bearing
32. Spring
22 33. Holder Assy.
26
25 24 34. Brush
35. Screw
36. O–ring
37. Frame
38. Washer
39. Screw
40. Bolt
23 41. Ring
27 22
21
35
30 34 39
28 29 31 34 38
32
33 36 37 40
D–02119
773 BICS Loader

Disassembly and Assembly
A
Remove the starter thru–bolts [A].
CD–08924
Remove the bolts for the brush holders [B].

B
CD–08925
Remove the starter end cap [C].

C
CD–08926
Remove the starter housing/armature assembly from the

reduction gear drive [D].
D
CD–08927
773 BICS Loader

Disassembly and Assembly (Cont’d)
A
Remove the armature and brushes from the starter
housing [A].
CD–08928
Remove the bolts from the reduction gear housing [B].

B
CD–08929
Remove the reduction gear housing [C].

C
CD–08930
773 BICS Loader

Cleaning and Inspection
A
Use a brush and air pressure to clean the drive, field coils,
armature and starter housing.
NOTE: DO NOT use solvent to clean the drive

assembly. The solvent will remove the
lubricant and the drive will slip.
Check the following items:
Armature
Broken or burned insulation A–01995
Loose connections at commutator
Open or grounded circuits [A] & [B]
Worn shaft or bearings
Rough commutator B
Brush Holders
Broken springs
Broken insulation
Spring tension
Field Coils
Broken or burned insulation
Electrical continuity
Brush connections
Drive Gears
Worn teeth
Tooth engagement A–01994
773 BICS Loader

STARTER (DENSO)
Parts Identification
1. Bearing 9
2. Armature
3. Bearing 7
4. Frame
5. Brush Spring 5 8
6
6. Brush Holder
7. Cover
8. Bolt 4
12. Gasket
9. Bolt 13. Switch
10. Bolt 3 14. Nut
11. Cover
2 15. Washer
16. Nut
17. Washer
1 18. Roller
19. Retainer
20. Idler Gear
21. Ball
10 22. Spring
11
15 12
14
16
18 17
20 19 13
15
16
23
14
22
21
36
35
34
33
32 23. Housing
26
25 24. Screw
25. Washer
24 30 26. O–ring
28 27. Housing
29 28. O–ring
31 29. Snap Ring
30. Collar
29 31. Pinion Gear
27 32. Spring Seat
33. Spring
34. Clutch
35. Spring
36. Pinion Shaft
D–02297
773 BICS Loader

STARTER (DENSO) (Cont’d)
A 1
Disassembly
Remove the cable (Item 1) [A] from the magnetic switch.
N–15158
Remove the bolts (Item 1) [B]. B
N–15159
Remove the frame (Item 1) [C] from the magnetic switch. C
1 N–15160
Remove the bolts (Item 1) [D] from the brush cover (Item
2) [D]. D
Remove the cover (Item 2) [D].
1 1
N–15161
773 BICS Loader

A
2
Using a needle nose pliers, pull the brush springs (Item
1) [A] back and remove the brushes (Item 2) [A].
NOTE: The brushes are non–replaceable. If the 1

brushes are worn order a new brush holder
(for the negative brushes) and yolk (for the
positive brushes).
Remove the brush holder (Item 3) [A] from the end of the 3
armature. N–00980
Remove the armature (Item 1) [B] from the frame.

B
Remove the bearings (Item 2) [B] from both ends of the
armature.
1
2 2
N–00981
Remove the bolts (Item 1) [C] from the starter housing.

C
1
1
N–15162
Remove the starter housing (Item 1) [D] from the

magnetic switch. D
1
N–15163
773 BICS Loader

A
Remove the ball (Item 1) [A] from the pinion shaft.
N–15164
Tap the starter pinion/clutch assembly (Item 1) [B] out of

the starter housing. B
1
N–15165
Remove the O–ring (Item 1) [C]. C
1
N–15166
Press down on the pinion (Item 1) [D] and retainer (Item

2) [D]. D
2
N–00987
773 BICS Loader

A
Remove the snap ring (Item 1) [A].
1
N–15011
Remove the retainer (Item 1) [B] and pinion (Item 2) [B].

Remove the spring seat (Item 3) [B] and spring (Item 4)
B
[B].
3 1
4 2
N–00988
Remove the pinion shaft (Item 1) [C] and spring (Item 2)

[C] from the over running clutch (Item 3) [C]. C
3
1 2
N–00989
Remove the spring (Item 1) [D] from the magnetic switch

housing. D
1
N–15167
773 BICS Loader

A
Remove the idler gear (Item 1) [A], retainer (Item 2) [A]
and rollers (Item 3) [A] from the magnetic switch housing.
2
1
N–15168
Remove the washer (Item 1) [B] from the idler gear shaft.
B
1
N–15169
Remove the bolts (Item 1) [C] from the magnetic switch. C
1 1
N–15150
Remove the cover (Item 1) [D], gasket (Item 2) [D] and

switch (Item 3) [D].
D
1
3 2
N–15151
773 BICS Loader

773ServiceManual#6900092–ElectricalSystemSectionPart1of2
A
Inspection And Repair
Inspect the brush cover for discoloration, indication the
starter has been overheated.
Inspect the pinion teeth for wear and damage.
Armature Short–Circuit Test: Use a growler tester, put the
armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [A]. A short circuited armature causes the blade
to vibrate and be attracted to the core. An armature which
is short–circuited must be replaced.
B–14455
Armature Winding Ground Test: Use a circuit tester, touch

one probe to a commutator segment and the other probe
B
to the armature core [B]. There should be no continuity.
If there is continuity, the armature is grounded and must
be replaced.
N–00996
Armature Winding Continuity Test: Use a circuit tester,

touch the probes to two commutator segments [C]. There
C
should be continuity at any point. If there is no continuity,
the winding is open–circuited, replace the armature.
N–00997
Commutator Run–Out Test: check the commutator

run–out as shown in [D]. D
Service Limit – 0.020 inch (0,4 mm)
If the commutator exceeds the service limit, repair as
needed.
B–14458
773 BICS Loader

A
Inspection And Repair (Cont’d)
Measure the segment mica depth (Item 1) [A]. 1
Service Limit – 0.008 inch (0,2 mm)
If it is worn, replace the armature.
Check the commutator surface for burned spots which
usually indicates an open–circuit, and correct it using
#400 sand paper.
B–14460
Check the field windings for wear and damage.

Check all the connections for clean and tight solder joints.
B
Field Winding Ground Test: Use a circuit tester, touch one
probe to the field winding end of the brush and the other
probe to the surface of the frame [B]. There should be no
continuity. If there is continuity, the field windings are
grounded.
Replace the frame.
N–00999
Field Windings Continuity Test: Use a circuit tester, touch

one probe to the wire and the other probe to the brush [C].
C
There should be continuity. If there is no continuity, the
field windings are open–circuited.
Replace the frame.
N–15005
Inspect the brushes for wear and damage.

D
Replace the brush holder and yoke if the brushes need
replacement.
Check brush spring, for damage or rust. Replace as
needed.
Brush Holder Insulation Test: Use a circuit tester, touch
one probe to the positive brush holder plate and the other
probe to the holder plate [D]. There should be no
continuity. If there is continuity, replace or repair.
N–15006
773 BICS Loader

A
Inspection and Repair (Cont’d)
NOTE: Assemble the over running clutch, pinion

shaft, springs, and pinion for this test.
Inspect the pinion, it must rotate freely in the direction of
the starter rotation and locked in the opposite rotation.
Pull the pinion out (to the engaged position) [A] and allow
it to snap back to the retracted position. The pinion must
fully return to the retracted position.
The following tests should be done without the armature
assembly. Install the magnetic switch in the switch
N–15012
housing.
NOTE: Each test should be performed a short time
(3 to 5 seconds) to prevent the magnetic
switch winding from burning. Each test B 50
should be performed with 12 volts. C
Pull–In Test: Connect the wires as shown in [B]. When

connecting Terminal C and M.T. are closed, the pinion
should engage.
M.T.
B–14471
Hold–In Test: With the same conditions as in the pull–in

test, open the connecting Terminal C [C]. The pinion
should remain in the engaged position.
C 50
C
M.T.
B–14470
Return Test: With the same conditions as in the hold–in

test, open the connecting Terminal 50 [D]. The pinion D 50
should return immediately.
C
M.T. . . . Main Terminal to which the main cable from the
battery is connected.
C . . . . . . C–Terminal to which the wire from the field
windings is connected.
50 . . . . . 50–Terminal to which the wire from the starting
switch or stator relay is connected.
M.T.
B–14469
773 BICS Loader

STARTER (DENSO) (Cont’d) Ammeter
A
No Load Test
50
The following test should be done after reassembling the M.T.
starter:
Clamp the starter in a vise. Using a 12 volt battery and
ammeter, connect the positive wire of the battery, and the
ammeter to the terminal [A]. Connect the negative wire
tot he starter body. Using a jumper wire, connect the 50
terminal to the main terminal.
The starter should show smooth and steady rotation
immediately after the pinion is engaged, it should draw
less than the specified current. Starter
B–14440
Service Limit – 220 Amp. Maximum Draw
Assembly
B
Clean all parts and apply high temperature grease to the
armature bearing, return spring, steel ball, over running
clutch, and idler gear rollers.
Install the switch plunger (Item 1) [B], gasket (Item 2) [B]
and cover (Item 3) [B] on the switch housing.
1 3
2
N–15151
Install the bolts (Item 1) [C].

C
1 N–15150
Install the washer (Item 1) [D] on the idler gear shaft.

D
N–15169
773 BICS Loader

A
Assembly (Cont’d)
Install the rollers (Item 1) [A] in the retainer (Item 2) [A].
1
2
N–15007
Install the roller/retainer assembly (Item 1) [B] on the idler

gear shaft. B
N–15152
Install the idler gear (Item 1) [C] over the retainer.

C
N–15153
Install the spring (Item 1) [D] in the magnetic switch

housing. D
1
N–15167
773 BICS Loader

A
Assembly (Cont’d)
Install the spring (Item 1) [A] over the pinion shaft (Item 3
2) [A]. Install the pinion shaft (Item 2) [A] in the over
running clutch (Item 3) [A]. 2 1
Stand the clutch assembly on end.
N–00989
Install the spring (Item 1) [B] and spring seat (Item 2) [B]
on the pinion shaft.
B
2
N–15010
Install the pinion (Item 1) [C] and retainer (Item 2) [C] on

the pinion shaft.
C
3
Press down on the pinion (Item 1) [C] and install the snap
ring (Item 3) [C] on the pinion shaft.
2
Pull the retainer (Item 2) [C] over the snap ring (Item 3)
[C]. 1
N–15011
Install the O–ring (Item 1) [D] in the starter housing.

D
1
N–15166
773 BICS Loader

A
Assembly (Cont’d)
Install the pinion shaft/over running clutch assembly (Item
1) [A] in the starter housing.
1
N–15165
Install the ball (Item 1) [B] in the end of the pinion shaft.
B
N–15164
Install the starter housing (Item 1) [C] on the magnetic

switch housing.
C
1
N–15163
Install the bolts (Item 1) [D] in the starter housing. Tighten

the bolts to 60–104 in.–lbs. (6,7–11,8 Nm) torque. D
1
1
N–15162
773 BICS Loader

A
Assembly (Cont’d)
Install the bearings (Item 1) [A] & [B] on both ends of the
armature.
N–15013
N–15014
Install the armature (Item 1) [C] in the frame.

C
N–00981
773 BICS Loader

A
Assembly (Cont’d)
Install the frame/armature assembly (Item 1) [A] on the
housing.
N–15154
NOTE: Make sure the notch (Item 1) [B] in the frame

matches up with the notch (Item 2) [B] in the
housing.
B
2
N–15155
Install the brush holder (Item 1) [C] on the end of the

armature.
C
1
N–15156
Using the needle nose pliers, pull the brush springs (Item
1) [D] back and install the brushes (Item 2) [D].
D
2
N–15157
773 BICS Loader

A
Assembly (Cont’d)
Install the brush cover (Item 1) [A] and bolts (Item 2) [A].
Tighten the bolts to 23–40 in.–lbs. (3,0–5,0 Nm) torque. 3
1
Install the thru bolts (Item 3) [A]. Tighten the bolts to
60–104 in.–lbs. (7–12 Nm) torque.
2
2
3 N–15159
Install the cable (Item 1) [B] on the magnetic switch.
Tighten the nut to 18–26 ft.–lbs. (24–35 Nm) torque.
B 1
N–15158
773 BICS Loader

STANDARD INSTRUMENT PANEL
A
Pry the rubber light mount loose from the operator cab
(both sides) [A].
P–03995
Lower the light from the operator cab and locate the three
instrument panel mounting bolts (Item 1) [B] (both sides).
B
1
Remove the three mounting bolts (Item 1) [B].
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels.
1
P–03955
Pull the left instrument panel down and disconnect the

wire harness connectors from the panel. Remove the
C
panel [C].
P–03951
Repeat steps [A] and [B]. Pull the right instrument panel
down and disconnect the wire harness connectors from D
the panel. Remove the panel [D].
Reverse the removal procedure to install the instrument
panel.
P–03953
773 BICS Loader

FRONT LIGHTS
A
The front lights are mounted in the upper corners of the
operator cab [A].
P–03956
Pry the rubber light mount free from the operator cab [B]. B
P–03995
Pull the light down and remove the three mounting bolts
(Item 1) [C] from the instrument panel. C
Disconnect the front light connector from the instrument 1
panel. Remove the front light from the operator cab.
Reverse the removal procedure to install the front light.
P–03955
773 BICS Loader

RELAY SWITCHES
Location
A
The loader engine harness has relay switches switches 2
located beneath the engine air cleaner [A] & [B].
There are five switches (Item 1) [A] on the BOSS®
equipped loader.
The switches are for the starter, switch power, glow plug,
brake and shutdown.
1
P–03886
There are four switches (Item 1) [B] on the Standard

equipped loader.
B
2
The switches are for the starter, switch power, glow plug
and brake.
Remove the screw (Item 2) [A] & [B] from the mounting
tab on the switch and replace if the switch malfunctions.
P–03884
773 BICS Loader

ENGINE SERVICE
Page
Number
AIR CLEANER
BLOWER HOUSING/FAN GEARBOX
Blower Fan Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12
Tension Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
CRANKSHAFT AND BEARINGS
Servicing The Crankshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . 7–68
CRANKSHAFT GEAR
CYLINDER BORE
Checking The Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–72
CYLINDER HEAD
Servicing The Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–59
Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–59
ENGINE
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34
ENGINE COMPRESSION
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36 ENGINE
SERVICE
ENGINE MUFFLER
ENGINE SPEED CONTROL

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
FAN GEARBOX
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–20
Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–25
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–15
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14
FLYWHEEL
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35
FUEL CAMSHAFT
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–60
773 BICS Loader

ENGINE SERVICE (Cont’d)
Page
Number
FUEL INJECTION NOZZLES
Checking The Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–46
FUEL INJECTION PUMP

Adjusting Shut–off Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39
Checking The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39
Timing The Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–43
GLOW PLUGS
Checking The Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–37
IDLER GEAR AND CAMSHAFT
Servicing The Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–57
Servicing The Idler Gear And Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–58
OIL PUMP
Checking Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–62
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–61
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–60
PISTON AND CONNECTING ROD
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–66
Servicing The Piston And Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . 7–64
RADIATOR
ROCKER ARM AND SHAFT

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–53
TIMING GEARS
Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–59
TIMING GEARCASE COVER

TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
VALVE CLEARANCE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–53
VALVE, VALVE SEAT AND GUIDE

Checking The Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–50
Reconditioning The Valve And Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . 7–51
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–52
WATER PUMP
773 BICS Loader

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 only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3

Engine will not start. 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis–firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure warning. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop. 9, 10, 11

1. Alternator belt is loose or damaged. 28. Worn valve and seats.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the crankcase.
6. Fuel tank empty. 33. Switch/sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect flywheel alignment.
17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores.
773 BICS Loader

ENGINE SPEED CONTROL
A
1
N–00810
B
or death. W–2059–0598
1
Raise the lift arms and install an approved lift arm device.
(See Page 1–1.)
Remove the two mounting bolts (Item 1) [A] and nuts from
the speed control mounting bracket.
C
Installation: Tighten the mounting bolts and nuts evenly
until the speed control lever moves back and forth at a
comfortable tension.
1
Pull the speed control away from the loader frame and
disconnect the speed control rod (Item 1) [B] from the
control.
2
Installation: Be sure to install the control rod in the
bottom hole of the speed control.
Installation: Install the stop bracket (Item 1) [C] in the P–04068

same location. It is necessary for the front and rear stop
on the bracket to be located correctly.
Reverse the removal procedure to install the engine
speed control.
Disassembly
Loosen the two control lever mounting bolts (Item 2) [A]
and remove the mounting nuts (Item 2) [C].
Assembly: Do not lubricate the engine speed control.
Replace any worn or damaged parts if necessary.
773 BICS Loader

ENGINE MUFFLER
A
Remove the exhaust pipe clamp (Item 1) [A] from the
muffler (Item 2) [A]. 3
Disconnect the exhaust pipe from the muffler.
2
Remove the left side mounting bolt (Item 3) [A] from the
muffler.
1
P–03881
Remove the right side mounting bolt (Item 1) [B] from the
muffler. B
Installation: Tighten the muffler mounting bolts to 25–28
Remove the muffler from the loader.
Reverse the removal procedure to install the engine
muffler.
1
P–03872
773 BICS Loader

RADIATOR
A
Remove the rear grill. (See Page 5–1.) 1
Do not remove radiator cap when the engine is

hot. You can be seriously burned. P–03971
W–2070–1285
Open the drain valve (Item 1) [A] on the engine block and
drain the coolant into a container.
B
Loosen the radiator cap (Item 1) [B].
1
Disconnect the over flow hose (Item 2) [B] from the
radiator filler neck.
Raise the oil cooler and fasten out of the way.
2
N–00833
Loosen the hose clamp (Item 1) [C] from the left side
radiator hose and disconnect the hose from the radiator.
C
1
Remove the radiator mounting bolt (Item 2) [C].
P–04200
Loosen the hose clamp (Item 1) [D] from the right side
radiator hose and disconnect the hose from the radiator.
D
Remove the radiator mounting bolt (Item 2) [D].
2
1
P–04199
773 BICS Loader

RADIATOR (Cont’d)
A
Remove the two rubber stops (Item 1) [A] from the top of
the radiator. 1
N–00836

procedure is the same. B
Lift the radiator up and remove it from the loader [B].
Reverse the removal procedure to install the radiator.
P–04192
773 BICS Loader

BLOWER HOUSING/FAN GEARBOX
A
NOTE: Photo’s may be different, but the procedure
is the same for all models.
Put jackstands under the rear corners of the loader.
1
P–04287
Raise the lift arms and install an approved lift arm device.
(See Page 1–1.)
B
1
3
or death. W–2059–0598

P–04290
Remove the hydraulic fluid reservoir. (See Page 2–1.)
Remove the two mounting bolts (rear bolt first), from the
gas cylinder mounting bracket (Item 1) [A]. C
(9–10 Nm) torque.
Disconnect the breather hose (Item 1) [B] from the
electrical harnesses on the loader frame. 1
Installation: Make sure the breather hose is unrestricted
when routing.
Oil Level
Remove the nuts (Item 2) [B] from the u–bolt which
mounts the fan belt shield (Item 3) [B] to the blower fan.
Remove the fan belt shield (Item 3) [B] from the blower P–04285
fan.
Installation: Be sure to tighten the shield so it does not
interfere with the fan belt. D
Remove the fan drive belt (Item 1) [C] from the pulley on
the blower fan. 2
NOTE: When checking the fan gearbox oil level, be 1
sure the level does not go above the top of 1
the shaft in the gearbox [C]. Use a light
colored 90W gear lube if the level is low.
1
Remove the four mounting bolts (Item 1) [D] and spacer
tubes (Item 2) [D] from the blower fan.
NOTE: Remove the two rear mounting bolts first.
Installation: Tighten the four mounting bolts to 25–28
ft.–lbs. (34–38 Nm) torque. P–04289
773 BICS Loader

BLOWER HOUSING/FAN GEARBOX (Cont’d)
A
Lower the blower fan from the housing until it rests on the
steering linkage plate [A].
P–04291
Remove the strip of sealant along the top of the blower

housing [B].
B
Installation: Use R.T.V. sealant to reseal the blower
housing.
P–04298
Loosen the electrical harnesses from the frame of the

loader [C]. C
Slide the blower fan and housing forward and remove
both from the loader.
P–04299
Installation: Use sealant on each end of the spacer

tubes (Item 1) [D] to prevent the tubes from falling out of D
the housing during installation. 1
P–04301
773 BICS Loader

A
To replace the blower housing grill, remove the four
mounting bolts (Item 1) [A] from the grill.
Install the new grill and replace the mounting bolts. 1
P–04297
773 BICS Loader

Tension Pulley Removal And Installation
A
Loosen the idler pulley bolt [A]. 1
Installation: Install the retainer bracket (Item 1) [A] for

the fan belt at the 3 o’clock position.
P–00580 P–00585
Remove the spacers, bolt and washer from the arm [B].
B 1
P–00582
Installation: Put a small amount of grease around the

outside edge (Item 1) [C] on the grease rings.
C
1
P–00581
Remove the bolt (Item 1) [B] & [D] from the idler pulley
pivot arm (Item 6) [D]. D
6
Remove the thrust washer (Item 2) [D], O–rings (Item 3) 3
[D] and spring (Item 4) [D].
Check all parts for damage or wear and replace them as 4
needed. 3
NOTE: When making any repairs, replace the bronze 2
bushing (Item 5) [D] with a new style nylon 1
bushing. Clean all parts and assemble dry. 5
Do not lubricate. (See Parts Manual for
correct part numbers.)
Reverse the removal procedure to install the tension
pulley. N–00303
773 BICS Loader

A
Blower Fan Disassembly And Assembly
Remove the lock nut and spacer [A].
torque.
CD–09952
Use the following procedure to remove the fan from the

shaft. B 2
AVOID INJURY OR DEATH 1

Wear safety goggles to prevent eye injury
when drilling or grinding.
W–2108–1186
Install the nut (Item 1) [B] on the tapered shaft to protect P–03006
the shaft and threads.
Install the puller on the fan as shown [B]. C
As the center bolt (Item 2) [B] is tightened, periodically
strike the bolt head to loosen the fan from the shaft .
Remove the fan from the tapered shaft [C].
CD–09953
To remove the blower housing mounting plate, remove

the six bolts (Item 1) [D]. D
1
1
CD–09954
773 BICS Loader

Blower Fan Disassembly And Assembly (Cont’d)
A
Installation: Clean the surface where the blower housing
contacts the loader frame. Put a bead of R.T.V. sealant on
the blower housing [A].
CD–08954
773 BICS Loader

FAN GEARBOX
Identification
1. Seal
2. Snap Ring (Small)
3. Shims (1.0 inch O.D.)
4. Bearing
5. Shaft (Long)
6. Shims (2.0 inch O.D.) 1
7. Long Key
8. Shaft (Short)
9. Short Key
10. Long Housing
11. Nut 18
12. Gear
13. Washer
14. Screw
15. Square Shim 1 6
* 16. Short Housing 2 3
17. Bolt 4
18. Snap Ring (Large) 7 4
19. Cap 5
20. Long Housing Assy.
21. Short Housing Assy.
22. Fill Plug
8
22
2
4
12 9
13 12
14
10
*16
21
11
15
17
20 12
20
3
13
14
18
19
* Individual Part not available. (See Note Page 7–15.) TS–01002
773 BICS Loader
FAN GEARBOX (Cont’d)
A
Disassembly 3
NOTE: When repairing the gearbox order the
following as needed.
1. Complete Assembly
2. Long Housing Assembly
3. Long Housing
4. Short Housing Assembly (See Note Below) 1
5. Internal Parts
2
NOTE: The short housing is only available as an
assembly. See the parts identification page
7–14 for reference. (Order parts from Melroe P–03005
Parts Sales.)
NOTE: Be sure to count the number and thickness of

shims during disassembly. Install the shims B
in the original location during assembly.
NOTE: Always replace seals during assembly.

Replace the parts in the gearbox as needed.
Remove the fan and blower housing mounting plate. (See Part Number
Page 7–8.) Tag
Long Housing
Loosen the set bolts (Item 1) [A] and remove the pulley
(Item 2) [A].
Remove the long key (Item 3) [A]. P–02983
Remove the four mounting bolts and the part number tag
[B].
C
Remove the oil from the gearbox.

W–2108–1186
P–02999
Drill an 1/8 inch (3 mm) hole in the seal. Use a slide
hammer tool to remove the seal [C].
D
Remove the small snap ring [D].
P–02964
773 BICS Loader

A
Remove the small shims [A].
P–02963
Remove the screw and washer from the shaft [B].

B
P–02966
Support the lower flange and press the shaft from the
bearing [C]. C
NOTE: The gear and the other bearing (pulley end)
will be removed with the shaft.
P–03004
Support the bearing and press the shaft from the bearing
[D]. D
P–03298
773 BICS Loader

A
Short Housing
Remove the end cap [A].
Use care not to damage the housing.
P–02997
W–2108–1186 B
Drill an 1/8 inch (3 mm) hole in the seal. Use a slide

hammer tool to remove the seal [B].
P–02996
Remove the large snap ring from the flange end of the
housing [C].
C
P–02970
Remove the large shims from the housing [D].

D
NOTE: Use the same size and thickness of shims
during assembly.
P–02969
773 BICS Loader

A
Remove the screw and washer (Item 1) [A] from the
shaft.
1
P–02978
Remove the snap ring from the cap end of the housing
[B].
B
P–02973
Press the shaft from the housing [C].

C
NOTE: Both bearings may come out of the housing
with the shaft. If one bearing remains in the
housing use a non metal object to tap the
bearing from the housing.
P–02998
Press the bearing from the tapered end of the shaft [D].
D
P–03088
773 BICS Loader

A
Press the bearing, shims and gear from the shaft [A].
P–03001
Remove the key from the shaft [B]. B
P–02972
773 BICS Loader

A
Assembly
NOTE: See Note Page 7–15 when ordering parts for
the Fan Gearbox.
NOTE: Do not install the seals and cap in the

housing until after the backlash has been
checked.
NOTE: Use care when pressing the bearings into the

aluminum housing. The housing can be P–02961
damaged if too much pressure is used.
Long Housing
B
NOTE: For procedures requiring the use of LOCTITE
#518 adhesive, thoroughly clean and dry
Press a affected
bearing onparts
the short keyedthe
before end of the long shaft
application of
[A]. LOCTITE #518.
Install the long housing on the shaft [B].
Be sure the bearing is seated in the bore at the lower end
of the housing.
P–02960
Install a bearing on the long keyed end of the shaft [C]. C

Support the lower bearing and press the other bearing in
the housing until the bearings seat in the housing [C].
P–02962
Install on the bearing, the same number and size shims

that were removed during disassembly [D]. D
P–02963
773 BICS Loader

A
Assembly (Cont’d)
Install the small snap ring in the groove above the shims
[A].
P–02964
Install the gear key in the flange end of the shaft [B].
B
P–02965
Align the key and gear. While supporting the bearing on

the other end, press the gear on the shaft until it seats
against the bearing [C].
C
P–02967
Install the washer (Item 1) [D].

Put liquid adhesive (LOCTITE #242) on the screw D
threads. Install and tighten the screw [D].
P–02966
773 BICS Loader

Assembly (Cont’d)
A
Short Housing
Install a bearing in the flanged end of the housing [A].
P–02968
Install the large shims on the bearing (flanged end) [B] B
P–02969
Install the large snap ring in the groove above the shims
[C]. C
P–02970
Install the short key (Item 1) [D].

D
Align and press the gear on the shaft (teeth toward the
tapered end of the shaft) [D].
P–02971
773 BICS Loader

A
Assembly (Cont’d)
After the gear is seated, drive the key down inside the
gear key way [A].
NOTE: This will prevent damage to the shims when

the bearing is installed later.
P–02975
Install the shaft in the housing, tapered end in the bearing

at the round flange end of the housing [B]. B
P–02976
Install on the shaft, the same number and size shims that
were removed during disassembly [C]. C
P–02977
Install a bearing on the gear end of the shaft [D]. D
P–02974
773 BICS Loader

A
Assembly (Cont’d)
Install the snap ring in the groove above the bearing [A].
P–02973
Install the washer (Item 1) [B] on the shaft. Put liquid

adhesive (LOCTITE #242) on the screw threads and
install the screw [B].
B
P–02978
773 BICS Loader

773ServiceManual#6900092–EngineServiceSectionPart1of3
A
Checking Backlash
NOTE: For procedures requiring the use of LOCTITE
#518 adhesive, thoroughly clean and dry
affected parts before the application of
LOCTITE #518.
The backlash tolerance between the gears should be
0.005–0.008 inch (0,127–0,203 mm).
To check the gear backlash use the following procedure:
Put the short housing in a vise, square flange facing up
as shown [A].
P–02987
Install the same size and number of square shims (if B

present during disassembly) between the two housings
[B].
Set the long housing on the short housing with the sealant
(LOCTITE 518) which is a gasket eliminator that cures to
flexible seal between the mounting surfaces.
NOTE: If square shims are used, put a small amount

of (LOCTITE 518) on both sides of all shims.
P–02981
Install the four mounting bolts through the flange holes

[C]. C
Install the part number tag [C].
Install and tighten the nut to 25–28 ft.–lbs. (34–38 Nm)
torque.
Part Number
Tag
P–02983
Install the long key (Item 1) [D] and the pulley (Item 2) [D].
Install a bolt in the set screw hole to maintain a 1.0 inch
D
(25,4 mm) distance from the shaft center to the bolt head 1.0’’
(to be used with a dial indicator) [D].
(25,4 mm)
P–02984
773 BICS Loader

Checking Backlash (Cont’d)
A
Put the fan nut (Item 1) [A] on the shaft and tighten snugly.
Install a locking pliers on the fan nut and support the
handle against the long housing [A].
P–02982
Using a magnetic based dial indicator mounted on a

bench vise, touch the dial stem on the bolt (Item 1) [B].
B
1
Hold the locking pliers against the long housing and rotate
the pulley back and forth to read the dial gauge [B].
If the backlash is GREATER than 0.008 inch (0,203 mm),
do the following:
1. Remove a square shim(s) (if present) between the
two housings.
2. Remove a large shim(s) from the tapered end of
the short shaft and add a small shim (s) of the
same thickness between the bearing and the gear
on the screw end of the shaft.
P–02979
If the backlash is LESS than 0.005 inch (0,127 mm) do the
following:
1. Add a square shim(s) between the two housings.
2. Remove a small shim(s) between the bearing and
the gear on the screw end of the short shaft and
add a large shim(s) of the same thickness between
the snap ring and the bearing on the tapered end
of the shaft.
773 BICS Loader

A
Checking Backlash (Cont’d)
When the backlash is correct, install the seals, cap and
gear oil as follows:
Remove the bolts from the flanges and separate the two
housings.
Put liquid adhesive (LOCTITE #242) on the outside
diameter of the seal(s) [A].
P–03089
Install the seal(s) flush with the housing surface [B] & [C].
Clean any oil from the flange surface.
B LONG HOUSING
Install the long housing on the short housing flange.

Install the four bolts and part number tag.
Install and tighten the nuts to 25–28 ft.–lbs. (34–38 Nm)
torque.
P–02985
C SHORT HOUSING
P–02986
773 BICS Loader

AIR CLEANER
A
Loosen the hose clamp (Item 1) [A] on the air cleaner
hose. 1
Loosen the clamp (Item 2) [A] from the hose on the
engine manifold. 2
P–03885
Remove the two mounting bolts (Item 1) [B] from the top
mount of the air cleaner. B
P–03883
Remove the lower mounting bolt (Item 1) [C] and relay

switch mounting bracket (Item 2) [C] from the air cleaner. C
Installation: Tighten the three mounting bolts to 25–28 1
P–03884
BOSS® Loaders Only: Disconnect the wire harness

connector (Item 1) [D] from the air cleaner sensor on the D
air cleaner.
Remove the air cleaner from the engine compartment.
1
Reverse the removal procedure to install the air cleaner.
P–04203
773 BICS Loader

ENGINE
A
Put jackstands under the rear corners of the loader. 2
4
3
1
Raise the lift arms and install an approved lift arm support P–04191

or death. W–2059–0598

Drain the hydraulic reservoir. (See Page 2–1.)
P–03964
Disconnect the steering linkage. (See Page 3–1.)
Remove the battery from the loader. (See Page 1–1.)
C
Drain the engine coolant from the cooling system. (See
Page 1–1.) 1
Remove the air cleaner. (See Page 7–28.)
Remove the muffler. (See Page 7–5.)
Disconnect the operating system unit (Item 1) [A] (if
equipped) from the back of the operator cab.
Disconnect the engine harness connector (Item 2) [A] 3
from the operator cab harness.
Remove the harness clamp (Item 3) [A] and remove 2
engine harness from the clamp.
P–04190
Disconnect the wires from the engine coolant sensor
(Item 1) [B] (on BOSS™ models only).
Pull the coolant sensor harness (Item 4) [A] through the D
hole in the loader frame. 1
Disconnect the BICS™ harness connector (Item 1) [C]
and the control harness connector (Item 2) [C] from the
engine harness. 2
Remove the clamp (Item 3) [C] from the drive belt housing
and remove the engine harness from the clamp.
Mark the four drive motor hoses (Item 1) [D] for correct
installation.
Disconnect the four drive motor hoses (Item 1) [D] from
the hydrostatic pump.
1
Disconnect the motor case drain hose (Item 2) [D] from P–04194
the hydrostatic pump.
773 BICS Loader
ENGINE (Cont’d)
A
Disconnect the wire harness connector (Item 1) [A] from
the fuel level sender on the fuel tank.
1
P–04198
Disconnect the pilot pressure hose (Item 1) [B] to the tilt

lock valve, from the fitting on the hydraulic pump. B
NOTE: (Item 1) [B] is on early models only. 2
Disconnect the outlet tube/hose (Item 2) [B] to the main
control valve, from the fitting on the hydraulic pump.
Remove the mounting bolt (Item 3) [B] and nut from the
right front engine mount. 1
P–04196
Remove the mounting bolt (Item 1) [C] and nut from the
left front engine mount.
C
Installation: Tighten the mounting bolts to 70 ft.–lbs. (95
Nm) torque.
P–04197
Disconnect the hand pump (Item 1) [D] from the fuel line
connected to the fuel tank. Cap the fuel lines. D
P–04210
773 BICS Loader

ENGINE (Cont’d)
A
Disconnect the fuel return hose (Item 1) [A] from the
injector.
P–04195
Disconnect the radiator hoses (Item 1) [B] & [C] from the
engine. B
P–04204
C
1
P–04218
Remove the mounting bolt and nut (Item 1) [D] from the
left rear engine mount. D
Installation: Tighten the mounting bolt to 70 ft.–lbs. (95
Nm) torque.
P–04215
773 BICS Loader

ENGINE (Cont’d)
A
Remove the mounting bolt and nut (Item 1) [A] from the
right rear engine mount.
Installation: Tighten the mounting bolt to 70 ft.–lbs. (95
Nm) torque.
P–04214
Disconnect the ground cable (Item 1) [B] from the loader

frame.
B
P–04219
Disconnect the rear light harness connectors (Item 1) [C]

from the engine harness. C 2
Remove the belt shield mounting bolt (Item 2) [C].
P–04212
Disconnect the engine speed control rod (Item 1) [D] from

the linkage. D
P–04211
773 BICS Loader

ENGINE (Cont’d)
A
Disconnect the fuel shut–off solenoid connector (Item 1)
[A].
Remove the mounting bolt (Item 2) [A] from the fuel timer
module and belt shield. 1
P–04206
Remove the fuse block (Item 1) [B] from the belt shield. B
Remove the belt shield.
P–04217
A tool needs to fabricated to be used in the removal

procedure. This tool allows the engine/hydrostatic pump C 13’’
assembly to be lifted evenly for easier removal. Use the
dimensions shown in [C] to make the engine removal tool.
2.5’’
1–1/2’’ I.S. Dia.

2–1/2’’ O.S. Dia.
2.5’’
1–1/2’’ Square Tubing 1/4’’ (4)

Thick Gusset
1’’
16’’
4’’
2’’
45° 9’’
1’’
4’’
2’’
1’’
.5’’
.375’’
.3125’’ (2)
Use Two 3/8’’ x 1–1/4’’ Bolts

for Drilled and Tapped Holes. MC–01799
773 BICS Loader

ENGINE (Cont’d)
A
1
Install the chain hoist on the eyelet (Item 1) [A] of the
removal tool.
Fasten a chain to other end of the removal tool with two
bolts as shown in [C].
Fasten securely one end of the chain to one of the lifting
brackets on the engine [A].
Fasten securely the other end of the chain to the other
lifting bracket on the engine [A].
NOTE: You may need to adjust the chain which
fastens to the engine a couple of times to
reach the correct lifting position.

loader.
Reverse the removal procedure to install the engine.
P–04216
2
Engine Mount Replacement B 1
Use the following procedure to install new engine mounts:
3
Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount 4
locations.
Replace all four engine mounts two front and two rear.
5
Use the parts shown to install the new engine mounts [B]:
6
Square Nut – (Item 1) – Used on left side engine mounts
Hex Nut – (Item 2) – Used on right side engine mounts 7
MC–01771
Mount Washer – (Item 3)
Engine Mount – (Item 4)

C Engine
Tube Spacer – (Item 5) Mounting
Bracket
Snubbing Washer – (Item 6) Washer
Mounting Bolt – (Item 7) Loader Engine

Frame Mount
Install the new engine mount as shown in the cut away
side view [C].
Tighten the mounting bolts to 70 ft.–lbs. (95 Nm) torque.
Snubbing Spacer
Washer MC–01765
773 BICS Loader

FLYWHEEL
A
Remove the three belt shield clips (Item 1) [A] and 1
remove the shield from the drive belt housing.
P–04230
Loosen and remove the drive belt tension pulley (Item 1)

[B]. B
Remove the drive belt. (Refer to Page 1–1 for drive belt
adjustment procedure.)
1
P–04223
Remove the six mounting bolts (Item 1) [C] from the

engine flywheel (Item 2) [C].
C
Installation: Apply engine oil to the threads and seats
before tightening. Tighten to 72–80 ft.–lbs. (98–108 Nm)
torque.
1
Remove the flywheel from the engine.
Installation: Be sure to align the hole (Item 3) [C] in the 3
flywheel with the pin located on the crankshaft.
Reverse the removal procedure to install the flywheel.
2
P–04234
Flywheel Ring Gear

D
The ring gear (Item 1) [D] on the flywheel is an
interference fit. Heat the ring gear enough to expand the
gear. Hit the ring gear evenly around the gear to remove
it from the flywheel.
Clean the outer surface of the flywheel thoroughly so the
new ring gear will fit smoothly onto the flywheel.
Clean the new ring gear and heat it to a temperature of
450°–500° F. (232°–260°C.)
1
Fit the ring gear on the flywheel and be sure the gear is
seated correctly. P–04237
773 BICS Loader

ENGINE COMPRESSION
Checking
A
1
procedure:
MEL10630 – Engine Compression Kit
MEL1352 – Compression Adapter
The engine must be at operating temperature.
Remove the glow plugs. (See Page 7–38.)
Install the correct compression adapter (Item 1) [A] into
the cylinder head.
P–04305
Connect the compression gauge to the adapter [B].

Make sure the engine speed control is fully backward
B
(engine idle).
Disconnect the fuel stop solenoid.
Crank the engine with the starter at 200–300 RPM.
If the measurement is below the allowable limit, check the
cylinder, piston ring, top clearance, valve and cylinder
head.
Compression Pressure should be 412–469 PSI
(2840–3233 kPa)
Allowable Limit (minimum) is 327 PSI (2255 kPa) P–04308
No more than 10% variance among cylinders.

C
Push the button on the compression gauge to release
pressure [C].
Connect the fuel stop solenoid.
P–04309
773 BICS Loader

GLOW PLUGS
Checking The Glow Plugs
A
Disconnect the glow plug cables and leads.
Use an ohmmeter to check the glow plugs [A].
P–04304
Touch one probe to the end of the glow plug and the other
probe to the body of glow plug [B].
B
The reading must be between 1 and 2 ohms [A]. If the
resistance is infinite, the coil of the glow plug is broken.
Repeat the procedure for each glow plug.
P–04310
773 BICS Loader

GLOW PLUGS (Cont’d)
A
1
Remove the nut (Item 1) [A] from the top of each glow
plug.
Disconnect the engine harness wire (Item 2) [A] from the
glow plug.
3
Remove the glow plug connecting strap (Item 3) [A]. 2
P–04300
Loosen and remove the glow plug (Item 1) [B]. B

1
P–04302
Photo [C] shows the glow plug assembly removed from

the engine. Inspect the glow plugs and replace when C
necessary.
P–04307
773 BICS Loader

FUEL INJECTION PUMP
A
Checking The Injection Pump
The injection pump contains parts which have a very
close tolerance and its operation has a direct effect on the
performance of the engine.

can penetrate skin or eyes, causing serious B–08235
W–2072–0496

procedure:
MEL1237 – Adapter Fuel Line
MEL1173A – Pressure Gauge
To check the discharge pressure at the fuel injection
pump, use the following procedure:
Disconnect a high pressure fuel line from the injection
pump. Loosen the other end of the same fuel line so it can
be turned away from the fitting.
Connect the adapter fuel line (Item 1) [A] to the fitting and
connect the pressure gauge (Item 2) [A].
Turn the flywheel to increase the pressure. If the pressure
can not reach the allowable limit, replace the injection
pump assembly.
Fuel Tightness of Pump Element
Allowable Limit . . . . . . . . . . . . . . 2133 PSI (14707 kPa)
Measure the time needed to decrease the pressure from
2133–1990 PSI (14707 –13721 kPa). If the measurement
is less than the allowable limit, replace the delivery valve.
B
Fuel Tightness of Delivery Valve
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . 5 Seconds Linkage Lever
0.050’’
Adjusting Shut–Off Linkage (1,27 mm)
Adjust shut–off linkage for maximum distance of 0.050
inch (1,27 mm) between the lever and stop when solenoid
plunger is seated [B].
Stop
B–13704
773 BICS Loader

FUEL INJECTION PUMP
A 1
Clean the area around the injection pump thoroughly.
Do not bend the high pressure fuel injection

tubes when removing or installing them.
I–2029–0289
P–04319
Disconnect the high pressure fuel lines (Item 1) [A] from
the fuel injectors.
B
Disconnect the fuel shut–off linkage (Item 1) [B].
P–04306
Disconnect the fuel inlet hose (Item 1) [C] and the fuel
return hose (Item 2) [C] from the injection pump vent.
C
1 2
P–04312
Cap the inlets on the injection pump vent where the hoses
were removed [D].
D
Remove the high pressure fuel lines (Item 1) [D] from the
injection pump.
P–04316
773 BICS Loader

FUEL INJECTION PUMP (Cont’d)
A 2
Remove the seven mounting bolts (Item 1) [A] from the

intake manifold (Item 2) [A].
Remove the intake manifold from the engine.
Installation: Replace the manifold gasket if it is worn or
damaged.
1
P–04356
Remove the four mounting bolts (Item 1) [B] and two nuts
(Item 2) [B] from the injection pump. B
Do not attempt to maintain or adjust unless

you are trained and have the correct 1 2
equipment.
I–2028–0289
P–04357
Remove the injection pump (Item 1) [C] and shim(s) from

the engine. C
NOTE: The pin (Item 2) [C] located on the control
rack, needs to be installed correctly during
installation. See the following procedure for 2
correct installation.
P–04359
773 BICS Loader

A

you are trained and have the correct
equipment.
I–2028–0289
P–04363
Installation: Remove the side cover (Item 1) [A] from the
injection pump chamber.
Be sure the spring (Item 1) [B] is located in the injection B
pump chamber as shown.
P–04362
Install the shim(s) (Item 1) [C] on the injection pump

mounting surface. Refer to Timing the Injection Pump C
Page 7–43 for information on number of shims used.
1
P–04364
Install the injection pump in the engine.

Put the pin (Item 1) [D] on the control rack in the slot of
D
the fork lever (Item 2) [D] located inside the injection
pump chamber. 1
If the pin is not correctly installed in the fork

lever, the engine will run over maximum speed, 2
resulting in serious damage to the engine.
I–2086–1195
P–04360
773 BICS Loader

A
Timing The Injection Pump

you are trained and have the correct
equipment. 1
I–2028–0289
P–04306
Timing the injection pump is done by changing the
number of shims between the injection pump and the
injection pump mounting surface.
Disconnect the number one cylinder high pressure line
B
from the injection pump.
Disconnect the fuel shut–off linkage (Item 1) [A] from the 1
injection pump.
Turn the fuel supply lever (Item 2) [A] to the ON position
(to the right).
Install a short plastic tube (Item 1) [B] in the number one
cylinder port of the injection pump. The tube should fit
securely in the port and point upward.
P–04361
Rotate the engine in the direction shown [C].

Continue rotation until flywheel timing mark just appears
C 22.5°
in the window (Item 1) [C]. 19°
Rotation
NOTE: The flywheel has two timing marks. The first
mark to appear in the window with the
rotation shown is 22.5°. The first mark is used
for 773 loaders. The second mark to appear MC–01542
in the window is 19° which is used for 753 Rotation
Direction 1
loaders.
Rotate slowly until fuel just starts to flow upward into the
plastic tube.
At this instant, the 22.5° or 19° BTDC timing mark on the
flywheel should be aligned with the mark in the window P–04315
(Item 1) [C].
Add or subtract shim(s) (Item 1) [D] as needed to adjust D

the fuel delivery timing.
1
NOTE: Adding or removing one shim will vary the
timing by 1.5°. Adding shims retards timing.
P–04364
773 BICS Loader

FUEL INJECTION NOZZLES
A 1

can penetrate skin or eyes, causing serious
P–04311
W–2072–0496
The following are some problems caused by faulty

B
injectors:
– Engine is hard to start or will not start
– Rough engine operation and idle
– Engine will not have full power
– Excessive exhaust smoke
P–04318
Do not bend the high pressure fuel injection
tubes when removing or installing them.
I–2029–0289
C 1
Disconnect the fuel return hoses (Item 1) [A] & [B] from
the injectors.
Disconnect the high pressure fuel lines (Item 1) [C] from
the fuel injectors and from the injection pump.
Remove the high pressure fuel lines from the engine.
P–04330
Remove the retainer nut from the top of the fuel injectors
(Item 1) [D]. D
Remove the fuel return tube (Item 2) [D] from the fuel
injectors.
1
P–04353
773 BICS Loader

FUEL INJECTOR NOZZLES (Cont’d)
A
Remove the injector nozzle (Item 1) [A] from the cylinder
head. 1
P–04354
Photo [B] shows the injector nozzle removed from the

cylinder. Inspect the injector and replace if necessary. B
Installation: be sure the nozzle cap (Item 1) [B] and
copper washer (Item 2) [B] are in the correct position.
Replace the nozzle cap and copper washer when
installing new or used injectors.
2
P–04358
773 BICS Loader

FUEL INJECTOR NOZZLE (Cont’d)
A
Checking The Injector Nozzle
2
Do not disassemble or test the fuel injector
nozzles unless you have the correct service 3
and testing tools. 4
I–2027–0284 5
(1) Nozzle Holder
(2) Adjusting Washer
The tool listed will be needed to do the following 6 (3) Nozzle Spring
procedure: (4) Push Rod
7 (5) Distance Piece
OEM1064 – Injector Nozzle Tester (6) Nozzle Piece
(7) Nozzle Retaining Nut
Disassemble and clean the injector nozzle. PI–09981
The nozzle release pressure can be adjusted by adding
or removing spacer(s) (Item 2) [A] from the top of the
nozzle spring (Item 3) [A].
Each spacer will change the release pressure by about
142 PSI (980 kPa).
Fuel Injection Pressure . . . . . . . . . . . . . . 1991–2133 PSI
(13728–14707 kPa)
Assemble the injector nozzle. Connect the nozzle to the

tester with the nozzle down [B]. B
Operate the hand lever at a slow rate and record the
opening pressure. If the pressure is not correct,
disassemble the nozzle and add or remove spacers (Item
2) [A] as needed.
When the injector nozzle is assembled, tighten the nozzle
body to 43–58 ft.–lbs. (59–79 Nm) torque.
Check for inside leakage. Operate the hand lever until the
pressure is 1850 PSI (12755 kPa). Keep the nozzle under
this pressure for 10 seconds, check to see if fuel leaks
from the nozzle. If fuel leaks, replace the nozzle.
A–02513
Check that the spray pattern is correct [C]: C

1. Fuel does not come out the side of the nozzle. CORRECT WRONG
2. Drops of fuel are not present at the nozzle.
3. The injector has an even flow coming from the

nozzle.
A–02621
773 BICS Loader

CYLINDER HEAD
A
Remove the nuts from the valve cover, remove the valve
cover and gasket [A].
PI–09982
Remove the fuel injector nozzles. (See Page 7–44.)

Remove the glow plugs. (See Page 7–38.)
B 1
Remove the belt shield. (See Page 3–1.)

Remove the alternator. (See Page 6–1.)
Remove the rocker arm and shaft assembly (Item 1) [B].
Remove the push rods (Item 2) [B]. 2
Remove the intake and exhaust manifolds.
B–14332
Remove the water return hose [C].

C
B–14333
Remove the cylinder head bolts in order of #18 to #1 [D].

D
Installation: Put oil on the bolt threads. Tighten the bolts
in the correct sequence to 67–72 ft.–lbs. (91–98 Nm)
torque.
NOTE: Retighten the cylinder head bolts in the
correct sequence after the engine has been
run for 30 minutes.
FRONT PI–09985
773 BICS Loader

CYLINDER HEAD (Cont’d)
A
Remove the cylinder head from the engine block.
Installation: Always use new head gasket and new
O–ring. Make sure the O–ring is seated over the dowel
[A].
B–14334

Use a valve spring compressor to compress the valve
B
spring [B].
1
4
3
5 2
6
PI–09987
Remove the valve cap (Item 1) [B] & [C] and valve spring
collet (Item 2) [B] & [C]. C 5
Remove the valve spring retainer (Item 3) [B] & [C] and
the spring (Item 4) [B] & [C]. 4
Remove the seal (Item 6) [B]& [C] and the valve (Item 5) 3
[B]& [C]. 6
2 1
Valve
Spring
Retainer
Seal
Collets Cap
B–04122
Remove the thermostat housing. Remove the thermostat

from the cylinder head [D]. D
B–03643
773 BICS Loader

CYLINDER HEAD (Cont’d)
A 1
Servicing The Cylinder Head
Clean the surface of the cylinder head.
Put a straight edge (Item 1) [A] on the cylinder head.
NOTE: Do not put the straight edge across the
combustion chambers.
Put the feeler gauge (Item 2) [A] between the straight
edge and the surface of the cylinder head. 2
A–02735
Put the straight edge on the cylinder head’s four sides and
two diagonal as shown in figure [B]. B
The maximum distortion of the head surface is ± 0.002
inch (± 0,05 mm). If the measurement exceeds the
specification, replace the cylinder head.
PI–09988
Top Clearance
Install the cylinder head gasket. Put the piston (Item 1) [C]
C 2
being checked at T.D.C.
Put three pieces of 0.060 inch (1,5 mm) diameter solder
(Item 2) [C] on the top of the piston. Use grease to hold
them in position.
NOTE: Position the solder so they do not touch the
valves.
Turn the piston to bottom dead center.
Install the cylinder head and tighten to the correct torque 1
in the correct sequence. (See Page 7–47.) 3
PI–09989
Turn the crankshaft until the piston exceeds T.D.C.
Remove the cylinder head.
Remove the solder wire (Item 3) [C] and measure it.
If the measurement exceeds the specifications, check the
oil clearance of the crank pin journal or the piston pin.
Top Clearance . . . . . . 0.022–0.028 inch (0,55–0,7 mm)
773 BICS Loader

VALVE, VALVE SEAT AND GUIDE
A
Checking The Valve Guide
Remove the valve and spring from the cylinder head.
(See Page 7–48.)
Clean the valve seat and combustion chamber.
Install the valve into the guide. Measurement the valve
recessing or protrusion with a depth gauge [A].
B–03634
If the measurement exceeds the allowable limit, replace

the valve or cylinder head [B]. B 2 3
Protrusion . . . . . . . . . . . . . . . . . . . . 0.002 inch (0,05 mm)
Recessing . . . . . . . . . . . . . . . . . . . . 0.006 inch (0,15 mm)
Allowable Limit (Recessing) . . . . . . 0.016 inch (0,4 mm)
1
1
1. Cylinder Head Surface

2. Recessing
3. Protrusion PI–09990
Remove the carbon from the valve guide.

Measure the valve stem O.D. [C].
C
Measure the valve guide I.D. [C].
Calculate the clearance, if the clearance exceeds the
allowable limit, replace the valve and/or valve guide.
Valve Guide I.D. . . . . . . . . . . . . . . . . 0.3156–0.3161 inch
(8,015–8,03 mm)
Valve Stem O.D. . . . . . . . . . . . . . . . 0.3134–0.3142 inch
(7,96–7,98 mm)
Clearance Between Valve Stem
and Guide . . . . . . . . . . . . . . . . . . . . 0.0016–0.0026 inch
(0,04–0,07 mm)
Allowable Limit . . . . . . . . . . . . . . . . . 0.004 inch (0,1 mm) B–14335
D 7.87’’ (200 mm)
3.15’’ (80 mm) 1.57’’

0.787’’ 0.51–0.511’’ (40 mm)
To remove and replace the valve guide, make the driver (20 mm) (12,96–12,98 mm)
tool as shown in figure [D].
0.295–0.303’’
(7,5–7,7 mm)
0.2’’ 0.393’’
(5,0 mm) (10,0 mm) 0.71’’
(18,0 mm)
0.31’’ 0.59’’
(8,0 mm) 0.51’’
(15,0 mm) (13,0 mm)
MC–01364
773 BICS Loader

VALVE, VALVE SEAT AND GUIDE (Cont’d)
A
Checking The Valve Guide (Cont’d)
Press the used valve guide out of the cylinder head using
the special driver tool [A].
1
Put oil on the outside diameter of the new valve guide.
Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 & 2) [A],
press the new guide until the tool contacts the cylinder
head.
Ream the valve guide to the correct specifications. 2
PI–09992
Reconditioning The Valve And Valve Seat

Grind the valve face to the correct angle using a valve
B
refacer [B].
PI–09993
Grind the valve seat surface in the cylinder head to the
correct angle [C].
C
Exhaust
Intake
15° 45° (30°)
PI–09994
Check the seat surface and valve face (Item 1) [D].
If the seat surface is to wide, use a 15 degree cutter (Item
D 1 2
2) [D] to get the correct width (Item 3) [D].
15°
Valve Seat Width
Intake . . . . . . . . . . . . . . . . . . . . . . 0.084 inch (2,12 mm)
Exhaust . . . . . . . . . . . . . . . . . . . . . 0.084 inch (2,12 mm)
Valve Seat & Face Angle
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° 3
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
PI–09995
773 BICS Loader

VALVE, VALVE SEAT AND GUIDE (Cont’d)
A
Valve Spring
Measure the length of the valve spring. If the
measurement is less than the allowable limit, replace the
spring [A].
Free Length . . . . . . . 1.642–1.661 inch (41,7–42,2 mm)
Allowable Limit . . . . . . . . . . . . . . . . 1.622 inch (41,2 mm)
Put the spring on a flat surface, place a square on the side
of the spring [A].
Rotate the spring and measure the maximum tilt. If the
measurement exceeds the allowable limit, replace the
spring. B–03680
Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 inch (1,0 mm)

B
Place the spring on a tester and compress to specified
length [B].
Read the compressed load on the gauge. If the
measurement exceeds allowable limit, replace the spring.
Setting Length . . . . . . . . . . . . . . . . 1.378 inch (35,0 mm)
Setting Load . . . . . . . . . . . . . . . . . . . . 26.4 lbs. (117,6 N)
Allowable Limit . . . . . . . . . . . . . . . . . . 22.5 lbs. (100,0 N)
A–02759
773 BICS Loader

VALVE CLEARANCE
Adjustment
A
Adjust the valve clearance as follows:
Loosen the lock nut (Item 1) [A].
2 1
Turn the adjustment screw (Item 2) [A] until the correct
clearance is obtained.
NOTE: The clearance is measured between the

rocker arm and valve stem tip (Item 3) [A].
3
B–05568
Adjust the valve clearance as follows:

0.008 inch (0,20 mm) Intake & Exhaust
B
Use the following sequence to set the valves [B] & [C]:
a. With the rocker arm rocking (valves 7 & 8) on No. 4
cylinder set clearance at No. 1 cylinder (valves 1 & 2).
1 2 3 4 5 6 7 8
b. With the rocker arm rocking (valves 3 & 4) on No. 2
c. With the rocker arm rocking (valves 1 & 2) on No. 1
d. With the rocker arm rocking (valves 5 & 6) on No. 3
cylinder set clearance at No. 2 cylinder (valves 3 & 4). B–05569
C
Cylinder Number 1 2 3 4
Valve Number 1 2 3 4 5 6 7 8
ROCKER ARM AND SHAFT Valve

I = Intake I E I E I E I E
E = Exhaust
Checking
Measure the rocker arm I.D. (Item 1) [C] with the inside
micrometer.
Measure the rocker arm shaft O.D. (Item 2) [C] with a
outside micrometer. D
If the clearance exceeds the allowable limit, replace the
bushing.
If the clearance still exceeds the allowable limit after the 2 1
bushing is replaced, replace the rocker arm shaft.
Oil Clearance Between Rocker Arm
& Shaft . . . . . 0.0006–0.0015 inch (0,016–0,038 mm)
Rocker Arm Shaft
O.D. . . . . . . . . . . 0.550–0.551 inch (13,97–13,98 mm)
Rocker Arm I.D. 0.5512–0.5516 inch (14,0–14,01 mm)
B–03697
773 BICS Loader

TIMING GEARCASE COVER
A
Remove the fuel injection pump. (See Page 7–40.)
Remove the cylinder head, rocker arms and push rods.
(See Page 7–47.)
Disconnect the two governor springs (Items 1 & 2) [A] 3
from the fork lever (Item 3) [A]. 1
B–14336
Remove the speed control plate with the governor springs

[B].
B
B–14337
Remove the start spring (Item 1) [C] from the fork lever
(Item 2) [C]. C
Installation: Be careful; do not drop the spring into the 2
gearcase.
B–14338
Remove the crankshaft pulley nut.

D
Installation: Tighten the nut to 101–116 ft.–lbs.
Use a puller and remove the crankshaft pulley [D].
B–03694
773 BICS Loader

TIMING GEARCASE COVER (Cont’d)
A
Remove the crankshaft pulley (Item 1) [A] and key (Item
2) [A].
Remove the bolts from the timing gearcase cover. 1
2
Installation: Tighten the bolts to 13–15 ft.–lbs. (18–20
Nm) torque.
B–14339
Remove the timing gearcase cover [B].

B
B–04095
Remove the crankshaft oil slinger (Item 1) [C], O–ring

(Item 2) [C] and collar (Item 3) [C]. C 1
2
B–14340
Installation: Install new O–rings and oil seal into the

timing gearcase cover [D].
D
NOTE: When a new timing gearcase cover is
installed, to establish the correct position of
the injection pump fuel rack stop before
removing it from the old timing gearcase
cover, the distance from the machined
surface of the gearcase (gasket surface) to
the end of the stop should be measured. The
stop should then be installed in the new
gearcase and set to the same distance that
was previously measured. Do not try to test O–rings
operate the engine to establish if it has
enough power. The adjustment must be set Oil Seal
by a qualified service personnel for the
injection pump. B–03617
773 BICS Loader

IDLER GEAR AND CAMSHAFT
A 4
Remove the timing gearcase cover. (See Page 7–54.)
Remove the snap ring (Item 3) [A] from the idler gear
shaft (Item 1) [A]. 5
Installation: Make sure the timing marks are in correct 3 1
alignment when installing the timing gears [A].
2
(1) Idle Gear
(2) Idle Collar
(3) External Snap Ring
(4) Cam Gear
(5) Camshaft B–14341
Remove the idler gear (Item 1) [B].

Remove the idler gear collar (Item 2) [B].
B 1
Remove the idler gear shaft mounting bolts.
Align the holes on the camshaft gear with the camshaft
retainer plate bolts.
Remove the bolts.
Installation: Tighten the camshaft retainer bolts to 2
17–20 ft.–lbs. (23–27 Nm) torque.
B–03699
Remove the camshaft from the engine block [C].

C
B–03655
Installation: Check the camshaft end play, if the

clearance exceeds the allowable limit, replace the
camshaft retainer plate [D]. D
Camshaft End Play . 0.003–0.009 inch (0,07–0,22 mm)
Allowable Limit . . . . . . . . . . . . . . . . . 0.012 inch (0,3 mm)
0.003–0.009’’
(0,07–0,22 mm)
PI–10002
773 BICS Loader

IDLER GEAR AND CAMSHAFT (Cont’d)
A
Servicing The Camshaft
Measure the camshaft bearing in the engine block [A].
B–03620
Measure the camshaft journal [B].

Calculate the oil clearance. If the clearance exceeds the
B
allowable limit, replace the camshaft.
Bearing I.D. . . . 1.575–1.576 inches (40,0–40,03 mm)
Journal O.D. . . 1.572–1.573 inches (39,93–39,95 mm)
Oil Clearance of Camshaft
Journal . . . . . . . . . . 0.002–0.004 inch (0,05–0,09 mm)
A–02761
Measure the cam lobes at their highest point [C].

If the measurement is less than the allowable limit,
C
replace the camshaft.
Cam Lobe Height . . . . . . . . . . 1.318 inches (33,47 mm)
Allowable Limit . . . . . . . . . . . . 1.316 inches (33,42 mm)
B–05001
Put the camshaft in V–blocks. Install a dial indicator [D].

Turn the camshaft at a slow rate. If the misalignment D
exceeds the allowable limit, replace the camshaft.
Camshaft Alignment
Allowable Limit . . . . . . . . . . . . . . . 0.003 inch (0,08 mm)
A–02760
773 BICS Loader

IDLER GEAR AND CAMSHAFT (Cont’d)
A
Servicing The Idler Gear And Shaft
Measure the O.D. of the idler gear shaft [A].
Measure the I.D. of the idler gear busing [A].
bushing.
Idler Gear Shaft O.D. . . . . . . . . . . . 1.258–1.259 inches
(31,96–31,97 mm)
Idler Gear Bushing I.D. . . . . . . . . . . 1.259–1.261 inches
(32,0–32,03 mm)
Clearance Between Idler Shaft &
Gear Bushing . . . 0.001–0.003 inch (0,025–0,07 mm) PI–10003
To replace the idler gear bushing, make a driver tool as

B 1.378’’ (35 mm)
shown in figure [B].
6.38’’ (162 mm)
1.575’’
(40 mm) 1.575’’
(40 mm)
1.413–1.415’’
(35,9–35,95 mm) 1.258–1.259’’
(31,96–31,97 mm)
MC–01366
Use a press and special driver tool, to remove the old

bushing and install the new bushing [C].
C
PI–10004
773 BICS Loader

TIMING GEARS
A
Checking Backlash
When the gears are installed, check the backlash of the
gears.
Install a dial indicator [A].
Hold one gear while turning the other gear [A].
If the backlash exceeds the allowable limit, check the oil
clearance of the shaft and gear. If the oil clearance is
correct, replace the gear.
Crank Gear &
Idler Gear . . . . . . 0.002–0.004 inch (0,042–0,112 mm) PI–10005
Cam Gear &
Idler Gear . . . . . . 0.002–0.005 inch (0,042–0,115 mm)
Injection Pump Gear &
Idler Gear . . . . . . 0.002–0.005 inch (0,042–0,115 mm)
Oil Pump Gear &
Idler Gear . . . . . 0.002–0.004 inch (0,042–0,109 mm)
773 BICS Loader

FUEL CAMSHAFT
A 2

Remove the idler gear. (See Page 7–56.)
Remove the bolt (Item 1) [A] from the retainer plate (Item
2) [A].
Installation: Tighten the bolt to 60–72 in.–lbs. (6,8–8,1
Nm) torque.
1
Remove the fuel camshaft retainer plate (Item 2) [A].
B–14342
Remove the fuel camshaft and fork lever assembly (Item

1) [B] at the same time. B
B–14343
Governor
The governor serves to keep the engine speed constant C 1
5 4
by automatically adjusting the amount of fuel supplied to
the engine according to changes in the load. 3
Disassemble and assemble the governor and fuel 2 9
camshaft as shown in figure [C].
Check all the parts for wear or damage and replace as 12
needed.
6
7
8 10
11
13
1. Start Spring
2. Governor Spring
3. Governor Spring
4. Fork Lever
5. Fork Lever
6. Fork Lever Shaft
7. For Lever Holder
8. Governor Lever
9. Fuel Camshaft
10. Governor Ball Case
11. Steel Balls
12. Governor Sleeve
13. Steel Ball
PI–10008
773 BICS Loader

CRANKSHAFT GEAR
A
Remove the idler gear. (See Page 7–56.)
Remove the crankshaft gear with a puller [A].
Remove the crankshaft key.
Installation: Install the crankshaft key. Heat the
crankshaft gear to 176°F (80°C) and fit it on the
crankshaft.
B–03686
OIL PUMP
B
1
Remove the crankshaft gear.
Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [B].
Installation: Tighten the nut on the oil pump shaft to 2
46–54 ft.–lbs. (62–73 Nm) torque.
Remove the oil pump mounting bolts. Remove the oil
pump (Item 2) [B].
B–03658
Installation: Tighten the oil pump mounting bolts to
60–72 in.–lbs (6,9–8,1 Nm) torque.
C
Oil Pump Service
Measure the clearance between the lobes of the inner
rotor and outer rotor [C].
B–03616
Measure the clearance between the outer rotor and pump

body [D]. D
oil pump.
Clearance Between Inner &
Outer Rotor . . . . . . 0.004–0.006 inch (0,10–0,16 mm)
Clearance Between Outer Rotor
& Body . . . . . . . . . . 0.004–0.008 inch (0,11–0,19 mm)
A–02732
773 BICS Loader

OIL PUMP (Cont’d)
A
Oil Pump Service (Cont’d)
Put a piece of press gauge on the rotor face [A].
Install the cover and tighten the bolts.
Remove the cover carefully. measure the width of the
press gauge [A].
oil pump.
End Clearance . . . . . 0.004–0.006 inch (0,11–0,15 mm)
PI–10009
Checking Engine Oil Pressure

Remove the oil pressure sensor.
B
Install a pressure gauge [B].
Start the engine and run until it is at operating
temperature.
If the oil pressure is less than the allowable limit, check the
following items:
* Engine Oil Level Low
* Oil Pump Defective
* Oil Galley Plugged
* Oil Strainer Plugged
* Excessive Clearance at the Rod & Main Bearings PI–10010
* Relief Valve Stuck
At Idle Speed Allowable Limit . . . . . . . . 7 PSI (49 kPa) C 2
At Rated Speed . . . . . . . . . . . 43–65 PSI (294–441 kPa) 3
Allowable Limit . . . . . . . . . . . . . . . . . . . 36 PSI (245 kPa)
Relief Valve
The relief valve prevents damage of the lubricating
system due to high pressure. This relief valve is a ball
type.
Remove the valve seat (Item 2), [C] ball (Item 3) [C] and 1
spring (Item 1) [C].
PI–10011
Check the parts for wear or damage and replace as
needed.
773 BICS Loader

PISTON AND CONNECTING ROD
A
Remove the cylinder head. (See Page 7–47.)
Remove the top edge from the cylinder bore with a ridge
reamer.
Remove the oil pan. 1
Remove the oil pump strainer (Item 1) [A].

Turn the flywheel and put a pair of connecting rods at
bottom dead center.
Remove the connecting rod bolts. B–14344
Installation: Tighten the connecting rod bolts to the

following torque. B
W/O Flange Bolt . . . . . . . . . 27–30 ft.–lbs. (37–41 Nm)
W/Flange Bolt . . . . . . . . . . . 33–36 ft.–lbs. (45–49 Nm)
Remove the rod cap and bearing [B].

Use a hammer handle and push the piston/connecting
rod assembly out of the cylinder bore [B].
NOTE: Make sure the pistons are marked so they will
be returned to the same cylinder bore.
PI–10013
Installation: When inserting the piston into the cylinder,

face the mark on the connecting rod to the injection pump C
[C].
Repeat the procedure to remove the other piston/
connecting rod assemblies from the engine block.
82.8
82.8
A–02903
Remove the piston rings [D].

D 2
Remove the snap ring (Item 3) [D] and piston pin (Item 1)
[D].
3
Separate the piston (Item 2) [D] from the connecting rod
(Item 4) [D]. 1
4
B–03621
773 BICS Loader

PISTON AND CONNECTING ROD (Cont’d)
A 2
Installation: When installing new rings, assemble the
ring so the mark (Item 1) [A] near the gap faces the top
of the piston. When installing the oil ring, place the
expander joint (Item 2) [A] on the opposite side of the oil
ring gap (Item 3) [A].
180°
3
PI–10015
Installation: When reassembling, align the marks (Item

1) [B] on the connecting rod and piston (Item 2) [B]. Heat
the piston to 176–212°F. (80–100°C.) and tap the piston
B 3 4
pin into position. Place the piston rings so that there are
gaps every 120 degrees (Items 3, 4 & 5) [B] with no gap
facing the piston pin in the cylinder.
1
5
PI–10014
Servicing The Piston And Connecting Rod

Measure the I.D. of the piston pin bore in both horizontal
C
and vertical directions [C].
the piston.
Piston Pin Bore I.D. . . . . . . . . . . . . . . . 0.984–0.985 inch
(25,0–25,013 mm)
Allowable Limit . . . . . . . . . . . . . . 0.986 inch (25,05 mm)
A–02733
Measure the O.D. of the piston pin (Item 1) [D].

D
Measure the I.D. of the connecting rod small end (Item 2)
[D].
Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the bushing. If it still exceeds the
specifications, replace the piston pin.
Piston Pin O.D. . . 0.984–0.985 inch (25,0–25,011 mm)
Bushing I.D. . . . . 0.985–0.986 inch (25,03–25,04 mm) 2
Oil Clearance Between Piston Pin
& Bushing . . . 0.0006–0.0015 inch (0,014–0,038 mm)
Service Replacement 1
Part . . . . . . . . . . 0.0006–0.003 inch (0,015–0,07 mm) B–03633
773 BICS Loader

A
Servicing The Piston And Connecting Rod (Cont’d)
6.38’’ (162 mm)
To replace the connecting rod small end bushing, make 1.063’’ (27 mm)
a driver tool as shown in figure [A].
1.378’’ (35 mm)
1.098–1.1004’’
(27,9–27,95 mm) 0.984–0.985’’
(25,0–25,011 mm)
MC–01366
Use a press and special driver tool to remove the small
end bushing [B].
Installation: Clean the small end bushing and bore. Put
B
oil on the bushing and press into the connecting rod until
it is flush [B].
PI–10016
Install new piston ring into the lower part of the cylinder
bore. Measure the ring gap with a feeler gauge [C].
If the gap exceeds the allowable limit, replace the cylinder
C
liner.
Compression Ring Gap . . . . . . . . . . . 0.012–0.019 inch
(0,3–0,5 mm)
Oil Ring Gap . . . . . . . . 0.010–0.016 inch (0,25–0,4 mm)
B–03622
Remove the carbon from the ring grooves. Measure the

clearance between the ring and groove with a feeler D
gauge [D].
piston.
Compression Ring . . . . . . . . . . . . . . 0.008 inch (0,2 mm)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . 0.006 inch (0,15 mm)
PI–10017
773 BICS Loader

A
Connecting Rod Alignment
NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
doing this check.
Install the piston pin into the connecting rod.

Install the connecting rod on a alignment tool.
Put the gauge over the piston pin and move it against the
face plate.
If the gauge does not fit squarely against the face plate,
measure the space between the gauge and face plate B–04067
[A].
the connecting rod.
Rod Alignment . . . . . . . . . . . . . . . . 0.002 inch (0,05 mm)
773 BICS Loader

CRANKSHAFT AND BEARINGS
A
Remove the piston and connecting rod assemblies. (See
Page 7–63.)
Remove the engine flywheel. (See Page 7–35.)
Remove the bolts which fasten the bearing case cover to
the block.
Installation: Tighten the bearing case cover bolts to
13–15 ft.–lbs. (18–21 Nm) torque.
Install two bolts into the bearing case cover and pull the
cover out [A]. B–03648
Installation: When installing the cover (Item 1) [B], make

sure the casting mark (Item 2) [B] is in the down position.
B
B–14345
Before removing the crankshaft/main bearings, check the

end play. Install a dial indicator. Measure the end play by
moving the crankshaft back and forth [C].
C
the thrust washers.
End Play . . . . . . . . . . 0.006–0.012 inch (0,15–0,31 mm)
B–09565
Remove the main bearing case bolt (Item 1) [D].

D
Installation: Make alignment of the bearing case hole 2
(Item 2) [D] with the hole in the block. Put oil on the bolt
threads and tighten to 51–54 ft.–lbs. (69–73 Nm) torque.
B–14346
773 BICS Loader

CRANKSHAFT AND BEARINGS (Cont’d)
A
Remove the crankshaft/main bearing assembly from the
engine block [A].
Mark the bearing case halves for correct installation.
PI–10020
Remove the two bearing case bolts [B].

Remove the bearing case and bearing.
B
Installation: Tighten the bearing case bolts to 34–38
B–04092
Installation: When installing the main bearing case

assemblies, face the mark FLYWHEEL to the flywheel
side of the engine block [C]. Be sure the thrust washers
C
with its oil grooves face outward.
PI–10021
Servicing The Crankshaft And Bearings

Put the crankshaft on V–blocks. Install a dial indicator on D
the center journal [D].
Turn the crankshaft at a slow rate.
If the misalignment exceeds the allowable limit, replace
the crankshaft.
Alignment . . . . . . . . . . . . . . . . . . . . 0.003 inch (0,08 mm)
A–02763
773 BICS Loader

A
Servicing The Crankshaft And Bearings (Cont’d)
Tighten the connecting rod cap bolts as follows:
W/O Flange Bolt . . . . . . . . . 27–30 ft.–lbs. (37–41 Nm)
W/Flange Bolt . . . . . . . . . . . 33–36 ft.–lbs. (45–49 Nm)
120
A–02727
Measure the crankpin O.D. [B].

Calculate the oil clearance.
B
Crankpin Bearing I.D. . . . . . . . . . . . 1.850–1.852 inches
(47,0–47,05 mm)
Crankpin O.D. 1.849–1.850 inches (46,96–46,98 mm)
Oil Clearance . . 0.0009–0.003 inch (0,025–0,087 mm)
A–02716
Check the wear on the crankshaft sleeve [C]. C

If the wear exceeds the allowable limit or the seal leaks
oil, replace the sleeve.
Wear of Sleeve . . . . . . . . . . . . . . . . 0.004 inch (0,1 mm)
PI–10022
The special tool set (Kubota Code Number:

07916–32091) will be needed to replace the crankshaft D 2
sleeve. 2
1 3
Remove the sleeve.
Install the sleeve guide (Item 1) [D] and stop (Item 2) [D].
Heat the sleeve to about 300°F (150°C). Install the sleeve
on the crankshaft using the special driver tool (Item 3) [D].
PI–10023
773 BICS Loader

A
Measure the I.D. of the No. 1 crankshaft bearing [A].
B–03631
Measure the O.D. of the crankshaft journal [B]. B

Calculate the oil clearance.
crankshaft bearing.
Bearing I.D. . . 2.046–2.049 inches (51,98–52,04 mm)
Journal O.D. . . 2.044–2.045 inches (51,92–51,94 mm)
Oil Clearance . . . . . . 0.002–0.005 inch (0,04–0,12 mm)
B–03618
REMOVAL TOOL
To remove the front bearing make the driver tool as shown
in figure [C].
C 5.31’’ (135 mm)
0.8’’
(20 mm)
2.0413–2.0433’’
(51,85–51,90 mm)
2.83’’
(72 mm)
0.8’’ (20 mm)

2.2382–2.2402’’
1.57’’ R (56,85–56,90 mm)
0.4’’
(40 mm) (10 mm) MC–01367
INSTALLATION
To install the front bearing make the driver tool as shown
in figure [D]. D 5.12’’ (130 mm)
0.8’’
TOOL
(20 mm)
0.35’’
(9 mm)
2.2382–2.2402’’
2.83’’ (56,85–56,90 mm)
(72 mm)
0.8’’ (20 mm)

2.0412–2.0433’’
(51,85–51,90 mm)
1.57’’ R 0.4’’
(40 mm) (10 mm)
MC–01365
773 BICS Loader

A 0.165–0.177’’
(4,2–4,5 mm)
Remove the front bearing (Item 1) [A] with the special
removal tool.
Installation: Clean the new bearing and bore, apply oil
on them. Install the new bearing with the installation driver
tool [A].
PI–10024
Clean the crankshaft journal and bearing. Put a strip of

press gauge on the center journal.
B
Install the main bearing case halves and tighten the bolts.
Remove the bearing case halves.
Measure the flattened press gauge [B].
crankshaft bearing.
Crankshaft Journal
O.D. . . . . . . . . 2.044–2.045 inches (51,92–51,94 mm)
Bearing I.D. . . 2.046–2.048 inches (51,98–52,03 mm)
Oil Clearance . . . . . . 0.002–0.004 inch (0,04–0,10 mm)
Allowable Limit . . . . . . . . . . . . . . . . . 0.008 inch (0,2 mm) PI–10025
773 BICS Loader

CYLINDER BORE
A
Checking The Cylinder Bore
Use a gauge to check the inside measurement of the
cylinder bore [A].
B–04066
Measure the six points as shown in figure [B] to find the

maximum wear. B
The specification is 3.425–3.426 inches (87,0–87,02
mm). The wear limit is +0.006 inch (+0,15 mm).
If the cylinder bore is not within specifications, re–bore the
cylinder for oversize piston.
A–02717
773 BICS Loader

WATER PUMP
A
Remove the water pump from the timing gearcase cover
[A].
B–05318
Put the water pump in a vise and remove the nut [B].
Remove the pulley using a puller. Remove the key and
B
snap ring.
B–05324
Drive the shaft out of the impeller side of the water pump
housing [C]. C
B–05325
Install the new seals [D]. Install the shaft.

D
Installation: Put the water pump in a vise and tighten the
nut to 50–57 ft.–lbs. (68–77 Nm) torque. Always use a
new gasket when installing the water pump on the timing
gearcase cover.
A–02783
773 BICS Loader

773 BICS Loader

SYSTEMS ANALYSIS
Page
Number
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

(S/N 509648900 & Above) (S/N 509617300 & Avove)
Additional Inspection For Loaders With Advanced Hand Controls . . . . 8–3
Inspecting Deactivation Of The Auxiliary Hydraulics System
(Engine STOPPED – Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Inspecting The Bics™ System Controller
Inspecting The Seat Bar Sensors (Engine Running) . . . . . . . . . . . . . . . 8–3
Inspecting The Traction Lock (Engine Running) . . . . . . . . . . . . . . . . . . . 8–3
Inspecting The Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Additional Inspection For Loaders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
(S/N 509648899 & Below) (S/N 509617299 & Below)
Inspecting The Deactivation Of The Auxiliary Hydraulics System
Inspecting The Bics™ System Controller
Inspecting The Seat And Seat Bar Sensors (Engine Running) . . . . . . . 8–5
Inspecting The Traction Lock (Engine Running) . . . . . . . . . . . . . . . . . . . 8–5
Inspecting The Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . 8–5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–6
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–7
Troubleshooting Guide
BICS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8
Seat Bar Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–11
Seat Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10
Traction Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–9
BICS™ SYSTEM CONTROLLER
SYSTEMS
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE ANALYSIS
Controls Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–28
SEAT BAR SENSOR
BICS™ Controller Seat Sensor Circuit Test . . . . . . . . . . . . . . . . . . . . . . . 8–18
Seat Bar Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16
SEAT SENSOR
BICS™ Controller Seat Sensor Circuit Test . . . . . . . . . . . . . . . . . . . . . . . 8–14
Seat Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–12
TRACTION LOCK

773 BICS Loader
SYSTEMS ANALYSIS
Page
Number
BOBCAT OPERATION SENSING SYSTEM (BOSS®)
BOSS® DIAGNOSTIC TOOL
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–21
BOSS® INSTRUMENT PANEL
MONITOR SERVICE CODES
Alphabetic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–22
Numeric Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–22
Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–23
OPERATION SENSING SYSTEM UNIT
RPM SENSOR
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–21
SENDER AND SENSOR
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–28
Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–28
TROUBLESHOOTING THE BOSS® & L.C.D. DISPLAY
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–25
773 BICS Loader

(S/N 509648900 & Above) (S/N 509617300 & Above)
Inspecting The BICS™ Controller
A 1
(Engine STOPPED – Key ON)
1. Sit in the operator’s seat. Turn key ON, lower the 2
seat bar and disengage the parking brake pedal.
Press the green PRESS TO OPERATE Button. All 3
five BICS controller lights should be ON (Items 1, 4
2, 3, 4 & 5) [A].
2. Engage the parking brake pedal and raise the seat 5
bar fully. System Activated (Item 1), Seat Bar (Item
2), Valve (Item 3) and Traction lights (Item 4) [A]
should be OFF.
NOTE: Record what lights are blinking (if any) and
number of blinks. Refer to Page 8–4.
3. Exit the loader and press Traction Lock Override P–10157
button. Traction light (Item 4) [A] should be ON.
Press override button again and Traction light
(Item 4) [A] should be OFF.
Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED – Key ON)
4. Sit in the operator’s seat. Lower the Seat Bar.
Press the green PRESS TO OPERATE Button.
Press the auxiliary hydraulics switch. The auxiliary
switch light will come ON. Raise the Seat Bar. The AVOID INJURY OR DEATH
light should be OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING) The Bobcat Interlock Control System (BICS)
must deactivate the lift, tilt and traction drive
5. Sit in the operator’s seat. Lower the seat bar. functions. If it does not, contact your dealer for
Engage the parking brake pedal. Fasten the seat service. DO NOT modify the system.
belt.
W–2151–0394
6. Start the engine and operate at low idle. Press the
green PRESS TO OPERATE Button. While
raising the lift arms, raise the Seat Bar fully. The lift
arms should stop. Repeat using the tilt function.
Inspecting The Traction Lock (Engine RUNNING)
7. Fasten the seat belt, disengage the parking brake
pedal, press the green PRESS TO OPERATE
Button and raise the Seat Bar fully. Move the
steering levers slowly forward and backward. The
Traction lock should be engaged. Lower the Seat
Bar. Press the green PRESS TO OPERATE
Button.
8. Engage the parking brake pedal and move the
Traction lock should be engaged.
Inspecting The Lift Arm By–Pass Control
9. Raise the lift arms 6 feet (2 meters) off the ground.
Stop the engine.
Turn the lift arm by–pass control knob clockwise
1/4 turn. Then pull up and hold the lift arm by–pass
control knob until the lift arms slowly lower.
Additional Inspection For Loaders With Advanced
Hand Controls
10. Sit in the operator’s seat and fasten the Seat Belt.
Lower the Seat Bar, start the engine and press the
green PRESS TO OPERATE Button.
11. Raise the lift arms about 6 feet (2 meters) off the
ground.
12. Turn the key OFF and wait for the engine to come
to a complete stop.
13. Turn the key ON. Press the green PRESS TO
OPERATE Button, move the left hand control
toward the operator. The lift arms should not lower.
14. Move the right hand control away from the
operator. The bucket (or attachment) should not tilt
forward.
773 BICS Loader

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (S/N 509648900 & Above) (S/N 509617300 & Above) (Cont’d)
Troubleshooting Chart
The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller
lights are off or flashing. Have the service procedure performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.
Flashing Indicator Means System Problem
Effect on Operation (See Your Bobcat Dealer for Service)
of Loader
Indicator When Light Is Number of
Light Light ON Light OFF OFF Flashes Cause
System PRESS TO OPERATE PRESS TO OPERATE Lift, tilt and traction 2 System Activated circuit shorted to
Activated button is activated button not activated functions will not battery voltage.*
operate. 3 System Activated circuit shorted to
ground.
Seat Bar Seat Bar Down. Seat Bar Up. Lift, tilt and traction 2 Seat bar sensor circuit shorted to
functions will not battery voltage*.
operate. 3 Seat bar sensor circuit shorted to
ground.
Valve Control Valve Control Valve Lift and tilt functions 2 Valve output circuit shorted to battery
Can Be Used. Cannot Be Used. will not operate. voltage*.
3 Valve output circuit shorted to ground.
3 Valve output circuit is not grounded.
Traction Loader can be Loader cannot be Loader cannot be 1 Traction lock hold coil circuit is open.
moved forward moved forward and moved forward and 2 Traction lock hold coil circuit shorted
& backward. backward. backward. to battery voltage*.
3 Traction lock hold coil circuit shorted
to ground.
4 Traction lock pull coil circuit is open.
5 Traction lock pull coil circuit is shorted
to battery voltage*.
to ground.
Power BICS Controller BICS Controller is Lift, tilt and traction
is operating not operating functions will not N/A N/A
correctly. correctly. operate.
* Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted
to system voltage.
NOTES:
(1) If the System Activated and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If
one of the lights stay OFF, check the circuit for continuity.
(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.
(3) Flashing patterns will repeat every 3.25 seconds.
773 BICS Loader

(S/N 509648899 & Below) (S/N 509617299 & Below) A
Inspecting The BICS™ Controller 1
(Engine STOPPED – Key ON) 2
1. Sit in the operator’s seat. Turn key ON, lower the
seat bar and disengage the parking brake. All five 3
BICS Controller lights should be ON (Items 1, 2, 3, 4
4 & 5) [A].
5
2. Engage the parking brake, raise the seat bar fully.
Seat bar light (Item 2) [A], valve light (Item 3) [A]
and traction light (Item 4) [A] should be OFF.
3. Raise up slightly off the seat. Seat light (Item 1) [A]

should be OFF. P–03760
NOTE: Record what lights are blinking (if any) and

number of blinks. Refer to BICS
Troubleshooting Chart, Page 8–7.
4. Exit the loader and press traction lock override
button. Traction light (Item 4) [A] should be ON.
Press override button again and traction light (Item
4) [A] should be OFF.
(Later Model Loaders Only) Inspecting Deactivation
Of The Auxiliary Hydraulics System
(Engine STOPPED – Key ON)
5. Sit in the operator’s seat. Lower the seat bar.
Press the auxiliary hydraulics auxiliary switch. The
auxiliary switch light will come ON. Raise the seat
bar. The light should be OFF.
Inspecting The Seat And Seat Bar Sensors
(Engine Running)
6. Sit in the operator’s seat, lower the seat bar and
engage the parking brake. Fasten the seat belt.
7. Start the engine and operate at low idle. While

raising the lift arms, raise the seat bar fully. The lift
arms should stop. Repeat using the tilt function.
Inspecting The Traction Lock (Engine Running)
8. Fasten the seat belt, disengage the parking brake,
and raise the seat bar fully. Move the steering
levers slowly forward and backward. The traction
lock should be engaged. Lower the seat bar.
9. Engage the parking brake pedal and move the

traction lock should be engaged.
Inspecting The Lift Arm By–Pass Control
Early Models with or without mechanical Hand Controls
Raise the lift arms six feet (2 m) off the ground. Stop the
engine, pull and hold the by–pass control knob. Push the
toe of the left foot pedal or move the left hand control in
toward the operator (hand controls) and the lift arms
should lower slowly.
Later Models with or without machanical Hand Controls
Raise the lift arms six feet (2 m) off the ground. Stop the
engine. Turn the lift Arm By–Pass Control Knob clockwise
1/4 turn. Then pull up and hold the Lift Arm By–Pass
Control Knob until the lift arms slowly lower.
773 BICS Loader
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Clean area behind
(S/N 509648899 & Below) (S/N 509617299 & A and under seat.
Below)(Cont’d)
Maintenance
Clean any debris, dirt or objects from under or behind the
operator seat [A] & [B]. The rear of the seat must move
up and down.
Inspect both Seat Rail Covers [B] for wear or damage.
Replace if necessary.
Clearance is necessary under the seat spring (Item 1) [B]
and the seat, to allow the seat to move up and down freely.
With adequate clearance, the seat sensor will be allowed
to function properly. P–03763
Inspect seat bar pivot area for tightness of linkage bolts.

Operator
Replace parts that are damaged. Use only genuine
B Seat
Melroe replacement parts.
Seat Seat
1 Spring
Sensor
Seat Rail
AVOID INJURY OR DEATH Cover
The Bobcat Interlock Control System (BICS)
must deactivate the lift, tilt and traction drive
functions. If it does not, contact your dealer for
service. DO NOT modify the system. MC–02043
W–2151–0394
773 BICS Loader

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (S/N 509648899 & Below) (S/N 509617299 & Below)(Cont’d)

of Loader
Seat Operator in Seat No Operator in Seat Lift and tilt functions 2 Seat sensor circuit shorted to battery
will not operate. voltage*.
3 Seat sensor circuit shorted to ground
Seat Bar Seat Bar Down Seat Bar Up Lift, tilt and traction 2 Seat bar sensor circuit shorted to
ground.
Valve Control Valve Can Control Valve Lift and tilt functions 1 Valve output circuit is open.
Be Used Cannot Be Used will not operate. 2 Valve output circuit shorted to battery
voltage*.
moved forward & moved forward and moved forward and 2 Traction lock hold coil circuit shorted
backward. backward. backward. to battery voltage*.
to ground.
to ground.
is operating not operating functions will not
NOTES:
(1) If the seat and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If one of the lights
stay OFF, check the circuit for continuity.
(4) If seat indicator light does not go ON, check for debris, dirt or objects under or behind the seat.
NOTE: On some early models with BICS controller S/N 200,000 and Above only, If the Seat Bar is lowered before
the seat sensor is activated, a 10 second delay will occur before the valve and traction lights come on.
to system voltage.
773 BICS Loader

(Cont’d)
Troubleshooting Guide
The following troubleshooting guide is provided for
assistance in locating and correcting BICS system
problems. It is recommended that these procedures be Check for correct function after adjustments,
done by authorized Bobcat Service Personnel only. repairs or service. Failure to make correct
death.
W–2004–1285
BICS CONTROLLER
PROBLEM SOLUTION #
Power indicator light does not come ON. 1, 2, 3, 6

All indicator lights flashing. 4
One of the indicator lights flashing. 5
Intermittent indicator lights. 6, 7, 8, 9
SOLUTION SUGGESTIONS
1. Check that ignition switch ON.

2. Check BICS 10 amp. fuse.
3. Check wiring and connections. Make sure the connector is securely connected
to the controller. Remove controller and pull on connector to check.
4. Look at indicator light windows, if they are milky white in appearance it is most
likely caused by moisture in the controller. Allow to dry or replace the controller.
5. Refer to BICS troubleshooting chart for your loader. (See Page 8–4 & 8–7.)
6. Check wire connections to make sure connectors are locked into place.
7. Check pins in connectors for pins pushed back or bent.
8. Move the system wiring back & forth to try to find area that may be causing the
intermittent connection.
9. Use sensor tester MEL1428 to isolate problem between sensor and controller
and wiring.
773 BICS Loader

(Cont’d)
Troubleshooting Guide (Cont’d)
death.
W–2004–1285
TRACTION LOCK
PROBLEM SOLUTION #
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7, 8

Intermittent activation of traction lock. 9, 10, 11
1. Check that controller power indicator light is ON.

2. Make sure brake pedal is not engaged.
3. Maneuver loader to allow brake discs to move and remove pressure on the brake
wedge so it can retract.
4. If all lights indicate the brake should be released, but it doesn’t, check the brake
25 amp. fuse.
5. When checking fuse, also check other fuses. Check the fuse block for correct
orientation and location of fuses. (See Electrical System, Page 6–1.)
6. To test the solenoid, the pull coil should be 0.4 to 0.5 ohms and the hold coil 10.5 to
11.0 ohms.
7. Check brake solenoid and cover mounting hardware for the correct torque.
8. Remove brake cover and check wedges for binding in the wedge guides.
9. Check wire connections for loose connector body.
10. Check for loose or bent pins in connectors.

11. Check for loose spade connectors in fuse holder.
773 BICS Loader

(Cont’d)
assistance in locating and correcting BICS system Check for correct function after adjustments,
problems It is recommended that these procedures be repairs or service. Failure to make correct
done by authorized Bobcat Service Personnel only. repairs or adjustments can cause injury or
death.
W–2004–1285
SEAT SENSOR
PROBLEM SOLUTION #
Seat indicator light does not come ON with operator in seat.. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11
Seat indicator light stays ON when operator out of seat. 2, 3, 6, 10, 11, 12, 13, 14
Intermittent indicator light during operation. 11, 15, 16, 17, 18
1. Check to make sure power indicator light is ON.

2. Check for debris under and around seat.
3. Look for any obstruction around seat.
4. Check to make sure seat rail lowers when weight is in seat.
5. Raise cab and check for magnet collar movement when weight is added to seat.
(Magnet collar should extend approximately 3/8’’ beyond the sensor assembly
with weight in the seat).
6. Use sensor tester to check operation of sensor and controller. Follow instructions
on tester.
7. Check to make sure the magnet guide pin is in place.
8. Check for contamination on magnets such as metal particles or for shipping plate
over magnets.
9. Check to make sure both magnets are in collar.
10. Check for binding of magnet collar or bushing with hex head on other side for
binding.
11. Check for correct mounting. One spring for standard seat. Two springs for
suspension seats. Thick washers should be under front seat mounting rails on
both sides.
12. Check for loose hardware mounting magnet collar. Check to make sure the
magnet collar bushing is threaded on all the way so it is contacting seat rail.
13. Check to make sure seat rail raises when weight is removed from the seat.
14. Raise cab and check for magnet collar movement when weight is removed from
seat. (Magnet collar should extend approximately 1/8 inch beyond the sensor
assembly without weight in seat.)
15. With smaller operators that operate with the seat forward some mounting
alterations may be required. (See solution suggestions 16, 17 and 18.)
16. Adjust suspension seat to lightest weight setting.
17. Check to make sure the seat rails move up and down freely when weight is added.
18. Add washer between the bushing the magnet collar assembly slides on and the
seat rail. This will reduce the amount of seat travel required to activate the system.
Must check, with seat moved all the way back, that indicator light does not stay
on with operator out of seat. If light does not go out with operator out of the seat,
the washer must be removed.
773 BICS Loader

(Cont’d)
death.
W–2004–1285
SEAT BAR SENSOR
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5, 6
1. Check controller power indicator light . It must be ON.

2. Check sensor wire connection.
3. Use the BICS sensor tester (MEL1428) to check sensor and controller.
4. Check for loose hardware.

5. Check keyed bushing to make sure magnet collar rotates with seat bar.
6. Check magnet collar magnets for contamination such as metal particles.
773 BICS Loader

SEAT SENSOR
A
Seat Sensor Test
Use Sensor Tester (MEL1428) for the following 2
procedure:
Disconnect the short adatper test leads if connected.
NOTE: Clean any debris, dirt or objects from under

or behind the operator seat before starting
the test. The rear of the seat must move up
and down.

Disconnect the seat sensor connector (Item 1 – Inset)
[A].
Connect Sensor Tester (Item 2) [A] inline as shown to the
seat sensor.
N–00960 P–04705
Move the toggle switch (Item 1) [B] on the sensor tester

to the Absent position. B
Turn the key to the ON position. DO NOT START THE
ENGINE.
The power light (Item 2) [B] will illuminate, if the light is not
on, check the tester or wiring harness.
1
Sit on the operator seat.
P–04698
The Sensor Test light (item 1) [C] should illuminate.

C
Get off the operator seat. The Sensor Test light (Item 1)
[C] should go off.
If the above tests fail, there is a problem with the seat 1
sensor.
Disconnect the Sensor Tester.
Replace the Seat Sensor. (See Page 8–13.)
If the above tests pass, run BICS™ controller seat sensor
circuit test. (See Page 8–14.)
P–04699
773 BICS Loader

SEAT SENSOR (Cont’d)
A
Locate the seat sensor (Item 1) [A] beneath the operator
cab.
Remove the sensor connector (Item 1) [B] from the

holder and disconnect from the harness. 1
Remove the magnet collar mounting bolt (Item 2) [B] and
washer (Item 1) [C].
Installation: Tighten the bolt to 180–200 in.–lbs. (21–23 P–03987
Nm) torque.
B
2
3
DO NOT overtighten the magnet mounting 1
bolt to prevent damage to the magnet.
I–2089–1095
4
Remove the magnet (Item 2) [C] from the sensor (Item 3)
[B].
Installation: If the magnet collar (Item 2) [C] is tapered, N–00960
install the tapered end to the seat. If the magnet collar
(Item 2) [C] is not tapered, install as shown [C].
Remove the sensor mounting bolt (Item 4) [B] and nut.
C
5
Installation: Tighten the nut and bolt (Item 4) [B] until
light pressure is applied to the sensor (Item 3) [B].
3
2
1
4
Be careful to not overtighten the sensor

mounting bolt and nut to prevent breakage of
the sensor. P–04041
I–2088–1095
Remove the sensor (Item 3) [C].

D
NOTE: Be sure not to lose the magnet collar
alignment pin (Item 4) [C] which is located in
the sensor (Item 3) [C] when removing the
sensor. 1
Remove the threaded bushing (Item 5) [C] from the seat

track mounting bolt (Item 1) [D].
Inspect all parts for damage and wear and replace if
necessary.
Reverse the removal procedure to install the seat sensor.
P–04044
773 BICS Loader

SEAT SENSOR (Cont’d)
BICS™ Controller Seat Sensor Circuit Test
A
Use Sensor Tester (MEL1428) for the following 2
procedure:
NOTE: Clean any debris, dirt or objects from under
or behind the operator seat before starting
the test. The rear of the seat must move up
and down.

Disconnect the seat sensor connector (Item 1 – Inset)
[A].
Connect MEL1428 Sensor Tester (Item 2) [A] inline as
shown to the seat sensor.
N–00960 P–04705

ENGINE. B
The power light (Item 1) [B] will illuminate, if the light is not
on, check the tester or wiring harenss.
3
Move the toggle switch (Item 2) [B] on the sensor tester
to the Present position.
2
NOTE: The sensor test light (Item 3) [B] is activated
by the seat sensor switch. 1
P–04703
The Seat light (Item 1) [C] on the controller will illuminate. C

Move the toggle switch to Absent position, the seat light
on the controller will go off.
If the tests above fail, there is a problem with the BICS
system controller or the wiring harness.
1
P–04706
773 BICS Loader

BICS™ SYSTEM CONTROLLER
A
2

The controller mounting bolts are located on the back of 1
the operator cab [A].
Remove the top mounting bolt (Item 1) [A] from the
controller.
Loosen the two lower mounting bolts (Item 2) [A].
P–03997
NOTE: The operator seat is removed in photo [B] for
clarity purpose only. The seat does not need
B
to be removed to remove the controller.
Slide the controller (Item 1) [B] up and remove it from the 1

back of the operator cab.
Disconnect the electrical harness from the controller and
remove the controller from the loader.
P–03994
NOTE: Install the harness connector (Item 1) [C] into

the controller (Item 2) [C] before installing the
controller.
C
Be sure the connector to the BICS system

controller are correctly engaged in the
controller when installing the controller. An 1
audible snap can be heard when the
connector is correctly installed. Try to pull the
connector out of the controller, if it cannot be P–04707
removed it has been correctly installed [C].
I–2087–1095
Installation: Tighten the controller mounting bolts to

80–90 in.–lbs. (9–10 Nm) torque.
Reverse the removal procedure to install the controller.
773 BICS Loader

SEAT BAR SENSOR
Seat Bar Sensor Test
A
Use Sensor Tester (MEL1428) for the following
procedure: 1
P–04702
Connect Sensor Tester (Item 1) [B] inline as shown to the

seat bar sensor connectors. See inset [B]. B
ENGINE.
The toggle switch (Item 2) [C] can be in either the Absent 1
or Present position.
P–04701
P–04700
The power light (Item 1) [C] will illuminate, if the light is not
on, check the tester or wiring harness. C
P–04698
Lower the seat bar. The Sensor Test light (Item 1) [D]
should illuminate. D
Raise the seat bar. The Sensor Test light (Item 1) [D]
should go off.
1
If the above tests fail, there is a problem with the seat bar
sensor.
Disconnect the Sensor Tester.
Replace the Seat Bar Sensor. (See Page 8–17.)
If the above tests pass, run BICS controller seat bar
circuit test. (See Page 8–18.)
P–04699
773 BICS Loader

SEAT BAR SENSOR (Cont’d)
A
1
P–04702
Remove the mounting bolt (Item 1) [B] from the pivot

bushing. B
Installation: Tighten the mounting bolt to 25–28 ft.–lbs.
Remove the sensor mounting bolt (Item 2) [B] and nut. 1
2
Be careful to not overtighten the sensor
mounting bolt and nut to prevent breakage of P–03246
the sensor.
I–2088–1095
Installation: Be sure the tabs on the pivot bushing are

C
positioned in the slotted hole (Item 1) [C] of the operator
cab as shown.
Pull the seat bar back and remove the assembly as
follows:
NOTE: The sensor assembly [D] is shown removed 1
from the operator cab for clarity purpose
only. The sensor assembly can be removed
without removing the seat bar from the
operator cab.
Remove the pivot bushing mounting bolt (Item 1) [D] and
washer (Item 2) [D] from the pivot bushing (Item 3) [D]. P–03247
Installation: Tighten the pivot bushing mounting bolt to

180–200 in.–lbs. (21–23 Nm) torque.
D
Remove the pivot bushing (Item 3) [D], sensor (Item 4)
[D], magnet (Item 5) [D] and plastic bushing (Item 6) [D] 3 6 2
from the seat bar. 1
Inspect all parts for damage and wear and replace if

necessary.
Reverse the removal procedure to install the seat bar
sensor.
Left Side
4 5 of Seat Bar
P–03284
773 BICS Loader

SEAT BAR SENSOR (Cont’d)
A
BICS™ Controller Seat Bar Sensor Circuit Test
Use Sensor Tester (MEL1428) for the following
procedure:
1

P–04701
Connect Sensor Tester (Item 1) [B] inline as shown to the
seat bar sensor connectors. See inset [A].
ENGINE. P–04702
No power light on the sensor tester check the tester or

wiring harness.
B
Power light illuminated, move the toggle switch (Item 2)
[B] on the sensor tester (Item 1) [B] to the Present 3
position.
NOTE: The sensor test light (Item 3) [B] is only 2

activated by the seat bar. It will be off with the
seat bar up or on with the seat bar down.
1
P–04703
The seat bar light (Item 1) [C] on the BICS controller

should illuminate. C
P–04704
Move the toggle switch (Item 1) [D] on the sensor tester

to the Absent position. D
The Seat Bar light (Item 1) [C] should go off.
If the tests above fail, there is a problem with the BICS™
system controller or the wiring harness.
P–04699
773 BICS Loader

TRACTION LOCK
A
P–04712
1
Do not modify the electrical wiring connected 2
to the traction lock solenoid or any part of the
traction lock system. The traction lock
provides the locking function of the parking
brake. Service work on the traction lock system P–04135
should only be performed by a qualified
technician. Use only genuine Bobcat parts if
repair is necessary.
W–2165–0100
B
NOTE: The loader control panel is removed for
clarity purpose only. The traction lock can be
removed without removing the control panel.
Remove the Do Not Modify sta–strap (P/N 6665527) from

the electric solenoid connector (Item 1) [A].
Installation: Install a new Do Not Modify sta–strap (P/N 1
6665527) on the electric solenoid connector.
P–04138
electric solenoid mounting bracket.
(34–38 Nm) torque. Be sure the solenoid mounting
bracket is installed in the same position. The solenoid
mounting surface has a slight angle which tips the top of
the solenoid toward the rear of the loader when installed
correctly. See inset photo [A].
Remove the electric solenoid and bracket assembly from
the chaincase cover [B].
Remove and inspect the compression spring (Item 1) [B]
for wear or damage. Replace if necessary. The spring
may also stay with the shaft when the electric solenoid
and bracket are removed from the chaincase.
Installation: Install the compression spring (Item 1) [B]
on the collar located on the electric solenoid.
773 BICS Loader

TRACTION LOCK (Cont’d)
A
Remove the traction lock assembly (Item 1) [A] from the
chaincase.
P–04134
Remove the shaft mounting bolt (Item 1) [B], washer and

spring from the assembly shaft (Item 2) [B]. Remove the
B
wedge (Item 3) [B] and inspect all parts for damage or
wear. Replace if necessary.
Installation: Thoroughly clean and dry the shaft
mounting bolt (Item 1) [B], the shaft (Item 2) [B] and
wedge (Item 3) [B]. Use LOCTITE #242 when 2
assembling these parts to the traction lock assembly. 1
P–04139
Failure to use LOCTITE may allow the traction

lock assembly to loosen up which can cause
damage to the traction lock system.
I–2090–1095
Refer to Page 8–3 for the traction lock inspection

procedure.
773 BICS Loader

BOSS® DIAGNOSTIC TOOL
Procedure
A
The tool listed will be needed to do the following 1
procedure:
MEL1400 – Diagnostic Tool
Stop the engine.
Remove the dust cap from the diagnostic connector plug.
Connect the diagnostic tool plug (Item 1) [A] into the
loader connector.
Use the instructions from the BOSS® Operation & P–03871
Maintenance Manual to make service checks of BOSS®
system operating unit and other components [A].
SENDER AND SENSOR B
Service Checks 2
Use the following information when checking the senders

and sensor with a volt/ohmmeter.
Component Value
TEMPERATURE SENDER
70 degrees F. (21 degrees C.) . . . . . . . . . . . 970 ohms
80 degrees F. (27 degrees C.) . . . . . . . . . . 1013 ohms
ENGINE OIL PRESSURE SENDER 1
0 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ohms Max.
6 PSI (41 kPa) . . . . . . . . . . . . . . . . . . . . . . . 7 ohms Min.
50 PSI (345 kPa) . . . . . . . . . . . . . . . . . . . . . . . . 49 ohms P–04313
70 PSI (483 kPa) . . . . . . . . . . . . . . . . . . . . . . . . 59 ohms
TRANSMISSION CHARGE PRESSURE SENDER
0 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–5 ohms
100 PSI (690 kPa) . . . . . . . . . . . . . . . . . . . . . . . 58 ohms
C
130 PSI (896 kPa) . . . . . . . . . . . . . . . . . . . . . . . 75 ohms
150 PSI (1034 kPa) . . . . . . . . . . . . . . . . . . . . . 87 ohms
1
FUEL SENDER
Full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ohms
Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 ohms
RPM SENSOR
Adjustment
Continuity Resistance of 3000–3500 ohms.
Disconnect the connector (Item 1) [B] from the engine
harness. P–04317
Loosen the jam nut (Item 2) [B] on the RPM sensor.
Turn the RPM sensor (Item 1) [C] in until it makes contact
with the engine flywheel.
Turn the jam nut until it contacts the flywheel housing. The
jam nut should not be tightened, it needs to turn with the
RPM sensor when the sensor is turned back out for
adjustment.
Turn the RPM sensor and the jam nut out from the
flywheel. Set a clearance of 0.050 inch (1,27 mm)
between the jam nut and the housing with a feeler gauge
[C].
Retighten the jam nut.
NOTE: The plastic tip is used as a gauge to set a new
RPM SENSOR, the plastic tip is designed to
come off after the engine is started.
773 BICS Loader
MONITOR SERVICE CODES
The following list references the defect codes that are
transmitted to the instrument panel display which can
occur. Some service procedures for correcting the
problems can be found in this manual and other
procedures must be performed ONLY BY QUALIFIED
BOBCAT SERVICE PERSONNEL. Instructions are necessary before operating or
or death.
W–2003–0199
Service Codes
SUBJECT DISPLAY READS CONDITION

Engine Coolant Level ECL 1 SHUTDOWN, No Coolant
Engine Coolant Temp. EC–1.1 SHUTDOWN, Engine Temperature

EC–2.1 WARNING, Engine Temperature
EC 3 Wiring Not Connected
EC 4 Wiring Shorted
EC 5 High Sensor Voltage
EC 7 Sensor Out Of Range
Engine Oil Pressure EP 1 SHUTDOWN, Pressure
EP 2 WARNING, Pressure
EP 3 Wiring Not Connected
EP 4 Wiring Shorted
EP 5 High Sensor Voltage
EP 7 Sensor Out Of Range
Engine Speed ES 1 SHUTDOWN, Engine Speed Too High
ES–2.1 WARNING, Engine Speed Slightly High
ES–6 Sensor No Signal
ES–7 Sensor Out Of Range
Air Filter AF 2 WARNING, Restriction Too High
AF 6 Sensor No Signal
Battery b–2.1 WARNING, Bad Battery
b–2.2 WARNING, Battery Voltage
Fuel Level FUEL2 WARNING, Low Level
FUEL3 Wiring Not Connected
FUEL4 Wiring Shorted
FUEL5 High Sensor Voltage
FUEL7 Sensor Out Of Range
773 BICS Loader

MONITOR SERVICE CODES (Cont’d)
Service Codes (Cont’d)
SUBJECT DISPLAY READS CONDITION

Hydrostatic Charge HF1–2 WARNING, High Restriction (1st Filter)
Filter Conditions HF1–6 Sensor No Signal
HF2–2 WARNING, High Restriction (2nd Filter)
HF2–6 Sensor No Signal
Hydrostatic Fluid HP 1 SHUTDOWN, Pressure
HP 2 WARNING, Pressure
HP 3 Wiring Not Connected
HP 4 Wiring Shorted
HP 5 High Sensor Voltage
HP 7 Sensor Out Of Range
Hydrostatic Fluid HC 1 SHUTDOWN, Temperature
Temperature HC 2 WARNING, Temperature
HC 3 Wiring Not Connected
HC 4 Wiring Shorted
HC 5 High Sensor Voltage
HC 7 Sensor Out Of Range
773 BICS Loader

TROUBLESHOOTING THE BOSS® & LCD DISPLAY
Chart
SUBJECT SYMPTOM INDICATES TO CORRECT SYMPTOM

BOSS Temperature related 12 volt supply and 1. Check stored defects with the BOSS tool.
shutdown codes BOSS failure. *2. If defect list has EC1, HC1, EC2.1, HC2. EP3,
when no heating EP7, HP7, B2.2, low fuel, Fuel 7 and last
occurs. occurrence hr. readings are within a hundredth,
the BOSS is defective and must be replaced.
* NOTE: You may have some or all of the 3. Using a voltmeter, check the alternator output.
codes listed. You will have high
temps, high press, low voltage
and low fuel.
LCD Display Intermittent code of Sensor No Signal or 1. ES6 will occur if the loader is stalled or shutdown
ES6 while engine No RPM’s. during run cycle. The code is generated due to the
running. lack of RPM and the existence of residual
pressure in the system.
Display is dead – No Lack of 5.0 volts 1. Check pin A for 5.0 volts. If 5.0 volts is present
Icons, Bar Graphs, regulated power. replace the display.
Hourmeter. 2. If no power exists at pin A, install BOSS backup
to confirm the BOSS system.
LCD DISPLAY 3. If the problem still exists, check the harness for
continuity.
CONNECTOR
A B C D E
Orange
Purple/White
Black
Purple/Red
12 Volt – Back Light

Orange
Ground
Negative Com. .5 to 1.5 Volts
Positive Com. 3.5 to 4 Volts
5.0 Volts Regulated Power
Power Display Operation
During an active Low voltage (5.0) 1. Turn the ignition switch OFF. Re–starting will
WARNING display, triggered reset. return hourmeter reading.
reset occurs and the 2. If re–starting will not return hourmeter reading,
hourmeter becomes check pins B & C as stated in Step 5 below.
all zero’s.
Garbled message, The display is not fault 1. Turn the ignition switch OFF and re–start. A
missing segments, tolerant. Also can be fault is an invalid message that the display tries
etc. an indication of poor to display. Generally a fault occurs if
internal connections. communications of two messages are combined
on the display.
After glow sequence 1. Turn the key OFF and re–start.
or after a WARNING
goes away, the Icon
remains ON.
No Bar Graphs, no Bad display or BOSS 1. Plug in the BOSS tool and start the engine.
Hours. is not communicating. 2. If data is being received by the BOSS tool, the
BOSS unit is not the cause of the problem.
3. If no data is received at the BOSS tool.
disconnect the LCD display.
*4. If messages are now received at the tool, the
display is the problem. If problem still exists go to
* NOTE: The display has caused the Step 5.
problem by locking the 5. Check pins B & C for signal.
communication lines and 6. If there is no signal, install BOSS backup unit.
stopping communications from 7. If the problem still exists, check the harness for
the BOSS. continuity.
773 BICS Loader

OPERATION SENSING SYSTEM UNIT
A
Raise the loader operator cab. (See Page 1–1.) 1
1
Loosen the three nuts (Item 1) [A] from the sensing
system unit (Item 2) [A].
Slide the unit forward in the mounting slots and remove 2
it from the operator cab.
P–04043
Use a screw driver and remove the two connectors (Item

1) [B] from the sensing system unit (Item 2) [B]. B
Installation: Put the heads of the mounting bolts into the
slots of the operator cab and slide the unit back into place.
Tighten the three mounting nuts to 80–90 in.–lbs. (9–10 2
Nm) torque.
1
1
P–04042
773 BICS Loader

BOSS® INSTRUMENT PANEL
A
Pry the rubber light mount free from the operator cab
(both sides) [A].
P–03995
Lower the light from the operator cab to locate the three
instrument panel mounting bolts (Item 1) [B] (both sides). B
1
P–03955
Remove the three mounting bolts and pull the left panel
(Item 1) [C] down from the operator cab.
Installation: Be careful to not overtighten the panel
C
mounting bolts to prevent stripping the threaded holes of
the panels.
Disconnect the wire harness connectors from the panel
and remove the panel.
P–03958
Remove the three mounting bolts and pull the right panel
(Item 1) [D] down from the operator cab.
Installation: Be careful to not overtighten the panel D
mounting bolts to prevent stripping the threaded holes of
the panels.
Disconnect the wire harness connectors from the panel
and remove the panel.
P–03959
773 BICS Loader

ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
773ServiceManual#6900092–SystemsAnalysisSectionPart2of2
Controls Identification Chart
Attachment
Solenoid Harness Attachment
Switch Number Terminal Harness
Number Activated Activated Connector
Left Side Right Side
Control Handle RH Control Handle
Switches Switches
1 1 1 K
2 2 2 K
* 3 1 1 K
4 2 2,3 K, A, D
5 1 1,3 K, A, C
6 1 1,3 K, E
7 1 1,3 K, F
8 1 1,3 K, G Viewed from front

(pin side of connector)
9 1 1,3 K, H of loader.
10, 11, 12, – –– K
13, 14
RH – Loaders with Rear Hydraulics Option.

HFH – Loaders with High Flow Hydraulics Option.
* If harness terminals K & L are jumped together, switches 4 thru 9 provide flow on demand to female coupler.
(DETENT is not needed.)
* Terminal K is activated with Key switch ON.
Solenoid Hydraulic Wiring

Number Coupler Color
1 Front Dk. Green/

3 4 7 Female Red
1 7 2 Front Dk. Green/

3 Male Lt. Green
2
3 Diverter Yellow
(Rear Couplers)
4 Bleed – Rear Dk. Green/

Male & Female Yellow
TS–01494
NOTE: To relieve the hydraulic pressure trapped in the front auxiliary circuit, with the engine running, turn the
key switch quickly to the left (counterclockwise) past the OFF position. Hold key until the engine comes
to a complete stop.
773 BICS Loader

SPECIFICATIONS
Page
Number
DECIMAL AND MILLIMETER EQUIVALENTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
ENGINE SPECIFICATIONS
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
Crankshaft Re–Grind Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Fuel Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–6
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–7
Torque for General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
HYDRAULIC CONNECTION SPECIFICATIONS

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
O–Ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
O–Ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–13
Straight Thread O–Ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10
LOADER SPECIFICATIONS
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3 SPECIFICATIONS
Floor Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4
STANDARD TORQUE SPECIFICATIONS FOR BOLTS

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–16
TORQUE SPECIFICATIONS FOR LOADER

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–15
U.S. TO METRIC CONVERSION

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–17
773 BICS Loader

SKID STEER LOADER • Dimensions are given for loader equipped with standard tires and dirt bucket and
may vary with other bucket types. All dimensions are shown in inches. Respective
SPECIFICATIONS metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject
to change without notice.
93°
78.3 ‘‘C”
(1989)
46.8
(1189) 43°
148.7
28.9 (3777)
(734)
115.0
(2921)
87.5
76.3 (2223)
(1938)
62.1 26° 25°

(1577) 40.6
7.5 (1030)
‘‘B” (191) 8.6
101.7 (218)
‘‘A” (2583)
130.1
(3305) MC–1525
‘‘A” 10 – 16.5 TIRES – 66.0 in. (1676 mm) or 60.0 in. (1524 mm) ‘‘C” 60 in. BUCKET WIDTH – 61.0 in. (1549 mm)
31 – 15.5 x 15 TIRES – 66.0 in. (1676 mm) 66 in. BUCKET WIDTH – 68.1 in. (1731 mm)
‘‘B” 10 – 16.5 TIRES – 54.5 in. (1383 mm) or 48.5 in. (1231 mm)
31 – 15.5 x 15 TIRES – 50.0 in. (1270 mm)
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.
SPECIFICATIONS
PERFORMANCE
Rated Operating Capacity (SAE) . . . . . . 1700 lbs. (770 kg)
Tipping Load (SAE Rating) . . . . . . . . . . . 3800 lbs. (1720 kg)
Operating Weight . . . . . . . . . . . . . . . . . . . 5476 lbs. (2480 kg)
SAE Breakout Force – Lift . . . . . . . . . . . . 3040 lbs. (13522 kg)
– Tilt . . . . . . . . . . . . . 3200 lbs. (14234 kg)
Axle Torque . . . . . . . . . . . . . . . . . . . . . . . . 4700 ft.–lbs. (6373 Nm)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . 0–7.0 MPH (11,2 km/hr.)
CONTROLS
Vehicle Steering . . . . . . . . . . . . . . . . . . . . Direction and Speed controlled by two hand levers.
Loader Hydraulics
Lift and Tilt . . . . . . . . . . . . . . . . . . . . . . . . Controlled by separate foot pedals or optional hand controls.
Front Auxiliary (Optional) . . . . . . . . . . . . Controlled by electrical switch on RH steering lever.
Rear Auxiliary (Optional) . . . . . . . . . . . . Controlled by electrical switch on LH steering lever.
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand lever throttle: Key–Type starter switch and shutdown.
Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . . Glow Plug– Rocker Switch activated.
BOSS activated glow plugs (If so equipped).
Service Brake . . . . . . . . . . . . . . . . . . . . . Two independent hydrostatic systems controlled by two hand
operated steering levers.
Secondary Brake . . . . . . . . . . . . . . . . . . One of the hydrostatic transmissions
Parking Brake . . . . . . . . . . . . . . . . . . . . . . Mechanical Disc, foot operated pedal.
ENGINE
Make/Model . . . . . . . . . . . . . . . . . . . . . . . . Kubota/V2203EB
Fuel/Cooling . . . . . . . . . . . . . . . . . . . . . . . . Diesel/Liquid
Horsepower (SAE) . . . . . . . . . . . . . . . . . . Gross: 50 HP (37 kW) Net: 46 HP (34 kW)
Maximum Governed RPM . . . . . . . . . . . . 2800 RPM
High Idel RPM 2950–3050 RPM
Low Idle RPM 1125–1175 RPM
Torque @ 1600 RPM (SAE) . . . . . . . . . . Gross: 114 ft.–lbs. (154 Nm) Net: 102.5 ft.–lbs. (138 Nm)
Number of Cylinders . . . . . . . . . . . . . . . . . Four
Displacement . . . . . . . . . . . . . . . . . . . . . . . 134.0 cu. in. (2195 cm3)
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . 3.43/3.64 (87.0/92.4)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . Pressure System W/Filter
Crankcase Ventilation . . . . . . . . . . . . . . . . External
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Dry replaceable cartridge w/safety element
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel–Compression
773 BICS Loader
SPECIFICATIONS (Cont’d)
HYDRAULIC SYSTEM
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Driven, Gear Type
Pump Capacity . . . . . . . . . . . . . . . . . . . . . 15.0 GPM (56 L/min.) @ 2850 RPM
System Relief at Quick Couplers . . . . . . 3000 to 3050 PSI (20600 to 21029,7 kPa)
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full flow replaceable, 3 micron synthetic media element
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . Doubleacting;
Tilt cylinder has cushioning feature on dump & rollback
Bore Diameter:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . 2.25 (57,2)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . 3.50 (88,9)
Rod Diameter:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . 1.50 (38,1)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . 1.50 (38,1)
Stroke:
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . 26.00 (660,4)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . 14.50 (368,3)
Control Valve . . . . . . . . . . . . . . . . . . . . . . . 3–spool, open center type w/float detent on lift
and electrically controlled auxiliary spool.
Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . SAE standard tubes, hoses & fittings
Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . Bobcat Fluid (P/N 6563328); If fluid is not available, use
10W–30/10W–40 Class SE motor oil for temperature above 0°F (–18°C)
5W–30 Motor Oil for temperatures below 0°F (–18° C).
Hydraulic Function Time
Raise Lift Arms . . . . . . . . . . . . . . . . . . . . 3.49 Seconds
Lower Lift Arms . . . . . . . . . . . . . . . . . . . . 2.84 Seconds
Bucket Dump . . . . . . . . . . . . . . . . . . . . . . 1.93 Seconds
Bucket Rollback . . . . . . . . . . . . . . . . . . . 1.64 Seconds
ELECTRICAL
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . Belt driven, 55 amp, open
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, 625 cold cranking amps. @ 0°F. (–18°C);
160 minute reserve capacity at 25 amps.
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, Gear Reduction Type; 3.62 HP (2,7 kW)
Instrumentation . . . . . . . . . . . . . . . . . . . . . Gauges:Hourmeter, Fuel, Voltmeter, Engine Temperature.
Warning lights: Engine Temperature, Engine Oil Pressure, Hydraulic Oil
Temperature & Pressure, Hydraulic Filter.
Optional BOSS System Monitors; Engine Coolant Temperature,
Engine Oil Pressure, Engine Coolant Level, Hydraulic System
Temperature & Pressure, Hydraulic & Air Filters, RPM, Battery Condition,
Fuel Level & Machine Hours. Displays visual warnings & sounds
audible alarm. Also controls automatic shutdown function and
has diagnostic capability.
DRIVE SYSTEM
Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic 4 wheel drive
Transmission . . . . . . . . . . . . . . . . . . . . . . . Infinitely variable tandem hydrostatic piston pumps, driving 2 fully
reversing hydrostatic motors.
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . #80 HS endless roller chain & sprockets in sealed chaincase with
oil lubrication.
Total Engine to Wheel
Reduction . . . . . . . . . . . . . . . . . . . . . . . . . 33:1
Axle Size . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.00 (50,8)
Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . (8) 9/16”
CAPACITIES
Cooling System . . . . . . . . . . . . . . . . . . . . . 13 qts. (12,3 L)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 gals. (53,0 L)
Engine Oil W/Filter . . . . . . . . . . . . . . . . . . 7.5 qts. (7,1 L)
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . 24.0 qts. (23,0 L)
Hydraulic/Hydrostatic System . . . . . . . . . 8.5 gals. (32,2 L)
Chaincase Reservoir . . . . . . . . . . . . . . . . 9 gals. (34,1 L)
TIRES
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–16.5, 8 ply rating
Terra Grip . . . . . . . . . . . . . . . . . . . . . . . . . . 31 x 15.5–15, 8 ply rating
Recommended Pressure . . . . . . . . . . . Inflate tires to MAXIMUM pressure shown on the side wall of
the tire. DO NOT mix brands of tires used on the same loader.
FLOOR PRESSURE . . . . . . . . . . . . . . . . N/A
773 BICS Loader

ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
Fuel Injection Nozzles
Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990–2133 PSI (13721–14707 kPa)

Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Nozzle at 1849 PSI (12749 kPa)
Fuel Injection Pump
Fuel Tightness Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 sec: initial pressure 2133–1990 PSI (14707–13721 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 seconds
Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–19 degrees B.T.D.C.
High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2950–3050 RPM
Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1125–1175 RPM
Cylinder Bore
I.D. of Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4252–3.4261 (87,0–87,022)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.006 (+0,15)
Cylinder Head
Cylinder Head Surface Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) Max.

Thickness of Gasket (Used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0453–0.0492 (1,15–1,25)
(New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0512–0.0551 (1,3–1,4)
Top Clearance (Piston to Head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0217–0.0276 (0,55–0,70)
Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412–469 PSI (2840–3234 kPa)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 PSI (2255 kPa)
Difference Between Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10%
Valves
Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0835 (2,12)
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake 30 degrees exhaust 45 degrees
O.D. of Valve Stems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3134–0.3142 (7,96–7,98)
I.D. of Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3156–0.3161 (8,016–8,03)
Clearance Between Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016–0.0026 (0,04–0,07)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039 (0,1)
Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.007–0.0087 (0,18–0,22)
Valve Recessing (Protrusion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05)
(Recess) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 (0,15)
Valve Springs
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.64–1.66 (41,7–42,2)

Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.62 (41,2)
Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.378 (35,0)
Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.4 lbs. (117,6 N)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 lbs. (100,0 N)
Inclination Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Valve Timing
Intake Valve (Open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 degrees B.T.D.C.
(Close) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 degrees A.T.D.C.
Exhaust Valve (Open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 degrees B.T.D.C.
(Close) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 degrees A.T.D.C.
Rocker Arms
O.D. of Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5501–0.5506 (13,97–13,99)

I.D. of Rocker Arm Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5513–0.5529 (14,0–14,04)
Clearance Between Rocker Arm & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0007–0.0026 (0,02–0,06)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006(0,15)
773 BICS Loader
ENGINE SPECIFICATIONS (Cont’d)
Camshaft
Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5722–1.5728 (39.934–39,95)

Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5748–1.5758 (40,0–40,025)
Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002–0.0036 (0,05–0,091)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Alignment Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,08)
Cam Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.318 (33,47)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.316 (33,42)
End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0028–0.0087 (0,07–0,22)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,3)
Tappet
Clearance Between Tappet & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008–0.0024 (0,02–0,061)

Tappet O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9433–0.9441 (23,959–23,98)
Tappet Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9449–0.9457 (24,0–24,021)
Cylinders
Cylinder Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.425–3.426 (87,00–87,022)

Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.006 (+0,15)
Piston Rings
Ring Gap (Top & 2nd Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012–0.018 (0,3–0,45)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (1,25)
Ring Gap (Oil Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010–0.016 (0,25–0,4)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 (1,25)
Side Clearance of Ring Groove:
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zero Clearance
Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0037–0.0047 (0,094–0,12)
Oil RIng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008–0.002 (0,02–0,051)
Pistons
Piston Pin Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9843–0.9848 (25,0–25.014)

Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9862 (25,05)
Connecting Rod
Piston Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9843–0.9847 (25,0–25,011)

Small End Bushing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9852–0.9858 (25,025–25,04)
Clearance Between Piston Pin & Small End Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006–0.0015 (0,015–0,038)
Service Replacement Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006–0.003 (0,015–0,07 mm)
Connecting Rod Alignment Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05)
Oil Pump
Oil Pressure Rated RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43–64 PSI (294–441 kPa)

Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 PSI (248 kPa)
Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 PSI (98 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PSI (49 kPa)
Clearance Between Inner Rotor & Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039–0.0063 (0,1–0,16)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Outer Rotor & Pump Bocy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0043–0.0075 (0,11–0,19)
Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.001 (0,25)
End Clearance Between Inner Rotor & Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0041–0.0059 (0,103–0,15)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
773 BICS Loader

Crankshaft
Crankshaft Alignment Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0031 (0,08)

Oil Clearance Between Journal & Bearing #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016–0.0046 (0,04–0,117)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Journal O.D. #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0441–2.0449 (51,921[51,94)
Bearing I.D. #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0465–2.0488 (51,98–52,04)
Oil Clearance Between Journal & Bearing #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016–0.0041 (0,04–0,104)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Journal O.D. #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0441–2.0449 (51,92–51,94)
Bearing I.D. #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0465–2.0482 (51,98–52,02)
Oil Clearance Between Crank Pin & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0009–0.0034 (0,023–0,086)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2)
Crank Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8488–1.8492 (46,96–46,97)
Crank Pin Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8504–1.8522 (47,0–47,046)
Crankshaft Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059–0.0122 (0,15–0,31)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5)
Timing Gear
Timing Gear Backlash

Crank Gear – Idle Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016–0.0044 (0,041–0,112)
Idle Gear – Cam Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016–0.0045 (0,041–0,114)
Idle Gear – Injection Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016–0.0046 (0,041–0,117)
Idle Gear – Oil Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016–0.0043 (0,041–0,109)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,15)
Clearance Between Idle Gear Shaft & Idle Gear Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.001–0.0026 (0,025–0,066)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,10)
Idler Gear Side Clearance Idler Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008–0.020 (0,2–0,51)
Thermostat
Valve Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157–163°F (70–73°C)

Valve Fully Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185°F (85°C)
773 BICS Loader

A 1
Crankshaft Re–Grind Data
3 2
if the standard size bearing cannot be employed due to 2
excessive wear of the crankpin and crank journal use
undersize or oversize bearings.
For undersize or oversize bearing use, follow the
precautions noted below.
Grind the crankpin and journal with a wheel which has
specified round corner and width without shoulder [A].
2
1. 0.1299–0.1457’’ (3,3–3,7 mm) 5
2. 0.1102–0.1260’’ (2,8–3,2 mm) 4
PI–10026
3. Be sure to chamfer the oil hole circumference to

0.04–0.06’’ (1,0–1,5 mm) radius with and oil stone.
4. The crankpin must be fine finished to higher than

(0,4–5).
5. The crank journal must be fine–finished to higher

than (0,4–5).
6. The crank journal side surface must be

fine–finishedCODE
SIZE to higher
NO.than (1,6–5).
NAME OF BEARING BEARING MARK CRANKSHAFT PROCESSING DIM.
–0.008’’ Crankshaft Bearing 1
(0,2 mm) 17331–2391–1 0.008’’ minus (0,2 minus) 020 US
2.0363–2.037’’
–0.008’’ Crankshaft Bearing 2 (51,721–51,74 mm)
(0,2 mm) 17331–2393–1 0.008’’ minus (0,2 minus) 020 US
–0.016’’ Crankshaft Bearing 1 A
(0,4 mm) 17331–2392–1 0.016’’ minus (0,4 minus) 040 US
2.0284–2.0291’’
–0.016’’ Crankshaft Bearing 2 (51,521–51.54 mm)
(0,4 mm) 17331–2394–1 0.016’’ minus (0,4 minus) 040 US
–0.008’’ Crank Pin Bearing 1.8409–1.8415’’
(0,2 mm) 17331–2297–1 0.008’’ minus (0,2 minus) 020 US (46,759–46,775 mm)
B
–0.016’’ Crank Pin Bearing 1.8330–1.8337’’
(0,4 mm) 17331–2298–1 0.016’’ minus (0,4 minus) 040 US (46,559–46,575 mm)
Thrust Bearing 1 – 0.008’’ plus
+0.008’’ 15221–2395–1 (0,2 mm plus) 020 US
(+0,2 mm) 1.8330–1.8337’’
Thrust Bearing 2 – 0.008’’ plus (46,559–46,575 mm)
19202–2397–1 (0,2 mm plus)
C
+0.016’’ 15221–2396–1 (0,4 mm plus) 040 US 1.0315–1.0335’’
(+0,4 mm) (26,20–25,25 mm)
19202–2398–1 (0,4 mm plus)
773 BICS Loader

Torque For General Metric Bolts
Material
Thread Size
(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M 5 x 0.8 3–4 ft.–lbs.
(4–5 Nm)
M 6 x 1.0 6–7 ft.–lbs. 6–9 ft.–lbs.
(8–9 Nm) (8–12 Nm)
M 8 x 1.25 6–9 ft.–lbs. 11–16 ft.–lbs. 18–25 ft.–lbs.
(8–12 Nm) (15–22 Nm) (24–34 Nm)
(18–24 Nm) (30–41 Nm) (49–68 Nm)
(30–41 Nm) (54–73 Nm) (94–118 Nm)
(49–68 Nm) (79–108 Nm) (157–186 Nm)
773 BICS Loader

A

the system.
I–2003–0888
B–07575
O–ring Face Seal Connection

When the fitting is tightened, you can feel when the fitting B
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O–ring in position until the fittings are assembled [A]. Nut
Nut
Straight Thread O–ring Fitting
Washer Washer
Lubricate the O–ring before installing the fitting. Loosen
the jam nut and install the fitting. Tighten the jam nut until O–ring
the washer is tight against the surface [B]. O–ring
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will
restrict flow, which will slow hydraulic action and cause
heat. A–01852
Replace hoses which show signs of wear, damage or

weather cracked rubber. C
Always use two wrenches when loosening and tightening
hose or tubeline fittings. 1
Flare Fitting
Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat. Make 2
a mark across the flats of both the male and female parts
of the connection (Item 1) [C].
Use the chart below to find the correct tightness needed
(Item 2) [C]. If the fitting leaks after tightening, disconnect
it and inspect the seat area for damage. TS–01619
Flare Fitting Tightening Torque

Tubeline TORQUE NEW RE–ASSEMBLY
Outside Ft.–lbs. Rotate No. Rotate No.
Wrench Size Diameter Thread Size (Nm) of Hex Flats of Hex Flats
5/8’’ 5/16’’ 1/2’’ – 20 17 (23) 2–1/2 1
11/16’’ 3/8’’ 9/16’’ – 18 22 (30) 2 1
7/8’’ 1/2’’ 3/4’’ – 16 40 (54) 2 1
1’’ 5/8’’ 7/8’’ – 14 60 (81) 1–1/2 1
1–1/4’’ 3/4’’ 1–1/16’’ – 12 84 (114) 1 3/4
1–3/8’’ 1’’ 1–5/16’’ – 12 118 (160) 3/4 3/4
Revised May 98 773 BICS Loader

(Cont’d) A O–ring Flare
Primary
O–ring Flare Fitting Seal
The flare is the primary seal, the O–ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [A].
If necessary, the O–ring–flare fitting can be used without
an O–ring.
Use the following procedure to tighten the O–ring flare
fitting. Secondary
Seal
Tighten the nut until it contacts with the seat. Make a mark
P–13009
across the flats of both the male and female parts of the
connection (Item 1) [B].
Use the chart below to find the correct tightness needed
(Item 2) [B]. If the fitting leaks after tightening, disconnect
B Hex Flat Tightening Method
it and inspect the seat area for damage.

1
TS–01619
O–ring Flare Fitting Tightening Torque

* ** ***
Tubeline TORQUE NEW RE–ASSEMBLY
Outside Ft.–lbs. Rotate No. Rotate No.
Wrench Size Diameter Thread Size (Nm) of Hex Flats of Hex Flats
5/8’’ 5/16’’ 1/2’’ – 20 17 (23) 2–1/2 1
11/16’’ 3/8’’ 9/16’’ – 18 22 (30) 2 1
7/8’’ 1/2’’ 3/4’’ – 16 40 (54) 2 1
1’’ 5/8’’ 7/8’’ – 14 60 (81) 1–1/2 1
1–1/4’’ 3/4’’ 1–1/16’’ – 12 84 (114) 1 3/4
1–3/8’’ 1’’ 1–5/16’’ – 12 118 (160) 3/4 3/4
* If a torque wrench is used to tighten a new fitting to a ** If using the hex flat tightening method to tighten a new
used hose/tubeline. fitting to a new hose/tubeline.
* If a torque wrench is used to tighten a used fitting to a ** If using the hex flat tightening method to tighten a new
new hose/tubeline. fitting to a used hose/tubeline.
* If a torque wrench is used to tighten a new fitting to a *** If using the hex flat tightening method to tighten a used
new hose/tubeline. fitting to a new hose/tubeline.
773 BICS Loader

(Cont’d) A Copper Bonnet Orifice
O–ring Flare Fitting (Cont’d)
NOTE: O–ring flare fittings are not recommended in

all applications. Use the standard flare
fittings in these applications.
1
Do not use a O–ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from P–13572
sealing.
Use a standard flare fitting (Item 1) [A] as shown. B
When a O–ring flare fitting is used as a straight thread port
adapter the O–ring flare face is not used to seal. The 2
O–ring may come off the fitting and enter the system.
Always remove the O–ring (Item 1) [B] from the flare
face as shown.
An O–ring (Item 2) [B] is added to the flat boss of the
fitting to seal the connection in this application.
1
P–13573
773 BICS Loader

(Cont’d) A
Port Seal Fitting
The nut is the primary seal, the O–ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [A].
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Use the following procedure to tighten the port seal fitting:

Port seal and nut, washer and O–ring (O–ring Boss)
fittings use the same tightening torque valve chart.
Nut Seals
If a torque wrench cannot be used, use the following to Fitting
method.
Tighten the nut until it just makes metal to metal contact,
you can feel the resistance. Nut Seals
to Port
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
Secondary O–ring Seal

NOTE: If a torque wrench cannot be used, use the
hex flat tightening method as an approximate
guideline. P–13008
NOTE: Port seal fittings are not recommended in all

applications. Use O–ring boss fittings in
Port Seal and O–ring Boss
these applications. Tightening Torque
Fitting TORQUE
Nut Ft.–lbs.
Wrench Size Thread Size (Nm)
11/16’’ 9/16’’ – 18 22 (30)
15/16’’ 3/4’’ – 16 40 (54)
1–1/8’’ 7/8’’ – 14 60 (81)
1–1/4’’ 1–1/16’’ – 12 84 (114)
1–1/2’’ 1–5/16’’ – 12 118 (160)
Do not use port seal fittings when a thread in orifice (Item

1) [B] is used in the port. The orifice may interfere with the B
fitting and prevent it from sealing.
Use an O–ring boss fitting (Item 1) [B] as shown.
2
P–13571
773 BICS Loader

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
Use Bobcat hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not
available, use 10W–30 or 10W–40 SAE Motor Oil (5W–30 for 0°F [–18°C] and
Below).
DO NOT use automatic transmission fluids in the loader or permanent damage to the
transmission will result.
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.
W–2072–0496
When temperatures below zero degree F (–18°C) are common, the loader must be
kept in a warm building. Extra warm–up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will not flow easily and it makes
action of the hydraulic function slower. Loss of fluid flow to the hydrostatic
transmission pump (indicated by TRANS light ON) can cause transmission damage
in less than 60 seconds.
During cold weather 32°F (0°C) and

below, do not operate machine until
the engine has run for at least five (5)
minutes at less than half throttle.
This warm–up period is necessary
for foot pedal operation and safe
stopping. Do not operate controls
during warm–up period. When
temperatures are below –20°F
(30°C), the hydrostatic oil must be
heated or kept warm. The
hydrostatic system will not get
enough oil at low temperatures. Park
the machine in an area where the
temperature will be above 0°F
(–18°C), if possible.
W–2027–1285
773 BICS Loader

TORQUE SPECIFICATIONS FOR LOADER
Specifications
Item Ft.–Lbs. Nm
Air Cleaner Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Alternator Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 68
Axle Hub Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575–625 780–848
Axle Sprocket Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220–245 298–332
Bob–Tach Pivot Pin Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175–190 240–255

Bob–Tach Lever Pivot Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Brake Block Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65–70 88–95
Brake Lever Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65–70 88–95
Brake Pad Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65–70 88–95
Camshaft Retainer Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–20 23–27
Centering Spring Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Chaincase to Main Frame Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90–100 122–136
Connecting Rod Bolts:
W/O Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27–30 37–41
W/Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–36 45–49
Control Pedal Linkage Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21–25 28–34
Control Valve Mounting Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–16 20–22
Crankshaft Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101–116 137–157
Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67–72 91–98
Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–90 113–122
Front Panel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–20 22–27
Fuel Camshaft Retainer Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6 6,8–8,1
Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–18 20–24
Hydraulic Reservoir Strap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–20 22–27
Hydraulic Filter Housing Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 34
Hydrostatic Motor Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90–100 122–136
Hydrostatic Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65–70 88–95
Hydrostatic Pump Pulley Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175–200 237–271
Idler Gear Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–20 23–27
Injection Pump Mounting Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–20 23–27
Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36–51 46–69
Injector Nozzle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43–58 59–79
Main Bearing Case Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51–54 69–73
Main Bearing Case Half Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34–38 46–52
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–40 47–54
Motor Carrier Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125–140 170–190
Operator Cab Fastening Nuts (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50 54–68
Operator Cab Pivot Bolts & Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–35 34–47
Pedal Lock Linkage to Main Frame Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 9,5–10,8
Pedal Lock Linkage Tab Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 34
Pintle Arm Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50 54–68
Pintle Arm Lobe Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Pintle Bar Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 38
Pivot Pins Lock Bolt & Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–20 24–27
Rear Bearing Case Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–15 18–20
Seat Belt Fastening Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–45 54–61
Seat Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–11 12,2–15
Seat Bar Pivot Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–28 34–38
Steering Linkage Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 31
Steering Linkage Lock Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 31
Timing Gearcase Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–17 18–23
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105–115 142–156
773 BICS Loader

Added May 98 –9–15– Service Manual
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
The following table shows standard torque specifications for bolts with zinc
phosphate coating. Bolts purchased from Melroe that have zinc phosphate coating
are specified by the letter H following the part number.
THREAD
SIZE SAE GRADE 5 SAE GRADE 8
INCH. .250 80–90 110–120

LBS. (9,0–10,2) (12,4–13,6)
(Nm)
.3125 180–200 215–240
(20,3–22,6) 24,2–27,1)
.375 25–28 35–40
(34–38) (47–54)
.4375 40–45 60–65
(54–61) (81–88)
.500 65–70 90–100
(88–95) (122–136)
.5625 90–100 125–140
(122–136) (170–190)
.625 125–140 175–190
(170–190) (240–260)
FOOT .750 220–245 300–330
LBS. (300–330) (410–450)
(Nm)
.875 330–360 475–525
(450–490) (645–710)
1.000 475–525 725–800
(645–710) (985–1085)
1.125 650–720 1050–1175
(880–975) (1425–1600)
1.250 900–1000 1475–1625
(1200–1360) (2000–2200)
1.375 1200–1350 2000–2200
(1630–1830) (2720–2980)
1.500 1500–1650 2600–2850
(2040–2240) (3530–3870)
1.625 2000–2800 3450–3800
(2720–2980) (4680–5150)
1.750 2500–2750 4300–4800
(3390–3730) (5830–6500)
1.875 3150–3500 5500–6100
(4270–4750) (7450–8300)
2.000 3800–4200 6500–7200
(5150–5700) (8800–9800)
773 BICS Loader

DECIMAL AND MILLIMETER EQUIVALENTS
FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 0.015625 — 0.397 33/64 0.515625 — 13.097
1/32 0.03125 — 0.794 17/32 0.53125 — 13.494
3/64 0.046875 — 1.191 35/64 0.546875 — 13.891
1/16 0.0625 — 1.588 9/16 0.5625 — 14.288
5/64 0.078125 — 1.984 37/64 0.578125 — 14.684
3/32 0.09375 — 2.381 19/32 0.59375 — 15.081
7/64 0.109375 — 2.778 39/64 0.609375 — 15.478
1/8 0.1250 — 3.175 5/8 0.6250 — 15.875
9/64 0.140625 — 3.572 41/64 0.640625 — 16.272
5/32 0.15625 — 3.969 21/32 0.65625 — 16.669
11/64 0.171875 — 4.366 43/64 0.671875 — 17.066
3/16 0.1876 — 4.762 11/16 0.6875 — 17.462
13/64 0.203125 — 5.159 45/64 0.703125 — 17.859
7/32 0.21875 — 5.556 23/32 0.71875 — 18.256
15/64 0.234375 — 5.953 47/64 0.734375 — 18.653
1/4 0.2500 — 6.350 3/4 0.7500 — 19.050
17/64 0.265625 — 6.747 49/64 0.765625 — 19.447
9/32 0.28125 — 7.144 25/32 0.78125 — 19.844
19/64 0.296875 — 7.541 51/64 0.796875 — 20.241
5/16 0.3125 — 7.938 13/16 0.8125 — 20.638
21/64 0.328125 — 8.334 53/64 0.828125 — 21.034
11/32 0.34375 — 8.731 27/32 0.84375 — 21.431
23/64 0.359375 — 9.128 55/64 0.859375 — 21.828
3/8 0.3750 — 9.525 7/8 0.8750 — 22.225
25/64 0.390625 — 9.922 57/64 0.890625 — 22.622
13/32 0.40625 — 10.319 29/32 0.90625 — 23.019
27/64 0.421875 — 10.716 59/64 0.921875 — 23.416
7/16 0.4375 — 11.112 15/16 0.9375 — 23.812
29/64 0.453125 — 11.509 61/64 0.953125 — 24.209
15/32 0.46875 — 11.906 31/32 0.96875 — 24.606
31/64 0.484375 — 12.303 63/64 0.984375 — 25.003
1/2 0.5000 — 12.700 1 1.000 — 25.400
1 mm = 0.03937’’ 0.001’’ = 0.0254 mm
U.S. TO METRIC CONVERSION

TO CONVERT INTO MULTIPLY BY
LINEAR Miles Kilometers 1.609
MEASUREMENT Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Millimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0.7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
WEIGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Pounds/Sq. In. Kilopascal 6.895
WORK Foot–Pounds Newton–Metre 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPERATURE Fahrenheit Celsius 1.Subtract 32°
2. Multiply by 5/9
773 BICS Loader
ADVANCE HAND CONTROL SYSTEM (AHC)
Page
Number
ACTUATOR VOLTAGE TEST
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–8
AHC COMPONENTS
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–5
AHC/PWM CONTROLLER
Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–17
Decription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–16
Handle Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–18
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–15
Solenoid Coil Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–18
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–15
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–17

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–14
BICS™ VALVE
BICS™ Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–47
Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–46
Lift Arm By–Pass Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–45
Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–46
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)
Actuators Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10–30
Actuators Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–29
AHC Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10–26
AHC Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 10–27
AHC Steering Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–28
AHC Steering Lever Removal And Installation . . . . . . . . . . . . . . . . . . 10–28
Control Handle Unit Removal And Installation . . . . . . . . . . . . . . . . . . . 10–19
Control Unit Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–22
Switch Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 10–23
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC)
(W/PUSH BUTTON FLOAT
Actuators Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10–44
AHC/PWM Controller Removal And Installation . . . . . . . . . . . . . . . . . 10–33
AHC/PWM Controller Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–33
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–31
Control Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 10–41
Control Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 10–40
Control Lever Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–43 ADVANCED
Control Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 10–42 HAND CONTROL
Controller Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . 10–32 SYSTEM
Handle Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–36
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 10–34
Switch Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 10–37
HANDLE CONTROL UNIT TEST
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–11

773 BICS Loader
ADVANCE HAND CONTROL SYSTEM (AHC)
Page
Number
HYDRAULIC CONTROL VALVE
Anti–Cavitation/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–54
Anti–Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–55
Auxiliary Electrical Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–61
Auxiliary Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–60
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–52
H–Port Auxiliary Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–63
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–51
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–59
Lift and Tilt Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–57
Lift Base End Restrictor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–52
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–52
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–53
Port Relief Valve (Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–54
Port Relief Valve (Tilt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–55
Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–56
Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–62
SWITCH HANDLE
TROUBLESHOOTING (AHC)
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–6
WIRING SCHEMATICS –
WITH ADVANCED HAND CONTROL OPTIONS . . . . . . . . . . . . . . . . 10–3
773 BICS Loader

773 BICS Loader
AHC COMPONENTS
A
Identification
Steering Lever/Handle Control (Item1) [A]. 1
Handle Control Unit (Item 2) [A].
N–17774 N–17783
Control Valve Actuators (Item 1) [B]. B

1
N–17787
AHC/PWM Controller (Item 1) [C].

C
N–17777
BICS Controller (Item 1) [D].

D
P–10157
773 BICS Loader

TROUBLESHOOTING (AHC)
Chart
The Advance Hand Control System (AHC) has a built–in diagnostic function which uses the two lights on the left handle
to indicate the condition of the AHC System. The left light is lift and the right light is tilt.
The control module continually checks the system in the order listed. The checks start with the lift handle controller and
then the lift actuator. If no problems are present, it will then check the tilt handle controller and the tilt actuator. The system
will stop its check at the first problem and then flash the code. If the problem is in the tilt controller or actuator, the lift indicator
light will be ON and the tilt light flashing a code.
The system starts its diagnostics and calibration when the ignition key is turned ON. The left light will be ON for 0.5 second
and remain ON, then both lights will be ON for another 0.5 second. (This indicates the handles are wired properly and both
lights are working.)
LOADER WITH PRESS TO OPERATE BUTTON–At this time one of the following will happen:
1. Both lights will be OFF until the PRESS TO OPERATE BUTTON is engaged. (Normal Operation.)
2. The System goes into a flashing code. (See chart below for the problem.)
The following list shows the probable causes and troubleshooting procedures when the lights are flashing.
The system will continually flash the code signal with the key in the RUN position.
NUMBER PROBLEM CAUSE SOLUTION

OF FLASHES (Page 10–5 )
1 Handle not calibrated Handle controller not in neutral during start–up. 1

Mechanical handle controller malfunction. 4
Electrical handle controller problem. 6
2 Actuator not calibrated Control valve spool sticking or not centered during 5
shutdown.
Faulty actuator. 8
3 Handle Control Wiring Fault Disconnected connector or wire. 2
Broken wire. 3
Electrical handle controller problem. 6
4 Actuator Wiring Fault Disconnected connector or wire. 2
Broken wire. 3
Faulty actuator. 2,4,7
*5 Actuator Fault Faulty actuator. –
*Actuator fault (5 flashes) will only occur while the loader is in operation. The controller sensed the
actuator was out of sync with the hand controller unit. Normally this is caused from dust build up in the
actuator motor, which causes a poor connection at the motor brush. This fault will cause a loss of
power to the actuators. When the loader control unit is reset (The loader key is turned to the OFF
position then back to the ON position) you will not get an actuator fault (5 flashes), the system will reset
and say the system is OK or signal an alarm (2 or 4 flashes). When actuator faults (5 flashes) alarm
becomes more frequent replace the actuator.
773 BICS Loader

TROUBLESHOOTING (AHC) (Cont’d)
Chart (Cont’d)
SOLUTION
1. Turn the key OFF, put the hand controller in neutral position, turn the key ON. (The engine
does not have to be running for system recalibration or diagnostics).
2. Check wire connections for loose connector body, loose or bent pins in connectors.
3. Check for broken or damaged wire.
4. Check for stuck or sticky handle controller mechanism.
5. Turn the key OFF check to ensure spool moves freely, returns to neutral, turn the key ON.
6. Check the signal voltage from the handle controller unit. (See Page 10–10)
7. Check the signal voltage from the lift or tilt spool actuator. (See Page 10–8)
8. Check to insure the actuator moves freely on the actuator mounting bolt.
NOTE: If during operation one or both indicator light(s) goes out, this represents a reduced performance state.
This is caused by the actuator not being able to reach (full stroke) as commanded by the handle controller.
When the handle controller is returned to neutral and the actuator reaches neutral, the condition will clear
itself and the light will come back ON. Reduced speed in the lift or tilt circuits may be noticed. This will
not disable the loader, but may be an indication that an actuator is going bad.
When the wrong BICS™ controller, (Black face instead of Green face) is installed in an Advanced Hand
Control loader, and the key is turned to the ON position, the left light will come on for 0.5 seconds and
remain ON, then both lights will stay ON for an additional 0.5 seconds, then both lights will go out with
no flashing code, because there is no signal from the BICS to the control module. The BICS™ controller
lights will be ON, but the Advanced Hand Controller will not allow the loader hydraulics to function.
773 BICS Loader

Revised Nov. 01 –10–7– Service Manual
ACTUATOR VOLTAGE TEST
Procedure
A
With Test Harness;
The test harness (MEL1554) and a digital multimeter are
necessary to complete the following procedure.
Disconnect the actuator wire connector (Item 1) [A] for
the tilt or (Item 2) [A] for the lift circuit from the controls
harness. 2
NOTE: Each actuator has to be checked separately. 1
Install the test harness (Item 1) [B].
N–17781
Turn the key to the ON position with engine OFF.
With a digital multimeter, take a voltage reading at the four
prong terminal connector (Item 2) [B]. B 2
The sensor supply voltage between terminal 1 (ground)

and terminal 3 [C] should be 4.3 ± 0.1 volts (5.0 ± 0.1 volts 1
Hall–Effect).
The signal voltage reading between terminal 1 (ground)
and terminal 2 [C] should be from 1.55 to 1.85 volts (1.80
to 2.15 volts*).
NOTE: Terminal 4 [C] is an open terminal not used at
this time.
Without Test Harness;
A digital multimeter is necessary to complete this test. N–17782
The wiring harness connectors must remain connected to

complete this test. C
If the test harness (MEL1554) is not available the sensor
supply voltage test 4.3 ± 0.1 volts ( 5.0 ± 0.1 volts*) can
be taken between terminal 1 and terminal 3 on the tilt
control harness (Item 1) [D] and the lift control harness
(Item 2) [D].
The signal voltage reading 1.55 to 1.85 volts (1.80 to 2.15
volts*) can be taken between terminal 1 and terminal 2 on
the tilt control harness (Item 1) [D] and the lift control
harness (Item 2) [D]. 1
Wire Code For Tilt Control Harness: (Item 1) [D] 4 3 2
Terminal 1 .... Light Blue/Yellow

Terminal 2 .... LIght Blue/White P–13754
Terminal 3 .... Light Blue
Terminal 4 .... Open
Terminal 5 .... Pink/White
Terminal 6 .... Light Blue/Red D
Terminal 7 .... Black
Terminal 8 .... Pink/Yellow
Wire Code For Lift Control Harness: (Item 2) [A]
Terminal 1 . . . . Light Green/Yellow 1
Terminal 2 . . . . Light Green/White
Terminal 3 . . . . Light Green
Terminal 4 . . . . Open
Terminal 5 . . . . Brown/White
Terminal 6 . . . . Light Green/Orange
Terminal 7 . . . . Black
Terminal 8 . . . . Brown/Yellow
* Hall–Effect (Identified by yellow push button float
2
switch on left–hand handle. N–17781
773 BICS Loader

ACTUATOR VOLTAGE TEST (Cont’d)
Diagnosis Results For Tilt Actuator (top) Sensor Supply Voltage Test;
If the sensor supply voltage is 4.3 ± 0.1 volts (5.0 ± 0.1 volts Hall–Effect), continue on and check the signal voltage.
If the sensor supply voltage is less than 4.3 ± 0.1 volts (5.0 ± 0.1 volts*) or 0 volts, check the PWM fuse, check for shorts
or opens in the wiring harness. If there are no apparent shorts or opens change the AHC/PWM controller. (See Page
10–13.)
If the sensor supply voltage is more than 4.3 ±0.1 volts (5.0 ± 0.1 volts*) check for a short of the power wires in the wiring
harness. If there are no apparent shorts change the AHC/PWM controller. (See Page 10–15.)
Diagnosis Results For Tilt Actuator Signal Voltage Test;
If the signal voltage is in the range of 1.55 to 1.85 volts (1.80 ± 2.15 volts*), the system is functioning properly. The nominal
voltage reading is 1.72 volts (2.0 volts*).
If the signal voltage is not in the range of 1.55 to 1.85 volts (1.80 ± 2.15 volts*) check the hydraulic control valve spools
for a centering problem or replace the actuators. (See Page 10–29.)
Handle Out (Toward Side Screen):
1. Stop engine. Raise operator cab.
2. Connect the remote start switch (MEL1429A) to the loader.
3. Turn key to ON position with engine OFF to get a code indication from the indicator lights on the left control handle.
4. Check the sensor supply voltage. (See Page 10–8.)
5. Check the system to make sure it is functional, with no blinking indicator lights.
6. Move right AHC handle toward the side screen to full stroke. Hold in position and and take a voltage reading.
The voltage reading must be 0.13 volts (0.15 volts*) or greater.
If the voltage reading is less than 0.13 volts (0.15 volts*, replace the actuator. (See Page 10–29.)
While holding the handle toward the side screen turn the key to OFF position and wait five seconds..
7. Continue to hold the handle toward the side screen and turn the key to the ON position. Take a voltage reading.
(You will have a one blink alarm on the right indicator light.)
The voltage reading should be between 1.55 to 1.85 volts (1.80 to 2.15 volts*).
If the voltage is above 1.85 volts (2.15 volts*), repeat steps 5 thru 7, if the voltage is still above 1.85 volts (2.15
volts*) change the actuator.
If the voltage is below 1.55 volts (1.80 volts*) complete the following tests: (See Step 11 Below; Tests a & b.)
Handle In (Toward Center Of Cab):
8. Turn the key to OFF position and wait five seconds, then turn key to ON position. Check the system to make sure
it is functional, with no blinking indicator lights.
9. Move right AHC handle toward the center of the cab to full stroke. Hold in position and take a voltage reading.
The voltage reading must be 3.2 volts (3.72 volts *) or less.
If the voltage reading is more than 3.2 volts (3.72 volts *), check for shorts in the electrical connections, or replace
the actuator. (See Page 10–29.)
10. While the handle is held toward the center of the cab, turn the key to OFF position and wait five seconds.
11. Continue to hold the handle toward the center of the cab and turn the key to the ON position. Take a voltage reading.
(You will have a one blink alarm on the right indicator light.)
If the voltage is below 1.55 volts (1.80 volts*), repeat steps 8 thru 11 if the voltage is still below 1.55 volts (1.80
If the voltage is above 1.85 volts (2.15 volts*) complete the following tests:
a. Remove the pin from the actuator to the control spool. Watch the spool, if the spool continues to move toward
neutral after the pin is removed, replace the actuator. Also check the mounting hardware on the actuators and
control valve for wear and correct torque.
b. If the spool does not move, check the control valve for a sticky spool or sticky centering mechanism. Also check
the mounting hardware on the actuators and control valve for wear and correct torque.
* Hall–Effect (Identified by yellow push button float switch on left–hand handle.

773 BICS Loader
ACTUATOR VOLTAGE TEST (Cont’d)
Diagnosis Results For Lift Actuator (bottom) Sensor Supply Voltage Test;
If the sensor supply voltage is 4.3 ± 0.1 volts (5.0 ± 0.1 volts Hall–Effect), continue on and check the signal voltage.
If the sensor supply voltage is less than 4.3 ± 0.1 volts (5.0 ± 0.1 volts*) or 0 volts, check the PWM fuse, check for shorts
or opens in the wiring harness. If there are no apparent shorts or opens change the AHC/PWM controller. (See Page
10–13.)
If the sensor supply voltage is more than 4.3 ± 0.1 volts (5.0 ± 0.1 volts*) check for a short of the power wires in the wiring
harness. If there are no apparent shorts change the AHC/PWM controller. (See Page 10–15.)
Diagnosis Results For Lift Actuator Signal Voltage Test;
If the signal voltage is in the range of 1.55 to 1.85 volts (1.80 to 2.15 volts*), the system is functioning properly. The nominal
voltage reading is 1.72 volts (2.0 volts*).
If the signal voltage is not in the range of 1.55 to 1.85 volts (1.80 to 2.15 volts*) check the hydraulic control valve spools
for a centering problem or replace the actuators. (See Page 10–29.)
Handle Out (Toward Side Screen):
1. Stop engine. Raise operator cab.
2. Connect the remote start switch (MEL1429A) to the loader.
3. Turn key to ON position with engine OFF to get a code indication from the indicator lights on the left control handle.
(See Page 10–6.)
4. Check the sensor supply voltage. (See Page 10–8.)
5. Check the system to make sure it is functional, with no blinking indicator lights.
6. Move left AHC handle toward the side screen to full stroke. Hold in position and take a voltage reading.
The voltage reading must be 0.13 volts (0.15 volts*) or greater.
If the voltage reading is less than 0.13 volts (0.15 volts*), replace the actuator. (See Page 10–29.)
7. While holding the handle toward the side screen turn the key to OFF position.
8. Wait five seconds, then put the handle to the float position. Turn the key to ON position and take a voltage reading.
(You will have a one blink alarm on the left indicator light.)
If the voltage is above 1.85 volts (2.15 volts*), repeat steps 5 thru 8, if still above 1.85 volts (2.15 volts*), change
the actuator.
If the voltage is below 1.55 volts (1.80 volts*) complete the following tests: (See Step 12 Below; Tests a & b.)
Handle In (Toward Center Of Cab):
9. Turn the key to OFF position and wait five seconds, then turn key to ON position. Check the system to make sure
it is functional, with no blinking indicator lights.
10. Move left AHC handle toward the center of the cab to full stroke, in float position. Take a voltage reading.
The voltage reading must be 4.17 volts (3.72 volts*) or less.
If the voltage reading is more than 4.17 volts (3.72 volts*), check for shorts in the electrical connections, or replace
the actuator. (See Page 10–29.)
11. While the handle is in float position, turn the key to OFF position. Wait for five seconds.
12. Continue to keep the handle in the float position. Turn the key to ON position. Take a voltage reading.
(You will have a one blink alarm on the left indicator light.)
If the voltage is below 1.55 volts (1.80 volts*), repeat steps 9 thru 12, if the voltage is still below 1.55 volts (1.80
If the voltage is above 1.85 volts (2.15 volts*) complete the following tests:
a. Remove the pin from the actuator to the control spool. Watch the spool, if the spool continues to move toward
neutral after the pin is removed, replace the actuator. Also check the mounting hardware on the actuators and
control valve for wear and correct torque.
b. If the spool does not move, check the control valve for a sticky spool or sticky centering mechanism. Also check
the mounting hardware on the actuators and control valve for wear and correct torque.
* Hall–Effect (Identified by yellow push button float switch on left–hand handle.

773 BICS Loader
HANDLE CONTROL UNIT TEST
Procedure
A
Right Handle Test With Test Harness;
Disconnect the handle control harness (Item 1) [A].
Install the test harness (Item 1) [B]. 1
Move handle to the neutral position.
N–17536
Turn the key to the ON position with the engine OFF.
With a digital multimeter take a voltage reading at the four
prong terminal connector (Item 2) [B]. B 2
The sensor supply voltage between ground, terminal 1
and terminal 3 [C] should be 4.3 ± 0.1 volts (5.0 ± 0.1
volts Hall–Effect). 1
The signal voltage reading between the ground, terminal
1 and terminal 2 [C] should be 1.7 to 2.1 volts (1.97 ± 2.44
volts*).
NOTE: Terminal 4 [C] is an open terminal not used at
this time.
Right Handle Test Without Test Harness;
A digital multimeter is necessary to complete this test.
P–17780
For the switch handle harness connector color code. (See
Page 10–24.)
The test must be run at the eight pin switch handle C
connector (Item 1) [A]. The wiring harness connectors
must remain connected to complete this test.
Check the sensor supply voltage (4.3 ± 0.1 volts) (5.0 ±
0.1 volts*) between terminal G (Pink/Black) and terminal
F (Pink/Red).
Check the signal voltage between terminal G (Pink/Black)
and terminal H (Pink/Green). The voltage should be
between 1.7 to 2.1 volts (1.97 to 2.44 volts*).
1
Diagnosis Results for both Tests; 4 3 2
If the sensor supply voltage is 4.3 ± 0.1 volts (5.0 ± 0.1
volts*), continue on and check the signal voltage. P–13754
If the sensor supply voltage is less than 4.3 ± 0.1 volts

(5.0 ± 0.1 volts*) or 0 volts, check the PWM fuse, check
for shorts or opens in the wiring harness. If there are no
apparent shorts or opens change the AHC/PWM
controller. (See Page 10–15.)
If the sensor supply voltage is more than 4.3 ± 0.1 volts
(5.0 ± 0.1 volts*) check for a short to a power wire in the
wiring harness. If there are no apparent shorts, change
the AHC/PWM controller. (See Page 10–15.)
If the signal voltage is in the range of 1.7 to 2.1 volts (1.97
to 2.44 volts*) the system is functioning properly. The
nominal voltage reading is 1.89 volts (2.2 volts*). If the
signal voltage is not in the range of 1.7 to 2.1 volts (1.97
to 2.44 volts*) change the handle controller.
switch on left–hand handle.
773 BICS Loader
HANDLE CONTROL UNIT TEST (Cont’d)
A
Left Handle Test With Test Harness;
Disconnect the handle control harness (Item 1) [A].
Install the test harness (Item 1) [B]. 1
Move handle to the neutral position. N–17770
Turn the key to the ON position with the engine OFF.
With a digital multimeter take a voltage reading at the four
prong terminal connector (Item 2) [B]. B
The sensor supply voltage between ground, terminal 1 2
and terminal 3 [C] should be 4.3 ± 0.1 volts (5.0 ± 0.1
volts Hall–Effect).
The signal voltage reading between the ground, terminal
1 and terminal 2 [C] should be 1.7 to 2.1 volts (1.97 to 2.44
volts*).
NOTE: Terminal 4 [C] is an open terminal not used at 1
this time.
Left Handle Test Without Test Harness;
A digital multimeter is necessary to complete this test.
P–17771
For the switch handle harness connector color code. (See
Page 10–24.)
The test must be run at the eight pin switch handle
connector (Item 1) [A]. The wiring harness connectors
C
must remain connected to complete this test.
Check the sensor supply voltage (4.3 ± 0.1 volts) (5.0 ±
0.1 volts*) between terminal G (Brown/Black) and
terminal F (Brown/Red).
Check the signal voltage between terminal G
(Brown/Black) and terminal H (Brown/Green). The
voltage should be between 1.7 to 2.1 volts (1.97 to 2.44
volts*). 1
Diagnosis Results for both Tests; 4 3 2
If the sensor supply voltage is 4.3 ± 0.1 volts (5.0 ± 0.1

volts*), continue on and check the signal voltage. P–13754
If the sensor supply voltage is less than 4.3 ± 0.1 volts

(5.0 ± 0.1 volts*) or 0 volts, check the PWM fuse, check
for shorts or opens in the wiring harness. If there are no
apparent shorts or opens change the AHC/PWM
controller. (See Page 10–15.)
If the sensor supply voltage is more than 4.3 ± 0.1 volts
(5.0 ± 0.1 volts*) check for a short to a power wire in the
wiring harness. If there are no apparent shorts, change
the AHC/PWM controller. (See Page 10–15.)
If the signal voltage is in the range of 1.7 to 2.1 volts (1.97
to 2.44 volts*) the system is functioning properly. The
nominal voltage reading is 1.89 volts (2.2 volts*). If the
signal voltage is not in the range of 1.7 to 2.1 volts (1.97
to 2.44 volts*) change the handle controller.
switch on left–hand handle.
773 BICS Loader
HANDLE CONTROL UNIT TEST (Cont’d)
Right Handle (Tilt) Full Stroke Voltage Test

1. Turn the key to the ON position with engine OFF.
2. Check the Sensor Supply Voltage. (See Page 10–8.)
3. Move right AHC handle out or toward the side screen, hold and take a voltage reading. The voltage should be 0.13
volts (0.15 volts Hall–Effect) or greater. If the voltage is less than 0.13 volts (0.15 volts*) change the handle controller.
4. Allow the handle to go to neutral. Take a voltage reading. The voltage should be 1.7 to 2.1 volts (1.97 to 2.44 volts*).
If the voltage reading is either higher or lower, check for loose mounting hardware, or a bad handle controller.
5. Move the right AHC handle in toward the center of the cab to full stroke. Hold in position and take a voltage reading.
The voltage reading should be 4.17 volts(3.72 volts*) or less. If the voltage reading is higher, change the handle
controller unit. (See Page 10–19.)
6. Release the handle and allow it to go to neutral. Take a voltage reading. The voltage should be 1.7 to 2.1 volts (1.97
to 2.44 volts*). If the voltage is either higher or lower, check for loose mounting hardware, or a bad handle controller.
Left Handle (Lift) Full Stroke Voltage Test
1. Turn the key to the ON position with engine OFF.

2. Check the Sensor Supply Voltage. (See Page 10–8.)
3. Move left AHC handle out or toward the side screen, hold and take a voltage reading. The voltage should be 0.13
volts (0.15 volts*) or greater. If the voltage is less than 0.13 volts (0.15 volts*) change the handle controller.
4. Allow the handle to go to neutral. Take a voltage reading. The voltage should be 1.7 to 2.1 volts (1.97 to 2.44 volts*).
If the voltage reading is either higher or lower, check for loose mounting hardware, or a bad handle controller.
5. Move the left AHC handle in toward the center of the cab to float and take a voltage reading. The voltage reading
should be 3.2 volts (3.72 volts*) or less. If the voltage reading is higher, change the handle controller unit. (See Page
10–19.)
6. Release the control handle and allow it to go to neutral from the float position. Take a voltage reading. The voltage
should be 1.7 to 2.1 volts (1.97 to 2.44 volts*). If the voltage is either higher or lower, check for loose mounting
hardware, or a bad handle controller.
773 BICS Loader

8.
of Loader
System PRESS TO OPERATE PRESS TO OPERATE Lift, tilt and traction 2 System Activated circuit shorted to
Activated button is activated button not activated functions will not battery voltage.*
operate. 3 System Activated circuit shorted to
ground.
Seat Bar Seat Bar Down. Seat Bar Up. Lift, tilt and traction 2 Seat bar sensor circuit shorted to
ground.
Valve Control Valve Control Valve Lift and tilt functions 2 Valve output circuit shorted to battery
Can Be Used. Cannot Be Used. will not operate. voltage*.
moved forward moved forward and moved forward and 2 Traction lock hold coil circuit shorted
& backward. backward. backward. to battery voltage*.
to ground.
to ground.
is operating not operating functions will not N/A N/A
to system voltage.
NOTES:
(1) If the System Activated and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If
one of the lights stay OFF, check the circuit for continuity.
ADVANCED HAND CONTROLS (AHC)

7.
The AHC has a built–in diagnostic function which uses the two lights on the left handle.
Both lights will be ON when the AHC is functioning correctly. The lights will flash in a specific pattern to indicate a problem
(See Below). (See your Bobcat dealer for service information.)
FLASHING LIGHT MEANS SYSTEM PROBLEM

(See Your Bobcat Dealer for Service)
Number of Flashes 1 2 3 4 5
Left Hand Light
(Lift Circuit) Handle Not Actuator Not Wiring Fault Wiring Fault Actuator
Right Hand Light Calibrated Calibrated (Handle) (Actuator) Fault
(Tilt Circuit)
NOTE: Flashing patterns will repeat every six seconds. One blink will occur if Right or Left Hand Control is not
in neutral position before key is turned ON or engine is started and green PRESS TO OPERATE button
is activated.
773 BICS Loader

AHC/PWM CONTROLLER
A
1
Remove the four mounting bolts (Item 1) [A] from the
controller. 1
Disconnect the wiring harness connectors (Item 2) [A]

from the controller.
Remove the controller from the loader.
Test
2
• The wiring harness connectors must be connected to N–17777
the controller [A].
• Take voltage measurements by probing into wires near

B
the controller shown in figure [A]. All connectors must
remain plugged into their respectful harness.
• Turn the key to the ON position (Item 1) [B] with the 5

engine OFF.
2
• Turn the switches ON to get their appropriate readings. 3
(See chart listed below for switch locations.)
• Press the auxiliary hydraulic switch (Item 2) [B] twice. 1

4
Both Green lights will be ON.
• For individual voltage readings see Page 10–16. N–17919 P–10466
Key Switch
Auxiliary Hydraulic Switch
Item 1 [B]
Item 2 [B] C
Momentary Light Item 3 [B]
Detent Light Item 4 [B]
High Flow Switch Item 5 [B]
Proportional Flow Switch Item 1 [C]
Detent Switch Item 2 [C] 1
Rear Aux. Switch (Base & Rod) Item 3 [C] 3
Right
Left Steering
Steering Lever
Lever 2 Control
Control
P–13255 P–13254
773 BICS Loader

A
*Schematic Connector Number MC–02420

AHC/PWM CONTROLLER (Cont’d)
Description
Connector No. Pin No. Description Voltage Comments
C 430* A Battery Power 12.0
B Ground 0
C 428* 1 Power 12.0
2 Model Input 12. 0
3 Model Select–Input A Not Used
4 Model Select–Input B Not Used
5 Model Select–Input C Not Used
6 Open 0
C 429* A Diagnostic Light 4.0–11.0 Light ON–Light OFF
B Diagnostic Light 4.0–11.0 Light ON–Light OFF
C 431* 1 Attachment Control Signal 0 or 12.0
2 Signal from Lift Control Input Handle 0.80–1.89–2.90 Low–Neutral–High
Signal from Lift Control Input Handle (Float) 3.8
3 Return from Aux. Module Switch Input 9.5
4 Signal from Tilt Control Input Handle 0.80–1.89–2.90 Low–Neutral–High
5 Power to Tilt Spool Actuator Not Used
6 Signal from Lift Actuator Feedback Input 0.40–1.72–3.0 Low–Neutral–High
Signal from Lift Actuator Feedback Input (Float) 3.8
7 Return from Aux. Detent Switch Input 12.0
8 Power to Lift Spool Actuator Not Used
9 Signal from Tilt Actuator Feedback Input 0.40–1.72–3.0 Low–Neutral–High
10 Return from Aux. Rear Base Switch Input 11.0
11 BICS Status Input 0 or 12.0 Bar UP–Bar DOWN
12 Return from Aux. Rear Rod Switch Input 12.0
13 High Flow Solenoid Output 0 or 12.0
14 Diagnostic Input No function
15 Low Reference to Resistive Inputs Ground
16 Signal from Aux. Resistive Inputs 0.98–2.24–3.24 Low–Neutral–High
17 Lift Actuator Reverse Motor Output 0 to 12.0
18 Diverter Solenoid Output 12.0
19 BICS Aux. Lock Input 0 or 11.0 Bar UP–Bar DOWN
20 Auxiliary Relief Input 12.0 Key Left
21 Aux. Switch Module Detent Light 3.5 between 8.5 Light ON–Light OFF
22 Aux. Switch Module Momentary Light 3.5–8.5 Light ON–Light OFF
23 Lift Actuator Forward Motor Output 0 to 12.0
24 Aux. Spool Base End Output 0–6.0 Key Left (12 Volt)
25 High Reference to Resistive Inputs 4.3 ± 0.1
26 Power to Aux. Switch Module 9.99–10.68
27 AHC Status Output 0 or 12.0 Bar UP–Bar DOWN
28 Switch Power 12.0 Key On
29 Tilt Actuator Reverse Motor Output 0 to 12.0
30 Aux. Spool Rod End Output 0–6.0
31 Tilt Actuator Forward Motor Output 0 to 12.0
773 BICS Loader
Conditions A
• Auxiliary Hydraulic Switch lights will not come ON.
Check the following:
PWM fuse
Wires disconnected, shorted, or open.
Auxiliary hydraulic switch failure.
Module failure.
1
Use the voltage tests in the wire identification
section to determine the cause. (See Page
10–16.) 2
P–03272
The controller sends a diagnostic code to the Auxiliary
Hydraulic Switch lights when the conditions listed in the
chart below occur.
• When the lights are flashing, the key needs to be

turned OFF and then ON. If the problem still exists they
will continue to flash.
• Proportional flow cannot be engaged if the lights are
blinking.
• Continuous flow (detent) can be engaged if alternate
blinking lights are OFF after the key switch is turned
OFF and then ON (during a proportional flow switch
failure).
Momentary LED Detent LED

(Item 1) [A] (Item 2) [A] PROBLEM AREA PROBLEM CAUSE
Light Blinking Light OFF Base End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Open
• Solenoid failed. Perform solenoid
coil test.
• PWM module failed.
Light Off Light Blinking Rod End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Open
coil test.
Light Blinking Light Blinking Diverter Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Open
coil test.
*Blinking/OFF *OFF/Blinking Proportional Flow Switch • Wires Disconnected
(Right Handle) • Wires Shorted
• Wires Open
• Proportional flow switch failed.
Check voltage to switch.
Perform handle test.
*Alternate Blinking Lights
773 BICS Loader

Handle Testing
A
The right side steering lever handle switch (Item 1) [A]
controls the proportional flow to front auxiliary. Use a Ohm
meter to test the switch.
1
Disconnect the handle switch harness from the controls
harness (Item 1) [B]. Use the chart below to test the
handle switch.
Handle Switch Position

Test between
handle wires Full Left Center Full Right P–02129
Dk. Blue & 4.5–5.5 4.5–5.5 4.5–5.5
Dk. Blue/White K–Ohms K–Ohms K–Ohms
Dk. Blue/Yellow 0.5–1.5 2.3–2.7 3.5–4.5
B
& Dk. Blue/White K–Ohms K–Ohms K–Ohms 1
Dk. Blue/Yellow 3.5–4.5 2.3–2.7 0.5–1.5
& Dk. Blue K–Ohms K–Ohms K–Ohms
One K–Ohm is equal to 1000 Ohms.
NOTE: Push the switch gradually from center to

either left or right. The Ohm reading must
change gradually. Replace the handle switch
assembly if required.
N–17779
Solenoid Coil Testing
The front auxiliary solenoid coils (Item 1) [C] are located C
in the hydraulic control valve. Test the solenoid coils with
a Ohm test meter.
Disconnect the coil from the controls harness. The correct
reading is 1–5 Ohms.
1
N–17493
773 BICS Loader

CONTROL HANDLE (ADVANCED HAND CONTROL)
(AHC) A
Control Handle Unit Removal And Installation
To remove the handle control unit, slide the rubber handle
cover (Item 1) [A] up the handle.
control cover.
Remove the control cover.
1
N–17774
Disconnect the loader control harness (Item 1) [B] from

the handle control harness.
B
N–17783
773 BICS Loader

(AHC) (Cont’d) A
(Cont’d)
Using a small screwdrive remove the handle control
electrical connector from the clip [A].
P–13737
Using an allen wrench, remove the two mounting screws

(Item 1) [B] from the control unit.
B
NOTE: A small screwdriver (Item 2) [B] in the control
unit may be needed to hold the center spacer
from turning.
Installation: Tighten the control unit mounting screws to
85 in.–lbs. (9,6 Nm) torque.
1
1
N–17785
773 BICS Loader

(AHC) (Cont’d) A
(Cont’d)
Remove the mounting bolt and nut (Item 1) [A] from the
control handle and shaft.
Installation: Tighten the mounting bolt to 35 in.–lbs. (3,9
Nm) torque.
Remove the control unit (Item 2) [A] from the control
handle.
2
N–17380
NOTE: The control unit (Item 1) [B] can only be

replaced as a complete assembly.
Check the spacer (Item 2) [B] and screws (Item 3) [B] and
B 2
3
replace as needed.
N–17392
Installation: When installing the control unit into the

steering handle, check the routing of the switch handle
wire harness (Item 1) [C] to assure proper return of the
C
control handle to neutral.
N–17470
773 BICS Loader

(AHC) (Cont’d) A
Control Unit Connector
The wire connector (Item 1) [A] can be removed from the
handle control unit wires, use the following procedure.
1
N–17392
Remove the wedge (Item 1) [B] from the connector. B
1
1
P–13725 P–13732
With a pointed tool, lift the tab (Item 1) [C] and pull the wire
from the connector. C
Assembly: Install the wires into the connector as listed
below [C]:
1
1–Terminal – Red
2 3
2–Terminal – Black
1
3–Terminal – Green
P–17333
773 BICS Loader

(AHC) (Cont’d) A
Switch Handle Removal And Installation
Remove the handle control unit from the steering lever.
(See Page 10–19.)
To remove the switch handle the connector (Item 1) [A]

must be removed from the wires, use the following
procedure:
N–17786
1
P–13725 P–13732
Using a pointed tool, press down on the tab (Item 1) [C]

and pull the wire from the connector. C
Installation: Install the wires into the connector as listed
below [C]:
Right Steering Lever Switch Handle
1–Terminal – Pink/Red
2–Terminal – Pink/Black 1
3–Terminal – Pink/Green 3
2
Left Steering Lever Switch Handle
1–Terminal – Brown/Red 1
2–Terminal – Brown/Black
3–Terminal – Brown/Green
P–17335
773 BICS Loader

(AHC) (Cont’d) A
1
Switch Handle Removal And Installation (Cont’d)
Disconnect the right switch handle connectors (Items 1 &
2) [A] from the loader wiring harness connectors.
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [B] from loader wiring harness connectors.
Remove the connector locks and connectors from the
wires to remove the switch handle from the steering
handle. 2
Installation:The wire colors of the steering lever harness
are as follows: N–17779
Right Switch Handle

B
Eight–Pin Connecter 1 2
A–Terminal – Dark. Orange/White 3
B–Terminal – Green 4
C–Terminal – Dark Blue
D–Terminal – Dark Blue/White
E–Terminal – Dark Blue/Yellow
F–Terminal – Pink/Red
G–Terminal – Pink/Black
H–Terminal – Pink/Gray
Six–Pin Connector
A–Terminal – Orange
B–Terminal – Light Green/White N–17772
C–Terminal – Light Green
D–Terminal – Yellow
E–Terminal – Blank
F–Terminal – Blank
Left Switch Handle
Eight–Pin Connector
A–Terminal – Yellow
B–Terminal – Green
C–Terminal – Brown
D–Terminal – Orange
E–Terminal – Orange/Blue
F–Terminal – Brown/Red
G–Terminal – Brown/Black
H–Terminal – Brown/Green
Three–Pin Connector
A–Terminal – Orange/White
B–Terminal – Yellow/Red
C–Terminal – Yellow/Green
Two–Pin Connector
A–Terminal – Purple
B–Terminal – Purple/Blue
Two–Pin Connector (Water Kit)
A–Terminal – White
B–Terminal – Blue
773 BICS Loader

CONTROL HANDLE (ADVANCED HAND CONTROL
(AHC) (Cont’d) A
Roll the pistol grip handle cover (Item 1) [A] down.
Using a small screwdriver, lift the handle tabs (Item 2) [A] 2 2
and slightly rotate the switch handle.
N–17382
Pull the switch handle and wiring harness assembly (Item

1) [B] from the steering lever.
B
N–17383
Installation: When installing the switch handle and

wiring harness assembly into the steering handle, route C
the harness (Item 1) [C] to assure proper return of the
control handle to neutral position and minimize harness
movement.
N–17471
773 BICS Loader

(AHC) (Cont’d) A
AHC Handle Removal And Installation
1
Remove the handle control unit. (See Page 10–19.)
Remove the switch handle. (See Page 10–23.)
Remove the rubber handle cover (Item 1) [A] from the
handle.
N–17384
Using a small screwdriver, hold the handle spacer (Item

1) [B] and remove the allen head screws (Item 2) [B] from
B
the handle assembly.
1
Installation: Tighten the allen head screws to 35 in.–lbs.
(4 Nm) torque.
2 2
N–17385
773 BICS Loader

(AHC) (Cont’d) A
AHC Handle Disassembly And Assembly
Remove the handle sleeve (Item 1) [A] and bushings
(Item 2) [A] from the handle.
Check all parts for wear and replace as needed.
2
2
1
N–17394
Check the mounting bolt (Item 1) [B] that connects the

handle to the handle control unit for wear, replace as
B
needed.
N–17393
773 BICS Loader

(AHC) (Cont’d) A
AHC Steering Lever Removal And Installation 1
Remove the handle control unit. (See Page 10–19.)
Remove the switch handle from the steering lever. (See
Page 10–22.)
Remove the handle from the steering lever. (See Page
10–26.)
Loosen the two u–clamps (Item 1) [A] nuts.
Remove the steering lever from the cross shaft and
control panel. N–17773
The steering lever (Item 1) [B] must be replace as a

complete unit. B
The connector clip (Item 2) [B] can be replaced
separately from the steering lever.
P–13734
AHC Steering Lever Boot

Disconnect the switch handle harness connectors from
C
the loader wiring harness connectors. (See Page 10–24.)
Remove the connectors from the switch handle wiring
harness. (See Page 10–24.)
Loosen the two u–clamps (Item 1) [A] and remove the
steering lever.
1
Remove the four pop rivets from the boot retainer (Item
1) [C] and control panel.
Remove the steering lever boot.
N–17775
773 BICS Loader

(AHC) (Cont’d) A
Actuators Removal And Installation
NOTE: For correction installation of the actuator,
mark all the wire connections (Item 1) [A]
before disconnecting them.
Remove the steering levers/control panel assembly. (See
Page 3–1.)
Disconnect the wiring harness connectors (Item 1) [A] 1
from the actuator connectors.
1 N–17781
Remove the pins (Item 1) [B] from the actuator couplers.

B
Remove the two mounting bolts (Item 2) [B] from the
control valve mounting plate and actuator mounting 2
block. 1
Installation: Tighten the mounting bolts to 30 ft.–lbs.
(40,7 Nm) torque.
Remove the actuators and mounting block assembly.
N–17787
773 BICS Loader

(AHC) (Cont’d) A
Actuators Disassembly And Assembly
actuator mounting block.
Installation: Tighten the mount bolts to 10–12 ft.–lbs.
(13,5–16,2 Nm) torque.
NOTE: There must be a small amount of free play 1 1
between the actuators and the mount block
when properly installed.
N–17737
Check the mounting block (Item 1) [B] and bolts for wear
and replace as needed.
B
N–17738
Remove the rubber boot (Item 1) [C] and tie strap from the
actuator shaft.
C
Check the rubber boot (Item 1) [C] for wear and replace
as needed.
N–17739
Check the actuator wiring harness connector (Item 1) [D]

and replace if broken. D
Installation: Install the wires into the connector as listed
below. The terminal numbers are written on the back of 2
the connector (Item 2) [D].
Lift and Tilt Actuator
1 – Terminal–Black–Larger diameter wire (16 gauge)
2 – Terminal–Green–Larger diameter wire (16 gauge)
3 – Terminal–Red/Green–Larger diameter wire
(16 gauge)
4 – Terminal–Open
5 – Terminal–Red–Smaller diameter wire (18 gauge) 1
7 – Terminal–Open N–17742 N–17741
8 – Terminal–Black–Smaller diameter wire (18 gauge)
773 BICS Loader
(AHC) (W/PUSH BUTTON FLOAT) A
Components Identification
Control Handle (Item1) [A].
Handle Sensor (Item 2) [A]. 1
P–16536 N–22797
Control Valve Actuators (Item 1) [B]. B

1
1
N–19112
AHC Controller (Item 1) [C].

C
P–13797
773 BICS Loader

CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/PUSH BUTTON FLOAT)(Cont’d)
Controller Connector And Wire Identification
C–428
C–430
C–431
C–429
P/N PIN DESCRIPTION P/N PIN DESCRIPTION

C–430 CONNECTOR, METRI–PACK C–428 CONNECTOR, 8 WAY PLUG (LIFT) (TOP
Orange/White A SWITCHED BATTERY POWER ACTUATOR)
Black B GROUND Dk.Blue/White 1 LOW REFERENCE TO RESISTIVE INPUTS
C–431 MALE, 10–WAY Lt. Green/White 2 SIGNAL FROM LIFT ACTUATOR
Brown/Dk. Green A SIGNAL FROM LIFT CONTROL Dk. Blue 3 HIGH REFERENCE TO RESISTIVE INPUTS
HANDLE INPUT 4 OPEN
Purple/Yellow B FLOAT SWITCH ON/OFF Brown/White 5 LIFT SPOOL ACTUATOR MOTOR (–)
Pink/Dk. Green C SIGNAL FROM TILT CONTROL 6 OPEN
HANDLE INPUT 7 OPEN
Dk. Blue D TILT HIGH REFERENCE TO Brown/Yellow 8 LIFT SPOOL ACTUATOR MOTOR (+)
RESISTIVE INPUTS C–429 CONNECTOR, 8 WAY PLUG (TILT) (BOTTOM
Dk.Blue/White E TILT LOW REFERENCE TO ACTUATOR)
RESISTIVE INPUTS Dk. Blue/White 1 LOW REFERENCE TO RESISTIVE INPUTS
Dk.Blue/White F LIFT LOW REFERENCE TO Lt. Blue/White 2 SIGNAL FROM TILT ACTUATOR
RESISTIVE INPUTS Dk. Blue 3 HIGH REFERENCE TO RESISTIVE INPUTS
Dk. Blue G LIFT HIGH REFERENCE TO 4 OPEN
RESISTIVE INPUTS Pink/White 5 TILT SPOOL ACTUATOR MOTOR (–)
Purple/White H BICS INPUT STATUS 6 OPEN
Purple/Red J AHC STATUS OUTPUT 7 OPEN
K OPEN Pink/Yellow 8 TILT SPOOL ACTUATOR MOTOR (+)
773 BICS Loader

(AHC) (W/PUSH BUTTON FLOAT) (Cont’d) A
AHC/PWM Controller Removal And Installation
Raise the operator cab. (See Page 1–1.) 1
Remove the four mounting bolts (Item 1) [A] from the 1
controller.
Disconnect the wiring harness connectors (Item 2) [A]
from the controller.
Remove the controller from the loader.
Test 2
N–17777
• The wiring harness connectors must be connected to
the controller [A].
B
• Take voltage measurements by probing into wires near
the controller shown in figure [A]. All connectors must
remain plugged into their respectful harness.
• Turn the key to the ON position (Item 1) [B] with the 5

engine OFF. 2
3
• Turn the switches ON to get their appropriate readings.
(See chart listed below for switch locations.)
1
• Press the auxiliary hydraulic switch (Item 2) [B] twice. 4
Both Green lights will be ON.
N–17919 P–10466
• For individual voltage readings see Page 10–16.
Key Switch
Auxiliary Hydraulic Switch
Item 1 [B]
Item 2 [B] C
Momentary Light Item 3 [B]
Detent Light Item 4 [B]
High Flow Switch Item 5 [B]
Proportional Flow Switch Item 1 [C]
Detent Switch Item 2 [C] 1
Rear Aux. Switch (Base & Rod) Item 3 [C] 3
Right
Left Steering
Steering Lever
Lever 2 Control
Control
P–13255 P–13254
773 BICS Loader

(AHC) W/PUSH BUTTON FLOAT (Cont’d) A
Handle Sensor Removal And Installation
To remove the handle sensor, slide the rubber handle cover
(Item 1) [A] up the handle.
P–16581
Disconnect the loader control harness (Item 1) [B] from the

handle control harness.
B
N–22797
Using a small screwdriver remove the handle control

electrical connector from the clip (Item 1) [C] by pushing C
the connector down out of the connector clip (Item 2) [C].
2
1
N–22803
Using an allen wrench, remove one of the two mounting

screws (Item 1) [D] from the handle sensor. D
Installation: Tighten the handle sensor mounting screws
to 85 in.–lbs. (9,6 Nm) torque.
1
1
N–22790
773 BICS Loader

Handle Sensor Removal And Installation (Cont’d)
Remove the two plastic spacers (Item 1) [A] and the metal
spacer (Item 2) [A] from the handle sensor.
1
P–16580 N–22793
Remove the top mounting bolt (Item 1) [B] from the handle B
sensor.
P–16574
Remove the handle sensor (Item 1) [C] from the handle

assembly. C 3
NOTE: The sensor (Item 1) [C] can only be replaced as
a complete assembly.
Check the spacers (Item 2) [C] and screws (Item 3) [C] and
replace as needed.
1
3
3 2
P–16576
Installation: When installing the handle sensor into the

control handle, check the routing of the switch handle wire
D
harness (Item 1) [D] to assure proper return of the control
handle to neutral and minimize harness movement.
N–22799
773 BICS Loader

Handle Sensor Connector
The wire connector (Item 1) [A] can be removed from the
handle sensor wires, use the following procedure.
P–16578
1
1
P–13725 P–13732
With a pointed tool, lift the tab (Item 1) [C] and pull the wire C
from the connector.
Assembly: Install the wires into the connector as listed
below [C]: 1
1–Terminal – Red 2 3
2–Terminal – Black 1
3–Terminal – Green
P–17333
773 BICS Loader

Switch Handle Removal And Installation
To remove the switch handle, the connector (Item 1) [A]
must be removed from the wires.
N–22794
Remove the wedge (Item 1) [B] from the connector.

B
1
P–13725 P–13732
Using a pointed tool, press down on the tab (Item 1) [C] and
pull the wire from the connector.
Installation: Install the wires into the connector as listed C
below [C]:
Right Control Lever Switch Handle
1–Terminal – Red/White
2–Terminal – Black/White
3–Terminal – Purple/White
1
Left Control Lever Switch Handle 3
2
1–Terminal – Red/White
2–Terminal – Black/White
3–Terminal – Purple/White 1
P–17335
773 BICS Loader

1
Disconnect the right switch handle connectors (Items 1 &
2) [A] from the loader wiring harness connectors.
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [B] from loader wiring harness connectors.
Remove the connector locks and connectors from the
wires to remove the switch handle from the control handle.
2
Installation:The wire colors of the control lever harness
are as follows:
N–17779
Right Switch Handle B

Ten–Pin Connecter
A–Terminal – Orange 2
B–Terminal – White 1 3
C–Terminal – White/Black 4
D–Terminal – White/Red
E–Terminal – Dk. Green
F–Terminal – White/Lt. Green
G–Terminal – Blank
H–Terminal – Lt. Green
J–Terminal – Yellow
K–Terminal – Blank
A–Terminal – Pink/Red N–17772
B–Terminal – Pink/Black
C–Terminal – Pink/Lt. Green
Left Switch Handle
Ten–Pin Connector
A–Terminal – Orange
B–Terminal – Dk. Blue
C–Terminal – White
D–Terminal – Purple
F–Terminal – Tan
G–Terminal – Pink
H–Terminal – Blank
J–Terminal – Blank
K–Terminal – Blank
A–Terminal – Red/White
B–Terminal – Black/White
C–Terminal – Purple/White
Two–Pin Connector
A–Terminal – Black
B–Terminal – Red
Five–Pin Connector
A–Terminal – Dk. Green
B–Terminal – Brown
C–Terminal – Blank
D–Terminal – Yellow
773 BICS Loader

Roll the pistol grip handle cover (Item 1) [A] down.
Using a small screwdriver, lift the handle tabs (Item 2) [A]
and slightly rotate the switch handle. 2 2
N–22783
Pull the switch handle and wiring harness assembly (Item

1) [B] from the control lever. B
N–22784
Installation: When installing the switch handle and wiring

harness assembly into the control handle, route the C
harness (Item 1) [C] to assure proper return of the control
handle to neutral position.
1
N–22794
773 BICS Loader

Control Handle Removal And Installation
Remove the handle sensor (Item 1) [A]. (See Page 10–34.)
N–22792
Remove the switch handle (Item 1) [B]. (See Page 10–37.) B 1
P–16534
Remove the rubber handle cover (Item 1) [C] from the

handle. C
1
N–17384
Using a small screwdriver, hold the handle spacer (Item 1)

[D] and remove the allen head screws (Item 2) [D] from the D
handle assembly.
Installation: Tighten the allen head screws to 35 in.–lbs. 1
(4 Nm) torque.
2 2
N–17385
773 BICS Loader

Control Handle Disassembly And Assembly
Remove the handle sleeve (Item 1) [A] and bushings (Item
2) [A] from the handle.
Check all parts for wear and replace as needed.
2
2
1
N–17394
Check the mounting bolt (Item 1) [B] that connects the

handle to the handle sensor unit for wear, replace as
B
needed.
N–22796
773 BICS Loader

1
Control Lever Removal And Installation 1
Disconnect the electrical connectors (Item 1) [A] from the 1
control lever switch handle.
Remove the electrical connectors from the control lever
switch handle. (See Page 10–38.) 1
N–22667
Loosen the two u–clamps (Item 1) [B] nuts. B

Installation: Tighten the u–bolts so the lever can not be
moved either right or left when seated in the operator seat.
Control lever end (Item 2) [B] should be flush with 1
bellcrank. Be sure the control lever does not interfere with
the operator cab when lowering or raising the cab. The
distance between handles should be 18.25 inches [C].
Remove the control lever from the cross shaft and control
panel.
N–22658
18.25”
The control lever (Item 1) [D] must be replaced as a

complete unit. D
The connector clip (Item 2) [D] can be replaced separately
from the control lever.
P–13734
773 BICS Loader

Control Lever Boot
To replace the rubber boot (Item 1) [A] on the control panel,
remove the control lever. (See Page 10–42.)
Drill out the four rivets (Item 2) [A] located on the flange of
the rubber boot and remove the old boot. 2
Install the new boot and reinstall the control lever. (See
Page 10–42 for control lever installation.)
1
N–22659
773 BICS Loader

Actuators Disassembly And Assembly
Remove the actuator (Item 1) [A] from the hydraulic control
valve. (See Page 2–1.)
Installation: Tighten the mount bolts to 90–100 in.–lbs.
(130,2–11,3 Nm) torque.
1
N–18912
Check the mounting block (Item 1) [B] and bolts for wear
and replace as needed.
B
1
N–18940
Remove the rubber strap (Item 1) [C] from the mounting

shaft collar (Item 2) [C]. C
Remove the mounting bracket (Item 3) [C].
Check the rubber strap, mounting shaft collar, and 3
mounting bracket for wear and replace as needed.
2
1
N–18941
Check the actuator wiring harness connector (Item 1) [D]
and replace if broken.
Installation: Install the wires into the connector as listed D
below. The terminal numbers are written on the back of the
connector (Item 2) [D].
Lift and Tilt Actuator 2
1 – Terminal–Black/Green–Larger diameter wire (16
gauge)
2 – Terminal–Green–Larger diameter wire (16 gauge)
3 – Terminal–Red/Green–Larger diameter wire
(16 gauge)
5 – Terminal–Red–Smaller diameter wire (18 gauge)
6 – Terminal–Open 1
8 – Terminal–Black–Smaller diameter wire (18 gauge)
N–17742 N–17741
773 BICS Loader

BICS™ VALVE
A 2
To remove, replace or check the orifice for the lift arm
by–pass function, use the following procedure.

disassembly and keep all parts clean. Always N–17293
the system.
I–2003–0888 B
1
Remove the fitting (Item 1) [A] from the BICS valve.
The orifice (Item 1) [B] is slotted so a flat blade
screwdriver can be used to remove it.
Remove the orifice from the valve.
N–17294
Clean and inspect the orifice (Item 1) [C]. Replace as

needed. C
1
P–13727
773 BICS Loader

BICS™ VALVE (Cont’d)
Check Valve
A
Loosen and remove the check valve (Item 1) [A].
3
Installation: Tighten the check valve to 20 ft.–lbs. (27
Nm) torque.
2
N–17271
Inspect and clean the screen (Item 1) [B] on the end of

the check valve. B
Inspect the check valve for damage. Replace the O–rings
and back–up washers before installation.
Replace the check valve if necessary.
Lock Valve
There are two lock valves on the BICS valve, lift lock valve
(Item 2) [A] and tilt lock valve (Item 3) [A].
1
P–13728
Loosen and remove the lock valve (Item 1) [C] from the
valve.
C 1
Installation: Tighten the lock valve(s) to 25 ft.–lbs. (34
Nm) torque. Replace all the O–rings and back–up
washers before installation.
Inspect the lock valve(s) for damage.
Replace the lock valve(s) if necessary.
N–17295
773 BICS Loader

BICS™ Valve Solenoid
A
Loosen the mounting nut (Item 1) [A] at the solenoid. 1
N–17271
Remove the mounting nut (Item 1) [B], O–ring (Item 2)

[B], coil (Item 3) [B], O–ring (Item 4) [B].
B 3
Remove the solenoid cartridge (Item 5) [B] from the

valve. 4
5 1
Installation: Tighten the cartridge to 20 ft.–lbs. (27 Nm)
torque. 2
N–17298
Inspect the solenoid cartridge (Item 1) [C] for damage.

C 1
Replace all the O–rings and back–up washers before
installation.
Replace the solenoid cartridge as needed.
N–17299
773 BICS Loader

A
Loosen the six mounting bolts (Item 1) [A] at the BICS
valve.
Remove the mounting bolts (Item 1) [A].
1
1
N–17271
Remove the BICS valve assembly (Item 1) [B] from the

top of the control valve (Item 2) [B]. B 1
Installation: Always replace the four large O–rings (Item
3) [B] and small O–ring (Item 4) [B].
3
3
4
2
N–17302
Installation: The chart below lists the correct torque

specifications and tightening sequence [C] when
reinstalling the BICS™ valve assembly to the hydraulic
C
control valve. Thoroughly clean and dry bolts and threads
in valve. Use liquid adhesive LOCTITE #242.
3 6
Step Torque ♦Sequence
1 2
1 110–130 in.–lbs.
(12,4–14,7 Nm)
5 4
2 190–210 in.–lbs.
(21,5–23,7 Nm) 1, 2, 3, 4, 5 & 6
3* 190–210 in.–lbs.
(21,5–23,7 Nm) P–09587
*Torque must be 190–210 in.–lbs. (21,5–23,7 Nm) for

every bolt or the complete ♦sequence must be repeated.
773 BICS Loader

HYDRAULIC CONTROL VALVE
A 1
Raise the lift arms and install an approved lift arm support 2
device. (See Page 1–1.) N–17819
B 1

or death. W–2059–0598
Stop the engine. Use the lift lock valve knob to release the
hydraulic pressure. Raise the seat bar. N–17820

Raise the operator cab. (See Page 1–1.) C
Remove the actuators. (See Page 10–29.) 1
Clean the area around the control valve.
Mark all tubelines for correct installation. 2
Disconnect the wire harness connectors (Item 1) [A] from
the auxiliary solenoid connectors.
3
Disconnect the harness connector (Item 2) [A] from the
BICS valve solenoid connector.
2
Installation: Instll a never modify sta–strap around the N–17821
connector (Item 2) [A].
Disconnect the drain hoses (Item 3) [A] from the main
control valve.
Disconnect the outlet tubeline (Item 1) [B] from the
control valve.
Disconnect both tubelines (Item 2) [B] from the auxiliary
section of the control valve.
Disconnect the hose (Item 1) [C] from the lift arm by–pass systems, clean the work area before
control vavle. disassembly and keep all parts clean. Always
Disconnect the tilt tubelines (Item 2) [C]. ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
Disconnect the lift tubelines (Item 3) [C].
773 BICS Loader

HYDRAULIC CONTROL VALVE (Cont’d)
A 4

1
right side of the loader frame. 2
Loosen one mounting bolt (Item 2) [A] of the access
cover. Remove the control valve mounting bolt (Item 3)
[A] from the access cover.
P–04109

[B]. B
P–04108

the access slot [C]. C
Remove the control valve mounting bolt (Item 4) [A].
valve.
P–04110
773 BICS Loader

HYDRAULIC CONTROL VALVE (Cont’d) H3 H1
A H2
Identification Chart
Item 773 AHC Loader

C4
A1 Lift Cylinder Base End/Restrictor
B3 A3
A2 Tilt Cylinder Base End G3 D3
C3
A3 Auxiliary Hydraulics D2
G2 B2 A2 E2
B1 Lift Cylinder Rod End C2
F2 D1
B2 Tilt Cylinder Rod End G1 B1 A1 E1
B3 Auxiliary Hydraulics F1 C1
MR
C2 Load Check Valve/Tilt Function MC–02419
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Centering Spring
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs
E1 Port Relief Valve – 3500 PSI
E2 Anti–Cavitation/Port Relief Valve – 2500 PSI
F1 Anti–Cavitation Valve
F2 Port Relief Valve
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H2 Plug/Port Relief (Optional) – 2500 PSI
MR Main Relief Valve – 3000 PSI
773 BICS Loader

Added June 01 –10–51– Service Manual
A
Remove the BICS valve assembly from the control valve.
(See Page 10–49.)
Remove the four large O–rings (Item 1) [A] and small 1
O–ring (Item 2) [A]. Always replace these O–rings before
installing the BICS valve assembly. 1
The anti–cavitation valve, port relief valves and plugs are
at different locations in the control valve. Refer to Control 2
Valve Identification Chart for the correct location of the
parts. (See Page 10–51.)
N–17275
B 1

disassembly and keep all parts clean. Always 1
the system.
I–2003–0888
Mark each valve section, spool and related parts so that

they will be returned to its original valve location during
assembly.
N–17276
Load Check Valve
Loosen the load check valve plug (Item 1) [B]. C
Installation: Always use new O–ring. Tighten the plug to
35–40 ft.–lbs. (47–54 Nm) torque.
Remove the load check plug (Item 1) [C].
1
Remove the spring (Item 2) [C] and poppet (Item 3) [C].
3
2
N–17274
The auxiliary section (Item 1) [D] uses an orifice load

check poppet.
D 1

2
Remove the restrictor (Item 2) [D] from the lift section
base end port.
Check for damage and replace as needed.
N–17273
773 BICS Loader

Main Relief Valve
A
Loosen the main relief valve (Item 1) [A].
Installation: Tighten the main relief to 35–40 ft.–lbs.
N–17276
Remove the main relief valve (Item 1) [B] from the control
valve.
B
N–17272
Remove the O–rings, sleeve, and glide ring from the main
relief valve [C]. C
Installation: Always use new O–rings. sleeve, and glide
ring.
NOTE: See Page 2–1 for setting the pressure at the

main relief valve after the control valve is
installed in the loader.
N–17297
773 BICS Loader

Port Relief Valve (Lift)
A
Loosen the port relief valve (Item 1) [A] (Port E1).
Installation: Tighten port relief to 35–40 ft.–lbs. (47–54
Nm) torque.
2
1
N–17283
Remove the port relief valve from the control valve [B]. B
Remove the O–rings and back–up washer from the port
relief valve.
Installation: Always use new O–rings and back–up
washers.
Anti–Cavitation/Port Relief Valve

Loosen the anti–cavitation valve/port relief (Item 2) [A]
(Port E2).
Installation: Tighten cartridge to 35–40 ft.–lbs. (47–54
Nm) torque. N–17284
Remove the anti–cavitation valve/port relief from the

control valve [C].
C
Remove the O–rings and back–up washer from the
anti–cavitation/port relief.
washers.
N–17285
773 BICS Loader

Port Relief Valve (Tilt)
A
Loosen the port relief valve (Item 1) [A] (Port F2). 1
Installation: Tighten the anti–cavitation/port relief valve 2

to 35–40 ft.–lbs. (47–54 Nm) torque.
N–17276
Remove the port relief from the control valve [B]. B

Remove the O–rings from the port relief valve.
washers.
N–17278
C
Loosen the anti–cavitation valve (Item 2) [A] (Port F1).
Installation: Tighten the anti–cavitation valve to 35–40

Remove the anti–cavitation valve from the control valve
[C].
Remove the O–rings from the anti–cavitation valve.
washers.
N–17277
773 BICS Loader

Rubber Boot
A
Remove the two screws (Item 1) [A] on the rubber boot 1
retainer.
Installation: Tighten the screws to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.
N–17279
Remove the rubber boot (Item 1) [B] and retainer (Item

2) [B]. B
Remove the seal retainer (Item 3) [B] and O–ring (Item
4) [B].
1 3
2
N–17280
773 BICS Loader

Lift And Tilt Spool
A
Remove the rubber boot from the other end of the spool.
(See Page 10–56.) 1
Remove the two screws (Item 1) [A] from the end cap (lift
or tilt).
Installation: Tighten the screws to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.
2
Remove the end cap (Item 2) [A] (lift or tilt).
1
N–17286
Remove the spool (Item 1) [B], centering spring, back–up

washer and seal from the control valve.
B
1
2
N–17288
At the other end of the spool bore, remove the spool seal
(Item 1) [C] and O–ring (Item 2) [C]. C
1
NOTE: To install new spool seal (Item 2) [B], remove
the centering spring or See Page 10–62 for
seal replacement without removing the
centering spring.
N–17492
Installation: If both spools are removed at the same
time, mark the lift spool (Item 1) [D] and tilt spool (Item 2)
[D] so they will be put in their original bore. D 3
2
NOTE: The centering spring (Item 3) [D] is white on
all 700 series loaders.
1 3
N–17261
773 BICS Loader

A 2
Lift And Tilt Spool (Cont’d)
procedure;
MEL1285 – Spring Tool
Put the linkage end of the spool in the vice [A].
1
Install the spring tool (Item 1) [A] over the centering
spring.
NOTE: Be careful when removing the bolt from the

centering spring, because there is spring
pressure.
Loosen the bolt (Item 2) [A] holding the centering spring
to the spool.
Installation: Tighten the bolt to 90–100 in.–lbs.
(10,2–11,3 Nm) torque.
N–17287
Remove the adapter (Item 1) [B], spring cap (Item 2) [B],

spring (Item 3) [B], and washer (Item 4) [B] from the
B
spool. 2
3
4
1
N–17290
773 BICS Loader

Lift And Tilt Spool (Cont’d)
A O–ring
Lift Spool Only: To remove the plastic plug from the lift
spool:
Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
tap drill.
Plastic
Turn a 6–32 tap into the plug. Pull the tap and plug out of Plug
the spool. Be careful, do not break the tap. 0.60 inch
(15,2 mm)
Clean all the debris from the inside of the spool bore.
MC–02421
Installation: Slide the O–ring over the nipple on the
plastic plug. Install the plastic plug in the spool. Install the
bolt so that the end of the plug is about 0.60 inch (15,2
mm) from the end of the spool [A].
B
NOTE: During installation of the centering spring to
the spool, make sure the adapter is centered
in the washer hole (Item 1) [B]. If the adapter
is not centered, it can cause the bolt to break
during installation.
Inspection
Check the spools for wear or scratches. 1
Check that the centering springs are not broken. N–17260
Check that the load check valve seats are not worn.
Check the load check poppet for damage.
Check the rubber boots and retainers that they are not
worn or damage.
Replace all parts as needed.
773 BICS Loader

Auxiliary Spool
A 2
Remove the end cap screws (Item 1) [A] & [B].
Installation: Tighten the screws to 90–100 in.–lbs. 1 3
(10,2–11,3 Nm) torque.
6
5
4
N–17281
Remove the end cap (Item 2) [A] & [B], O–ring (Item 3)
[A] & [B].
B
Remove the large spring (Item 4) [A] & [B] and small
2
spring (Item 5) [A] & [B].
Remove the spring retainer (Item 6) [A] & [B]. 3 1
6
5
4
N–17264
Remove the auxiliary spool (Item 1) [C].

C
1
N–17263
773 BICS Loader

A
Auxiliary Electrical Solenoid
Remove the nut (Item 1) [A] from the end of the solenoid.
Installation: Tighten the nut to 9–12 in.–lbs. (1,02–1,36
Nm) torque.
N–17265
Remove the metal housing (Item 1) [B], coil (Item 2) [B],
and end plate (Item 3) [B].
Remove the electric solenoid valve (Item 4) [B].
B
4
Installation: Tighten the solenoid valve to 96–144
in.–lbs. (10,8–16,3 Nm) torque. 3
2
1
N–17267
Installation: Always install new O–rings and back–up

washers on the solenoid valve [C]. C
N–17269
773 BICS Loader

Spool Seal Installation
A
To install new spool seals when the centering spring is not
removed from the spool, use the following procedure:
Check the seal surface area in the control valve (Item 1)
[A] for rust, corrosion, scratches, etc. Correct any
irregularities before continuing.
1
N–17491
Put plastic material (Example: Plastic food wrap) on the

valve spool [B]. B
Put clean oil on the spool seal. Install the spool seal (Item
1) [B] on the spool. Be careful not to damage the seal on
the sharp edges.
NOTE: Seal must be installed with lip face toward

valve body. Lift face has largest outside
diameter. 1
Remove the plastic material.
Install the spool into the control valve.
CD–15080
Install the linkage end spool seal [C] into the control valve
(Item 1) [D]. C
Be careful not to damage the spool seal.
P–13746
Install the O–ring (Item 2) [D].

Continue assembling the control valve.
D
1
N–17492
773 BICS Loader

H–Port Auxiliary Section
A
Loosen the plug (Item 1) [A]. 1
Installation: Tighten the plug to 35–40 ft.–lbs. (47–54
Nm) torque.
N–17265
Remove the plug from the control valve [B]. B
N–17266
Depending on the application of the auxiliaries, the control

valve may be equipped with a port relief valve (Item 1) [C].
C
N–17474
If so equipped, remove the port relief from the control

valve [D].
D
Installation: Replace the O–rings and back–up washers.
Tighten the port relief valve 35–40 ft.–lbs. (47–54 Nm)
torque.
N–17284
773 BICS Loader

773–1
® Revision Number
29 May 1998
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 773 SALES MANAGER
Manual No. 6900092 (6–97)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below:
TAKE OUT PUT IN
ALPHABETICAL INDEX ALPHABETICAL INDEX
1–3 thru 1–4 1–3 thru 1–4
Section 2 Section 2
DO NOT REMOVE the Hydraulic Schematics
in Section 2
3–7 thru 3–14 3–7 thru 3–14
4–3 thru 4–6 4–3 thru 4–6
Section 5 Section 5
7–19 thru 7–24 7–19 thru 7–24
7–51 thru 7–52 7–51 thru 7–52
Section 9 Section 9
Printed in U.S.A.
773–2
® Revision Number
8 January 1999
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6900092 (6–97)

TAKE OUT PUT IN
Cover thru Section 1 Cover thru Section 1
(This includes Maintenance Safety Page, (This includes Maintenance Safety Page,
Alphabetical Index, i thru viii & Section 1) Alphabetical Index, i thru viii & Section 1)
2–1 thru 2–10 2–1 thru 2–10

2–27 thru 2–28 2–27 thru 2–28
2–57 thru 2–78 2–57 thru 2–78
2–85 thru 2–88 2–85 thru 2–94
3–5 thru 3–14 3–5 thru 3–14
3–51 thru 3–60 3–51 thru 3–60
4–7 thru 4–26 4–7 thru 4–26
5–1 thru 5–2 5–1 thru 5–2
5–19 thru 5–26 5–19 thru 5–26
5–31 thru 5–32 5–31 thru 5–32
6–3 thru 6–10 6–3 thru 6–10
7–1 thru 7–4 7–1 thru 7–4
7–7 thru 7–36 7–7 thru 7–36
Section 8 Section 8
Section 10
Insert new Advanced Hand Control Wiring
Schematics after Page 10–4.
773–3
Revision Number
13 June 2001
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6900092 (6–97)

TAKE OUT PUT IN REVISION DESCRIPTION
Cover Cover Revised With New Logo
MAINTENANCE SAFETY MAINTENANCE SAFETY Revised Text
ALPHABETICAL INDEX ALPHABETICAL INDEX Revised Text
v, vi v, vi Revised Text
1–3 thru 1–10 1–3 thru 1–10 Revised Text
1–17 thru1–18 1–17 thru 1–18 Revised Oil Chart
GLOSSARY OF HYD./ GLOSSARY OF HYD./
HYDRO. SYMBOLS HYDRO. SYMBOLS
FOR LOADERS FOR LOADERS Revised (6–2–98)
ALL ALL NEW Revised Information
HYDRAULIC/HYDROSTATIC HYDRAULIC/HYDROSTATIC
SCHEMATICS AND SCHEMATICS AND
LEGENDS LEGENDS
(Printed June 1997) (Printed June 2001)
Printed in U.S.A.
ALL 773 BICS ALL NEW 773 Changed to new format and added new harnesses
WIRING DIAGRAM WIRING SCHEMATIC
INDEXES, CONTENTS AND
LEGENDS AND WIRING WIRING SCHEMATICS
DIAGRAMS
(Printed February 1997) (Printed June 2001)

Section 10 Section 10 Added Push Button Float
10–3 thru 10–4 10–3 thru 10–4 Updated With New Information
ALL 773 ALL 773 Added New Harnesses
WIRING SCHEMATICS WIRING SCHEMATICS
WITH ADVANCED WITH ADVANCED
HAND CONTROL OPTIONS HAND CONTROL OPTIONS
(Printed January 1999) (Printed June 2001)
773–4
Revision Number
1 November 2001
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6900092 (6–97)

Printed in U.S.A.

773 6900092 SM 6-97

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Service

CORRECT CORRECT CORRECT

B-10731a B-13573 B-13561

WRONG WRONG WRONG

B-13574 B-15232 B-15281

B-13576 B-13577 B-6589

Revised Jan. 99 773 BICS Loader

1. Check that the ROPS/FOPS 9. The parking brake must

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be correctly 11. Bob–Tach wedges and

8. Check for correct function of 16. Lubricate the loader.

773 BICS Loader

18. Inspect the air cleaner for

19. Check the electrical charging

20. Check tires for wear and

21. Inspect for loose or broken

22. Operate the loader and check

23. Check for any field

24. Check for correct function of

Recommend to the owner that all

773 BICS Loader

Warnings on the machine and in the This notice identifies procedures

773 BICS Loader

773 BICS Loader

The four digit Model/Engine Combination module number

ENGINE SERIAL NUMBER

773 BICS Loader

STEERING LEVERS REAR AUXILIARY

REAR GRILL LIFT CYLINDER

TAIL LIGHTS LIFT ARM

FINAL DRIVE TRANSMISSION (CHAINCASE)

LIFT ARM SUPPORT DEVICE

LIFTING THE LOADER

773 BICS Loader

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–35

SEAT BAR RESTRAINT SYSTEM (Advanced Hand Controls)

SEAT BAR RESTRAINT SYSTEM (Foot Pedals)

SEAT BAR RESTRAINT SYSTEM (Mechanical Hand Controls)

STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6

TOWING THE LOADER

TRANSPORTING THE LOADER

773 BICS Loader

Instructions are necessary before operating or servicing machine.

ITEM SERVICE REQUIRED 8–10 50 100 250 500 1000

Instructions are necessary before operating or

LIFTING AND BLOCKING THE LOADER

Put jackstands under the front axles and rear

NOTE: Make sure the jackstands do not touch the

773 BICS Loader

Adequately designed ramps of sufficient

TOWING THE LOADER

773 BICS Loader

AVOID INJURY OR DEATH

STOPPING THE BOBCAT LOADER

773 BICS Loader

Never work on a machine with the lift arms up

The lift arm support device must be tight against the

Removing Lift Arm Support Device

Have a second person remove the lift arm support device.

773 BICS Loader

NOTE: When an Operator Cab Enclosure Kit is

Push the window out with your foot [D]. D

773 BICS Loader