Bobcat 751 Loader Service Manual 6900443 (6-12) – PDF DOWNLOAD

Description

Bobcat 751 Loader Service Manual 6900443 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 751 Loader Service Manual 6900443 (6-12) – PDF DOWNLOAD

Language : English
Pages : 458
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 751 Loader Service Manual 6900443 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
SERIAL NUMBER LOCATIONS 13
LOADER SERIAL NUMBER 13
ENGINE SERIAL NUMBER 13
DELIVERY REPORT 13
BOBCAT LOADER IDENTIFICATION 14
PREVENTIVE MAINTENANCE 15
SERVICE SCHEDULE 17
LIFTING AND BLOCKING THE LOADER 18
Procedure 18
TRANSPORTING THE LOADER 19
Procedure 19
TOWING THE LOADER 19
Procedure 19
STOPPING THE BOBCAT LOADER 19
LIFTING THE LOADER 20
Four Point Lift 20
Single Point Lift 20
LIFT ARM SUPPORT DEVICE 21
Engaging The Lift Arm Support Device 21
Disengaging The Lift Arm Support Device 22
OPERATOR CAB 23
Description 23
Raising The Operator Cab 23
Lowering The Operator Cab 24
Emergency Exit 25
SEAT BAR RESTRAINT SYSTEM (Foot Pedals) 26
Description 26
Seat Bar Inspection 26
Seat Bar Maintenance 26
SEAT BAR RESTRAINT SYSTEM (Mechanical Hand Controls) 27
Description 27
Seat Bar Inspection 27
Seat Bar Maintenance 27
SEAT BAR RESTRAINT SYSTEM (Advanced Hand Controls) 28
Description 28
Seat Bar Inspection 28
Seat Bar Maintenance 28
AIR CLEANER SERVICE 29
Replacing Filter Element 29
FUEL SYSTEM 31
Fuel Specifications 31
Filling The Fuel Tank 31
Fuel Filter 31
Removing Air From The Fuel System 32
ENGINE LUBRICATION SYSTEM 33
Checking Engine Oil 33
Oil Chart 33
Replacing Oil And Filter 33
ENGINE COOLING SYSTEM 35
Cleaning The Cooling System 35
Checking The Coolant Level 35
Replacing The Coolant 36
ALTERNATOR BELT 37
Adjusting 37
FAN GEARBOX 37
Checking And Maintaining 37
HYDRAULIC/HYDROSTATIC SYSTEM 38
Checking And Adding Fluid 38
Replacing Hydraulic/Hydrostatic Filter 38
Replacing Hydraulic Fluid 39
Breather Cap 40
SPARK ARRESTOR MUFFLER 41
Cleaning Procedure 41
TIRE MAINTENANCE 42
Wheel Nuts 42
Tire Rotation 42
Tire Mounting 42
FINAL DRIVE TRANSMISSION (CHAINCASE) 43
Checking and Adding Oil 43
Removing Oil From The Chaincase 43
DRIVE BELT 44
Adjusting the Drive Belt 44
Replacing The Drive Belt 45
LUBRICATION OF THE BOBCAT LOADER 46
Procedure 46
PIVOT PINS 47
BOB–TACH 48
Inspection and Maintenance 48
REMOTE START SWITCH 49
Procedure 49
HYDRAULIC SYSTEM 51
HYDRAULIC / HYDROSTATIC SCHEMATICS 53
GLOSSARY OF HYDRAULIC/HYDROSTATIC SYMBOLS FOR LOADERS 61
TROUBLESHOOTING 65
HYDRAULIC SYSTEM INFORMATION 66
Tightening Procedures 66
LIFT CYLINDER(S) 67
Checking The Lift Cylinders 67
Removal And Installation 67
TILT CYLINDER 68
Checking The Tilt Cylinder 68
Removal And Installation 68
Rod End Seal Replacement 69
HYDRAULIC CYLINDER IDENTIFICATION 70
Lift Cylinder Components 70
Tilt Cylinder Components 71
HYDRAULIC CYLINDERS 72
Disassembly 72
Assembly 74
MAIN RELIEF VALVE 80
Checking 80
Adjustment 81
Removal And Installation 81
BICS™ VALVE 82
Lift Arm By–Pass Orifice 82
Lock Valve 83
Check Valve 83
BICS™ Valve Solenoid 84
Removal 85
Installation 86
HYDRAULIC CONTROL VALVE 87
Removal And Installation 87
Identification Chart 90
Disassembly 91
Load Check Valve 91
Lift Base End Restrictor 91
Main Relief Valve 92
Port Relief Valve (Lift) 93
Anti–Cavitation 93
Rubber Boot 95
Lift Spool And Detent 96
Tilt Spool And Centering Spring 101
Inspection 103
Auxiliary Spool 104
Auxiliary Electric Solenoid 105
Port–Auxiliary Section 106
Cleaning and Inspection 106
Spool Seal Installation 107
HYDRAULIC PUMP 108
Checking The Output Of The Hydraulic Pump 108
Removal And Installation 110
Disassembly And Assembly 112
Inspection 114
Identification 114
HYDRAULIC FILTER HOUSING 115
Removal And Installation 115
HYDRAULIC FLUID RESERVOIR 116
Removal And Installation 116
CONTROL PEDALS 117
Removal And Installation 117
Pedal Adjustment 117
CONTROL INTERLOCK LINKAGE (Pedal or Mechanical Hand) 118
Adjustment 118
Removal And Installation 119
LIFT LOCK BY–PASS VALVE 120
Removal And Installation 120
Disassembly And Assembly 121
HYDROSTATIC SYSTEM 123
TROUBLESHOOTING 125
HYDROSTATIC SYSTEM INFORMATION 126
Replenishing Valve Function 126
Checking Charge Pressure 126
CONTROL PANEL 127
Removal And Installation 127
Steering Shaft Removal And Installation 128
Steering Shaft Disassembly And Assembly 128
Steering Lever Removal And Installation 129
Rubber Boot Replacement 129
STEERING LINKAGE 130
Removal And Installation 130
Steering Linkage Adjustment 132
HYDROSTATIC DRIVE MOTOR 136
Removal And Installation 136
Parts Identification 137
Disassembly 138
Assembly 143
HYDROSTATIC PUMP 149
Removal And Installation 149
Identification 152
Disassembly And Assembly 154
Inspection 162
DRIVE BELT HOUSING 164
Removal And Installation 164
SPRING LOADED DRIVE BELT TENSIONER PULLEY 166
Removal And Installation 166
Identification 167
Disassembly 168
Assembly 169
OIL COOLER 171
Removal And Installation 171
DRIVE SYSTEM 173
PARKING BRAKE 175
Removal And Installation 175
Disassembly And Assembly 175
PARKING BRAKE DISC 176
Removal And Installation 176
TRACTION LOCK GUIDES 177
Disassembly 177
Assembly 178
CHAINCASE FLUID 180
Removing Oil From The Chaincase 180
CHAINCASE COVERS 181
Center Chaincase Cover Removal And Installation 181
Front Chaincase Cover Removal And Installation 182
Rear Chaincase Cover Removal And Installation 182
MOTOR CARRIER 183
Shaft Seal Replacement 183
Removal And Installation 185
Disassembly 186
Assembly 187
AXLE SEAL 191
Removal and Installation 191
AXLE, SPROCKET AND BEARINGS 193
Removal And Installation 193
DRIVE CHAIN 197
Removal And Installation 197
MAIN FRAME 199
SEAT BAR (W/COMPRESSION SPRINGS) 201
Removal And Installation 201
Assembling Components 204
Compression Spring Disassembly And Assembly 204
OPERATOR CAB GAS CYLINDER 205
Removal And Installation 205
Disassembly And Assembly 205
OPERATOR CAB 206
Removal And Installation 206
OPERATOR SEAT 209
Removal And Installation 209
BOB–TACH 210
Bob–Tach Lever And Wedge 212
Removal And Installation 210
Bob–Tach Stops 213
LIFT ARMS 214
Removal And Installation 214
REAR GRILL 218
Removal And Installation 218
FUEL TANK 219
Removal And Installation 219
Fuel Level Sender 220
REAR DOOR 221
Removal And Installation 221
Door Latch Removal And Installation 222
Door Latch And Catch Adjustment 223
ELECTRICAL SYSTEM 225
ELECTRICAL SCHEMATICS 229
TROUBLESHOOTING 237
ELECTRICAL SYSTEM INFORMATION 238
Description 238
Fuse Location 238
BATTERY 239
Removal And Installation 239
Servicing The Battery 240
Using A Booster Battery (Jump Starting) 241
ALTERNATOR 242
Alternator Output Test 242
Rectifier (Diode) Test 242
Alternator Regulator Test 243
Removal And Installation 244
Adjusting The Alternator Belt 244
Disassembly And Inspection 245
Stator Continuity Test 245
Stator Ground Test 245
Rotor Continuity Test 246
Rotor Ground Test 246
Rectifier Continuity (Diode) Test 246
Assembly 247
STARTER 248
Removal And Installation 248
Parts Identification 249
Disassembly 250
Inspection And Repair 255
No Load Test 258
Assembly 258
STANDARD INSTRUMENT PANEL 265
Removal And Installation 265
FRONT LIGHTS 266
Removal And Installation 266
RELAY SWITCHES 267
Location 267
ENGINE SERVICE 269
TROUBLESHOOTING 271
ENGINE SPEED CONTROL 272
Removal And Installation 272
Disassembly 272
RADIATOR 273
Removal And Installation 273
ENGINE MUFFLER 274
Removal And Installation 274
BLOWER HOUSING/FAN GEARBOX 275
Removal And Installation 275
Tension Pulley Removal And Installation 278
Blower Fan Disassembly And Assembly 279
FAN GEARBOX 281
Identification 281
Disassembly 282
Assembly 287
Checking Backlash 292
AIR CLEANER 295
Removal And Installation 295
ENGINE 296
Removal And Installation 296
Engine Mount Replacement 301
FLYWHEEL 302
Removal And Installation 302
Flywheel Ring Gear 302
ENGINE COMPRESSION 303
Checking 303
GLOW PLUGS 304
Checking The Glow Plugs 304
Removal And Installation 305
FUEL INJECTION PUMP 306
Checking The Injection Pump 306
Adjusting Shut–Off Linkage 306
Removal And Installation 307
Timing The Injection Pump 310
FUEL INJECTION NOZZLES 311
Removal And Installation 311
Checking The Injector Nozzle 313
CYLINDER HEAD 314
Removal And Installation 314
Disassembly And Assembly 315
Servicing The Cylinder Head 316
Top Clearance 316
VALVE, VALVE SEAT AND GUIDE 317
Checking The Valve Guide 317
Valve Spring 319
VALVE CLEARANCE 320
Adjustment 320
ROCKER ARM AND SHAFT 320
Checking 320
TIMING GEARCASE COVER 321
Removal And Installation 321
IDLER GEAR AND CAMSHAFT 323
Servicing The Camshaft 324
Removal And Installation 323
Servicing The Idler Gear And Shaft 325
TIMING GEARS 326
Checking Backlash 326
FUEL CAMSHAFT 327
Removal And Installation 327
Governor 327
CRANKSHAFT GEAR 328
Removal And Installation 328
OIL PUMP 328
Removal And Installation 328
Oil Pump Service 328
Checking Engine Oil Pressure 329
Relief Valve 329
PISTON AND CONNECTING ROD 330
Removal And Installation 330
Servicing The Piston And Connecting Rod 331
Connecting Rod Alignment 333
CRANKSHAFT AND BEARINGS 334
Removal And Installation 334
Servicing the Crankshaft and Bearings 335
CYLINDER BORE 339
Checking The Cylinder Bore 339
WATER PUMP 340
Disassembly And Assembly 340
SYSTEMS ANALYSIS 341
BICS™ – BOBCAT INTERLOCK CONTROL SYSTEM 343
BICS™ (With Press To Operate Button) 343
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 343
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 343
Inspecting The Seat Bar Sensor (Engine RUNNING) 343
Inspecting The Traction Lock (Engine RUNNING) 343
Inspecting The Lift Arm By–Pass Control 343
Additional Inspection For Loaders With Advanced Hand Controls 343
Troubleshooting Chart 344
ADVANCED HAND CONTROLS (AHC) 344
Troubleshooting Chart 344
BICS™ (Without Press To Operate Button) 345
Inspecting The BICS Controller (Engine STOPPED –Key ON) 345
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED–Key ON) 345
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING) 345
Inspecting The Traction Lock (Engine RUNNING) 345
Inspecting The Lift Arm By–Pass Control 345
Maintenance 346
Troubleshooting Chart 347
BICS™ SYSTEM CONTROLLER 348
Troubleshooting Guide 348
Removal And Installation 349
SEAT BAR SENSOR 350
Troubleshooting Guide 350
Seat Bar Sensor Test 351
Removal And Installation 352
BICS™ Controller Seat Bar Sensor Circuit Test 353
SEAT SENSOR 354
Troubleshooting Guide 354
Seat Sensor Test 355
Removal And Installation 356
BICS™ Controller Seat Sensor Circuit Test 357
TRACTION LOCK 358
Troubleshooting Guide 358
Removal And Installation 359
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE 361
Controls Identification Chart 361
SPECIFICATIONS 363
LOADER SPECIFICATIONS 365
SPECIFICATIONS 365
PERFORMANCE 365
CONTROLS 365
ENGINE 365
HYDRAULIC SYSTEM 366
ELECTRICAL 366
DRIVE SYSTEM 366
CAPACITIES 366
TIRES 366
FLOOR PRESSURE 366
ENGINE SPECIFICATIONS 367
Fuel Injection Nozzles 367
Fuel Injection Pump 367
Cylinder Head 367
Valves 367
Valve Springs 367
Valve Timing 367
Rocker Arms 367
Camshaft 368
Tappet 368
Cylinders 368
Piston Rings 368
Pistons 368
Connecting Rod 368
Oil Pump 368
Crankshaft 369
Timing Gear 369
Thermostat 369
Crankshaft Re–Grind Data 370
Torque For General Metric Bolts 371
HYDRAULIC CONNECTION SPECIFICATIONS 372
O–Ring Face Seal Connection 372
Straight Thread O–ring Fitting 372
Tubelines And Hoses 372
Flare Fitting 372
O–Ring Flare Fitting 373
Port Seal Fitting 375
TORQUE SPECIFICATIONS FOR LOADER 376
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 377
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 378
DECIMAL AND MILLIMETER EQUIVALENTS 379
U S TO METRIC CONVERSION 379
ADVANCE HAND CONTROL SYSTEM (AHC) 381
ELECTRICAL SCHEMATICS W/ADVANCED HAND CONTROL OPTIONS 383
AHC COMPONENTS 389
Identification 389
TROUBLESHOOTING (AHC) 390
Chart 390
ACTUATOR VOLTAGE TEST 392
Procedure 392
HANDLE CONTROL UNIT TEST 395
Procedure 395
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 398
Troubleshooting Chart 398
ADVANCED HAND CONTROLS (AHC) 398
Troubleshooting Chart 398
AHC/PWM CONTROLLER 399
Removal And Installation 399
Description 400
Conditions 401
Troubleshooting Chart 401
Handle Testing 402
Solenoid Coil Testing 402
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) 403
Control Handle Unit Removal And Installation 403
Control Unit Connector 406
Switch Handle Removal And Installation 407
AHC Handle Removal And Installation 410
AHC Handle Disassembly And Assembly 411
AHC Steering Lever Removal And Installation 412
AHC Steering Lever Boot 412
Actuators Removal And Installation 413
Actuators Disassembly And Assembly 414
CONTROL HANDLE (ADVANCED HAND CONTROL) (AHC) (W/PUSH BUTTON FLOAT) 415
Components Identification 415
Controller Connector And Wire Identification 416
AHC/PWM Controller Removal And Installation 417
Handle Sensor Removal And Installation 418
Handle Sensor Connector 420
Switch Handle Removal And Installation 421
Control Handle Removal And Installation 424
Control Handle Disassembly And Assembly 425
Control Lever Removal And Installation 426
Control Lever Boot 427
Actuators Disassembly And Assembly 428
Components Identification 415
BICS™ VALVE 429
Lift Arm By–Pass Orifice 429
Check Valve 430
Lock Valve 430
BICS™ Valve Solenoid 431
Removal And Installation 432
HYDRAULIC CONTROL VALVE 433
Removal And Installation 433
Identification Chart 435
Disassembly And Assembly 436
Load Check Valve 436
Lift Base End Restrictor 436
Main Relief Valve 437
Port Relief Valve (Lift) 438
Anti–Cavitation/Port Relief Valve 438
Port Relief Valve (Tilt) 439
Anti–Cavitation Valve 439
Rubber Boot 440
Lift And Tilt Spool 441
Inspection 443
Auxiliary Spool 444
Auxiliary Electrical Solenoid 445
Spool Seal Installation 446
H–Port Auxiliary Section 447
SERVICE MANUAL REVISIONS 449
751–1 449
751–2 451
751–3 453
751–4 455
751-5 457

DESCRIPTION:

Bobcat 751 Loader Service Manual 6900443 (6-12) – PDF DOWNLOAD

S/N 515711001–515729999
S/N 515611001–515619999

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.

SAFETY INSTRUCTIONS:

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.

Wear tight fitting clothing and any other required safety apparel when operating or servicing the loader.
• Wear safety glasses when maintaining or servicing the loader.
• Exhaust gases can kill, vent engine exhaust outdoors.
• Know where fire extinguishers and first aid kits are located and how to use them.
• Do not run the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.
• 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.
• Clean the loader 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 welding or grinding painted parts. Wear a dust mask when grinding painted parts. Toxic dust
and gas can be produced.
• Stop the engine and let it cool before adding fuel. No smoking.
• Use the procedure in this manual for connecting and charging batteries.J
• Use the procedure in the Operator’s Manual for cleaning the spark arrestor muffler after each 100 hours of operation.

Customer Support: [email protected]

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