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BOBCAT 751 SKID STEER LOADER Service Repair Manual SN 515730001 & Above PDF
BOBCAT 751 SKID STEER LOADER Service Repair Manual SN 515730001 & Above PDF
BOBCAT 751 SKID STEER LOADER Service Repair Manual SN 515730001 & Above PDF
Manual
(S/N 515730001 & Above)
(S/N 515620001 & Above)
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6900975 (2-06) Printed in U.S.A. © Bobcat Company 2006
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.
RADIATOR...............................................................70-01
REAR DOOR ..........................................................50-01
REAR GRILL ..........................................................50-01
RECONDITIONING THE ENGINE ..........................70-01
REGULAR MAINTENANCE ....................................80-01
REMOTE START .....................................................10-01
TIRE MAINTENANCE..............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING THE LOADER ............................10-01
TROUBLESHOOTING.............................................70-01
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HEATER
SPECIFICATIONS
SPECIFICATIONS
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 side screens) is in function correctly.
good condition and is not
modified.
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).
18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.
19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tires for wear and Recommend to the owner that all
pressure. necessary corrections be made
before the machine is returned to
service.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.
SI SSL-0206 SM
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Figure 2
N-20521
DELIVERY REPORT
Figure 4
N-20515
XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
FRONT LIGHTS
OPERATOR SEAT
WITH SEAT BELT
GRAB HANDLES
TILT CYLINDER
+BUCKET
▼FRONT AUXILIARY
QUICK COUPLERS
●OPERATOR CAB
▼REAR WINDOW (ROPS & FOPS)
LIFT ARM
LIFT ARM
SUPPORT DEVICE
LIFT CYLINDERS
▼TAIL LIGHT
▼REAR LIGHT
*TIRES B-15629
REAR DOOR
B-15630
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Inspecting The BICS™ Controller (Engine STOPPED - 6. Fasten the seat belt, disengage the parking brake
Key ON) pedal, press the PRESS TO OPERATE LOADER
Button and raise the Seat Bar fully. Move the steering
Figure 10-10-5 levers slowly forward and backward. The TRACTION
lock should be engaged. Lower the Seat Bar. Press
the PRESS TO OPERATE LOADER Button.
10. Raise the lift arms about 6 feet (2 meters) off the
2. Raise the Seat Bar fully. All four BICS lights (Items 1,
ground.
2, 3, & 4) [Figure 10-10-5] [PRESS TO OPERATE
LOADER, SEAT BAR, LIFT & TILT VALVE and
11. Turn key OFF (Standard Panel), press the STOP
TRACTION*] on left instrument panel should be OFF
Button (Deluxe Panel, and wait for the engine to come
[Figure 10-10-5].
to a complete stop.
NOTE: Record what lights are blinking (if any) and the
12. Turn key ON (Standard Panel), press RUN/ENTER
number of light flashes. (See BICS™ SYSTEM
Button (Deluxe Panel. Press the PRESS TO
on Page 60-90-1.)
OPERATE LOADER Button, move the left hand
control toward the operator. The lift arms should not
Inspecting Deactivation Of The Auxiliary Hydraulics
lower.
System (Engine STOPPED - Key ON)
13. Move the right hand control away from the operator.
3. Sit in the operator's seat, lower the Seat Bar, and
The bucket (or attachment) should not tilt forward.
press the PRESS TO OPERATE LOADER Button.
Press the auxiliary hydraulics FLOW Button. The
auxiliary FLOW Button light will come ON. Raise the
Seat Bar. The light should be OFF.
Procedure
Figure 10-20-1
Put floor jack under the rear of the loader [Figure 10-20-
2].
B-7023A
Lift the rear of the loader and install jackstands [Figure
10-20-2].
Figure 10-20-3
WARNING
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. Failure to follow
instructions can cause injury or death [Figure 10-20-
1].
W-2003-1298
Put the floor jack under the front of the loader [Figure 10-
WARNING 20-3].
Lift the front of the loader and put jackstands under the
Put jackstands under the front axles and rear corners axle tubes [Figure 10-20-3].
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to NOTE: Make sure the jackstands do not touch the
fall or move and cause injury or death. tires. Make sure tires clear floor or any
W-2017-0286 obstacles.
Procedure
WARNING
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
Figure 10-30-1
A loader with an empty bucket or no attachment must be Use the following procedure to fasten the Bobcat loader
loaded backward onto the transport vehicle [Figure 10- to the transport vehicle to prevent the loader from moving
30-1]. during sudden stops or when going up or down slopes
[Figure 10-30-2].
The rear of the trailer must be blocked or supported (Item
1) [Figure 10-30-1] when loading or unloading the loader • Lower the bucket or attachment to the floor.
to prevent the front end of the trailer from raising up.
• Stop the engine.
Procedure
Figure 10-40-1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Lower the lift arm support device on top of the lift cylinder.
WARNING Hook the free end of the spring (Item 1) [Figure 10-50-2]
to the lift arm support device so there will be no
Service lift arm support device if damaged or if parts interference with the support device engagement.
are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop With the operator in the seat, seat belt fastened and seat
causing injury or death. bar lowered, start the engine.
W-2271-1197
Press the PRESS TO OPERATE LOADER button.
Figure 10-50-1
Figure 10-50-3
Raise the lift arms, until the lift arm support device drops
onto the lift cylinder rod [Figure 10-50-3].
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move pedals or the hand controls
until both pedals lock.
Install pin (Item 1) [Figure 10-50-3] into the rear of the lift
arm support device below the cylinder rod.
Figure 10-50-4
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
Raise the lift arms a small amount and the spring will lift
the support device off the lift cylinder rod. Lower the lift
arms. Stop the engine.
Raise the seat bar and move pedals (or hand controls)
until both pedals lock.
Figure 10-60-1
Move the Bob-Tach levers to engage the wedges [Figure If the wedge does not contact the lower edge of the hole
10-60-1]. The levers and wedges must move freely. [Figure 10-60-2] and [Figure 10-60-3], the attachment
will be loose and can come off the Bob-Tach.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-60-1]. Figure 10-60-4
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497
Figure 10-60-2
Description
Level II - Protection from falling trees, rocks; for Remove the nuts and plates [Figure 10-70-2] (both
machines involved in site clearing, overhead demolition sides).
or forestry.
Figure 10-70-3
Raising The Operator Cab
Figure 10-70-1
Raising The Operator Cab (Cont’d) Always stop the engine before raising or lowering the
cab.
Advanced Hand Controls Only
NOTE: Make sure the seat bar is fully raised or
lowered when lowering the cab. Always use
the grab handles to lower the cab.
Figure 10-70-4
WARNING Pull down on the bottom of the operator cab until it stops
at the latching mechanism [Figure 10-70-4].
Never modify operator cab by welding, grinding, Release the latching mechanism (Inset) [Figure 10-70-4]
drilling holes or adding attachments unless and pull the cab all the way down.
instructed to do so by Melroe Company. Changes to
the cab can cause loss of operator protection from Figure 10-70-5
rollover and falling objects, and result in injury or
death.
W-2069-1285
Emergency Exit
Figure 10-70-6
Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-70-8].
Figure 10-70-9
Push the rear window out of the rear of the operator cab.
Figure 10-70-7
The seat bar restraint system has a pivoting seat bar with
arm rests and hydraulic valve spool 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.
Raise the seat bar. Try to move each foot pedal. Pedals
must be firmly locked in the NEUTRAL position. There
must be no motion of the lift arms or tilt (attachment) WARNING
when the controls are moved.
AVOID INJURY OR DEATH
Pull the seat bar down, press the PRESS TO OPERATE • The seat bar system must lock the lift and tilt
LOADER Button, lower the lift arms. Operate the lift control pedals in neutral when the seat bar is up.
control. While the lift arms are going up, raise the seat Service the system if pedals do not lock
bar. The lift arms must stop. correctly.
W-2105-1285
Lower the seat bar, press the PRESS TO OPERATE
LOADER Button, lower the lift arms and put the
attachment flat on the ground. Stop the engine. Raise the
seat bar and operate the foot pedals to be sure that the
pedals are firmly locked in the NEUTRAL position.
Unfasten the seat belt.
Figure 10-81-1 Use compressed air to clean any debris or dirt from the
pivot parts (Item 1) [Figure 10-81-1]. Do not lubricate.
Inspect all mounting hardware. The correct bolt torque is
26 ft.-lbs. (35 Nm).
WARNING
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.
The seat bar restraint system [Figure 10-81-1] has a W-2355-0799
pivoting seat bar with arm rests .
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 up, the lift, tilt and traction drive
functions are deactivated.
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. Move each hand control back
and forth. There must be no zip-zip sound of the lift or tilt
actuators. If either actuator makes a sound while the seat
bar is raised, contact your dealer for service.
Procedure
Figure 10-90-1
Figure 10-90-4
Raise the operator cab (if required by the procedure). Connect the remote start tool to the engine harness
(See Raising The Operator Cab on Page 10-70-1.) connector (Item 1) [Figure 10-90-4].
Open the rear door of the loader. NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Kit will not operate.
Figure 10-90-2
WARNING
AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
the Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working in the engine area
it is important to remove the operator panel keys.
W-2357-0899
Procedure (Cont'd)
Figure 10-90-5
❏ Check wheel nut torque every 8 hours for the first 24 hours.
* Inspect the new belt after first 50 hours.
● Replace filter element after the first 50 hours and when the transmission warning light comes ON.
^ First oil and filter change must occur at 50 hours; 250 hours thereafter.
■ Or every 12 months.
Fuel Specifications
Contact your fuel supplier for local recommendations. Use a clean, approved safety container to add fuel of the
correct specifications. Add fuel only in an area that has
Filling the Fuel Tank free movement of air and no open flames or sparks. NO
SMOKING! [Figure 10-110-8].
Install and tighten the fuel fill cap (Item 1) [Figure 10-
WARNING 110-7].
Fuel Filter
Figure 10-110-9
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and
hand tighten.
Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-110-3.)
Checking
Figure 10-120-1
Replace the inner filter every third time the outer filter is
replaced or as indicated on Contents Page 70-01.
Figure 10-130-1
Keep the oil level between the marks on the dipstick. Remove the drain plug (Item 1) [Figure 10-130-2].
Use a good quality motor oil that meets API Service Drain the oil into a container and dispose of used oil in an
Classification of CD or better (See Oil Chart below). environmentally safe manner.
Oil Chart
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Figure 10-130-3
Check for leaks at the oil filter and check the oil level.
Figure 10-130-5
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285
Raise the oil cooler and clean the top of the radiator
[Figure 10-140-2].
Figure 10-140-1
WARNING
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1285
IMPORTANT
Connect a hose to the engine block drain valve (Item 1)
AVOID ENGINE DAMAGE
[Figure 10-140-5].
Always use the correct ratio of water to anti freeze.
Too much antifreeze reduces cooling system
Open the drain valve and drain all of the coolant into a
efficiency and may cause serious premature engine
container.
damage.
Too little antifreeze reduces the additives which
Close the drain valve.
protect the internal engine compo nents; reduces the
boiling point and freeze protection of the system.
Mix the coolant in a separate container. (See Capacities
Always add a premixed solution. Adding full strength
on Page SPEC-10-3, for correct capacity.)
concentrated coolant can cause seri ous premature
engine damage.
I-2124-0497
NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Open the rear door. Open the rear grill.
Add premixed coolant, 47% water and 53% propylene
Figure 10-140-4 glycol to the recovery tank if the coolant level is low.
Remove the radiator cap (Item 1) [Figure 10-140-4]. Stop the engine.
Figure 10-150-6
Stop the loader on a level surface. Lower the lift arms and Figure 10-150-9
tilt the Bob-Tach fully back.
Figure 10-150-7
Add the fluid as needed to bring the level to the top mark Put clean oil on the seal of the new filter element.
on the dipstick [Figure 10-150-7]. Do not fill above the
top mark. Install and hand tighten the filter element.
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person's body by
penetrating the skin and cause serious injury and
possibly death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Always clean up spilled fuel or oil. Keep heat, flames, Remove the case drain filter (Item 2) [Figure 10-150-11].
sparks or lighted tobacco away from fuel and oil. Drain the fluid into a container.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death. Drain the fluid into a container and recycle or dispose in
W-2103-1285 an environmentally safe manner.
Figure 10-150-10
Figure 10-150-12
Remove the left case drain filter (Item 1) [Figure 10-150- Raise the cab. (See Raising The Operator Cab on Page
12] and drain the fluid into a container. 10-70-1.)
Recycle or dispose of the fluid in an environmentally safe Remove the breather cap (Item 1) [Figure 10-150-13].
manner.
Figure 10-150-14
Replace the hydraulic/hydrostatic filter element. (See
Replacing Hydraulic/Hydrostatic Filter on Page 10-150-
1.)
Add the correct fluid to the reservoir until the fluid level is
between the marks on the dipstick. DO NOT fill above the
top mark on the dipstick.
Wheel Nuts
Figure 10-160-1
WARNING
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
IMPORTANT
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
See Wheel Nuts on Page 10-160-1 for the service
interval to check the wheel nuts. The correct torque is Tires are to be repaired only by an authorized person
105-115 ft.-lbs. (142-156 Nm) torque [Figure 10-160-1]. using the proper procedures and safety equipment.
Rotating Tires and rims must always be checked for correct size
before mounting. Check rim and tire bead for damage.
Check the tires regularly for wear, damage and pressure.
(See Tires on Page SPEC-10-3 for the correct tire
pressure.) The rim flange must be cleaned and free of rust.
Figure 10-160-2 The tire bead and rim flange must be lubricated with a
rubber lubricant before mounting the tire.
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-160-2].
It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Procedure
Figure 10-170-1
3. Lift Arm Pivot Pin (Both Sides) [Figure 10-170-3].
Figure 10-170-4
Figure 10-170-2
4. Base End Tilt Cylinder (Both Sides) [Figure 10-170-
4].
Procedure (Cont'd)
Figure 10-170-5
Figure 10-170-8
5. Rod End Tilt Cylinder [Figure 10-170-5].
Figure 10-170-6
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure
10-170-8].
6. Bob-Tach Pivot Pin (Both Sides) [Figure 10-170-6].
Check that the lock nuts are tightened to 18-20 ft.-lbs.
7. Bob-Tach Wedge (Both Sides) [Figure 10-170-6]. (24-27 Nm) torque.
CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-10
Checking The Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Checking The Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . 20-20-3
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-8
Lift Cylinders Removal And Installation . . . . . . . . . . . . . . . 20-20-2
Tilt Cylinder Removal And Installation . . . . . . . . . . . . . . . . 20-20-4