Bobcat 751 Loader Service Manual 6900975 (6-12) – PDF DOWNLOAD
FILE DETAILS:
Bobcat 751 Loader Service Manual 6900975 (6-12) – PDF DOWNLOAD
Language : English
Pages : 566
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Bobcat 751 Loader Service Manual 6900975 (6-12) – PDF DOWNLOAD
MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
Fire Prevention 13
SERIAL NUMBER LOCATIONS 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 15
LOADER IDENTIFICATION 16
SAFETY & MAINTENANCE 17
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 19
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 19
Inspecting Deactivation Of The Auxiliary Hydraulics 19
System (Engine STOPPED – Key ON) 19
Inspecting The Seat Bar Sensor (Engine RUNNING) 19
Inspecting The Traction Lock (Engine RUNNING) 19
Inspecting The Lift Arm By-Pass Control 19
Additional Inspection For Loaders With Advanced 19
Hand Controls (AHC) 19
LIFTING AND BLOCKING THE LOADER 21
Procedure 21
TRANSPORTING THE BOBCAT LOADER 23
Procedure 23
TOWING THE LOADER 25
Procedure 25
LIFT ARM SUPPORT DEVICE 27
Engaging The Lift Arm Support Device 27
Disengaging The Lift Arm Support Device 29
BOB-TACH 31
Inspection and Maintenance 31
OPERATOR CAB 33
Description 33
Raising The Operator Cab 33
Lowering The Operator Cab 34
Emergency Exit 35
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS) 37
Description 37
Inspecting the Seat Bar 37
Maintaining the Seat Bar 37
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) 39
Description 39
Inspecting the Seat Bar 39
Maintaining the Seat Bar 39
REMOTE START 41
Procedure 41
SERVICE SCHEDULE 43
Chart 43
FUEL SYSTEM 45
Fuel Specifications 45
Filling the Fuel Tank 45
Fuel Filter 46
Removing Air From The Fuel System 47
AIR CLEANER SERVICE 49
Checking 49
ENGINE LUBRICATION SYSTEM 51
Checking Engine Oil 51
Oil Chart 51
Replacing Oil And Filter 51
ENGINE COOLING SYSTEM 53
Cleaning The Cooling System 53
Checking The Coolant Level 53
Replacing The Coolant 54
HYDRAULIC/HYDROSTATIC SYSTEM 55
Checking And Adding Fluid 55
Replacing Hydraulic/Hydrostatic Filter 55
Replacing Hydraulic Fluid and Case Dain Filters 56
Breather Cap 57
TIRE MAINTENANCE 59
Wheel Nuts 59
Rotating 59
Mounting 59
LUBRICATION OF THE BOBCAT LOADER 61
Procedure 61
HYDRAULIC SYSTEM 63
HYDRAULIC/HYDROSTATIC SCHEMATICS 65
HYDRAULIC SYSTEM INFORMATION 67
Tighten Procedures 70
Troubleshooting Chart 71
CYLINDER(S) 73
Checking The Lift Cylinders 73
Lift Cylinders Removal And Installation 74
Checking The Tilt Cylinder 75
Tilt Cylinder Removal And Installation 76
Lift Cylinder Identification 78
Tilt Cylinder Identification 79
Disassembly 80
Assembly 82
MAIN RELIEF VALVE 85
Checking 85
Adjustment 86
Removal and Installation 86
BICS™ VALVE 87
Removal And Installation 87
Lift Arm By-Pass Orifice Dissembly And Assembly 88
Check Valve Dissembly And Assembly 89
Lock Valve Dissembly And Assembly 90
Solenoid Dissembly And Assembly 91
Solenoid Testing 92
HYDRAULIC CONTROL VALVE (FOOT CONTROL) 93
Removal And Installation 93
Identification Chart 97
Load Check Valve 98
Main Relief Valve 99
Port Relief Valve 100
Anti-Cavitation Valve 101
Plug 102
Rubber Boot 103
Lift And Tilt Lock Block 104
Lift Spool and Detent 105
Tilt Spool Removal And Installation 114
Auxiliary Spool Removal And Installation 116
Auxiliary Electric Solenoid Disassembly 117
Port-Auxiliary Section Disassembly 118
Cleaning And Inspection 118
HYDRAULIC CONTROL VALVE (AHC) 119
Removal And Installation 119
Actuator Removal And Installation 123
Identification Chart 124
Lift Base End Restrictor 125
Load Check Valve 125
Main Relief Valve 126
Port Relief Valve 127
Anti-Cavitation Valve 128
Plug 129
Lift Spool Removal And Installation 130
Tilt Spool Removal And Installation 131
Lift and Tilt Spool Disassembly And Assembly 132
Auxiliary Spool Removal And Installation 133
Auxiliary Electric Solenoid Disassembly 134
Port-Auxiliary Section Disassembly 135
Cleaning And Inspection 135
LIFT ARM BY-PASS CONTROL VALVE 137
Inspecting 137
Additional Inspection For Loaders With Advanced Hand Controls 137
Removal And Installation 137
Disassembly And Assembly 138
HYDRAULIC PUMP (ALUMINUM) 139
Checking The Output Of The Hydraulic Pump 139
Removal And Installation 140
Parts Identification 142
Disassembly And Assembly 143
Inspection 145
HYDRAULIC FILTER HOUSING 147
Removal And Installation 147
HYDRAULIC FLUID RESERVOIR 149
Removal And Installation 149
CONTROL PEDALS 151
Removal And Installation 151
Pedal Adjustment 151
BUCKET POSITION VALVE 153
Solenoid Removal And Installation 153
Solenoid Testing 153
Removal And Installation 154
Disassembly And Assembly 155
FRONT AUXILIARY PRESSURE RELIEF BLOCK 157
Removal And Installation 157
Disassembly And Assembly 158
Solenoid Testing 159
Solenoid Inspection 159
HYDROSTATIC SYSTEM 161
HYDROSTATIC SYSTEM INFORMATION 163
Troubleshooting Chart 163
Replenishing Valve Function 164
CONTROL PANEL 165
Removal and Installation 165
STEERING 167
Shock Removal And Installation 167
Steering Shaft Removal And Installation 167
Shaft Disassembly And Assembly 168
Lever Removal And Installation 169
Rubber Boot Replacement 169
Linkage Removal And Installation 170
Linkage Adjustment 172
Neutral Adjustment 175
STEERING (ADVANCE HAND CONTROL) (AHC) 179
Components Identification 179
Handle Control Unit Removal And Installation 180
Steering Handle Removal and Installation 183
Steering Handle Disassembly and Assembly 183
Lever Removal and Installation 184
Steering Lever Boot 184
STEERING (ADVANCED HAND CONTROL) (AHC) W/ PUSH BUTTON FLOAT 185
Components Identification 185
Handle Sensor Removal And Installation 185
Control Handle Removal And Installation 187
Control Handle Disassembly And Assembly 188
Control Lever Removal And Installation 189
Control Lever Boot 190
HYDROSTATIC MOTOR 191
Removal And Installation 191
Parts Identification 193
Disassembly 194
Assembly 199
Carrier Shaft Seal Replacement 205
Carrier Removal And Installation 207
HYDROSTATIC MOTOR 209
Carrier Parts Identification 209
Carrier Disassembly 210
Carrier Assembly 211
CHARGE PRESSURE 215
Sender Removal And Installation 215
Checking Charge Pressure 215
Adjusting 216
HYDROSTATIC PUMP 217
Replenishing/High Pressure Relief Valve 217
Removal And Installation 218
Parts Identification (Right Half) 220
Parts Identification (Left Half) 222
Hydraulic Pump Removal And Installation 224
Pump Separation 225
Disassembly 226
Assembly 232
DRIVE BELT 239
Shield Removal And Installation 239
Adjusting 240
Drive Belt Replacement 241
Tensioner Pulley Removal And Installation 242
Tensioner Pulley Parts Identification 243
Tensioner Pulley Disassembly 244
Tensioner Pulley Assembly 245
OIL COOLER 247
Removal and Installation 247
DRIVE SYSTEM 249
BRAKE 251
Pedal Removal And Installation 251
Pedal Disassembly And Assembly 251
Disc Removal And Installation 252
DRIVE COMPONENTS 255
Axle Seal Removal And Installation 255
Axle Sprocket And Bearings Removal And Installation 257
Chain Removal And Installation 262
CHAINCASE 265
Checking And Adding Oil 265
Removing The Oil 265
Front Cover Removal And Installation 266
Center Cover Removal And Installation 267
Rear Cover Removal And Installation 268
MAIN FRAME 269
SEAT BAR 271
Removal And Installation 271
Assembling Components 273
Compression Spring Disassembly And Assembly 275
OPERATOR CAB 277
Gas Cylinder Removal And Installation 277
Gas Cylinder Disassembly 279
Removal And Installation 280
OPERATOR SEAT 283
Removal And Installation 283
Slide Rail Removal And Installation 284
Cushion Removal And Installation 285
Back Removal And Installation 286
Shock Removal And Installation 287
BOB-TACH 289
Removal And Installation 289
Bob-Tach Lever And Wedge 291
Bob-Tach Stops 292
LIFT ARM 293
Removal And Installation 293
REAR GRILL 299
Gas Cylinder Removal And Installation 299
Removal And Installation 300
REAR DOOR 301
Removal And Installation 301
Door Latch And Catch Adjustment 302
Door Latch Removal And Installation 303
FUEL TANK 305
Removal And Installation 305
Fuel Level Sender 306
ELECTRICAL SYSTEM & ANALYSIS 307
ELECTRICAL SCHEMATICS 313
ELECTRICAL SYSTEM INFORMATION 311
WIRING SCHEMATICS 311
Troubleshooting Chart 318
Description 319
Fuse Location 320
Relay Switch Location 320
Solenoid Test 321
BATTERY 323
Removal And Installation 323
Servicing 324
Using A Booster Battery (Jump Starting) 325
ALTERNATOR 327
Adjusting The Alternator Belt 327
Alternator Output Test 327
Rectifier (Diode) Test 328
Alternator Regulator Test 328
Removal And Installation 330
Disassembly 331
Stator Continuity Test 331
Stator Ground Test 331
Rotor Continuity Test 332
Rotor Ground Test 332
Rectifier Continuity (Diode) Test 332
Assembly 333
STARTER 335
Checking 335
Removal And Installation 335
Parts Identification 336
Disassembly 337
Inspection And Repair 342
No Load Test 345
Assembly 345
INSTRUMENT PANEL 355
Left Panel 355
Right Panel – (Standard) (With Key Switch) 356
Right Panel – (Deluxe) (With Keyless Start) 357
Right Panel Setup Display Options (Deluxe) 359
Passwords 360
Option and Field Accessory Panels 362
Removal And Installation 363
LIGHTS 365
Front Removal And Installation 365
Rear Removal And Installation 366
BOBCAT CONTROLLER 367
Identification Chart 367
Removal And Installation 368
DIAGNOSTICS 369
Service Codes 369
BICS™ SYSTEM 373
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 373
Inspecting Deactivation Of The Auxiliary Hydraulics 373
System (Engine STOPPED – Key ON) 373
Inspecting The Seat Bar Sensor (Engine RUNNING) 373
Inspecting The Traction Lock (Engine RUNNING) 373
Inspecting The Lift Arm By-Pass Control 374
Additional Inspection For Loaders With Advanced 374
Hand Controls (AHC) 374
Troubleshooting Chart 375
Troubleshooting Guide 376
SEAT BAR SENSOR 377
Troubleshooting Chart 377
Test 378
Removal And Installation 379
BICS™ Circuit Test 380
TRACTION LOCK 381
Troubleshooting Chart 381
Inspecting 382
Solenoid Removal And Installation 382
Guide Removal 384
Guide Installation 386
ADVANCED HAND CONTROL (AHC) SYSTEM 389
Components Identification 389
ADVANCED HAND CONTROL (AHC) SYSTEM 390
Troubleshooting Guide 390
Parts Identification 391
AHC Controller Removal And Installation 392
Handle Control Unit Connector 393
Switch Handle Removal and Installation 394
Actuators Disassembly and Assembly 397
ADVANCED HAND CONTROL (AHC) SYSTEM 399
(W/PUSH BUTTON FLOAT) 399
Components Identification 399
Troubleshooting Guide 400
Controller Connector And Wire Identification 401
AHC Controller Removal And Installation 402
Handle Sensor Removal And Installation 402
Handle Sensor Connector 404
Switch Handle Removal And Installation 405
Actuators Disassembly And Assembly 407
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE 409
Controls Identification Chart 409
ENGINE SERVICE 411
TROUBLESHOOTING 413
Chart 413
ENGINE SPEED CONTROL 415
Removal And Installation 415
Disassembly 415
MUFFLER 417
Removal And Installation 417
Spark Arrestor Cleaning Procedure 418
AIR CLEANER 419
Replacing Filter Element(s) 419
Removal And Installation 421
RADIATOR 423
Removal And Installation 423
COOLING FAN 425
Drive Tension Pulley Removal And Installation 425
Gearbox/Blower Housing Removal And Installation 426
Blower Housing Grill Removal And Installation 428
Blower Disassembly And Assembly 428
Gearbox Parts Identification 430
Gearbox Disassembly 431
Gearbox Assembly 436
Gearbox Checking Backlash 441
ENGINE COMPONENTS AND TESTING 445
Compression Checking 445
Glow Plugs Checking 446
Glow Plugs Removal And Installation 447
Fuel Shut-Off Solenoid, Checking 448
Fuel Shut-Off Solenoid, Adjusting 449
Fuel Shut-Off Solenoid Removal And Installation 450
Checking 451
Fuel Injection Pump Removal And Installation 452
Timing The Injection Pump 455
Fuel Injector Removal And Installation 457
Fuel Injector Checking 459
Fuel Injector Disassembly 459
Fuel Injector Assembly 460
Valve Clearance Adjustment 460
Rocker Arm And Shaft Checking 461
Valve Timing, Checking 462
ENGINE 463
Removal And Installation 463
Engine Mount Replacement 469
FLYWHEEL AND HOUSING 471
Flywheel Removal And Installation 471
Ring Gear Removal And Installation 472
Housing Removal And Installation 473
RECONDITIONING THE ENGINE 475
Cylinder Head Removal And Installation 475
Cylinder Head Disassembly And Assembly 476
Cylinder Head Servicing 477
Cylinder Head Top Clearance 477
Checking The Valve Guide 478
Reconditioning The Valve And Valve Seat 479
Valve Spring 480
Rocker Arm And Shaft Checking 481
Timing Gearcase Cover Removal And Installation 482
Idler Gear And Camshaft Removal And Installation 484
Servicing The Camshaft 485
Servicing The Idler Gear And Shaft 486
Timing Gears Checking Backlash 487
Fuel Camshaft Removal And Installation 488
Fuel Camshaft Governor 488
Crankshaft Gear Removal And Installation 489
Oil Pump Removal And Installation 489
Oil Pump Service 489
Checking Engine Oil Pressure 490
Relief Valve 491
Piston And Connecting Rod Removal And Installation 491
Servicing The Piston And Connecting Rod 493
Connecting Rod Alignment 495
Crankshaft And Bearings Removal And Installation 496
Servicing The Crankshaft And Bearings 497
Checking The Cylinder Bore 501
Water Pump Disassembly And Assembly 502
HEATER 503
COMPONENTS 505
Identification 505
REGULAR MAINTENANCE 507
Filter Elements Removal And Installation 507
BASIC TROUBLESHOOTING 511
Cleaning The Heater Coil 511
Checking The Electrical System 513
Engine Coolant By-Passing The Heater Valve 518
Heater Valve Not Opening Or Closing 518
SYSTEM TROUBLESHOOTING CHART 521
Blower Motor Does Not Operate 521
Blower motor operators normally, but air flow is insufficient 521
HEATER UNIT 523
Removal And Installation 523
Disassembly And Assembly 524
HEATER COIL 525
Removal And Installation 525
HEATER FAN 527
Removal And Installation 527
Disassembly And Assembly 528
Wire Connector Removal and Installation 530
HEATER VALVE 533
Removal and Installation 533
Disassembly And Assembly 534
SPECIFICATIONS 535
LOADER SPECIFICATIONS 537
Specifications 537
Performance 537
Controls 537
Engine 538
Hydraulic System 538
Electrical 539
Drive System 539
Capacities 539
Tires 539
Floor Pressure 539
ENGINE SPECIFICATIONS 541
Fuel Injection Nozzles 541
Fuel Injection Pump 541
Cylinder Head 541
Valves 541
Valve Springs 542
Valve Timing 542
Rocker Arms 542
Camshaft 542
Tappet 542
Cylinders 543
Piston Rings 543
Pistons 543
Connecting Rod 543
Oil Pump 543
Crankshaft 544
Timing Gear 544
Thermostat 544
Crankshaft Re-Grind Data 545
LOADER TORQUE 547
Specifications 547
TORQUE SPECIFICATIONS FOR BOLTS 549
Torque for General SAE Bolts 549
Torque For General Metric Bolts 550
HYDRAULIC CONNECTION SPECIFICATIONS 551
O-ring Face Seal Connection 551
Straight Thread O-ring Fitting 551
Tubelines And Hoses 551
Flare Fitting 552
O-ring Flare Fitting 553
Port Seal Fitting 555
HYDRAULIC FLUID SPECIFICATIONS 557
Specifications 557
CONVERSIONS 559
Decimal And Millimeter Equivalents 559
U S To Metric Conversion 560
SMR 561
Revision No: 751-1 561
Revision No: 751-2 563
Revision No: 751-3 565
DESCRIPTION:
Bobcat 751 Loader Service Manual 6900975 (6-12) – PDF DOWNLOAD
(S/N 515730001 & Above)
(S/N 515620001 & Above)
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 Bobcat machine and attachments:
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
S.V