Bobcat 751 skid steer loader service repair manual sn：514711001 & above

7 5 1 EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM)

Service Manual (S/N 514711001 & Above) (S/N 514911001 & Above)

6724925 (5–97)

Printed in U.S.A.

© Melroe Company 1997

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s 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 W-2003-0903 instructions can cause injury or death.

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-12365

B-7469

Never service the Bobcat SkidSteer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-11799

B-15231

B-15280

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device.

Replace it if damaged.

Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged.

Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

WRONG

WRONG

B-6590

B-6580 B-16102

B-6589 B-16102

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust loader with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Never fill fuel tank with engine running, while smoking or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used.

Use eye protection approved for type of welding.

Keep rear door closed except for service. Close and latch door before operating the loader.

Lead-acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact.

Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

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.

MSW01-0805

ALPHABETICAL INDEX AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . .

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . .

AXLE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AXLE, SPROCKET AND BEARINGS . . . . . . . . . . . .

7–1 1–1 6–1 1–1 4–1 4–1

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 BICS™ SYSTEM CONTROLLER . . . . . . . . . . . . . . . . 8–1 BICS™ VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 BLOWER HOUSING/FAN GEARBOX . . . . . . . . . . . 7–1 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . 8–1 BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1 CHAINCASE COVERS . . . . . . . . . . . . . . . . . . . . . . . .

CHAINCASE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT AND BEARINGS . . . . . . . . . . . . . . . .

CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER LOCATION & COMPRESSION . . . . . . .

4–1 4–1 3–1 2–1 7–1 7–1 7–1 7–1

DECIMAL & MILLIMETER EQUIVALENTS . . . . . . .

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE BELT HOUSING . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–1 1–1 3–1 4–1

ELECTRICAL SYSTEM INFORMATION . . . . . . . . .

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . .

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . .

ENGINE MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . .

ENGINE TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6–1 7–1 7–1 1–1 1–1 7–1 9–1 7–1 7–1

FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 7–1 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . 1–1 FIXED DRIVE BELT TENSIONER PULLEY . . . . . . . 3–1 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 FRONT LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . 7–1 FUEL INJECTION NOZZLES . . . . . . . . . . . . . . . . . . . 7–1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . .

HYDRAULIC CYLINDER IDENTIFICATION . . . . . . .

HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC FILTER HOUSING . . . . . . . . . . . . . . . .

HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . .

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . .

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . .

HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . .

HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . .

HYDROSTATIC SYSTEM INFORMATION . . . . . . . .

2–1 2–1 2–1 2–1 2–1 9–1 1–1 2–1 2–1 3–1 3–1 3–1

INJECTION PUMP TIMING . . . . . . . . . . . . . . . . . . . . 7–1 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . .

LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFT CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFT LOCK BY–PASS VALVE . . . . . . . . . . . . . . . . . . .

LIFTING AND BLOCKING THE LOADER . . . . . . . .

LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . .

LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . .

1–1 5–1 2–1 8–1 1–1 1–1 9–1 1–1

MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . 1–1, 5–1 OPERATOR CAB GAS CYLINDER . . . . . . . . . . . . . . . 5–1 OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARKING BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . .

PEDAL INTERLOCK LINKAGE . . . . . . . . . . . . . . . . . .

PEUGEOT ENGINE TOOL KIT . . . . . . . . . . . . . . . . . .

PISTONS AND CONNECTING ROD . . . . . . . . . . . . .

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POSITIVE CRANKCASE VENTILATION VALVE . . .

4–1 4–1 2–1 7–1 7–1 1–1 7–1

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RELAY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE START SWITCH . . . . . . . . . . . . . . . . . . . . . .

7–1 5–1 5–1 6–1 1–1

SEAT BAR (W/COMPRESSION SPRINGS) . . . . . . .

SEAT BAR (W/GAS CYLINDER) . . . . . . . . . . . . . . . . .

SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . .

SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEAT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . .

SPRING LOADED DRIVE BELT TENSIONER PULLEY . . . . . . . . . . . . . . . . . . . . . . . . .

STANDARD INSTRUMENT PANEL . . . . . . . . . . . . . . .

STANDARD TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . .

STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . .

5–1 5–1 1–1 8–1 8–1 1–1 1–1 3–1 6–1 9–1 6–1 3–1 1–1

TILT LOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TORQUE SPECIFICATIONS FOR LOADER . . . . . . . 9–1 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 TRACTION LOCK GUIDES . . . . . . . . . . . . . . . . . . . . . . 4–1 TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . . 1–1 TROUBLESHOOTING . . . . . . . . . . . . 2–1, 3–1, 6–1, 7–1 U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . . 9–1

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SYSTEMS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

HYDROSTATIC SYSTEM

DRIVE SYSTEM 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.

MAIN FRAME

ELECTRICAL SYSTEM

ENGINE SERVICE

SYSTEMS ANALYSIS

SPECIFICATIONS

i

751 BICS Loader 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 (Including sidescreens) is in good condition and is not modified.

9. Enclosure door latches must open and close freely.

2. Check that ROPS mounting hardware is tightened and is Melroe approved.

10. Bob–Tach wedges and linkages must function correctly and be in good condition.

3. The seat belt must be correctly installed, functional and in good condition.

11. Safety treads must in good condition.

4. The seat bar and pedal interlocks must be correctly adjusted, clean and lubricated.

12. Check for correct function of indicator lamps (Optional on some models).

5. Machine signs must be legible and in the correct location.

13. Check hydraulic fluid level, engine oil level and fuel supply.

6. Steering levers and foot pedals must return to neutral.

14. Inspect for fuel, oil or hydraulic fluid leaks.

7. Check for correct function of the work lights.

15. Lubricate the loader.

8. The parking brake function correctly.

16. Check the condition of the battery and cables.

must

ii

751 BICS Loader Service Manual

17. Inspect the air cleaner for damage or leaks. Check the condition of the element.

18. Check the electrical charging system.

19. Check tires for wear and pressure.

20. Inspect for loose or broken parts or connections.

21. Operate the loader and check all functions.

22. Check for any field modification not completed.

23. 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.

iii

751 BICS Loader Service Manual

SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read 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.

W–2003–1289

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 English edition or French, German, Italian, Dutch & Spanish Portuguese, Finnish, Danish & Swedish.

• 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 Bobcat 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 versions.

• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

This notice identifies procedures which must be followed to avoid damage to the machine.

I–2019–0284

W–2044–1285

Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this symbol follow the safety message to avoid personal injury or death.

v

751 BICS Loader Service Manual

SAFETY INSTRUCTIONS (Cont’d) • Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing protection or loader special applications kit are required for some work. See your dealer for Melroe Safety equipment.

• Know where fire extinguishers and first aid kits are located and how to use them.

• 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.

• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti–freeze.

• 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 or Service Manuals for connecting the battery.

• Use the procedure in the Operation & Maintenance or Service Manuals for cleaning the spark arrestor muffler.

A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].

A

P–3705

vi

751 BICS Loader Service Manual

SERIAL NUMBER LOCATIONS

A

Always use the serial number of the loader when 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

N–00957

XXXXX Production Sequence (Series)

B

Model/Engine Version

1

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–05798

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].

vii

751 BICS Loader Service Manual

BOBCAT LOADER IDENTIFICATION FLASHERS (OPT.) FRONT LIGHTS (OPTIONAL) GRAB HANDLES

OPERATOR SEAT

STEERING LEVERS & HAND CONTROL LEVERS REAR AUXILIARY QUICK COUPLERS (OPTIONAL)

SEAT BELT

TILT CYLINDER

FRONT AUXILIARY QUICK COUPLERS (OPTIONAL)

SAFETY TREAD BUCKET BUCKET STEPS

OPERATOR CAB (ROPS & FOPS)

SEAT BAR REAR WINDOW (OPTIONAL)

LIFT ARM SUPPORT DEVICE

REAR GRILL LIFT CYLINDER TAIL LIGHTS (OPTIONAL) REAR LIGHTS (OPTIONAL)

REAR DOOR REAR LOADER TIE DOWN

TIRES*

B–12555 B–12556

* TIRES – Flotation tires (optional) are shown. The Bobcat loader is factory equipped with standard tires.

BUCKET – Several different buckets and other attachments are available for the Bobcat loader.

ROPS, FOPS – Roll Over Protective Structure, Falling Object 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 opertor cab as shown. Extra insulated cab is available as an option. (Reduced noise level.) viii

751 BICS Loader Service Manual

PREVENTIVE MAINTENANCE Page Number

PREVENTIVE MAINTENANCE

AIR CLEANER SERVICE Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 ALTERNATOR BELT Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 DRIVE BELT Adjusting The Drive Belt Equipped With The Fixed Drive Idler . . . . . . . 1–28 Adjusting the Drive Belt Equipped With The Spring Loaded Drive Idler 1–30 Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–32 ENGINE COOLING SYSTEM Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Propylene Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–19 1–19 1–20 1–20

ENGINE LUBRICATION SYSTEM Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 Replacing Oil & Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 FAN GEARBOX Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 FINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27 Removing Oil From The Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27 FUEL SYSTEM Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–15 1–15 1–15 1–16

HYDRAULIC/HYDROSTATIC SYSTEM Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–22 1–22 1–24 1–23

LIFT ARM SUPPORT DEVICE Disengaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 LIFTING AND BLOCKING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4

Continued On Next Page –1–1–

751 BICS Loader Service Manual

PREVENTIVE MAINTENANCE (Cont’d) Page Number LIFTING THE LOADER Four Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 Single Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 LUBRICATION OF THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–33 OPERATOR CAB Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–8 1–10 1–8 1–11

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–34 REMOTE START SWITCH Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–35 SEAT BAR RESTRAINT SYSTEM Description (Foot Pedals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Bar Inspection (Foot Pedals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Bar Maintenance (Foot Pedals) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description (Hand Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Bar Inspection (Hand Controls) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Bar Maintenance (Hand Controls) . . . . . . . . . . . . . . . . . . . . . . . . . .

1–12 1–12 1–12 1–13 1–13 1–13

SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 SPARK ARRESTOR MUFFLER Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–25 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 TIRE MAINTENANCE Tire mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26 TOWING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 TRANSPORTING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

–1–2–

751 BICS Loader Service Manual

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 Operation Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manual when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–1289

ITEM Engine Oil Air Cleaner Engine Cooling System Lift Arms, Cyl., Bob–Tach Pivot Pins and Wedges Engine Air System Tires Seat Belt, Seat Bar & Pedal Interlocks Bobcat Interlock Control System (BICS™) Safety Signs and Safety Tread Operator Cab Fuel Filter Hyd. Fluid, Hoses & Tubelines Final Drive Trans.

(Chaincase) Battery Control Pedals & Steering Wheel Nuts Parking Brake Alternator Belt Spark Arrestor Muffler Engine Oil & Filter Engine/Hydro. Drive Belt Fuel Filter Steering Shaft Hyd./Hydro. Filter Hyd. Reservoir Breather Cap Fan Drive Gearbox Final Drive Trans.

Hyd. Reservoir Hydraulic Motors Bobcat Interlock Control System (BICS™) Engine Timing Belt

SERVICE REQUIRED

8–10

50

100

250 1000 1600

Check the oil level and add oil as needed.

Check condition indicator. Service only when required.

Clean debris from oil cooler, radiator & grill. Check coolant level cold in recovery tank. Add coolant & water as needed.

Lubricate with multi–purpose lithium based grease (13 places).

Check for leaks & damaged components.

Check for damaged tires and correct air pressure.

Check the condition of seat belt. Check the seat bar & pedal interlocks for correct operation. Clean dirt and debris from moving parts.

Check BICS™ functions. Clean dirt, debris or objects from under or behind seat as required.

Check for damaged signs (decals) and safety tread. Replace any signs or safety treads that are damaged or worn.

Check the fastening bolts, washers & nuts. Check the condition of cab.

Remove the trapped water.

Check fluid level & add as needed. Check for damage & leaks. Repair & replace as needed.

Check oil level.

Check battery for damage, hold downs, cables, connections and electrolyte level. Add distilled water as needed.

Check for correct operation. Repair or adjust as needed.

Check for loose wheel nuts & tighten to 105–115 ft.–lbs.

(142–156 Nm) torque.

Check operations.

Check tension & adjust as needed.

Clean the spark chamber.

Replace oil & filter. * Check for wear or damage. Adjust as needed.

Replace filter element.

Grease two fittings. ♦ Replace the filter element.

Replace the reservoir breather cap.

Check gear lube level.

Replace the oil in the chaincase.

Replace the fluid.

Replace the case drain filters (2).

Check lift arm bypass control.

Replace the timing belt.

Check wheel nut torque every 8 hours for the first 24 hours. ♦ Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON. Or every 12 months. * Inspect the new belt after first 50 hours.

Replace break–in filter between 20–50 hours on a new loader.

–1–3–

751 BICS Loader Service Manual

A Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manuals, 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 [A].

W–2003–1289

LIFTING AND BLOCKING THE LOADER

B–07023

Procedure 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.

B

W–2017–0286

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

–1–4–

751 BICS Loader Service Manual

TRANSPORTING THE LOADER

A

Procedure

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

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A].

MC–01241

B

Be sure the transport and towing vehicles are of adequate size and capacity.

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. 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.

P–01656

P–01548

TOWING THE LOADER Procedure 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 SPECIFICATION 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 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.

6707867

MC–01242

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.

–1–5–

751 BICS Loader Service Manual

LIFTING THE LOADER

A

Four Point Lift

AVOID INJURY OR DEATH • Before lifting, check fasteners on four point lift.

• Never allow riders in the cab or bystanders

MC–01434

within 15 feet (5 meters) while lift the machine.

W–2160–0694

B The loader can be lifted with the four point lift which is available as a kit from your Bobcat loader dealer.

Attach cables or chains to lift eyes as shown [A].

Single Point Lift

MC–01664

AVOID INJURY OR DEATH • Before lifting, check fasteners on single point lift and operator cab.

• Assemble front cab fasteners as shown in manual.

• Never allow riders in the cab or bystanders

within 15 feet (5 meters) while lifting the machine.

W–2007–0694

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 [B].

The single point lift, supplied by Melroe Company is designed to lift and support the Bobcat loader without affecting roll over and falling object protection features of the operator cab.

–1–6–

751 BICS Loader Service Manual

LIFT ARM SUPPORT DEVICE

A 2

Never work on a machine with the lift arms up unless the lift arms are secured by a lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.

1

W–2059–0991

Engaging The Lift Arm Support Device

P–03923

Maintenance and service work can be done with the lift arms lowered. If the lift arms must be raised for service, use the following procedure:

B

Put jackstands under the rear corners of the loader.

1

Disconnect the spring from the lift arm support device retaining pin (Item 1) [A], hold onto the lift arm support device (Item 2) [A] and remove the retaining pin.

Lower the lift arm support device on top of the lift cylinder.

Hook the free end of the spring (Item 1) [B] to the lift arm support device so there will be no interference with the support device engagement.

With the operator in the seat, seat belt fastened and seat bar lowered, start the engine.

P–03927

Raise the lift arms, until the lift arm support device drops onto the lift cylinder rod [C].

C

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 until both pedals lock.

Install pin (Item 1) [C] into the rear of the lift arm support device below the cylinder rod.

Disengaging The Lift Arm Support Device Remove the pin from the lift arm support device.

1 Connect the spring (Item 1) [D] from the lift arm support device to the bracket below the lift arms.

P–03922

With the operator in the seat, seat belt fastened and seat bar lowered, start the engine.

D

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.

1

Raise the seat bar and move pedals until both pedals lock.

Disconnect the spring from the bracket.

Raise the support device into storage position and insert pin through lift arm support device and bracket [A].

Connect spring to pin [A].

P–03921

–1–7–

751 BICS Loader Service Manual

OPERATOR CAB 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.

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Melroe Company.

Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

ROPS/FOPS Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level l. Level ll is available.

W–2069–1285

Level l – Protection from falling bricks, small concrete blocks and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services.

Level ll – Protection from falling trees, rocks; for machines involved in site clearing, overhead demolition or forestry.

AVOID INJURY OR DEATH When operator cab is equipped with a cab enclosure kit (front door, side windows and top 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.

OPERATOR CAB Raising The Operator Cab Stop the loader on a level surface. Lower the lift arms.

Stop the engine. If the lift arms must be up while raising the operator cab, install the lift arm support device. (See Page 1–7.)

W–2156–0594

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 may allow the machine to tip backward causing injury or death.

W–2014–1285

–1–8–

751 BICS Loader Service Manual

OPERATOR CAB (Cont’d)

A

Raising The Operator Cab (Cont’d) If equipped with 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].

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.

P–03470

B AVOID INJURY OR DEATH 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

Use care when raising or lowering the operator cab to prevent damaging the shaft of the lift arm by–pass control.

I–2070–0596

–1–9–

751 BICS Loader Service Manual

OPERATOR CAB (Cont’d)

A

Raising The Operator Cab (Cont’d) 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].

P–05813

Lowering The Operator Cab

B

NOTE: Make sure the seat bar is fully raised or 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. Release the latching mechanism and pull the cab all the way down [B].

P–01565

Install the plate and nut (both sides) [C].

C

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

P–01518

If equipped with hand controls move the control linkage from the top hole to the BOTTOM hole (work position) on the control handle (both sides) [D].

D

P–03561

–1–10–

751 BICS Loader Service Manual

OPERATOR CAB (Cont’d)

A

Emergency Exit The front opening on the operator cab and rear window provide exits.

To exit through the rear window, use the following procedure: Pull on the tag on the top of the rear window to remove the rubber cord [A].

P–00660

B

Push the rear window out of the rear of the operator cab.

Exit through the rear of the operator cab [B].

P–05820

–1–11–

751 BICS Loader Service Manual

SEAT BAR RESTRAINT SYSTEM

A

Description (Foot Pedals) The seat bar restraint system has a pivoting seat bar with arm rests and has spring loaded interlocks for the lift and tilt control pedals. 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 pedals are locked when returned to the neutral position.

N–00561

B

AVOID INJURY OR DEATH The seat bar system must lock the lift and tilt control pedals in neutral when the seat bar is up. Service the system if pedals do not lock correctly.

W–2105–1285

Seat Bar Inspection (Foot Pedals) Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. 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.

P–03269

Raise the seat bar. Try to move each foot pedal. Pedals must be firmly locked in neutral position. There must be no motion of the lift arms or tilt (bucket) when the pedals are pushed.

C

P–03270

Interlock Shield

Pull the seat bar down, lower the lift arms. Operate the lift pedals. While the lift arms are going up, raise the seat bar and the lift arms should stop.

Clean

Lower the seat bar, lower the lift arms and place the bucket 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. Unbuckle the seat belt.

NOTE: S/N 514713033 & below and S/N 514911457 & below, a compressed gas strut is used [B].

S/N 514713034 & above and S/N 514911458 & above, compression springs are used on the seat restraint bar [A].

P–01640

Seat Bar Maintenance (Foot Pedals) See the SERVICE SCHEDULE Page 1–3 and on the loader for correct service interval.

Clean any debris or dirt from the moving parts [A] & [B] & [C]. Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).

AVOID INJURY OR DEATH Never operate loader without pedal lock shield 6705474 on both interlocks. Shields prevent foot from unlocking interlocks when leaving loader seat.

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 Melroe replacement parts.

W–2162–1194

–1–12–

751 BICS Loader Service Manual

SEAT BAR RESTRAINT SYSTEM

A

Description (Hand Controls) The seat bar restraint system has a pivoting seat bar with arm rests and has spring loaded interlocks for the lift and tilt hand controls. 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 controls are locked when returned to the neutral position.

N–00561

B

AVOID INJURY OR DEATH The seat bar system must lock the lift and tilt controls in neutral when the seat bar is up.

Service the system if hand controls do not lock correctly.

W–2155–0594 Seat Bar Inspection (Hand Controls) Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. 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 ground.

Raise the seat bar. Try to move each hand control. The controls must be firmly locked in neutral position. There must be no motion of the lift arms or tilt (bucket) when the controls are pushed.

P–03269

P–03270

C

Pull the seat bar down, 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.

Interlock Shield

Lower the seat bar, lower the lift arms and place the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the hand controls to be sure that they are firmly locked in the neutral position. Unbuckle the seat belt.

Clean

NOTE: S/N 514713033 & below and S/N 514911457 & below, a compressed gas strut is used [B].

S/N 514713034 & above and S/N 514911458 & above, compression springs are used on the seat restraint bar [A].

P–01640

Seat Bar Maintenance (Hand Controls) See the SERVICE SCHEDULE Page 1–3 and on the loader 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).

AVOID INJURY OR DEATH

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 Melroe replacement parts.

Never operate loader without interlock shield 6705474 on both interlocks. Shields prevent foot from unlocking interlocks when leaving loader seat.

W–2158–0594

–1–13–

751 BICS Loader Service Manual

AIR CLEANER SERVICE

A

Replacing Filter Element

2 1

Replace the large (outer) filter element only when the red ring shows in the 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.

If the machine is equipped with an inner 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–05791

Photo’s may appear different but the procedure is the same.

B

Service the air cleaner as follows:

1

Release the two dust cover clips (Item 1) [B].

Remove the dust cover.

1

P–05795

Remove the large filter element (Item 1) [C].

C

NOTE: Make sure all sealing surfaces are free of dirt and debris.

Install the new filter element.

Install dust cover.

Check the air intake hose for damage. Check the air cleaner housing for damage. Check to make sure all connections are tight.

1

P–05794

Only replace the inner filter element (Item 1) [D] under the following condition:

D

NOTE: Earlier models the inner filter is optional, on later models it is standard on all machines.

Replace the inner filter element every third time the outer filter is replaced.

1

P–05796

–1–14–

751 BICS Loader Service Manual

FUEL SYSTEM

A

Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1.

The following is one suggested blending guideline which should prevent fuel gelling problems: Temp. F° (C°)

No. 2

No.1

+15°(9°) Down to –20° (–29°) Below –20° (29°)

100% 50% 0%

0% 50% 100%

1

We recommend an operator contact their fuel supplier for local recommendations.

P–03935

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 free movement of air and no open flames or sparks. NO SMOKING! [B].

B–13456

C

Install and tighten the fuel fill cap [A].

Fuel Filter See the SERVICE SCHEDULE Page 1–3 for the service interval when to remove the water from the fuel filter.

2

Loosen the drain (Item 1) [C] at the bottom of the filter element to drain any water from the filter.

See the SERVICE SCHEDULE Page 1–3 for the service interval when to replace the fuel filter.

1

To replace the fuel filter element, use a filter wrench to remove the filter element (Item 2) [C].

P–05787

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 1–16.)

Photo’s may appear different but the procedure is the same.

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

–1–15–

751 BICS Loader Service Manual

FUEL SYSTEM (Cont’d)

A

Removing Air From The Fuel System After replacing the fuel filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system prior to starting the engine.

1

2

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. 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.

P–05787

B

W–2074–1285

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.

1

Close the vent (Item 1) [A] on the fuel filter housing.

Photo’s may appear different but the procedure is the same.

P–05793

Open the vent (Item 1) [B] on the fuel injection pump.

Operate the hand pump (priming bulb) (Item 2) [A] until the pump feels solid.

Tighten the vent plug.

Start the engine. It may be necessary to open the vent plug (at the fuel injection pump) briefly until the engine runs smoothly.

–1–16–

751 BICS Loader Service Manual

ENGINE LUBRICATION SYSTEM

A

Checking Engine Oil Check the engine oil level every day.

Before starting the engine for the work shift, open the rear door. Remove the dipstick (Item 1) [A].

1

Keep the oil level between the marks on the dipstick.

Use a good quality motor oil that meets API Service Classification of CC, CD or CE. (See Oil Chart below.)

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE) C°–34 –29

–23 –18

–13

–7

–1

+4

+10 +15

+21

+27 +32 +38

+43

+49

P–05784

+54 +60

SAE 40 or 20W–50

B

SAE 10W–30

SAE 15W–40

SAE 5W–30

SAE 30W

SAE 20W–20

SAE 10W

1 ⎧°–30 –20

–10

0

+10

+20 +30

+40 +50 +60

+70

+80 +90 +100 +110 +120 +130 +140

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE

P–05785

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.

–1–17–

751 BICS Loader Service Manual

ENGINE LUBRICATION SYSTEM (Cont’d)

A

Replacing Oil & Filter (Cont’d) 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.

Install and tighten the drain plug.

NOTE: Photo’s may appear procedure is the same.

different

but the

1

P–05782

Remove the filler cap (Item 1) [B] from the oil fill tube.

B

Put 6 qts. (5,7 L) of oil in the engine. (See Oil Chart Page 1–17.)

1

P–05784

Start the engine and let it run for several minutes. Stop the engine. Check for leaks at the oil filter and check the oil level.

C

The oil level should be between the top and bottom marks on the dipstick [C].

Bottom Mark

If the level has reached the bottom mark, add oil until it reaches the top mark.

Top Mark

P–05804

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

–1–18–

751 BICS Loader Service Manual

ENGINE COOLING SYSTEM

A

Check the cooling system every day to prevent 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.

• Engine is running.

• Tools are being used.

P–05771

W–2019–1285

B

Cleaning the Cooling System 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.

Checking the Coolant Level P–05777

Open the rear door. Check the coolant level in the coolant recovery tank (Item 1) [C] on the right side of the engine.

C

The coolant recovery tank must be 1/3 full.

1

P–05790

–1–19–

751 BICS Loader Service Manual

ENGINE COOLING SYSTEM (Cont’d)

A

Replacing The Coolant

1

Do not remove radiator cap when the engine is hot. You can be seriously burned.

W–2070–1285

Install jackstands under the rear corners of the loader.

P–05773

Raise the operator cab. (See Page 1–8 for the correct procedure.)

B

Open the rear door. Open the rear grill.

Remove the radiator cap (Item 1) [A].

Open the drain valve (Item 1) [B].

The drain valve is located on the engine block behind the hydrostatic pumps.

Drain the coolant into a container from the drain hose (Item 1) [C].

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.)

P–05811

C

NOTE: The loader is factory filled with propylene glycol coolant. (Purple Color) DO NOT mix propylene glycol with ethylene glycol.

Propylene Glycol Add premixed coolant, 47% water and 53% propylene glycol to the recovery tank if the coolant level is low.

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.

1

Use a refractometer to check the ratio of propylene glycol and water in your cooling system.

P–05785

Fill the radiator with the premixed coolant. Install the radiator cap.

Fill the coolant recovery tank 1/3 full.

Run the engine until it is at operating temperature. Stop the engine. Check the coolant level in the recovery tank when cool. Add coolant to the recovery tank as needed.

NOTE: When testing the freeze protection in the system, you must know if it is propylene glycol or ethylene glycol.

Use the proper scale (PG or EG) on the refractometer when testing.

If you are unsure of the mixture it is recommended to drain the system and refill with propylene glycol.

–1–20–

751 BICS Loader Service Manual

ALTERNATOR BELT

A

Adjusting The Alternator Belt

2

Stop the engine.

Raise the operator cab. (See Page 1–8.)

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 P–05792

Tighten the adjustment bolt and mounting bolt.

Lower the operator cab.

B

BOB–TACH Check for free movement of wedges and Bob–Tach levers.

The wedges (Item 1) [B] must extend far enough to engage the holes in the attachment.

1 P–01543

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 injury or death.

C

W–2102–0588

1

Replace wedges that are bent or broken.

FAN GEARBOX See the SERVICE SCHEDULE Page 1–3 for the correct service interval.

Checking And Maintaining Raise the operator cab. (See Page 1–8.)

P–05806

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.

Install and tighten the plug.

–1–21–

751 BICS Loader Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM

A

Checking And Adding Fluid Use only recommended fluid in the hydraulic system.

(See SPECIFICATIONS Section for the correct fluid, Page 9–1.)

To check the reservoir, use the following procedure:

2

Put the Bobcat 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–03972

B

The fluid level must be between the marks on the dipstick [B].

If fluid is needed, remove the fill cap (Item 2) [A].

P–03973

C

Clean the hydraulic reservoir fill screen and replace [C].

Add the fluid as needed to bring the level to the top mark on the dipstick [B].

P–03976

Replacing Hydraulic/Hydrostatic Filter

D

See the SERVICE SCHEDULE Page 1–3 for the correct service interval.

Open the rear door.

Use a filter wrench and remove the filter element (Item 1) [D].

1

NOTE: Photo’s may appear different, but the procedure is the same.

P–05775

–1–22–

751 BICS Loader Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Replacing Hydraulic Fluid See the SERVICE SCHEDULE Page 1–3 for the service interval.

The fluid must also be replaced if it becomes contaminated or after major repairs.

1

Remove the reservoir fill cap (Item 1) [A].

NOTE: Check to make sure the rubber gasket is installed on the fill cap [A].

Raise the operator cab. (See Page 1–8.)

P–03972

Disconnect the hose from the case drain filter (Item 1) [B] located on the reservoir, plug the filter and case drain hose.

B

Disconnect the hoses from the case drain filter (Item 1) [C] located on the left drive motor, plug the filter and case drain hose.

Remove the case drain filters (Item 1) [B] & [C] and drain the fluid into a container.

1

Replace the hydraulic/hydrostatic filter element.

Replace both hydrostatic motor case drain filters (Item 1) [B] & [C].

When all the fluid is removed from the reservoir, reconnect the hose to case drain filter on the reservoir.

P–05808

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.

C 1

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.

P–05812

W–2145–0290

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

Start the engine and operate the loader hydraulic controls. Stop the engine. Check for leaks. Check the fluid level in the reservoir and add as needed.

–1–23–

751 BICS Loader Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Hydraulic Reservoir Breather Cap

1

See SERVICE SCHEDULE Page 1–3 for the correct service interval.

Remove the breather cap (Item 1) [A].

P–05807

NOTE: Check to make sure the rubber gasket (Item 1) [B] is installed on the fill cap.

B

Clean the filter (Item 2) [B] from the breather cap.

1

Make sure the baffle washer (Item 3) [B] is installed in the hydraulic reservoir.

3

Replace the breather cap if it is worn or damaged, or beyond the 250 hour service life.

2 P–01502

–1–24–

P–01497

751 BICS Loader Service Manual

SPARK ARRESTOR MUFFLER

A

Cleaning Procedure 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.

1

P–05772

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 equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC.

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.

W–2050–1285

Make reference to local laws and regulations for spark arrestor requirements.

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety glasses or goggles. Failure to obey can cause serious injury.

I–2022–0595

W–2011–1285

Stop the engine. Open the rear door and rear grill.

Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.

Remove the plug (Item 1) [A] from the bottom of the muffler.

Start the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler.

W–2068–1285

Stop the engine. Put anti–seize coating on plug. 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

–1–25–

751 BICS Loader Service Manual

TIRE MAINTENANCE

A

Wheel Nuts See the SERVICE SCHEDULE Page 1–3 for the service 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 to the front [B].

P–01535

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 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 mounting. Check rim and tire bead for damage.

B–09976

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

–1–26–

751 BICS Loader Service Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

A

Checking and Adding Oil 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.

B

If the level is low, add oil through the check plug hole until 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 rear of the chaincase.

1

P–01616

C

Remove the drain plug (Item 1) [C] and drain the oil into a container.

NOTE: When installing the drain plug into the chaincase, always use a NEW drain plug gasket.

1

P–01619

–1–27–

751 BICS Loader Service Manual

DRIVE BELT

A

Adjusting The Drive Belt Equipped With The Fixed Drive Idler The tools listed will be needed to do the following procedure:

2

MEL1404 – Bar MEL1406 – Spring Scale

1

See the SERVICE SCHEDULE Page 1–3 for the service interval.

To adjust the drive belt between the engine flywheel and the hydrostatic pump pulley, use the following procedure: Stop the engine. Open the rear door.

Disconnect the negative (–) battery cable (Item 1) [A].

Remove the three belt shield holddown clips (Item 2) [A].

2

P–05799

B

Remove the belt shield (Item 1) [B].

Use the correct tools listed above to adjust the drive belt tensioning pulley and the drive belt.

1

P–05797

Install the Belt Tension Bar (MEL1404) on the drive belt [C].

C

The pin (Item 1) [C] must be pulled tight against the engine drive pulley and drive belt.

1

2

3

Position the pin (Item 2) [C] on top of the drive belt.

Make a mark (Item 3) [C] on the cast flange just above the tool handle.

P–05776

–1–28–

751 BICS Loader Service Manual

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].

Pull the tool handle up 1.25 inch (32 mm) (the width of the tool handle). The mark (Item 1) [B] should show on the bottom of the handle when the correct distance is reached. Record the reading on the spring scale.

Use the following belt tension specifications to adjust the drive belt tension:

P–05800

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 1.25 inch (32 mm) (the width of the tool handle).

B

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 lbs. (67 N) spring scale force.

USED BELT: With 12 lbs. (53 N) of force, the tool should move 1.25 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.

1 P–05786

The drive belt tensioning pulley (Item 1) [C] is located between the flywheel and pump pulley.

C

Loosen the locking nut (Item 2) [C] on the tensioning pulley rod.

2 3

Tighten or loosen the tensioning pulley by turning the adjusting nut (Item 3) [C].

1

P–05788

D

Reinstall the Belt Tension Bar [D] and check the tension specification.

Repeat the procedure until the correct specification is reached.

Reinstall the belt shield and holddown clips.

Reconnect the negative (–) battery cable.

P–05783

–1–29–

751 BICS Loader Service Manual

DRIVE BELT (Cont’d)

A

Adjusting The Drive Belt Equipped With The Spring Loaded Drive Ider To adjust the drive belt between the flywheel and the hydrostatic pump pulley, use the following procedure.

2

Stop the engine. Open the rear door.

Disconnect the negative (–) battery cable (Item 1) [A].

1

Remove the belt shield holddown clips (Item 2) [A].

Photo’s may appear different but the procedure is the same.

2

P–05799

B

Remove the belt shield (Item 1) [B].

The pulley tensioner is located between the flywheel and pump pulley.

1

P–05797

C

Loosen the bolt (Item 1) [C] on the spring loaded drive idler.

NOTE: The pointer (Item 2) [C] will be at the 7:00 position when the idler is not under spring tension.

1 2 N–00565

–1–30–

751 BICS Loader Service Manual

DRIVE BELT (Cont’d)

A

Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler (Cont’d)

1

Adjust the idler pulley adjusting nut (Item 1) [A] so that the arrow (Item 2) [A] on the idler pulley is bottomed out on the idler stop. (Arrow (Item 2) [A] will be approximately at the 9:00 position.)

2

N–00566

B

Loosen the idler pulley adjusting nut (Item 1) [B] slightly so that the idler pulley is operating on spring tension. (The arrow (Item 2) [B] will be approximately at the 8:30 position.)

1

Tighten the mounting bolt (Item 3) [B] 25–28 ft.–lbs.

(34–38 Nm) torque.

NOTE: Do not set the idler against the travel stop in the 9:00 position.

NOTE: This procedure is shown with the engine removed for photo clarity.

2

Run the engine for a few minutes.

3 N–00567

Stop the engine and recheck the pointer position.

Readjust if necessary.

After the idler has been in service readjust when the pointer reaches the 6:30 position.

Install the belt shield using the hold down clips.

Reconnect the negative (–) battery cable.

Close the rear door.

–1–31–

751 BICS Loader Service Manual

DRIVE BELT (Cont’d)

A

Drive Belt Replacement Stop the engine. Open the rear door.

2

Remove the negative (–) cable (Item 1) [A] from the battery.

The battery may be removed for additional working clearance. (See Page 6–1.)

1

Remove the belt shield holddown clips (Item 2) [A].

Remove the belt shield. (See Page 1–28.)

2

P–05799

B

Loosen the lock nut (Item 1) [B] and the adjusting nut (Item 2) [B].

1 2

P–05788

Remove the drive belt from the pump pulley and flywheel.

Remove the drive belt from the loader [C].

C

Install the new drive belt.

Re–install the fan drive belt.

Adjust the drive belt. (See Page 1–28 or 1–30.)

Connect the negative (–) cable to the battery.

P–05801

–1–32–

751 BICS Loader Service Manual

LUBRICATION OF THE BOBCAT LOADER

A

Procedure 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 Bobcat loader.

1

Always use a good quality lithium based multi–purpose grease when you lubricate the loader. Apply the lubricant until extra grease shows.

Lubricate the following locations on the loader every 8–10 hours.

P–03919

1. Rod End Lift Cylinder (Both Sides) [A].

B

2. Base End Lift Cylinder (Both Sides) [B].

2 P–01538

3. Lift Arm Pivot Pin (Both Sides) [C].

C

3

P–01536

4. Base End Tilt Cylinder (Both Sides) [D].

D 4

P–01540

–1–33–

751 BICS Loader Service Manual

LUBRICATION OF THE BOBCAT LOADER (Cont’d)

A

Procedure (Cont’d) 5. Rod End Tilt Cylinder [A].

5 P–00861

B

6. Bob–Tach Pivot Pin (Both Sides) [B].

7. Bob–Tach Wedge (Both Sides [B].

6

7 P–01564

8. 250 Hours: Steering Lever Shaft (2) [C].

C

8

P–05810

PIVOT PINS

D

All lift arm and cylinder pivots have a large pin held in position with a retainer bolt and lock nut (Item 1) [D].

Check that the lock nuts are tightened to 18–20 ft.–lbs.

(24–27 Nm) torque.

1

P–01630

–1–34–

751 BICS Loader Service Manual

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