MAINTENANCE SAFETY - Servicemanualperfect
2 of 356Dealer Copy -- Not for Resale
MAINTENANCE SAFETYWARNINGInstructions are necessary before operating or servicing machine. Read andunderstand the Operation & Maintenance Manual, Operator’s Handbook andsigns (decals) on machine. Follow warnings and instructions in the manualswhen making repairs, adjustments or servicing. Check for correct function afteradjustments, repairs or service. Untrained operators and failure to followW-2003-0903instructions can cause injury or death.Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety isinvolved!” Carefully read the message that Use the correct procedure to lift orlower operator cab.Cleaning and maintenance arerequired daily.WRONGWRONGWRONGB-11799B-15231B-15280Have good ventilation whenwelding or grinding paintedparts.Wear dust mask when grindingpainted parts. Toxic dust and gascan be produced.Avoid exhaust fume leaks whichcan kill without warning. Exhaustsystem must be tightly sealed.Disconnecting or loosening anyhydraulic tubeline, hose, fitting,component or a part failure cancause lift arms to drop. Do not gounder lift arms when raisedunlesssupportedbyanapproved lift arm support device.Replace it if damaged.Never work on loader with liftarms up unless lift arms are heldby an approved lift arm supportdevice. Replace if damaged.Never modify equipment or addattachments not approved byBobcat 16102Stop, cool and clean engine offlammablematerialsbeforechecking fluids.Never service or adjust loaderwith the engine running unlessinstructed to do so in themanual.Avoid contact with leakinghydraulic fluid or diesel fuelunder pressure. It can penetratethe skin or eyes.Never fill fuel tank with enginerunning, while smoking or whennear open flame.Keep body, jewelry and clothingawayfrommovingparts,electrical contact, hot parts andexhaust.Wear eye protection to guardfrom battery acid, compressedsprings, fluids under pressureand flying debris when enginesare running or tools are used.Use eye protection approved fortype of welding.Keep rear door closed except forservice. Close and latch doorbefore operating the loader.Lead-acid batteries produceflammable and explosive gases.Keep arcs, sparks, flames andlighted tobacco away frombatteries.Batteries contain acid whichburns eyes or skin on contact.Wear protective clothing. If acidcontacts body, flush well withwater. For eye contact flush welland get immediate medicalattention.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 & MaintenanceManual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcatreplacement parts. The Service Safety Training Course is available from your Bobcat dealer.MSW01-08053 of 356Dealer Copy -- Not for ResaleNever service the Bobcat SkidSteer Loader without instructions.
4 of 356Dealer Copy -- Not for Resale
FOREWORDThis manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustmentprocedures for the Bobcat loader and its component parts and systems. Refer to the Operation &Maintenance Manual for operating instructions, starting procedure, daily checks, etc.1. Check that the ROPS/FOPS(Including sidescreens) is ingood condition and is notmodified.9. Enclosure door latches mustopen and close freely.2. Check that ROPS mountinghardware is tightened and isMelroe approved.10. Bob–Tach wedges and linkagesmust function correctly and be ingood condition.3. The seat belt must be correctlyinstalled, functional and ingood condition.11. Safety treads must in goodcondition.4. The seat bar and pedalinterlocks must be correctlyadjusted, clean and lubricated.12. Check for correct function ofindicator lamps (Optional onsome models).5. Machine signs must be legibleand in the correct location.13. Check hydraulic fluid level,engine oil level and fuel supply.6. Steering levers and foot pedalsmust return to neutral.14. Inspect for fuel, oil or hydraulicfluid leaks.7. Check for correct function ofthe work lights and travel lights.15. Lubricate the loader.8. The parking brakefunction correctly.16. Check the condition of thebattery and cables.5 of 356 Dec. 92Revisedmust–3Dealer Copy -- Not for ResaleA general inspection of the following items must be made after the loader has had service or repair:750 Series LoaderService Manual
17. Inspect the air cleaner fordamage or leaks. Check thecondition of the element.18. Check the electrical chargingsystem.19. Check tires for wear andpressure.Dealer Copy -- Not for Resale20. Inspect for loose or brokenparts or connections.21. Operate the loader and checkall functions.22. Checkforanyfieldmodification not completed.Recommend to the owner that allnecessary corrections be madebefore the machine is returned toservice.6 of 356Revised Dec.92–2750 Series LoaderService Manual
CONTENTSSAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iSERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiDELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiBOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiPREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . aler Copy -- Not for ResaleMAINFRAMESPECIFICATIONS7 of 356–1750 Series LoaderService Manual
Dealer Copy -- Not for ResaleBoth new and rebuilt startersare available from Melroe.Available at your local Bobcat Dealer.8 of 3560750 Series LoaderService Manual
SAFETY INSTRUCTIONSInstructions 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 themanuals 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–2003–0299The following publications provide information on the safe use and maintenance of the loader and attachments:1. The Delivery Report is used to assure that complete instructions have been given to the new owner and that themachine is in safe operating condition.2. The Operation & Maintenance Manual delivered with the loader gives operating information as well as routinemaintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold.3. The loader has machine signs (decals) which instruct on the safe care and operation. The signs and their locationsare shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loaderdealers.Dealer Copy -- Not for Resale4. The FIEI Manual delivered with the loader gives general safety information.5. The Service Manual and Parts Manual are available from Bobcat loader dealers for use by mechanics to do shoptype service and repair work.Warnings on the machine and in themanuals are for your safety. Failure toobey warnings can cause injury ordeath.This notice identifies procedureswhich must be followed to avoiddamage to the machine.I–2019–0284W–2044–1285Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this symbolfollow the safety message to avoid personal injury. Wear tight fitting clothing and any other required safety apparel when operating or servicing the loader.Wear safety glasses when maintaining or servicing the loader.Exhaust gases can kill, vent engine exhaust outdoors.Know where fire extinguishers and first aid kits are located and how to use them.Do not run the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosivedust or gases. Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to checkfor leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. DO NOT use gasoline or diesel fuelfor cleaning parts. Use commercial nonflammable solvents. Clean the loader before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fireextinguisher near the loader when welding. Have good ventilation when welding or grinding painted parts. Wear a dust mask when grinding painted parts. Toxic dustor gas can be produced. Stop the engine and let it cool before adding fuel. No smoking! Use the procedure in this manual for connecting battery. Use the procedure in this manual for cleaning the spark arrestor muffler after each 100 hours of operation.9 of 356i750 Series LoaderService Manual
SERIAL NUMBER LOCATIONSAAlways use the serial number of the loader whenrequesting service information or when ordering parts.Early or later models (identification made by serialnumber) may use different parts, or it may be necessaryto use a different procedure in doing a specific serviceoperation.LOADER SERIAL NUMBERThe loader serial number plate is located on the inside ofthe left upright, above the grill [A].Explanation of loader Serial Number:XXXXXXXXXCD–06862Production Sequence(Series)BModel, Engine VersionThe serial number is near the fuel injection pump on theengine block [B].CD–06863CDELIVERY REPORTThe Delivery Report must be filled out by the dealer andsigned by the owner or operator when the Bobcat loaderis delivered. An explanation of the form must be given tothe owner. Make sure it is filled out completely [C].10 of 356ii750 Series LoaderService ManualDealer Copy -- Not for ResaleENGINE SERIAL NUMBER LOCATION
V.BOBCAT LOADER NGLEVERREAR AUXILIARYQUICK COUPLERS(OPT.)SEAT BELTFRONT AUXILIARYQUICK COUPLERSBUCKET {BUCKET STEPSSEAT BARSAFETY TREADOPERATOR CAB(ROPS & FOPS) DREAR GRILLLIFT ARM SUPPORT DEVICETAIL LIGHTDealer Copy -- Not for ResaleTILT CYLINDERLIFT ARMLIFTCYLINDERREAR LIGHTREAR DOORTIRES*B–12555B–12556* TIRES – Flotation tires are shown. The Bobcat loader is base–equipped with standard tires.{ BUCKET – Several different buckets and other attachments are available for the Bobcat loader.D ROPS, FOPS – Roll–Over Protective Structure, Falling Object Protective Structure, per SAE J1040and SAE J1043. The Bobcat loader is base–equipped with standard operator cabas shown.750 Series Loader11 of 356iiiService ManualRevised Dec. 92
Melroe has engine oilblended to our specificationsDealer Copy -- Not for Resalewhich meet or exceed the highestdemands of your engine.Available at your local Bobcat Dealer.12 of 356iv750 Series LoaderService Manual
PREVENTIVE MAINTENANCEPageNumberPREVENTIVEMAINTENANCEAIR CLEANERReplacement of the Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7ALTERNATOR BELTAdjusting the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15DIAGNOSTIC TOOLProcedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26DRIVE BELTAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22ENGINE COOLING SYSTEMCleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13Removing Coolant from the Cooling System . . . . . . . . . . . . . . . . . . . . . . 1–14FAN GEARBOXChecking Grease Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20FINAL DRIVE TRANSMISSION (CHAINCASE)Checking and Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20FUEL SYSTEMFilling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Removing Air from the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–91–91–91–10HYDRAULIC/HYDROSTATIC SYSTEMChecking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 1–17Hydraulic Reservoir Breater Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17Dealer Copy -- Not for ResaleENGINE LUBRICATION SYSTEMChecking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11Replacement of Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11LIFT ARM SUPPORT DEVICETo Disengage Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4To Engage Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4LIFTING AND BLOCKING THE LOADERProcedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2LIFTING THE LOADERProcedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3LUBRICATION OF THE LOADERProcedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23MONITOR SERVICE CODESChart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–27OPERATOR CABDescription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lowering the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Raising the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lowering the Operator Cab (W/Hand Controls) . . . . . . . . . . . . . . . . . . . .Raising the Operator Cab (W/Hand Controls) . . . . . . . . . . . . . . . . . . . . .13 of 356–1––1–1–51–51–51–5b1–5a750 Series LoaderService Manual
PREVENTIVE MAINTENANCE (Cont’d)PageNumberREMOTE START SWITCHProcedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–25SEAT BAR SYSTEMDescription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6SENDER AND SENSORSService Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26SERVICE CODESChart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28SERVICE SCHEDULEChart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1TIRE MAINTENANCETire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19TRANSPORTING THE LOADERProcedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3TROUBLESHOOTING THE B.O.S.S. & L.C.D. DISPLAYChart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–30USING AN BOOSTER BATTERY (JUMP STARTING)Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1614 of 356–1–0–750 Series LoaderService ManualDealer Copy -- Not for ResaleSPARK ARRESTOR MUFFLERCleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18
SERVICE SCHEDULEMaintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. Theservice schedule is a guide for correct maintenance of the Bobcat loader.WARNINGInstructions are necessary before operating or servicing machine. ReadOperation & Maintenance Manual, Handbook and signs (decals) onmachine. Follow warnings and instructions in the manuals when makingrepairs, adjustments or servicing. Check for correct function afteradjustments, repairs or service. Failure to follow instructions can causeinjury or death.W–2003–1289SERVICE SCHEDULEEngine OilAir CleanerEngine Cooling SystemLift Arms. Cyl., Bob–TachPivot Pins & WedgesEngine Air SystemTiresSeat Belt, Seat Bar &Pedal InterlocksSafety Signs & SafetyOperator CabFuel FilterHyd. Fluid, Hoses &TubelinesFinal Drive Trans.(Chaincase)BatteryControl Pedals & SteeringWheel NutsParking BrakeAlternator BeltEngine Oil & FilterSpark Arrestor MufflerEngine/Hydro. Drive BeltFuel FilterSeat BarSteering ShaftHyd./Hydro. FilterHyd. Reservoir Breather CapFan Drive GearboxFinal Drive Trans.Hyd. ReservoirCase Drain FiltersSERVICE REQUIRED8–10 50n100 250 1000Check the oil level & add oil as needed.Check display. Service only when required.Clean debris from oil cooler, radiator & grill. Check coolant level cold inrecovery tank. Add 50/50 ethylene glycol & water as needed.Lubricate with multi–purpose lithium based grease (20 places).Check for leaks & damaged components.Check for damaged tires & correct air pressure.Check the condition of seat belt. Check the seat bar & pedal interlockscorrect operation. Clean dirt & debris from moving parts.Check for damaged signs (decals) & safety tread. Replace any signs orsafety 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.Dealer Copy -- Not for ResaleITEMHOURSCheck cables & electrolite level.Check for correct operation. Repair or adjust as needed.L Check for loose wheel nuts & tighten to 105–115 ft.–lbs. (142–156Nm) torque.Check operation & adjust as needed.Check tension & adjust as needed.Replace oil & filter.Clean the spark chamber.[ Check for wear or damage. Make adjustment as needed.Replace filter element.Grease pivots as needed.Grease two fittings.D Replace the filter element.Replace the reservoir breather cap.Check gear lube level.Replace the oil in the chaincase.Replace the fluid.Replace the filters.L Check wheel nut torque every 8 hours for the first 24
The Service Manual and Parts Manual are available from Bobcat loader dealers for use by mechanics to do shop type service and repair work. . Service Manual 843,843B Service Manual #6566091 – Contents Section. iv 750 Series Loader Service Manual Melroe has engine oil
Human Factors in Safety Job Safety Analysis Kitchen Safety Laboratory Ladder Safety Laser Safety Lead Lift Trucks Machinery & Equipment Miscellaneous Office Safety Paper Industry Personal Side of Safety Personal Protective Equipment Respirator Safety. Retail Safety Management Safety Talks Supervision Tools Trenching & Shoring
to how maintenance can be performed to ensure equipment reaches or exceeds its design life have been developed in the United States. In addition to waiting for a piece of equipment to fail (reactive maintenance), we can utilize preventive maintenance, predictive maintenance, or reliability centered . maintenance. 5.2 Reactive Maintenance
Access to Owner’s Manuals and Maintenance Guides View Your Vehicle’s Service History Explore How-to videos and more MAINTENANCE INFORMATION INTRODUCTION The Importance of Scheduled Maintenance 36 Maintaining Your Warranty 37 MAINTENANCE LOG Using the Maintenance Log Charts 38 Maintenance Log 40 Explanation of Maintenance Items 56
Notification of successful maintenance Notification of maintenance will be sent via email. The progress of the maintenance application can be tracked by checking your NCCwebsite.org account for a new maintenance due date. After your maintenance has been approved, official certification documentation wil
Notification of successful maintenance Notification of maintenance will be sent via email. The progress of the maintenance application can be tracked by checking your NCCwebsite.org account for a new maintenance due date. After your maintenance has been approved, official certification documentation wil
and might include day-to -day maintenance work, and the purchase of maintenance stock. "Scheduled Maintenance Services" includes all routine maintenance functions per timelines as agreed upon and documented in the SOP. "Unscheduled Maintenance and Repair Services" includes minor maintenance and repair services which are not pre-identified.
Facilities Maintenance Division was organized in the late sixties when a small group of maintenance personnel within bus maintenance was assigned responsibility for maintenance of MDT's Central bus facilities under the direction of bus personnel. Facilities Maintenance Division was tasked with maintenance oversight of the existing transit system.
RM0008 Contents Doc ID 13902 Rev 9 3/995 4.3.1 Slowing down system clocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
