Bobcat 741 742 743 743 DS Loader Service Manual 6566109 (6-12) – PDF DOWNLOAD
FILE DETAILS:
Bobcat 741 742 743 743 DS Loader Service Manual 6566109 (6-12) – PDF DOWNLOAD
Language : English
Pages : 454
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Bobcat 741 742 743 743 DS Loader Service Manual 6566109 (6-12) – PDF DOWNLOAD
MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
SAFETY INSTRUCTIONS 9
SERIAL NUMBER LOCATIONS 11
LOADER SERIAL NUMBER 11
ENGINE SERIAL NUMBER 11
DELIVERY REPORT 11
BOBCAT SKID STEER LOADER IDENTIFICATION 12
PREVENTIVE MAINTENANCE 13
SERVICE SCHEDULE 15
LIFTING AND BLOCKING THE LOADER 16
Procedure 16
TRANSPORTING THE BOBCAT LOADER 17
Procedure 17
LIFT ARM SUPPORT DEVICE 18
Installation 18
OPERATOR CAB 19
Raising The Operator Cab 20
Lowering The Operator Cab 20
Seat Bar Description 21
Seat Bar Inspection 21
Seat Bar Maintenance 21
USING AN EXTRA BATTERY (JUMP STARTING) 22
Procedure 22
REMOTE START SWITCH 23
Procedure 23
HYDRAULIC SYSTEM 25
HYDRAULIC /HYDROSTATIC SCHEMATICS 27
TROUBLESHOOTING 47
HYDRAULIC SYSTEM INFORMATION 48
Flare Connections 48
O–ring Face Seal Connection 48
Tubelines And Hose 48
LIFT CYLINDER 49
Checking 49
Removal And Installation 49
TILT CYLINDER 51
Checking 51
Removal And Installation 51
HYDRAULIC CONTROL VALVE (Gresen) 53
Checking The Relief Valve 53
Main Relief Valve Removal And Installation 54
Removal and Installation 54
Disassembly And Assembly 55
Inlet Section 56
Tilt Section 56
Lift Section 58
Auxiliary Section 61
Valve Spool Bolt 63
Adjusting The Auxiliary Detent 63
HYDRAULIC PUMP (S/N 14999 & Below) 64
Checking The Output Of The Hydraulic Pump 64
Removal And Installation 65
HYDRAULIC PUMP (S/N 15001 & Above) 69
Removal And Installation 69
Vane Pump Drive Shaft Removal And Checking 71
Hydraulic Pump Starting Procedure 72
PORT BLOCK (S/N 14999 & Below) 73
40 Micron Filter (Bronze) 73
Cold Weather By–Pass Valve 74
Neutral By–Pass Valve 75
Removal And Installation 76
PORT BLOCK (S/N 15001 & Above) 77
Cold Weather By–Pass Valve Removal And Installation 77
Case Drain Relief Valve Removal And Installation 77
Removal And Installation 78
HYDRAULIC/HYDROSTATIC RESERVOIR 80
Checking And Adding Oil 80
Removing Hydraulic Oil 80
Removal And Installation 81
OIL COOLER 82
Removal And Installation (741) 82
Removal And Installation (742 & 743) 82
10 MICRON FILTER BY–PASS VALVE 83
Removal And Installation 83
HYDRAULIC CONTROL PEDALS (S/N 14999 & Below) 84
Removal And Installation 84
Adjustment 84
HYDRAULIC CONTROL PEDALS (S/N 15001 & Above) 85
Removal And Installation 85
Adjustment 85
PEDAL LOCK LINKAGE 86
Installation 86
Adjustment 86
HYDROSTATIC SYSTEM 87
TROUBLESHOOTING 89
Chart 89
HYDROSTATIC SYSTEM INFORMATION 90
High Pressure Relief/Replenishing Valve Function 90
STEERING LEVERS 91
Removal And Installation 91
Repairing The Steering Levers 93
STEERING LINKAGE 94
Adjustment 94
Removal And Installation 95
Repairing The Pintle Lever 96
HYDROSTATIC MOTOR 98
Removal 98
HYDROSTATIC PUMP 99
Checking The High Pressure Relief Replenishing Valves 99
To Use The Special Tool Kit (MEL1173) 99
Checking Charge Pressure (S/N 14999 & Below) 100
Checking Charge Pressure (S/N 15001 & Above) 100
Removal 101
Installation 103
TOW VALVES 104
DRIVE SYSTEM 105
PARKING BRAKE 107
Adjustment 107
Removal and Installation 108
Block and Pucks 109
AXLES, SEALS AND BEARINGS 111
Removal 111
Installation 112
FINAL DRIVE CHAIN 116
Removal and Installation 116
REDUCTION GEARCASE 118
Removal and Installation 118
Checking Reduction Gearcase 119
Disassembly and Assembly 119
Reduction Gearcase Seal 124
Installation 125
CHAINCASE FLUID 126
Replacing Chaincase Fluid 126
MAIN FRAME 127
OPERATOR CAB (S/N 19999 & Below) 129
Removal And Installation 129
OPERATOR CAB (S/N 20001 & Above) 131
Removal And Installation 131
REAR DOOR 134
Removal And Installation 134
Door Latch Adjustment 135
LIFT ARMS 136
Removal And Installation 136
BOB–TACH 138
Removal And Installation 138
Tilt Cylinder Rod End Seal 139
Disassembly And Assembly 140
FUEL TANK (S/N 19999 & Below) 142
Removal And Installation 142
FUEL TANK (S/N 20001 & Above) 143
Removal And Installation 143
Fuel Tank Sender Switch 144
ELECTRICAL SYSTEM 145
ELECTRICAL SCHEMATICS 148
ELECTRICAL SYSTEM INFORMATION 175
Description 175
TROUBLESHOOTING 175
Chart 175
BATTERY 176
Checking The Battery 176
Removal And Installation 176
ALTERNATOR 177
Alternator Belt Adjustment (741) 177
Alternator Belt Adjustment (742) 178
Alternator Belt Adjustment (743) 179
Removal And Installation 180
Disassembly And Assembly 181
MELROE ALTERNATOR 183
Checking the Alternator Output 183
Checking The Alternator Regulator 184
Removal And Installation 185
Disassembly And Assembly 186
STARTER 189
Checking The Starter 189
Removal And Installation 189
Disassembly And Assembly 190
Disassembly And Assembly (Gear Reduction) 191
Replacing The Brushes 192
Cleaning and Inspection 193
ENGINE SERVICE 195
ENGINE SERVICE (Deutz 741) 197
TROUBLESHOOTING 199
Chart 199
FUEL SYSTEM 200
Fuel System Service 200
Venting Air From The Fuel System 200
Fuel Filters 201
Fuel Water Trap 202
Fuel Lift Pump 202
Fuel Injection Pump 202
Injection Pump Removal And Installation 203
Fuel Delivery Adjustment 206
FUEL INJECTION NOZZLES 207
Removal And Installation 207
Injection Disassembly And Repair (In The Shop) 207
BLOWER FAN 208
Removal And Installation 208
Disassembly And Assembly 208
ENGINE SERVICE 210
Engine Removal 210
CYLINDER HEAD AND VALVES 215
Removal 215
Disassembly And Assembly 215
Checking Piston Crown Clearance 218
Cylinder Head Installation 218
CYLINDER, PISTONS AND CONNECTING RODS 221
Disassembly And Assembly 221
OIL PUMP, FILTER HOUSING AND RELIEF VALVE 224
Oil Pump Removal And Installation 224
Oil Pressure Relief Valve 224
ENGINE FRONT COVER 225
Removal 225
Disassembly And Assembly 225
Installation 228
GOVERNOR 229
Removal And Disassembly 229
CAMSHAFT 230
Removal And Installation 230
CRANKSHAFT 231
Removal 231
Inspection 231
Assembly 231
UNIVERSAL JOINT 234
Removal And Installation 234
FLYWHEEL 235
Removal And Installation 235
Ring Gear Removal And Installation 236
ENGINE OIL COOLER 236
ENGINE SHROUDING 236
ENGINE MOUNTS 237
Replacing Engine Mounts 237
MUFFLER 238
Removal And Installation 238
STARTER 239
Removal And Installation 239
ENGINE SERVICE (Ford 742) 241
TROUBLESHOOTING 245
Chart 245
CHECKS AND ADJUSTMENTS 246
Oil Pressure 246
Valve Clearance 246
Compression 246
Carburetor, Throttle And Governor Adjustments 247
Governor Oil Level 249
Ignition System 249
Spark Plug Wires Resistance Test 249
Spark Plug Test 249
Distributor Tests 250
Test Connections 250
Dwell Angle Check 250
Spark Strength Tests 250
Ignition System Tests 250
Battery To Coil Voltmeter Test 250
Starting Ignition Circuit Voltmeter Test 251
Breaker Point Gap Adjustment 251
Ignition Timing 251
Timing Marks Location 251
Initial Ignition Timing 252
CARBURETOR REPAIR 252
ENGINE DIAGNOSIS AND TESTING 252
Camshaft Lobe Lift 252
Crankshaft End Play 253
Flywheel Surface Alignment Check 253
Camshaft End Play 254
ENGINE REMOVAL 254
ENGINE REPAIR 258
Cylinder Head 258
Valve Guides 258
Grinding The Valve Seats 258
Valves 259
Grinding Valves 259
Selecting Fitting Of The Valves 259
Camshaft Repair 259
Crankshaft 259
Repairing Journals 259
To Check Crankshaft Or Connection Rod Bearings With Plastigage 259
Install Pistons 260
Installing Piston Rings 261
Installing The Piston Pins 261
Valve Rocker Arm And Shaft Assembly 261
Push Rods 261
CYLINDER BLOCK 261
Finishing The Cylinder Walls 261
CYLINDER HEADS 262
Cleaning The Cylinder Heads 262
Checking The Cylinder Heads 262
TAPPETS 262
Cleaning The Tappets 262
Checking The Tappets 262
CAMSHAFT 263
Cleaning And Checking The Camshaft 263
CRANKSHAFT 263
Checking The Crankshaft 263
FLYWHEEL 263
Checking The Flywheel 263
CONNECTING RODS 263
Cleaning The Connecting Rods 263
Checking The Connecting Rods 263
PISTONS, PINS AND RINGS 264
Cleaning The Pistons, Pins And Rings 264
Checking The Pistons, Pins And Rings 264
MAIN BEARINGS AND CONNECTING ROD BEARINGS 264
Cleaning Bearings 264
Checking Bearings 264
CYLINDER BLOCK 264
Cleaning The Cylinder Block 264
Checking The Cylinder 265
OIL PUMP 265
Cleaning The Oil Pump 265
Checking The Oil Pump 265
VALVE ROCKER ARM COVER AND ROCKER ARM SHAFT 266
Removing And Disassembly Of The Rocker Arm Shaft 266
Installing Rocker Arm Shaft 266
VALVE PUSHRODS 267
Removal 267
Installation 267
INTAKE MANIFOLD 267
Removal 267
Installation 267
CYLINDER HEAD 268
Removal 268
Installation 268
VALVE SPRING, RETAINER AND STEM SEAL (With The Cylinder Head Removed) 269
Removing The Valve Spring 269
Installing The Valve Spring 269
VALVE SPRING, RETAINER AND STEM SEAL (With The Cylinder Head Installed) 269
Install The Valve Spring 270
WATER PUMP 271
Removal 271
CYLINDER FRONT COVER, TIMING CHAIN AND CRANKSHAFT SPROCKETS 271
Removal 271
Removing the Timing Cover 272
Installation Of The Timing Cover 272
FRONT OIL SEAL 272
Removal 272
Installation 273
TIMING CHAIN TIGHTENING 273
Removal 273
Installation 273
CAMSHAFT AND VALVE LIFTERS 273
Removal 273
Installation 274
OIL PAN 275
Removal 275
Installation 276
OIL PUMP 276
Removal 276
Installation 276
CRANKSHAFT REAR OIL SEAL 276
Removal 276
Installation 277
MAIN BEARINGS 277
Removal 277
Installation 277
CONNECTING ROD BEARINGS 278
Removal 278
Installation 278
PISTONS AND CONNECTING RODS 278
Removal 278
Installation 279
CAMSHAFT BEARINGS 279
Removal 280
CRANKSHAFT 280
Removal 280
Installation 280
UNIVERSAL JOINT 281
Removal 281
Installation 281
FLYWHEEL 281
Removal 281
FLYWHEEL RING GEAR 282
Removal 282
Installation 282
MUFFLER 282
Removal 282
RADIATOR 282
Removal 282
Installation 285
BLOWER HOUSING 285
Removal 285
STARTER 286
Removal 286
Installation 286
ENGINE SERVICE (Kubota 743) 287
TROUBLESHOOTING 289
Chart 289
FUEL FILTER 290
Replacing The Fuel Filter 290
Removing Air From The Fuel System 290
GLOW PLUG 290
Checking 290
FUEL INJECTION PUMP 291
Checking The Injection Pump 293
Removal and Installation 291
Timing The Injection Pump 292
FUEL INJECTOR NOZZLES 294
Removal And Installation 294
Checking the Nozzles 295
ENGINE 296
Removal 296
Installation 299
RADIATOR AND OIL COOLER 300
Removal And Installation 300
BLOWER HOUSING 303
Removal And Installation 303
ENGINE FLYWHEEL AND U–JOINT 304
Removal And Installation 304
FLYWHEEL RING GEAR 304
MUFFLER 305
Removal And Installation 305
CYLINDER HEAD 306
Removal 306
Disassembly 307
Servicing 307
Valve Guide Installation 309
Assembly 311
Installation 311
ENGINE REPAIR 312
Gearcase Removal 312
Timing Gear, Camshaft And Oil Pump Removal 314
Pistons And Crankshaft Removal 315
Timing Gear And Camshaft Service 317
Servicing The Connecting Rods And Pistons 318
Crankshaft Service 320
Cylinder Liner Service 321
Lubrication System 322
Oil Pump Service 323
Water Pump Service 323
ENGINE ASSEMBLY 325
Crankshaft Installation 325
Installing The Pistons 325
Installing The Camshaft And Timing Gears 325
Gearcase Installation 327
ENGINE SERVICE (Mitsubishi 742) 329
TROUBLESHOOTING 331
Chart 331
VALVE CLEARANCE 332
Adjustment 332
ENGINE COMPRESSION 333
Checking 333
IGNITION TIMING 334
Procedure 334
DISTRIBUTOR 335
Removal And Installation 335
Point Gap Adjustment 335
Disassembly And Assembly 336
Checking Centrifugal Advance 336
Checking Vacuum Advance 336
CARBURETOR 337
Description 337
Removal And Installation 340
Disassembly And Assembly 341
Inspection 341
Adjustment 341
Governor Adjustment 342
FUEL PUMP 343
Removal And Installation 343
Inspection 343
Check The Fuel Pump 343
Fuel Filter 343
ENGINE BELT SHIELD 344
Removal And Installation 344
REAR GRILL 345
Removal And Installation 345
ENGINE 346
Removal And Installation 346
OIL COOLER AND BLOWER HOUSING 350
Removal And Installation 350
RADIATOR 353
Removal And Installation 353
ENGINE MUFFLER 354
Removal And Installation 354
ENGINE FLYWHEEL AND U–JOINT 355
Removal And Installation 355
Flywheel Ring Gear 355
ROCKER ARMS 356
Removal 356
Inspection 357
Installation 357
CAMSHAFT 360
Removal And Installation 360
Inspection 360
CYLINDER HEAD 361
Removal And Installation 361
Inspection 362
VALVES 363
Removal 363
Installation 363
Reconditioning The Valve And Valve Seat 364
Valve Seat Inserts 364
Valve Guide 365
Valve Spring 365
PISTON AND CONNECTING ROD 367
Removal 367
Disassembly 367
Inspection 368
Assembly 368
Installation 369
PISTON PIN 371
Assembly Of The Tool 371
Removal 371
Installation 372
CYLINDER LINERS 373
Checking 373
CRANKSHAFT AND MAIN BEARINGS 374
Description 374
Removal 374
Checking 374
Checking Oil Clearance (Plastic Gauge) 375
Installation 375
Crankshaft End Play 376
Rear Oil Seal 376
TIMING BELT 377
Adjustment 377
Removal 378
Inspection 379
Assembly 380
FRONT CASE AND OIL PAN 382
Removal And Installation 382
OIL PUMP 383
Removal 383
Inspection 383
Installation 383
Relief Valve 384
FRONT CASE SEAL 385
Removal And Installation 385
WATER PUMP 386
Removal And Installation 386
Inspection 386
THERMOSTAT 387
Removal And Installation 387
Inspection 387
SPECIFICATIONS 389
741 DEUTZ 391
LOADER SPECIFICATIONS 393
OPERATIONS & PERFORMANCE 393
ENGINE 393
HYDRAULIC SYSTEM 394
ELECTRICAL 394
DRIVE SYSTEM 394
CAPACITIES 394
TIRES 394
MACHINE WEIGHT 394
ENGINE SPECIFICATIONS 395
Fuel System 395
Governor, Front Cover and Throttle 395
Cylinder Head and Valves 395
Cylinder, Piston and Connecting Rod 395
Cylinders 396
Camshaft, Crankshaft, Bearings 396
Lubrication System 396
Engine Fastener Torque (Deutz Engine) 397
742 FORD 399
LOADER SPECIFICATIONS 401
OPERATIONS & PERFORMANCE 401
ENGINE 401
HYDRAULIC SYSTEM 402
ELECTRICAL 402
DRIVE SYSTEM 402
CAPACITIES 402
TIRES 402
MACHINE WEIGHT 402
ENGINE SPECIFICATIONS, 742 (Ford) 403
Fuel Specifications 403
Fuel System 403
Engine Oil 403
Lubrication System 404
Cylinder Heads 404
Valve Mechanism 404
Camshaft 405
Crankshaft 405
Connecting Rod 405
Piston 405
Piston Rings 406
Cylinder Block 406
Ignition System 406
Engine Fastener Torque 407
743 & 743DS KUBOTA 409
LOADER SPECIFICATIONS 411
OPERATIONS & PERFORMANCE 411
ENGINE 411
HYDRAULIC SYSTEM 412
ELECTRICAL 412
DRIVE SYSTEM 412
CAPACITIES 412
TIRES 412
MACHINE WEIGHT 412
ENGINE SPECIFICATIONS, 743 (Kubota) 413
Fuel Injection Nozzles 413
Fuel Injection Pump 413
Cylinder Head 413
Valves 413
Valve Springs 413
Rocker Arms 413
Camshaft 413
Cylinders 414
Piston Rings 414
Pistons 414
Crankshaft 414
Oil Pump 414
Engine Oil 414
Engine Bolt Torques 415
742 MISTUBISHI 417
LOADER SPECIFICATIONS 419
OPERATIONS & PERFORMANCE 419
ENGINE 419
HYDRAULIC SYSTEM 420
ELECTRICAL 420
DRIVE SYSTEM 420
CAPACITIES 420
TIRES 420
ENGINE SPECIFICATIONS 421
General 421
Cylinder Head 421
Cylinder Block 421
Piston 421
Piston Pin 421
Connecting Rod 422
Crankshaft 422
Flywheel 422
Camshaft 422
Valve Train 422
Valve Guide 423
Valve Spring 423
Rocker Arm And Shaft 424
Oil Pump 424
Fuel Pump 424
Carburetor 424
Water Pump 424
Thermostat 424
Starter 425
Alternator 425
Distributor 425
Spark Plugs 425
Engine Torque 425
TECHNICAL DATA 427
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 429
DECIMAL AND MILLIMETER EQUIVALENTS 430
U S TO METRIC CONVERSION 430
TORQUE FOR GENERAL METRIC BOLTS 431
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 432
SERVICE MANUAL REVISIONS 433
740-1 433
740-2 435
740-3 437
740-4 439
740-5 441
740-6 443
740-7 445
740-8 447
740-9 449
740-10 451
740-11 453
DESCRIPTION:
Bobcat 741 742 743 743 DS Loader Service Manual 6566109 (6-12) – PDF DOWNLOAD
741 (S/N 501720001 & Above),
742 (S/N 501820001 – 501822999),
743 (S/N 501920001 & Above) &
743DS (S/N 502551001 & Above)
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the 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 routin e
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
editions.
• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.
• The Skid–Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish versions.
• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V