Bobcat 730, 731, 732 Skid-Steer Loader Repair Service Manual - 6556583

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This workshop repair service manual PDF download for the 730, 731, 732 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Loader 730
Bobcat Loader 731
Bobcat Loader 732


TABLE OF CONTENTS :

PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
TECHNICAL DATA
ALPHABETICAL INDEX
SERVICE BULLETINS
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6556583 (4–79)
Total Pages : 300


This Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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MAINTENANCE SAFETY
CONTENTS
    FOREWORD
    
PREVENTIVE MAINTENANCE
    INTRODUCTION
        Symbols
        Serial Number Identification
        Loader Serial Number
        Engine Serial Number
        Pre–Delivery Inspection
        30 Hour Inspection
    SERVICE SCHEDULE
    ENGINE SERVICE (General)
        Engine Oil And Filter
        Checking Oil
        Adding Oil
        Replacement Oil And Filter
        Crankcase Breather
        Air Cleaner System
        Fuel System (730, 732)
            Fuel Filter (Inline)
        Fuel System (731)
            Fuel Pump
            Carburetor
            732 Carburetor Adjustment
            Idle Adjusting Needle
            Throttle Idle Adjustment
        Engine Cooling System
            Removing Coolant From System (732)
        Engine Electrical System (730, 731 & 732)
            ROPS Electrical System
            Installing New Battery
        Ignition System (730 & 732)
            Making Adjustment Of Spark Plug Gap
            Making Adjustment Of Point Gap
    HYDRAULIC FLUID AND FILTER
        Fluid
        Filter
    TRANSMISSION AND DRIVE SYSTEM
        Drive Chains
        Brakes
        Fluid
    TIRES
        Tire Rotation
    LOADER LUBRICATION
    BOB–TACH AND PIVOT PINS
    THE ENGINE MUFFLER
    
HYDRAULIC SYSTEM
    HYDRAULIC/HYDROSTATIC SCHEMATICS
    TROUBLESHOOTING
    HYDRAULIC SYSTEM INFORMATION
        37° Flare Connections
        Straight Thread O–Ring Fitting
        Tubelines And Hoses
    HYDRAULIC CONTROL VALVE
        Relief Valve
        Removal Of The Control Valve
        Disassembly Of The Control Valve
        Inlet Section
        Tilt Section
        Lift Section
        Lift Section
        Adjusting The Auxiliary Detent
    HYDRAULIC PUMP
        Checking Output Of The Hydraulic Pump
        Removing The Hydraulic Pump
        Disassembly Of The Hydraulic Pump
        Removing And Checking The Pump Shaft
        Installing The Hydraulic Pump
        Starting Procedure For The Hydraulic Pump
    LIFT CYLINDERS
        Checking The Lift Cylinders
        Removing The Lift Cylinder
        Disassembly Of The Cylinders
        Assembly Of The Cylinder
        Installation Of The Lift Cylinder(s)
    TILT CYLINDER
        Checking The Tilt Cylinder
        Removing The Tilt Cylinder
        Disassembly Of The Tilt Cylinder (Cessna)
        Assembly Of The Tilt Cylinder
        Installation Of The Tilt Cylinder
    HYDRAULIC/HYDROSTATIC RESERVOIR
        Removing The Hydraulic/Hydrostatic Reservoir
        Installing The Hydraulic/Hydrostatic Reservoir
    OIL COOLER
        Removing The Oil Cooler On The 730, 731)
        Removing The Oil Cooler From The 732
        Installing The Oil Cooler
    MICRON FILTER BY–PASS VALVE
        Removing By–Pass Valve
        Installation Of The By–Pass Valve
    CONTROL PEDAL
        Removing Hydraulic Control Pedal
        Installing The Hydraulic Control Pedal
        Adjusting the HydraulicControl Pedal
        
HYDROSTATIC SYSTEM
    HYDROSTATIC CIRCUIT
    HYDROSTATIC TROUBLESHOOTING
    STEERING LINKAGE ADJUSTMENT 
    REPLENISHING VALVES
        Checking Replenishing Valves
    BY–PASS VALVE
    PUMP ASSEMBLY–REMOVAL AND INSTALLATION
    HYDROSTATIC PUMP ASSEMBLY – REPAIR
        Hydrostatic Pump Disassembly
        Hydrostatic Pump Inspection
        Yoke, Pintle Bearing, etc.–Assembly to Housing
        #2 Pump Assembly
        #1 Pump Assembly
    REMOVING AND INSTALLING HYDROSTATIC MOTORS
        Removing
        Installing
    HYDROSTATIC MOTOR REPAIR
        Disassembly
        Inspection
        Assembly
        Timing Of The Motor
        Initial Running Of The Motor
    TOW VALVES
        Installing Tow Valve
        
DRIVE SYSTEM
    PARKING BRAKE
        Adjustment
        Removal And Installation
        Block And Pucks
    AXLES, SEALS AND BEARINGS
        Removal
        Installation
    FINAL DRIVE CHAIN
        Removal And Installation
    REDUCTION GEARCASE
        Removal And Installation
        Checking Reduction Gearcase
        Disassembly And Assembly
        Reduction Gearcase Seal
        Installation
    CHAINCASE FLUID
        Replacing Chaincase Fluid
        
MAIN FRAME
    ROPS REMOVAL AND INSTALLATION
    PIVOT PIN REPLACEMENT
    BOB–TACH
        Checking Wedges
        Bob–Tach Removal
        Bob–Tach Installation
        Bob–Tach Pins
        Bob–Tach Over–Center Stop
        Bob–Tach Frame
    LIFT ARMS
    
ELECTRICAL SYSTEM
    ROPS ELECTRICAL SYSTEM
        Wiring Diagram (ROPS Electrical Circuit) S/N 12999 & Below
        Wiring Diagram (ROPS Electrical Circuit) S/N 13000 & Above
    GENERAL INFORMATION
         Troubleshooting The Flywheel Alternator (730)
        Engine Electrical (730) S/N 12999 & Below
        Engine Wiring Diagram (730) S/N 12999 & Below
        Troubleshooting
        To Check the Regulator Module
    ELECTRICAL CIRCUIT (731, 732
        Electrical Troubleshooting
        Engine Electrical System (731) S/N 5006–11001 & Above
        Engine Wiring Diagram (731) 4999–11999 & Below
         Engine Wiring Diagram (731) 5006–11001 & Above
        Engine Electrical System (732) S/N 11999 & Below
        Engine Electrical System (732) S/N 12000 & Above
        Engine Wiring Diagram (732) S/N 11999 & Below
        Engine Wiring Diagram (732) S/N 12000 & Above
        CHART A
        Engine Electrical System (731) S/N 4999–11999 & Below
    ALTERNATOR BELT ADJUSTMENT AND REPLACEMENT (731, 732)
        Check Condition Of Battery And Cables
        Check Wiring
        Check Alternator Output
        Checking Regulator
    ALTERNATOR SERVICE
        Alternator Removal
        Alternator Disassembly
        Checking Rotor
        Checking Stator
        Checking Diode Trio
        Checking Rectifier
        Alternator Assembly and Installation
        Checking Starter
        Removing Starter
        Starter Disassembly
        Starter Cleaning and Inspection
        Brush Replacement
        Starter Assembly
        
ENGINE SERVICE
    730 - ENGINE SERVICE (WISCONSIN ENGINE)
        TROUBLESHOOTING
        ENGINE IGNITION SYSTEM
            Distributor Maintenance
            Timing Procedure
            Spark Plugs
        CARBURETOR SERVICE
            Adjustments
            Float Adjustment
            Governor Adjustment
        REMOVAL OF ENGINE
        REMOVAL OF ACCESSORIES
        REMOVAL OF FLYWHEEL
        REMOVAL OF AIR HOUSING
        REMOVAL OF CARBURETOR AND MANIFOLD
        REMOVAL OF CYLINDER HEADS
        REMOVAL OF GEAR COVER
        REMOVAL OF CAMSHAFT
        REMOVAL OF IDLER GEAR AND SHAFT
        REMOVAL OF OIL PAN
        REMOVAL OF OIL PUMP
        REMOVAL OF PISTONS AND CONNECTING RODS
        REMOVAL OF VALVES AND SEAT INSERTS
        REMOVAL OF CYLINDER BLOCK
        REMOVAL OF CRANKSHAFT
        REMOVAL OF CAMSHAFT
        REMOVAL OF VALVE TAPPETS
        INSTALLATION OF VALVE TAPPETS
        INSTALLATION OF CAMSHAFT
        INSTALLATION OF CRANKSHAFT
            Three Bearing Crankshaft
        INSTALLATION OF CYLINDER BLOCKS
        INSTALLATION OF PISTON RINGS
         INSTALLATION OF VALVES AND SEAT INSERTS
        INSTALLATON OF PISTONS AND CONNECTING RODS
        INSTALLATION OF OIL PUMP
        OIL PAN INSTALLATION
        INSTALLATION OF IDLER GEAR AND SHAFT
        INSTALLATION OF CAMSHAFT GEAR
        INSTALLATION OF GEAR COVER
        INSTALLATION OF CYLINDER HEAD
        INSTALLATION OF CARBURETOR AND MANIFOLD ASSEMBLY
        INSTALLATION OF AIR HOUSING
        INSTALLATION OF FLYWHEEL
        INSTALLATION OF ACCESSORIES
    731 - ENGINE SERVICE (DEUTZ ENGINE–F2L411D)
        TROUBLESHOOTING
        ENGINE MOUNTS
        FUEL SYSTEM
            Fuel And Control Linkage Adjustment
            Venting Air From Fuel System
            Fuel Filters
            Fuel Lift Pump
            Fuel Injection Pump
            Removal Of Injection Pump
            Injection Pump Service
            To Install Injection Pump
            Adjustment Of Fuel Delivery
        FUEL INJECTION NOZZLES
            Removal
            Disassembly & Repair
            Installation
        ENGINE SERVICE
        ENGINE REMOVAL
        BLOWER FAN
            Removal
            Installation
            Disassembly
            Assembly
        CYLINDER HEAD AND VALVES
            Removal
            Disassembly
            Installation of Cylinder Head
            Repair And Assembly
        CYLINDERS, PISTONS,CONNECTING RODS
            Assembly
        OIL PUMP, FILTER HOUSING AND RELIEF VALVE
            Oil Pump Removal
            Installation
            Oil Pressure Relief Valve
            Filter Housing
        ENGINE FRONT COVER
            Removal
            Disassembly & Inspection
            Assembly
            Installation
        GOVERNOR
            Removal And Disassembly
            Assembly And Installation
        CAMSHAFT (Engine Must Be Removed)
            Removal
            Installation
            Crankshaft Removal
            Inspection
            Assembly
        FLYWHEEL
    731 - ENGINE SERVICE (DEUTZ ENGINE–F2L511)
        TROUBLESHOOTING
        ENGINE MOUNTS
        FUEL SYSTEM
            Fuel System Adjustment
            Venting Air From Fuel System
            Fuel Filters
            Fuel Lift Pump
            Fuel Injection Pump
            Removal of Injection Pump
            Injection Pump Service
            To Install Injection Pump
            Checking Adjustment Of Fuel Delivery
        FUEL INJECTION NOZZLES
            Removal
            Disassembly And Repair Of Injector (In Shop)
            Installation Of Injector
        ENGINE SERVICE
        ENGINE REMOVAL
        BLOWER FAN
            Removal Of Blower Fan
            Installation
            Disassembly
            Assembly
        CYLINDER HEAD AND VALVES
            Removal And Disassembly
            Repair And Assembly
            Checking Piston Crown Clearance And Installation Of Cylinder Head
        CYLINDER, PISTONS AND CONNECTING RODS
            Assembly
        OIL PUMP, FILTER HOUSING AND RELIEF VALVE
            Oil Pump Removal
            Installation
            Oil Pressure Relief Valve
        ENGINE FRONT COVER
            Removal
            Disassembly And Inspection
            Assembly
            Installation
        GOVERNOR
            Removal And Disassembly
            Assembly And Installation
        CAMSHAFT (Engine Must Be Out Of Machine)
            Removal
            Installation
            Crankshaft Removal
            Inspection
            Assembly
        FLYWHEEL
        ENGINE OIL COOLER
    732 - ENGINE SERVICE (FORD ENGINE )
        TROUBLESHOOTING
        CHECKS AND ADJUSTMENTS
            Oil Pressure
            Valve Clearance
            Carburetor, Throttle And Governor Adjustments
            Compression
            Ignition System
                Coil To Ground Voltmeter Test
                Spark Plug Wires Resistance Test
                Spark Plug Test
                Distributor Tests
                Test Connections
                Dwell Angle Check
                Spark Strength Tests
            Ignition System Tests
                Battery to Coil Voltmeter Test
                Starting Ignition Circuit Voltmeter Test
                Breaker Point Gap Adjustment
            Ignition Timing
                Timing Mark Locations
                Initial Ignition Timing
        CARBURETOR REPAIR
        ENGINE DIAGNOSIS AND TESTING
            Camshaft Lobe Lift
            Crankshaft End Play
            Flywheel Face Alignment Check
            Camshaft End Play
        ENGINE OVERHAUL
            Cylinder Head
            Valve Guides
            Grinding Valve Seats 
            Valves
            Grinding Valves
            Select Fitting Of Valves
            Camshaft Repair
            Crankshaft
            Reconditioning Journals
            To Check Crankshaft or Connecting Rod Bearings With Plastigage
            Pistons, Pins And Rings
                To Install Pistons
                To Install Piston Rings
                Installing Piston Pins
                Valve Rocker Arm And/Or Shaft Assembly
                Push Rods
            Cylinder Block
                Finishing Cylinder Walls
            Cylinder Heads
                Cleaning
                Inspection
            Tappets
                Cleaning
                Inspection
            Camshaft
                Cleaning And Inspection
            Crankshaft
                Inspection
            Flywheel
                Inspection
            Connecting Rods
                Cleaning
                Inspection
            Pistons, Pins And Rings
                Cleaning
                Inspection
            Main And Connecting Rod Bearings
                Cleaning
                Inspection
            Cylinder Block
                Cleaning
                Inspection
         OIL PUMP
            Cleaning
            Inspection
        REMOVAL OF ENGINE
        VALVE ROCKER AND ARM COVER, ROCKER ARM AND/OR SHAFT
            Removal And Disassembly
            Installation
        VALVE PUSHROD
            Installation
        INTAKE MANIFOLD
            Removal
            Installation
        CYLINDER HEAD
            Removal
            Installation
        VALVE SPRING, RETAINER AND STEM SEAL (CYLINDER HEAD REMOVED)
            Removal
            Installation
        WATER PUMP
            Removal
            Installation
        CYLINDER FRONT COVER, TIMING CHAIN AND CRANKSHAFT SPROCKETS
            Removal
            Remove Timing Cover
            Installation
        FRONT OIL SEAL
            Removal
            Installation
        TIMING CHAIN TIGHTENER
            Removal
            Installation
        CAMSHAFT AND VALVE LIFTERS
            Removal
            Installation
        FLYWHEEL RING GEAR
            Removal
            Installation
        OIL PAN
            Removal
            Installation
        OIL PUMP
            Removal
            Installation
        CRANKSHAFT REAR OIL SEAL
            Removal
            Installation
        MAIN BEARINGS
            Removal
            Installation
        CONNECTING ROD BEARINGS
            Removal
            Installation
        PISTONS AND CONNECTING RODS
            Removal
            Installation
        CRANKSHAFT
            Removal
            Installation
        CAMSHAFT BEARINGS
            Removal of Camshaft
            Installation
            
TECHNICAL DATA
    730 - ENGINE SPECIFICATIONS (WISCONSIN)
        ENGINE SPECIFICATIONS, 730 (Wisconsin)
            Fuel Specifications
            Engine Oil
            Valve Mechanism
            Crankshaft
            Idler Gear
            Connecting Rod
            Piston, Piston Pin, Piston Rings
            Ignition System
            Distributor Advance Characteristics
            Starter
            Engine Torque Specifications
        LOADER SPECIFICATIONS
            OPERATIONAL & PERFORMANCE
            Engine
            LOADER HYDRAULICS
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            MACHINE WEIGHT
    731 - ENGINE SPECIFICATIONS (DEUTZ - F2L411D)
        ENGINE SPECIFICATIONS, 731 (Deutz–F2L–411)
            Fuel System
            Governor, Front Cover And Throttle
            Cylinder Head And Valves
            Cylinder, Piston And Connecting Rod
            Camshaft, Crankshaft, Bearings
            Lubrication System
            Torque Specification (Deutz Engine F2L411D)
            Special Tools (Deutz F2L411D)
        LOADER SPECIFICATIONS
            OPERATIONAL & PERFORMANCE
            ENGINE
            LOADER HYDRAULICS
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            MACHINE WEIGHT
    731 - ENGINE SPECIFICATIONS (DEUTZ - F2L511)
        ENGINE SPECIFICATIONS, 731 (Deutz F2L511)
            Fuel System
            Governor, Front Cover And Throttle
            Cylinder Head And Valves
            Cylinder, Piston And Connecting Rod
            Camshaft, Crankshaft, Bearings
            Lubrication System
            Torque Specifications (F2L511 Deutz Engine)
            Special Tools (F2L511 Deutz)
        LOADER SPECIFICATIONS
            OPERATIONAL & PERFORMANCE
            ENGINE
            LOADER HYDRAULICS
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            MACHINE WEIGHT
    732 - ENGINE SPECIFICATIONS (FORD)
        ENGINE SPECIFICATIONS, 732 (Ford)
            Fuel Specifications
            Engine Oil
            Lubrication System
            Cylinder Heads
            Valve Mechanism
            Camshaft
            Crankshaft
            Connecting Rod
            Piston
            Piston Pin
            Piston Rings
            Cylinder Block
            Ignition System
            Starter
            Torque Specifications for Engine
            Special Tools (Ford)
        LOADER SPECIFICATIONS
            OPERATIONAL & PERFORMANCE
            ENGINE
            LOADER HYDRAULICS
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            MACHINE WEIGHT
    TECHNICAL DATA
        LOADER TORQUE SPECIFICATIONS
        HYDRAULIC/HYDROSTATIC TRANSMISSION FLUID
        CONVERSIONS
            Decimal And Millimeter Equivalents
            U.S. To Metric Conversion
        STANDARD TORQUE SPECIFICATIONS FOR BOLTS
        
ALPHABETICAL INDEX

SERVICE BULLETINS
    730–001
    730–002
    730–003
    730–004
    730–005
    730–006
    730–007
    730–008
    730–009
    730–010
    
SERVICE MANUAL REVISIONS
    730–1
    730–2
    730–3
    
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