Bobcat 741, 742, 743 & 743DS Skid-Steer Loader Repair Service Manual - 6566109

741 (S/N: 501720001 & Above), 742 (S/N: 501820001 – 501822999), 743 (S/N: 501920001 & Above) & 743DS (S/N: 502551001 & Above) 
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This workshop repair service manual PDF download for the 741, 742, 743 & 743DS Bobcat 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 741, 742, 743 & 743DS 
741 (S/N: 501720001 & Above)
742 (S/N: 501820001 – 501822999)
743 (S/N: 501920001 & Above)
743DS (S/N: 502551001 & Above)


TABLE OF CONTENTS :

PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
SPECIFICATIONS
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6566109 (4–88)
Total Pages : 452


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
    SAFETY INSTRUCTIONS
    SERIAL NUMBER LOCATIONS
    LOADER SERIAL NUMBER
    ENGINE SERIAL NUMBER
    DELIVERY REPORT
    BOBCAT SKID STEER LOADER IDENTIFICATION
    
PREVENTIVE MAINTENANCE
    SERVICE SCHEDULE
    LIFTING AND BLOCKING THE LOADER
        Procedure
    TRANSPORTING THE BOBCAT LOADER
        Procedure
    LIFT ARM SUPPORT DEVICE
        Installation
    OPERATOR CAB
        Raising The Operator Cab
        Lowering The Operator Cab
        Seat Bar Description
        Seat Bar Inspection
        Seat Bar Maintenance
    USING AN EXTRA BATTERY (JUMP STARTING)
        Procedure
    REMOTE START SWITCH
        Procedure
        
HYDRAULIC SYSTEM
    HYDRAULIC /HYDROSTATIC SCHEMATICS
    TROUBLESHOOTING
    HYDRAULIC SYSTEM INFORMATION
        Flare Connections
        O–ring Face Seal Connection
        Tubelines And Hose
    LIFT CYLINDER
        Checking
        Removal And Installation
    TILT CYLINDER
        Checking
        Removal And Installation
    HYDRAULIC CONTROL VALVE (Gresen)
        Checking The Relief Valve
        Main Relief Valve Removal And Installation
        Removal and Installation
        Disassembly And Assembly
        Inlet Section
        Tilt Section
        Lift Section
        Auxiliary Section
        Valve Spool Bolt
        Adjusting The Auxiliary Detent
    HYDRAULIC PUMP (S/N 14999 & Below)
        Checking The Output Of The Hydraulic Pump
        Removal And Installation
    HYDRAULIC PUMP (S/N 15001 & Above)
        Removal And Installation
        Vane Pump Drive Shaft Removal And Checking
        Hydraulic Pump Starting Procedure
    PORT BLOCK (S/N 14999 & Below)
        40 Micron Filter (Bronze)
        Cold Weather By–Pass Valve
        Neutral By–Pass Valve
        Removal And Installation
    PORT BLOCK (S/N 15001 & Above)
        Cold Weather By–Pass Valve Removal And Installation
        Case Drain Relief Valve Removal And Installation
        Removal And Installation
    HYDRAULIC/HYDROSTATIC RESERVOIR
        Checking And Adding Oil
        Removing Hydraulic Oil
        Removal And Installation
    OIL COOLER
        Removal And Installation (741)
        Removal And Installation (742 & 743)
    10 MICRON FILTER BY–PASS VALVE
        Removal And Installation
    HYDRAULIC CONTROL PEDALS (S/N 14999 & Below)
        Removal And Installation
        Adjustment
    HYDRAULIC CONTROL PEDALS (S/N 15001 & Above)
        Removal And Installation
        Adjustment
    PEDAL LOCK LINKAGE
        Installation
        Adjustment
        
HYDROSTATIC SYSTEM
    TROUBLESHOOTING
        Chart
    HYDROSTATIC SYSTEM INFORMATION
    High Pressure Relief/Replenishing Valve Function
    STEERING LEVERS
        Removal And Installation
        Repairing The Steering Levers
    STEERING LINKAGE
        Adjustment
        Removal And Installation
        Repairing The Pintle Lever
    HYDROSTATIC MOTOR
        Removal
    HYDROSTATIC PUMP
        Checking The High Pressure Relief Replenishing Valves
            To Use The Special Tool Kit (MEL1173)
        Checking Charge Pressure (S/N 14999 & Below)
        Checking Charge Pressure (S/N 15001 & Above)
        Removal
        Installation
    TOW VALVES
    
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
    OPERATOR CAB (S/N 19999 & Below)
        Removal And Installation
    OPERATOR CAB (S/N 20001 & Above)
        Removal And Installation
    REAR DOOR
        Removal And Installation
        Door Latch Adjustment
    LIFT ARMS
        Removal And Installation
    BOB–TACH
        Removal And Installation
        Tilt Cylinder Rod End Seal
        Disassembly And Assembly
    FUEL TANK (S/N 19999 & Below)
        Removal And Installation
    FUEL TANK (S/N 20001 & Above)
        Removal And Installation
        Fuel Tank Sender Switch
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION
        Description
    TROUBLESHOOTING
        Chart
    BATTERY
        Checking The Battery
        Removal And Installation
    ALTERNATOR
        Alternator Belt Adjustment (741)
        Alternator Belt Adjustment (742)
        Alternator Belt Adjustment (743)
        Removal And Installation
        Disassembly And Assembly
    MELROE ALTERNATOR
        Checking the Alternator Output
        Checking The Alternator Regulator 
        Removal And Installation
        Disassembly And Assembly
    STARTER
        Checking The Starter
        Removal And Installation
        Disassembly And Assembly
        Disassembly And Assembly (Gear Reduction)
        Replacing The Brushes
        Cleaning and Inspection
        
ENGINE SERVICE
    ENGINE SERVICE (Deutz 741)
        TROUBLESHOOTING
            Chart
        FUEL SYSTEM
            Fuel System Service
            Venting Air From The Fuel System
            Fuel Filters
            Fuel Water Trap
            Fuel Lift Pump
            Fuel Injection Pump
            Injection Pump Removal And Installation
            Fuel Delivery Adjustment
        FUEL INJECTION NOZZLES
            Removal And Installation
            Injection Disassembly And Repair (In The Shop)
        BLOWER FAN
            Removal And Installation
            Disassembly And Assembly
        ENGINE SERVICE
            Engine Removal
        CYLINDER HEAD AND VALVES
            Removal
            Disassembly And Assembly
            Checking Piston Crown Clearance
            Cylinder Head Installation
        CYLINDER, PISTONS AND CONNECTING RODS
            Disassembly And Assembly
        OIL PUMP, FILTER HOUSING AND RELIEF VALVE
            Oil Pump Removal And Installation
            Oil Pressure Relief Valve
        ENGINE FRONT COVER
            Removal
            Disassembly And Assembly
            Installation
        GOVERNOR
            Removal And Disassembly
        CAMSHAFT
            Removal And Installation
        CRANKSHAFT
            Removal
            Inspection
            Assembly
        UNIVERSAL JOINT
            Removal And Installation
        FLYWHEEL
            Removal And Installation
            Ring Gear Removal And Installation
        ENGINE OIL COOLER
        ENGINE SHROUDING
        ENGINE MOUNTS
            Replacing Engine Mounts
        MUFFLER
            Removal And Installation
        STARTER
            Removal And Installation
    ENGINE SERVICE (Ford 742)
        TROUBLESHOOTING
            Chart
        CHECKS AND ADJUSTMENTS
            Oil Pressure
            Valve Clearance
            Compression
            Carburetor, Throttle And Governor Adjustments
            Governor Oil Level
            Ignition System
            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 Marks Location
                Initial Ignition Timing
        CARBURETOR REPAIR
        ENGINE DIAGNOSIS AND TESTING
            Camshaft Lobe Lift
            Crankshaft End Play
            Flywheel Surface Alignment Check
            Camshaft End Play
        ENGINE REMOVAL
        ENGINE REPAIR
            Cylinder Head
            Valve Guides
            Grinding The Valve Seats
            Valves
            Grinding Valves
            Selecting Fitting Of The Valves
            Camshaft Repair
            Crankshaft
            Repairing Journals
            To Check Crankshaft Or Connection Rod Bearings With Plastigage
            Install Pistons
            Installing Piston Rings
            Installing The Piston Pins
            Valve Rocker Arm And Shaft Assembly
            Push Rods
        CYLINDER BLOCK
            Finishing The Cylinder Walls
        CYLINDER HEADS
            Cleaning The Cylinder Heads
            Checking The Cylinder Heads
        TAPPETS
            Cleaning The Tappets
            Checking The Tappets
        CAMSHAFT
            Cleaning And Checking The Camshaft
        CRANKSHAFT
            Checking The Crankshaft
        FLYWHEEL
            Checking The Flywheel
        CONNECTING RODS
            Cleaning The Connecting Rods
            Checking The Connecting Rods
        PISTONS, PINS AND RINGS
            Cleaning The Pistons, Pins And Rings
            Checking The Pistons, Pins And Rings
        MAIN BEARINGS AND CONNECTING ROD BEARINGS
            Cleaning Bearings
            Checking Bearings
        CYLINDER BLOCK
            Cleaning The Cylinder Block
            Checking The Cylinder
        OIL PUMP
            Cleaning The Oil Pump
            Checking The Oil Pump
        VALVE ROCKER ARM COVER AND ROCKER ARM SHAFT
            Removing And Disassembly Of The Rocker Arm Shaft
            Installing Rocker Arm Shaft
        VALVE PUSHRODS
            Removal
            Installation
        INTAKE MANIFOLD
            Removal
            Installation
        CYLINDER HEAD
            Removal
            Installation
        VALVE SPRING, RETAINER AND STEM SEAL (With The Cylinder Head Removed)
            Removing The Valve Spring
            Installing The Valve Spring
        VALVE SPRING, RETAINER AND STEM SEAL (With The Cylinder Head Installed)
            Install The Valve Spring
        WATER PUMP
            Removal
        CYLINDER FRONT COVER, TIMING CHAIN AND CRANKSHAFT SPROCKETS
            Removal
            Removing the Timing Cover
            Installation Of The Timing Cover
        FRONT OIL SEAL
            Removal
            Installation
        TIMING CHAIN TIGHTENING
            Removal
            Installation
        CAMSHAFT AND VALVE LIFTERS
            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
        CAMSHAFT BEARINGS
            Removal
        CRANKSHAFT
            Removal
            Installation
        UNIVERSAL JOINT
            Removal
            Installation
        FLYWHEEL
            Removal
        FLYWHEEL RING GEAR
            Removal
            Installation
        MUFFLER
            Removal
        RADIATOR
            Removal
            Installation
        BLOWER HOUSING
            Removal
        STARTER
            Removal
            Installation
    ENGINE SERVICE (Kubota 743)
        TROUBLESHOOTING
            Chart
        FUEL FILTER
            Replacing The Fuel Filter
            Removing Air From The Fuel System
        GLOW PLUG
            Checking
        FUEL INJECTION PUMP
            Checking The Injection Pump
            Removal and Installation
            Timing The Injection Pump
        FUEL INJECTOR NOZZLES
            Removal And Installation
            Checking the Nozzles
        ENGINE
            Removal
            Installation
        RADIATOR AND OIL COOLER
            Removal And Installation
        BLOWER HOUSING
            Removal And Installation
        ENGINE FLYWHEEL AND U–JOINT
            Removal And Installation
        FLYWHEEL RING GEAR
        MUFFLER
            Removal And Installation
        CYLINDER HEAD
            Removal
            Disassembly
            Servicing
            Valve Guide Installation
            Assembly
            Installation
        ENGINE REPAIR
            Gearcase Removal
            Timing Gear, Camshaft And Oil Pump Removal
            Pistons And Crankshaft Removal
            Timing Gear And Camshaft Service
            Servicing The Connecting Rods And Pistons
            Crankshaft Service
            Cylinder Liner Service
            Lubrication System
            Oil Pump Service
            Water Pump Service
        ENGINE ASSEMBLY
            Crankshaft Installation
            Installing The Pistons
            Installing The Camshaft And Timing Gears
            Gearcase Installation
    ENGINE SERVICE (Mitsubishi 742)
        TROUBLESHOOTING
            Chart
        VALVE CLEARANCE
            Adjustment
        ENGINE COMPRESSION
            Checking
        IGNITION TIMING
            Procedure
        DISTRIBUTOR
            Removal And Installation
            Point Gap Adjustment
            Disassembly And Assembly
            Checking Centrifugal Advance
            Checking Vacuum Advance
        CARBURETOR
            Description
            Removal And Installation
            Disassembly And Assembly
            Inspection
            Adjustment
            Governor Adjustment
        FUEL PUMP
            Removal And Installation
            Inspection
            Check The Fuel Pump
            Fuel Filter
        ENGINE BELT SHIELD
            Removal And Installation
        REAR GRILL
            Removal And Installation
        ENGINE
            Removal And Installation
        OIL COOLER AND BLOWER HOUSING
            Removal And Installation
        RADIATOR
            Removal And Installation
        ENGINE MUFFLER
            Removal And Installation
        ENGINE FLYWHEEL AND U–JOINT
            Removal And Installation
            Flywheel Ring Gear
        ROCKER ARMS
            Removal
            Inspection
            Installation
        CAMSHAFT
            Removal And Installation
            Inspection
        CYLINDER HEAD
            Removal And Installation
            Inspection
        VALVES
            Removal
            Installation
            Reconditioning The Valve And Valve Seat
            Valve Seat Inserts
            Valve Guide
            Valve Spring
        PISTON AND CONNECTING ROD
            Removal
            Disassembly
            Inspection
            Assembly
            Installation
        PISTON PIN
            Assembly Of The Tool
            Removal
            Installation
        CYLINDER LINERS
            Checking
        CRANKSHAFT AND MAIN BEARINGS
            Description
            Removal
            Checking
            Checking Oil Clearance (Plastic Gauge)
            Installation
            Crankshaft End Play
            Rear Oil Seal
        TIMING BELT
            Adjustment
            Removal
            Inspection
            Assembly
        FRONT CASE AND OIL PAN
            Removal And Installation
        OIL PUMP
            Removal
            Inspection
            Installation
            Relief Valve
        FRONT CASE SEAL
            Removal And Installation
        WATER PUMP
            Removal And Installation
            Inspection
        THERMOSTAT
            Removal And Installation
            Inspection
            
SPECIFICATIONS
    741 DEUTZ
        LOADER SPECIFICATIONS
            OPERATIONS & PERFORMANCE
            ENGINE
            HYDRAULIC SYSTEM
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            MACHINE WEIGHT
        ENGINE SPECIFICATIONS
            Fuel System
            Governor, Front Cover and Throttle
            Cylinder Head and Valves
            Cylinder, Piston and Connecting Rod
            Cylinders
            Camshaft, Crankshaft, Bearings
            Lubrication System
            Engine Fastener Torque (Deutz Engine)
    742 FORD
        LOADER SPECIFICATIONS
            OPERATIONS & PERFORMANCE
            ENGINE
            HYDRAULIC SYSTEM
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            MACHINE WEIGHT
        ENGINE SPECIFICATIONS, 742 (Ford)
            Fuel Specifications
            Fuel System
            Engine Oil
            Lubrication System
            Cylinder Heads
            Valve Mechanism
            Camshaft
            Crankshaft
            Connecting Rod
            Piston
            Piston Rings
            Cylinder Block
            Ignition System
            Engine Fastener Torque
    743 & 743DS KUBOTA
        LOADER SPECIFICATIONS
            OPERATIONS & PERFORMANCE
            ENGINE
            HYDRAULIC SYSTEM
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            MACHINE WEIGHT
        ENGINE SPECIFICATIONS, 743 (Kubota)
            Fuel Injection Nozzles
            Fuel Injection Pump
            Cylinder Head
            Valves
            Valve Springs
            Rocker Arms
            Camshaft
            Cylinders
            Piston Rings
            Pistons
            Crankshaft
            Oil Pump
            Engine Oil
            Engine Bolt Torques
    742 MISTUBISHI
        LOADER SPECIFICATIONS
            OPERATIONS & PERFORMANCE
            ENGINE
            HYDRAULIC SYSTEM
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
        ENGINE SPECIFICATIONS
            General
            Cylinder Head
            Cylinder Block
            Piston
            Piston Pin
            Connecting Rod
            Crankshaft
            Flywheel
            Camshaft
            Valve Train
            Valve Guide
            Valve Spring
            Rocker Arm And Shaft
            Oil Pump
            Fuel Pump
            Carburetor
            Water Pump
            Thermostat
            Starter
            Alternator
            Distributor
            Spark Plugs
            Engine Torque
    TECHNICAL DATA
        HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
        DECIMAL AND MILLIMETER EQUIVALENTS
        U.S. TO METRIC CONVERSION
        TORQUE FOR GENERAL METRIC BOLTS
        STANDARD TORQUE SPECIFICATIONS FOR BOLTS
        
SERVICE MANUAL REVISIONS
    740-1
    740-2
    740-3
    740-4
    740-5
    740-6
    740-7
    740-8
    740-9
    740-10
    
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