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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