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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