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Bobcat 742 Troubleshooting

The Bobcat 742 skid steer loader driveline system components: a 98 cu.in (1.6L) Ford 1498 4-cycle 4-cylinder liquid-cooled gasoline engine with a rated power of 34 hp (25.4 kW), and 1-speed hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 11 gal/min (41.6 l/min). The system relief pressure is 2400 psi (165 bar). The Bobcat 742 is equipped with a radial-lift loader boom, 80HS drive chains, and 7.00x15 standard tires. The skid steer loader has a max lift height of 109" (2770 mm) to hinge pin and dump height of 86.3" (2190 mm). The rated operating capacity is 1300 lbs (590 kg), and tipping load is 2600 lbs (1180 kg).

Engine Troubleshooting

Engine hard to start or will not start
Gas tank is empty - Fill gasoline up.
Incorrect fuel grade - Use quality fuel.
Air or water in fuel system - Remove water or air from fuel system.
Defective spark plug wire connection - Check the spark plug wire connection, repair or replace.
Spark plug is defective - Spark plug need to be replaced.
Defective ignition - Inspect ignition system and change failed components.
Plugged fuel filter - Replace fuel filter.
Restricted fuel lines - Clean fuel system lines.
Dirty or faulty fuel pump - Service or change fuel pump.
Carburetor components worn out - Repair or replace parts.
Poor engine compression - Check cylinder block and replace damaged components.

Irregular engine running
Ignition system is defective - Check ignition and replace faulty components.
Clogged air filter - Clean or replace.
Spark plug is defective - Change spark plug.
Fuel pump is clogged or faulty - Clean or change fuel pump.
Valve clearance is wrong - Adjust valve clearance.
Bad ignition timing - Ignition timing needs to be adjusted correctly.
Too low idle RPM - Correct idle adjustment.

Engine stops after starting
Spark plug is defective - Install new spark plug.
Dirty or defective carburetor - Service or change carburetor.
Ignition coil is defective - Ignition coil must be replaced.
Weak or damaged valve springs - Valve springs need to be changed.
Valves sticking - Valves need to be cleaned.

Engine overheated
Not enough engine oil - Fill up the oil to required level.
Engine overload - Load reducing required.
Carburetor mixture is too lean - Use proper settings.
Ignition timing is incorrect - Adjust ignition timing correctly.
Improper valve setting - Adjust valves correctly.
Dirty radiator core or defective radiator cap - Change cap or clean radiator.
Engine coolant is insufficient - Refill to the correct level and inspect system for leaks.
Faulty thermostat - Change thermostat.
Water pump is defective - Install new water pump.

Engine noise or knocking
Low octane gasoline - Use correct fuel.
Engine overloaded - Load reducing required.
Engine oil level low - Check and refill engine oil.
Too low idle RPM - Adjust idle speed.
Fuel pump is faulty or clogged - Service or replace fuel pump.
Crankshaft or main bearings are worn out - Need to install new components.
Valve clearance is not correct - Adjust valve clearance.
Worn cylinder bore or piston rings - Change defective parts.

Engine power loss
Carburetor is dirty or improperly adjusted - Carburetor needs to be adjusted correctly or cleaned.
Dirty air filter element - Replace or service air filter.
Fuel pump is dirty or defective - Clean or change fuel pump.
Defective ignition - Test ignition and replace failed parts.
Cylinder head gasket is damaged - Replace the head gasket.
Valves are stuck or burned - Clean or replace valves.
Cylinder block components are faulty - Change defective parts.
Oil filter is blocked - Replace or service oil filter.

Engine uses too much fuel
Clogged air filter - Clean or replace air filter.
Carburetor main jet adjustment is improper - Adjust the carburetor main jet correctly.
Spark plug is faulty or loose - Tighten or change the spark plug.
Improper ignition timing - Adjust ignition timing correctly.
Stuck, worn, or burned valves - Service or replace valves.
Sleeve, rings, or piston are damaged - Replace faulty parts.
Valve clearance is incorrect - Adjust valve clearance according to specifications.
Low engine compression - Inspect cylinder block and change defective components.

High oil consumption
Seals or gaskets are defective - New components need to be installed.
Damaged valve guides or valve stems - Need to replace the valves.
Damaged or seized piston rings - Have piston rings replaced.
Piston or cylinder liner is scuffed - Inspect liner and piston, replace as necessary.

Engine backfires
Carburetor fuel mixture is too lean - Adjust carburetor correctly.
Clogged fuel lines - Clean fuel lines.
Improper ignition timing - Adjust ignition timing correctly.
Valve setting is improper - Set the valves properly.
Air filter element is plugged - Service or replace air filter.

Drive System Troubleshooting

Machine will not move in either direction or one direction
Hydraulic fluid is insufficient - Fill the system to proper hydraulic fluid level.
Drive chain malfunction - Check drive chain and change faulty parts.
Input drive shaft malfunction - Repair or install a new drive shaft.
Relief valver is broken - Repair or install a new relief valve.
Dirty hydraulic filter or suction line - Service suction line or replace hydraulic filter.
Faulty foot or hand controls - Inspect and repair if necessary.
Defective drive pump or motor - Change or repair faulty component.

Loss of power
Clogged hydraulic oil filter - Check, clean, or change as necessary.
Open or damaged relief valve - Close or replace relief valve.
Transmission parts are faulty or damaged - Inspect and change faulty parts.
Input drive shaft malfunction - Repair or replace drive shaft.
Air leaks in hydraulic system - Bleed air from hydraulic system.

Drive system overheating
Hydraulic oil level is low - Fill the system to proper hydraulic oil level.
Hydraulic fluid filter is clogged - Check, clean, or change as necessary.
Defective relief valve - Repair or change.
Defective drive pump or hydraulic motor - Inspect and change as required.
Plugged hydraulic oil cooler - Clean cooling fins as required.
Transmission overloading - Load should be reduced.

Drive system is noisy
Incorrect oil viscosity - Use proper oil viscosity.
Air in hydraulic system - Air bleeding is required.
Damaged drive pump or hydraulic motor - Change or repair faulty component.
Worn or defective mechanical parts of drive system - Inspect the components for defect or damage and repair as needed.

Hydraulics Troubleshooting

Hydraulic system overheated
Hydraulic pressure incorrectly adjusted - Set pressure correctly.
Faulty or improperly adjusted main relief valve - Replace or set up the relief valve.
Contaminated hydraulic fluid - The fluid must be changed.
Hydraulic fluid level is low - Add fluid to the hydraulic system.
Hydraulic pump is defective - Change or repair hydraulic pump if required.

Boom can't lift or drop
Lift controls failure - Change or repair.
Defective hydraulic pump - Repair or install new hydraulic pump.
Hydraulic control valve malfunction - Repair or change the valve.
Damaged hydraulic cylinder - Replace or repair boom cylinder.
Hydraulic fluid level low - Add fluid as required.

Bucket does not function
Bucket tilt controls are defective - Check and repair as required.
Defective hydraulic pump - Repair or install new hydraulic pump.
Hydraulic control valve malfunction - Repair or replace the valve.
Hydraulic bucket cylinder is defective - Replace or repair cylinder.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.

Bucket or lift arm runs slowly
Defective hydraulic pump - Flow-rate hydraulic pump and replace pump if necessary.
Hydraulic cylinder oil leakage - Repair leak by replacing the seals.
Hydraulic oil is insufficient - Fill the system to proper hydraulic oil level.
Hydraulic control valve is defective or set improper - Adjust properly or repair.
Hydraulic pressure has dropped - Correct adjustment is required.

Bucket or boom is jerky
There is air in the hydraulic system - Air bleeding is required.
Hydraulic oil filter clogging - Clean or replace the filter.
Hydraulic oil is contaminated - Fill up with fresh hydraulic oil.
Cylinder tube or rod scoring - Replace defective component.

Hydraulic pump makes excessive noise
Not enough oil or hydraulic system leaking - Correct hydraulic leaks or top up oil as needed.
Dirty hydraulic filter - Clean or change the filter.
Suction line clogging - Need to service the suction line.
Air trapped in hydraulic pump - Bleed air from hydraulics.
Worn pump components - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery won’t charge
Electrical cable connections are loose or corroded - Tighten or service connections.
Faulty battery terminal connectors - Replace terminal connectors.
Faulty cell in battery - Install a new battery.
Loose or defective belt - Belt needs to be adjusted or replaced.

Starter turns slowly
Low battery output - Battery is drained, charge it.
Battery won’t hold charge - Service charging system or install new battery.
Bad terminals or disconnected battery cables - Connect wiring correctly or install new terminals.

Starter is not cranking
Battery is drained or worn - Need to charge or replace the battery.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Battery power is low - Battery needs to be recharged.
Starter motor failure - Starter should be replaced.