Bobcat 700 720 721 722 Loader Service Manual 6556619 – PDF DOWNLOAD

Description

Bobcat 700 720 721 722 Loader Service Manual 6556619 – PDF DOWNLOAD

FILE DETAILS:

Bobcat 700 720 721 722 Loader Service Manual 6556619 – PDF DOWNLOAD

Language : English
Pages : 244
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat 700 720 721 722 Loader Service Manual 6556619 – PDF DOWNLOAD

FORWARD:
This manual gives instructions for correct service and adjustment of the Bobcat, and detailed
overhaul instructions of the engine, drive system, loader hydraulic/hydrostatic system and
general mainframe components.
Refer to the Owner’s Manual for general operating instructions (Starting Procedure, Daily
Checks, Bucket Operation, Minor Maintenance, etc.).
A general inspection of the following items should be made whenever the machine has had
service or repair:
1. Check hydraulic fluid level, engine oil level and fuel supply.
2. Inspect for any sign of fuel, oil or hydraulic fluid leaks.
3. Make lubrication of the machine.
4. Check battery condition and cables.
5. Inspect air cleaner system for damage or leaks. Check element and make replacement,
if necessary.
6. Check electrical charging system (belts, sheaves, etc.).
7. Check for loose chains by lifting the machine and turning the wheels by hand.
8. Check tires for wear and pressure.
9. Check the Bob–Tach attachment for condition. Inspect the wedges for damage or wear.
10. Inspect safety items for condition (Operator Enclosure, Seat Belt, Safety Treads, Lights,
etc.).
11. Make a visual inspection for loose or broken parts or connections.
12. Operate the loader; check all functions.
Advise the owner if any of the above items are in need of repair

TABLE OF CONTENTS:

Bobcat 700 720 721 722 Loader Service Manual 6556619 – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 5
PREVENTIVE MAINTENANCE 7
INTRODUCTION 9
Symbols 9
Serial Number Identification 9
Loader Serial Number 9
Engine Serial Number 9
Pre–Delivery Inspection 10
30 Hour Inspection 10
SERVICE INTERVALS 11
SERVICE SCHEDULE 12
ENGINE SERVICE (General) 14
Engine Oil And Filter 14
Checking Oil 15
Adding Oil 15
Replacement Oil And Filter 15
Crankcase Breather 15
Air Cleaner System 16
Fuel System (720, 722) 17
Fuel Filter 19
Fuel System (721) 19
Fuel Pump 19
Carburetor 19
Carburetor Adjustment 20
Idle Adjusting Needle (722) 20
Throttle Idle Adjustment (722) 20
Engine Cooling System 20
Removing Coolant From System (722) 20
Engine Electrical System(720, 721 & 722) 21
Installing New Battery 22
Ignition System (720 & 722) 22
Making Adjustment Of Spark PlugGap 24
Making Adjustment Of Point Gap 24
HYDRAULIC/HYDROSTATIC FLUID AND FILTER 24
Fluid 24
Filters 25
Replacing The 25 Micron Filter 25
Replacing The 10 Micron Filter 25
TRANSMISSION AND DRIVE SYSTEM 26
Chain Adjustment 26
Brakes 27
Brake Adjustment 27
TIRES 27
Tire Rotation 27
LOADER LUBRICATION 28
BOB–TACH AND PIVOT PINS 28
HYDRAULIC SYSTEM 29
HYDRAULIC / HYDROSTATIC SCHEMATICS 31
OPERATION OF THE HYDRAULIC SYSTEM 41
GENERAL INFORMATION 42
Clean Area 42
Air Leaks 42
Tubelines, Hoses, Fittings 42
37° Flare Connections 42
Straight Thread O–Ring Connections 42
Pipe Thread Connections 43
Tubelines And Hoses 43
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM 43
PROBLEM ANALYSIS CHARTS 44
CHARGING THE VANE PUMP AND CHECKING FOR SUCTION LEAKS 45
Charging The Pump When No Source Of Air Pressure Is Available 45
Another Method To Check The System For Air Leaks 45
Removing Air From System 46
CHECKING RELEASE PRESSURE 48
Indicator Switch For Charge Pressure 48
Machines Without Auxiliary Hydraulic Tubelines 48
Machines With Auxiliary Hydraulic Tubelines 48
CHECKING THE CONDITION OF THE VANE PUMP 49
Checking Vane Pump 49
VANE PUMP SERVICE 49
To Remove The Vane Pump 49
Disassembly 49
Inspection And Service 50
Assembly 50
To Install The Vane Pump 50
CONTROL VALVE AND HYDRAULIC CYLINDER CHECKS 50
Checking The Lift Cylinders 50
Checking The Tilt Cylinders 50
HYDRAULIC CYLINDER REPAIR 51
Removing Cylinders 51
To Disassemble A Hydraulic Lift Or Tilt Cylinder 51
To Replace The Cylinder Seals 52
To Assemble The Hydraulic Cylinder 53
CONTROL VALVE REPAIR 53
Relief Valve Repair 53
To Remove The Control Valve 53
To Disassemble The Control Valve 55
To Repair The Float Detent Of The Lift Spool 56
To Assemble The Detent Assembly 56
Inspection, Repair And Assembly Of Control Valve 56
Restrictor For Tilt Hydraulic Circuit 57
Restrictor For Lift Hydraulic Circuit (Gresen Valve Only) 57
HYDROSTATIC SYSTEM 59
CIRCUIT DESCRIPTION 61
10 MICRON FILTER 62
TROUBLESHOOTING CHART 64
PROBLEM ANALYSIS CHARTS 65
STEERING LINKAGE 68
Adjustment Of The Steering Linkage 69
To Remove The Steering Lever Assembly 69
Adjustment Of The Hydrostatic Motors 70
TWO SPEED CONTROL 70
CHECKING THE HYDROSTATIC SYSTEM 71
Charge Pressure Check (Levers In Neutral) 71
Charge Pressure Check (Levers Engaged) 71
BY–PASS VALVE SERVICE 72
Checking The By–Pass Valve 72
To Remove The By–Pass Valve 72
REPLENISHING VALVE 72
Checking The Replenishing Valves 72
HYDROSTATIC MOTOR REPLACEMENT 73
REPLACEMENT OF HYDROSTATIC PUMP ASSEMBLY 73
Removal (700, 720, 722) 73
Removal (721) 74
HYDROSTATIC RECONDITIONING 74
Transmission Pump 75
Hydrostatic Motor 75
To Disassemble Pump Or Motor 76
Inspection Of Pump And Motor 78
Hydrostatic Motor Modification 78
Assembly Of Pump And Motor 79
START–UP AFTER REPAIR 81
Hydrostatic Pump Elbows 82
FINAL DRIVE SYSTEM (MECHANICAL) 83
TROUBLESHOOTING THE MECHANICAL TRANSMISSION 85
REPAIR AND REPLACEMENT OF BRAKE ASSEMBLY 86
Removal Of Caliper Assembly 86
Removal Of Lever Assembly 86
Linkage Rod Assembly 86
FINAL DRIVE 87
CHAIN REMOVAL AND INSTALLATION 88
To Remove And Install Chains 88
Primary Drive Chain Removal 88
To Install The Primary Drive Chain 88
Secondary Drive Chain Removal 88
To Install The Secondary Drive Chain 88
Final Drive Chain Removal 89
To Install The Final Drive Chain 89
MOTOR SPROCKET SERVICE 89
Motor Sprocket Removal 89
To Install The Motor Sprocket 90
UPPER JACKSHAFT SERVICE 90
To Remove The Upper Jackshaft 90
Assembly 91
To Install Upper Jackshaft Sprocket 91
IDLER SPROCKET SERVICE (PRIMARY AND SECONDARY) 91
SERVICING LOWER JACKSHAFT SPROCKET 92
To Remove The Lower Jackshaft Assembly 92
Lower Jackshaft Bearing Replacement 92
FINAL DRIVE TIGHTENER SERVICE 93
To Remove Final Drive Tightener 93
To Remove Final Drive Idler Sprocket And Bearing 93
To Install Final Drive Idler Bearing 93
WHEEL AND AXLE REPAIR (LOT A 700) 94
To Remove Axle Assembly 94
To Install New Axle Bearing And Seal 95
To Install The Axle 95
WHEEL AND AXLE REPAIR (LOT B AND LATER 700, 720, 721& 722) 96
To Remove The Axle Assembly 96
Axle Bearing And Seal Replacement 97
To Install The Axle 97
AXLE REINFORCEMENT (LOT B & LATER 700) 98
MAIN FRAME 99
THE BOB–TACH 101
Removal And Replacement of Bob–Tach 101
LOADER LIFT ARM ASSEMBLY 102
Replacement Of Lift Arms 102
GRILL ASSEMBLY 102
FUEL TANK 103
Fuel Tank Removal 103
Shield For The Fuel Tank 103
ELECTRICAL SYSTEM 105
ELECTRICAL CIRCUITRY 107
PROBLEM ANALYSIS CHARTS 107
ADJUSTMENT OF ALTERNATOR BELT 113
REPLACEMENT OF ALTERNATOR BELT 113
ELECTRICAL CHECKS (700/720) 114
To Check Indicator Circuit 114
To Check Resistor 114
To Check Field Relay 114
To Check Alternator Output 114
ELECTRICAL CHECK (721/722) 115
To Check Wiring 115
To Check Alternator Output 115
To Check The Regulator 115
GENERATOR SERVICE (700, 720, 721, 722) 115
Alternator Removal 115
Disassembly 116
To Check Rotor 116
To Check Stator 116
To Check Diode Trio 116
To Check Rectifier 117
Assembly 117
STARTER SERVICE 117
To Check The Starter 117
To Remove Starter 117
Disassembly (722) 118
Cleaning And Inspection 119
Bruch Replacement 120
Assembly 120
ENGINE SERVICE 121
ENGINE SERVICE (WISCONSIN ENGINE – 700, 720) 123
TROUBLESHOOTING THE ENGINE 125
ENGINE IGNITION SYSTEM 700/720/722 126
Distributor Maintenance 126
Timing Procedure (700, 720) 126
Spark Plug 127
HIGH TEMPERATURE SAFETY SWITCHES 127
CARBURETOR SERVICE 127
Carburetor and Adjustment 127
Carburetor Removal 127
Carburetor Reconditioning 128
Disassemble The Throttle Body 128
To Disassemble The Fuel Bowl 129
To Assemble The Fuel Bowl And Air Intake Assembly 129
To Assemble The Throttle Body 130
To Assemble The Fuel Bowl To The Throttle Body 130
LP CARBURETOR SERVICE 130
To Remove The LP Carburetor From The Engine 131
Disassembly 131
Cleaning And Inspection 131
Assembly 132
Vaporizer – Primary Regulator Service 133
Disassembling The Vaporizer 134
Assembling The Vaporizer 134
Adjusting The Vaporizer 135
LP Fuel Filter Lock – Off 136
To Disassemble The Fuel Filter Lock–Off 136
ENGINE OVERHAUL 136
Engine Removal 136
Disassembly Of Flywheel 137
Air Shrouding 137
Carburetor And Manifolds 137
Cylinder Head 137
Gear Cover 138
Camshaft Gear 138
Idler Gear And Shaft 138
Oil Pan 138
Oil Pump 138
Pistons And Connecting Rods 138
Piston rings (Engine With 4–Ring Pistons) 139
Cylinder Blocks 139
Valves And Seat Inserts 140
Crankshaft 140
Three Bearing Crankshaft 140
Camshaft 141
Valve Tappets 141
Governor Adjustment 141
Storage Of Engines 142
Returning Engine To Service 142
Returning Compression To Engine 142
ENGINE SERVICE (DEUTZ ENGINE – 721) 143
TROUBLESHOOTING THE ENGINE 145
FUEL SYSTEM 146
Fuel And Control Linkage Adjustment 146
Air Venting Fuel System 146
Fuel Filters 146
Fuel Lift Pump 147
FUEL INJECTION PUMP 147
Checking 147
Removal Of Injection Pump 147
Injection Pump Service 147
To Install Injection Pump 147
Adjustment Of Fuel Delivery 148
FUEL INJECTION NOZZLES 149
Removing Fuel Injection Nozzles 149
Disassembly And Repair Of Injection Nozzles 149
Installation Of Injection Nozzles 149
ENGINE SERVICE 149
Engine Removal 150
Blower Fan 150
Removal 150
Installation 150
Disassembly 150
Assembly 151
Cylinder Head and Valves 151
Removal 151
Disassembly 151
Repair And Assembly 151
Installation Of Head 153
Cylinders, Pistons,Connecting Rods 154
Assembly 155
OIL PUMP, FILTER HOUSING AND RELIEF VALVE 155
Oil Pump Removal 155
Installation 156
Oil Pressure Relief Valve 156
Filter Housing 156
ENGINE FRONT COVER 156
Removal 156
Disassembly And Inspection 156
Assembly 157
Installation 158
GOVERNOR 158
Removal And Disassembly 158
Assembly And Installation 159
CAMSHAFT 159
Removal 159
Installation 160
Crankshaft Removal 160
Inspection 160
Assembly 160
FLYWHEEL 161
ENGINE SERVICE (FORD ENGINE – 722) 163
TROUBLESHOOTING THE ENGINE 165
CHECKS AND ADJUSTMENTS 166
Oil Pressure 166
Valve Clearance 166
Compression 166
Carburetor, Throttle And Governor Adjustments 167
Ignition System 171
Coil To Ground Voltmeter Test 171
Coil Relocation & Vacuum Hose Installation (Early 722 Loaders) 171
Spark Plug Wires Resistance Test 172
Spark Plug Test 172
Distributor Tests 172
Test Connections 172
Dwell Angle Check 172
Spark Strength Tests 174
Ignition System Tests 174
Battery To Coil Voltmeter Test 174
Starting Ignition Circuit Voltmeter Test 174
Breaker Point Gap Adjustment 175
Ignition Timing 175
Timing Mark Locations 175
Initial Ignition Timing 175
CARBURETOR REPAIR 176
ENGINE DIAGNOSIS ANDTESTING 176
Camshaft Lobe Lift 176
Crankshaft End Play 177
Flywheel Face Alignment Check 177
Camshaft End Play 177
Checking Engine Compression 177
Understanding The Results Of The Test 178
ENGINE OVERHAUL 178
Cylinder Head 178
Valve Guides 178
Grinding Valve Seat 179
Valves 179
Grinding Valves 179
Select Fitting Of Valves 179
Camshaft Repair 179
Crankshaft 179
Reconditioning Journals 179
To Check Crankshaft or Connecting Rod Bearings With Plastigage 179
To Install Pistons 180
To Install Piston Rings 180
Installing Piston Pins 181
Valve Rocker Arm And/Or Shaft Assembly 181
Push Rods 181
Cylinder Block 181
Finishing Cylinder Walls 181
Cylinder Heads 181
Cleaning 181
Inspection 181
Tappets 182
Cleaning 182
Inspection 182
Camshaft 182
Cleaning And Inspection 182
Crankshaft 182
Flywheel 182
Connecting Rods 182
Pistons, Pins And rings 183
Main And Connecting Rod Bearings 183
Cylinder Block 183
Oil Pump 184
REMOVAL OF ENGINE 184
VALVE ROCKER ARM COVER, ROCKER ARM AND/OR SHAFT 185
Removal And Disassembly 185
Installation 185
VALVE PUSH ROD 186
Removal 186
Installation 186
INTAKE MANIFOLD 186
Removal 186
Installation 186
CYLINDER HEAD 186
Removal 186
Installation 187
VALVE SPRING, RETAINER AND STEM SEAL (CYLINDER HEAD REMOVAL) 188
Removal 188
Installation 188
CYLINDER HEAD INSTALLED 188
Removal 188
Installation 188
WATER PUMP 189
CYLINDER FRONT COVER, TIMING CHAIN AND CRANKSHAFTSPROCKETS 189
Removal 189
Remove Timing Cover 190
Installation 190
FRONT OIL SEAL 191
Removal 191
Installation 191
TIMING CHAIN TIGHTENER 191
Removal 191
Installation 191
CAMSHAFT AND VALVE LIFTERS 191
Removal 191
Installation 192
FLYWHEEL RING GEAR 193
Removal 193
Installation 193
OIL PAN 193
Removal 193
Installation 193
OIL PUMP 194
Removal 194
Installation 194
CRANKSHAFT REAR OIL SEAL 194
Removal 194
Installation 194
MAIN BEARINGS 194
Removal 195
Installation 195
CONNECTING ROD BEARINGS 195
Removal 195
Installation 195
PISTONS AND CONNECTING RODS 195
Removal 195
Installation 196
CRANKSHAFT 197
Removal 197
Installation 197
CAMSHAFT BEARINGS 198
Removal Of Camshaft 198
Installation 198
TECHNICAL DATA 199
ENGINE SPECIFICATIONS (700, 720 WISCONSIN) 201
ENGINE SPECIFICATIONS, 700/720 (Wisconsin) 203
Fuel Specifications 203
Engine Oil 203
Valve Mechanism 203
Crankshaft 204
dler Gear 204
Connecting Rod 204
Piston, Piston Pin, Piston Rings 204
Ignition System 204
Distributor Advance characteristics 204
Starter 204
Engine Torque Specifications 204
700/720 LOADER SPECIFICATIONS 205
OPERATIONAL & PERFORMANCE 205
ENGINE 205
LOADER HYDRAULICS 205
ELECTRICAL 205
POWER TRAIN 205
CAPACITIES 205
TIRES 205
ENGINE SPECIFICATIONS (721 DEUTZ) 207
ENGINE SPECIFICATIONS, 721 (Deutz) 209
Fuel System 209
Governor, Front Cover And Throttle 209
Cylinder Head And Valves 209
Cylinder, Piston And Connecting Rod 209
Camshaft, Crankshaft, Bearings 210
Lubrication System 211
Torque Specifications (Deutz Engine) 211
Special Tools (Deutz) 211
721 LOADER SPECIFICATIONS 212
OPERATIONAL & PERFORMANCE 212
ENGINE 212
LOADER HYDRAULICS 212
ELECTRICAL 212
POWER TRAIN 212
CAPACITIES 212
TIRES 212
MACHINE WEIGHT (Less Attachments) 212
ENGINE SPECIFICATIONS (722 FORD) 213
ENGINE SPECIFICATIONS, 722 (Ford) 215
Fuel Specifications 215
Engine Oil 215
Lubrication System 216
Cylinder Heads 216
Valve Mechanism 216
Camshaft 216
Crankshaft 217
Connecting Rod 217
Piston 217
Piston Pin 217
Piston Rings 217
Cylinder Block 218
Ignition System 218
Starter 218
Torque Specifications for Engine 219
Special Tools (Ford) 219
Carburetor Tool 219
722 LOADER SPECIFICATIONS 220
OPERATIONAL & PERFORMANCE 220
ENGINE 220
LOADER HYDRAULICS 220
ELECTRICAL 220
POWER TRAIN 220
CAPACITIES 220
TIRES 220
TECHNICAL DATA 221
LOADER TORQUE SPECIFICATIONS 223
HYDRAULIC/HYDROSTATIC TRANSMISSION FLUID 223
SPECIAL TOOLS 223
Main Frame & Hydraulics Tools 223
Hydrostatic System Tools 223
DECIMAL AND MILLIMETER EQUIVALENTS 224
U S TO METRIC CONVERSION 224
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 225
ALPHABETICAL INDEX 227
SERVICE MANUAL REVISIONS 231
720-001 231
720-002 233
720-003 235
720-004 237
720-005 239
720-01 241
720-02 243

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