Bobcat 700, 720, 721, 722 Skid-Steer Loader Repair Service Manual – 6556619

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This workshop repair service manual PDF download for the 700, 720, 721, 722 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 700
Bobcat Loader 720
Bobcat Loader 721
Bobcat Loader 722

TABLE OF CONTENTS :

PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
TECHNICAL DATA
ALPHABETICAL INDEX
SERVICE MANUAL REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6556619 (3–87)
Total Pages : 242

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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 INTERVALS
SERVICE SCHEDULE
ENGINE SERVICE (General)
Engine Oil And Filter
Checking Oil
Adding Oil
Replacement Oil And Filter
Crankcase Breather
Air Cleaner System
Fuel System (720, 722)
Fuel Filter
Fuel System (721)
Fuel Pump
Carburetor
Carburetor Adjustment
Idle Adjusting Needle (722)
Throttle Idle Adjustment (722)
Engine Cooling System
Removing Coolant From System (722)
Engine Electrical System(720, 721 & 722)
Installing New Battery
Ignition System (720 & 722)
Making Adjustment Of Spark PlugGap
Making Adjustment Of Point Gap
HYDRAULIC/HYDROSTATIC FLUID AND FILTER
Fluid
Filters
Replacing The 25 Micron Filter
Replacing The 10 Micron Filter
TRANSMISSION AND DRIVE SYSTEM
Chain Adjustment
Brakes
Brake Adjustment
TIRES
Tire Rotation
LOADER LUBRICATION
BOB–TACH AND PIVOT PINS

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
OPERATION OF THE HYDRAULIC SYSTEM
GENERAL INFORMATION
Clean Area
Air Leaks
Tubelines, Hoses, Fittings
37° Flare Connections
Straight Thread O–Ring Connections
Pipe Thread Connections
Tubelines And Hoses
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM
PROBLEM ANALYSIS CHARTS
CHARGING THE VANE PUMP AND CHECKING FOR SUCTION LEAKS
Charging The Pump When No Source Of Air Pressure Is Available
Another Method To Check The System For Air Leaks
Removing Air From System
CHECKING RELEASE PRESSURE
Indicator Switch For Charge Pressure
Machines Without Auxiliary Hydraulic Tubelines
Machines With Auxiliary Hydraulic Tubelines
CHECKING THE CONDITION OF THE VANE PUMP
Checking Vane Pump
VANE PUMP SERVICE
To Remove The Vane Pump
Disassembly
Inspection And Service
Assembly
To Install The Vane Pump
CONTROL VALVE AND HYDRAULIC CYLINDER CHECKS
Checking The Lift Cylinders
Checking The Tilt Cylinders
HYDRAULIC CYLINDER REPAIR
Removing Cylinders
To Disassemble A Hydraulic Lift Or Tilt Cylinder
To Replace The Cylinder Seals
To Assemble The Hydraulic Cylinder
CONTROL VALVE REPAIR
Relief Valve Repair
To Remove The Control Valve
To Disassemble The Control Valve
To Repair The Float Detent Of The Lift Spool
To Assemble The Detent Assembly
Inspection, Repair And Assembly Of Control Valve
Restrictor For Tilt Hydraulic Circuit
Restrictor For Lift Hydraulic Circuit (Gresen Valve Only)

HYDROSTATIC SYSTEM
CIRCUIT DESCRIPTION
10 MICRON FILTER
TROUBLESHOOTING CHART
PROBLEM ANALYSIS CHARTS
STEERING LINKAGE
Adjustment Of The Steering Linkage
To Remove The Steering Lever Assembly
Adjustment Of The Hydrostatic Motors
TWO SPEED CONTROL
CHECKING THE HYDROSTATIC SYSTEM
Charge Pressure Check (Levers In Neutral)
Charge Pressure Check (Levers Engaged)
BY–PASS VALVE SERVICE
Checking The By–Pass Valve
To Remove The By–Pass Valve
REPLENISHING VALVE
Checking The Replenishing Valves
HYDROSTATIC MOTOR REPLACEMENT
REPLACEMENT OF HYDROSTATIC PUMP ASSEMBLY
Removal (700, 720, 722)
Removal (721)
HYDROSTATIC RECONDITIONING
Transmission Pump
Hydrostatic Motor
To Disassemble Pump Or Motor
Inspection Of Pump And Motor
Hydrostatic Motor Modification
Assembly Of Pump And Motor
START–UP AFTER REPAIR
Hydrostatic Pump Elbows

FINAL DRIVE SYSTEM (MECHANICAL)
TROUBLESHOOTING THE MECHANICAL TRANSMISSION
REPAIR AND REPLACEMENT OF BRAKE ASSEMBLY
Removal Of Caliper Assembly
Removal Of Lever Assembly
Linkage Rod Assembly
FINAL DRIVE
CHAIN REMOVAL AND INSTALLATION
To Remove And Install Chains
Primary Drive Chain Removal
To Install The Primary Drive Chain
Secondary Drive Chain Removal
To Install The Secondary Drive Chain
Final Drive Chain Removal
To Install The Final Drive Chain
MOTOR SPROCKET SERVICE
Motor Sprocket Removal
To Install The Motor Sprocket
UPPER JACKSHAFT SERVICE
To Remove The Upper Jackshaft
Assembly
To Install Upper Jackshaft Sprocket
IDLER SPROCKET SERVICE (PRIMARY AND SECONDARY)
SERVICING LOWER JACKSHAFT SPROCKET
To Remove The Lower Jackshaft Assembly
Lower Jackshaft Bearing Replacement
FINAL DRIVE TIGHTENER SERVICE
To Remove Final Drive Tightener
To Remove Final Drive Idler Sprocket And Bearing
To Install Final Drive Idler Bearing
WHEEL AND AXLE REPAIR (LOT A 700)
To Remove Axle Assembly
To Install New Axle Bearing And Seal
To Install The Axle
WHEEL AND AXLE REPAIR (LOT B AND LATER 700, 720, 721& 722)
To Remove The Axle Assembly
Axle Bearing And Seal Replacement
To Install The Axle
AXLE REINFORCEMENT (LOT B & LATER 700)

MAIN FRAME
THE BOB–TACH
Removal And Replacement of Bob–Tach
LOADER LIFT ARM ASSEMBLY
Replacement Of Lift Arms
GRILL ASSEMBLY
FUEL TANK
Fuel Tank Removal
Shield For The Fuel Tank

ELECTRICAL SYSTEM
ELECTRICAL CIRCUITRY
PROBLEM ANALYSIS CHARTS
ADJUSTMENT OF ALTERNATOR BELT
REPLACEMENT OF ALTERNATOR BELT
ELECTRICAL CHECKS (700/720)
To Check Indicator Circuit
To Check Resistor
To Check Field Relay
To Check Alternator Output
ELECTRICAL CHECK (721/722)
To Check Wiring
To Check Alternator Output
To Check The Regulator
GENERATOR SERVICE (700, 720, 721, 722)
Alternator Removal
Disassembly
To Check Rotor
To Check Stator
To Check Diode Trio
To Check Rectifier
Assembly
STARTER SERVICE
To Check The Starter
To Remove Starter
Disassembly (722)
Cleaning And Inspection
Bruch Replacement
Assembly

ENGINE SERVICE
ENGINE SERVICE (WISCONSIN ENGINE – 700, 720)
TROUBLESHOOTING THE ENGINE
ENGINE IGNITION SYSTEM 700/720/722
Distributor Maintenance
Timing Procedure (700, 720)
Spark Plug
HIGH TEMPERATURE SAFETY SWITCHES
CARBURETOR SERVICE
Carburetor and Adjustment
Carburetor Removal
Carburetor Reconditioning
Disassemble The Throttle Body
To Disassemble The Fuel Bowl
To Assemble The Fuel Bowl And Air Intake Assembly
To Assemble The Throttle Body
To Assemble The Fuel Bowl To The Throttle Body
LP CARBURETOR SERVICE
To Remove The LP Carburetor From The Engine
Disassembly
Cleaning And Inspection
Assembly
Vaporizer – Primary Regulator Service
Disassembling The Vaporizer
Assembling The Vaporizer
Adjusting The Vaporizer
LP Fuel Filter Lock – Off
To Disassemble The Fuel Filter Lock–Off
ENGINE OVERHAUL
Engine Removal
Disassembly Of Flywheel
Air Shrouding
Carburetor And Manifolds
Cylinder Head
Gear Cover
Camshaft Gear
Idler Gear And Shaft
Oil Pan
Oil Pump
Pistons And Connecting Rods
Piston rings (Engine With 4–Ring Pistons)
Cylinder Blocks
Valves And Seat Inserts
Crankshaft
Three Bearing Crankshaft
Camshaft
Valve Tappets
Governor Adjustment
Storage Of Engines
Returning Engine To Service
Returning Compression To Engine
ENGINE SERVICE (DEUTZ ENGINE – 721)
TROUBLESHOOTING THE ENGINE
FUEL SYSTEM
Fuel And Control Linkage Adjustment
Air Venting Fuel System
Fuel Filters
Fuel Lift Pump
FUEL INJECTION PUMP
Checking
Removal Of Injection Pump
Injection Pump Service
To Install Injection Pump
Adjustment Of Fuel Delivery
FUEL INJECTION NOZZLES
Removing Fuel Injection Nozzles
Disassembly And Repair Of Injection Nozzles
Installation Of Injection Nozzles
ENGINE SERVICE
Engine Removal
Blower Fan
Removal
Installation
Disassembly
Assembly
Cylinder Head and Valves
Removal
Disassembly
Repair And Assembly
Installation Of Head
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 And Inspection
Assembly
Installation
GOVERNOR
Removal And Disassembly
Assembly And Installation
CAMSHAFT
Removal
Installation
Crankshaft Removal
Inspection
Assembly
FLYWHEEL
ENGINE SERVICE (FORD ENGINE – 722)
TROUBLESHOOTING THE ENGINE
CHECKS AND ADJUSTMENTS
Oil Pressure
Valve Clearance
Compression
Carburetor, Throttle And Governor Adjustments
Ignition System
Coil To Ground Voltmeter Test
Coil Relocation & Vacuum Hose Installation (Early 722 Loaders)
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 ANDTESTING
Camshaft Lobe Lift
Crankshaft End Play
Flywheel Face Alignment Check
Camshaft End Play
Checking Engine Compression
Understanding The Results Of The Test
ENGINE OVERHAUL
Cylinder Head
Valve Guides
Grinding Valve Seat
Valves
Grinding Valves
Select Fitting Of Valves
Camshaft Repair
Crankshaft
Reconditioning Journals
To Check Crankshaft or Connecting Rod Bearings With Plastigage
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
Flywheel
Connecting Rods
Pistons, Pins And rings
Main And Connecting Rod Bearings
Cylinder Block
Oil Pump
REMOVAL OF ENGINE
VALVE ROCKER ARM COVER, ROCKER ARM AND/OR SHAFT
Removal And Disassembly
Installation
VALVE PUSH ROD
Removal
Installation
INTAKE MANIFOLD
Removal
Installation
CYLINDER HEAD
Removal
Installation
VALVE SPRING, RETAINER AND STEM SEAL (CYLINDER HEAD REMOVAL)
Removal
Installation
CYLINDER HEAD INSTALLED
Removal
Installation
WATER PUMP
CYLINDER FRONT COVER, TIMING CHAIN AND CRANKSHAFTSPROCKETS
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
ENGINE SPECIFICATIONS (700, 720 WISCONSIN)
ENGINE SPECIFICATIONS, 700/720 (Wisconsin)
Fuel Specifications
Engine Oil
Valve Mechanism
Crankshaft
dler Gear
Connecting Rod
Piston, Piston Pin, Piston Rings
Ignition System
Distributor Advance characteristics
Starter
Engine Torque Specifications
700/720 LOADER SPECIFICATIONS
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
POWER TRAIN
CAPACITIES
TIRES
ENGINE SPECIFICATIONS (721 DEUTZ)
ENGINE SPECIFICATIONS, 721 (Deutz)
Fuel System
Governor, Front Cover And Throttle
Cylinder Head And Valves
Cylinder, Piston And Connecting Rod
Camshaft, Crankshaft, Bearings
Lubrication System
Torque Specifications (Deutz Engine)
Special Tools (Deutz)
721 LOADER SPECIFICATIONS
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
POWER TRAIN
CAPACITIES
TIRES
MACHINE WEIGHT (Less Attachments)
ENGINE SPECIFICATIONS (722 FORD)
ENGINE SPECIFICATIONS, 722 (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)
Carburetor Tool
722 LOADER SPECIFICATIONS
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
POWER TRAIN
CAPACITIES
TIRES
TECHNICAL DATA
LOADER TORQUE SPECIFICATIONS
HYDRAULIC/HYDROSTATIC TRANSMISSION FLUID
SPECIAL TOOLS
Main Frame & Hydraulics Tools
Hydrostatic System Tools
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION
STANDARD TORQUE SPECIFICATIONS FOR BOLTS

ALPHABETICAL INDEX

SERVICE MANUAL REVISIONS
720-001
720-002
720-003
720-004
720-005
720-01

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