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


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 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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