bobcat 700 | 720 | 721 | 722 service manual2-6 2-9 hydraulic system 700, 720, 721, 722 loader...

BC-S-700,720+

BBoobbccaattService Manual

700, 720,721, & 722

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF BOBCAT OR IT’S SUCCESSORS. BOBCAT AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

Serv

ice

Man

ual

http://www.jensales.com/products/bobcat-skid-steer-loader-service-manual-bc-s-700-720.html

MELROE

Service Manual

INGERSOLL-RAND Printed in U.S.A.


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.

CONTENTS

Page Number

ALPHABETICALINDEX ........................................... 9-1 ELECTRICAL SYSTEM ........................................... 6-1 ENGINE SERVICE ............................................... 7-1 HYDRAULIC SySTEM ............................................ 2-1 HYDROSTATIC SySTEM ......................................... 3-1 MAIN FRAME ................................................... 5-1 MECHANICAL TRANSMISSION ................................... 4-1 PREVENTIVE MAINTENANCE .................................... 1-1 TECHNICAL DATA ............................................... 8-1

I

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

HYDROSTATIC DRIVE SYSTEM

MECHANICAL TRANSMISSION

MAIN FRAME

ELECTRICAL SYSTEM

ENGINE SERVICE

TECHNICAL DATA

ALPHABETICAL INDEX

700, 720, 721, 722 Loader Service Manual


ENGINE SERVICE


Paragraph Number

1-3

Page Number

1-4

HYDRAULIC/HYDROSTATIC FLUID & FILTER .......... 1-4 1-10

INTRODUCTION ..................................... 1-1 1-1

LOADER LUBRICATION .............................. 1-7 1-14

SERVICE INTERVALS ............................... , 1-2 1-3

TIRES .............................................. 1-6 1-13

TRANSMISSION & DRIVE SYSTEM .................... 1-5 1-12

A WARNING

DO NOT service the Bobcat loader without instructions or taking the necessary safety precautions. Before working on the loader, see the warnings and instructions at the beginning of this Service Manual. After making the repair or adjustment, always check the function of the loader. Failure to obey warnings may cause injury or death.




1-3.3 Air Cleaner System

The air cleaner system must be kept clean and free from defects for good engine performance and long service life.

Service air cleaner as follows:

1. Remove and clean dust cup every day (Fig. 1-16).

2. Do not remove element unless replacement is necessary.

NOTE: Be sure (1) gasket surfaces are clean before installing new element and (2) be sure gasket is in correct place.

3. Check complete air cleaner system and make replacement of any parts with defects. Be sure hose connections are tight.

4. Check running operation of air cleaner system as follows:

a. Start engine and run at idle.

b. Close air inlet on air cleaner. The engine speed must become slower, then stop (722 only). Check the condition indicator for the red ring (720, 721); if the red ring appears, the system is good.

c. If the engine does not stop, the system has a leak. Check, and make repairs as necessary.

5. Check hose from air cleaner to carburetor for damage caused by the hose clamp not being correct at carburetor inlet (Fig. 1-6a).

{

Fig. 1-14 Crankcase Breather (720) Fig. 1-15 Crankcase Breather (721)

Gasket

\ I~ Rubber Baffle

I ()ICj

Fig. 1-16 AirCleaner Assembly

-1-6-

Dust Cup .----.

C-01024



HYDRAULIC SYSTEM

CHARGING THE VANE PUMP &

Paragraph Number

CHECKING FOR SUCTION LEAKS .................. 2-4

CHECKING RELEASE PRESSURE .................... 2-5

CHECKING THE CONDITION OF THE VANE PUMP .................................. 2-6

CONTROL VALVE & HYDRAULIC CYLINDER CHECKS ............................... 2-8

CONTROL VALVE REPAIR ........................... 2-10

GENERAL INFORMATION ............................ 2-2

HYDRAULIC CYLINDER REPAIR. . . . . . . . . . . . . . . . . . . .. 2-9

OPERATION OF THE HYDRAULIC SYSTEM .......................................... 2-1

PROBLEM ANALYSIS CHART ......................... 2-3

VANE PUMP SERVICE ............................... 2-7

A WARNING


·1-

Page Number

2-7

2-8

2-8

2-10

2-12

2-4

2-11

2-3

2-6

2-9

HYDRAULIC SYSTEM



3-4.1 Adjustment Of The Steering Linkage

1. Put the machine on safe blocks.

2. Tilt the ROPS and hold it with a support.

3. Disconnect the control linkage at the pump control arms.

4. Loosen the left steering support (Fig. 3-4) and move it sideways until the roller contacts the tank wall and the stop contacts the steering shaft at the same time. Tighten the support bolts.

5. Loosen the right steering support and move it until there is 0.0625 inch (1,6 mm) clearance between the two pads (Fig. 3-4). 1ighten the support bolts.

6. Tighten the 0.3125 inch bolt until the length of the spring is 2.5625 inch (65 mm) with the steering levers in neutral position (Fig. 3-5).

7. Loosen the right steering roller. Slide it vertically until both rollers contact the plate at the same time (Fig. 3-6).

8. Start the engine and let it run at idle. Put the pintle control arms on the transmission pump in neutral position (no wheel movement).

9. Loosen the lock nuts on the linkage rods. Turn the swivel to make alignment with holes in the pintle arms. 1ighten the lock nuts, and the bolts which hold the linkage in place (Fig. 3-7).

10. Lower the ROPS and install the fastening screws. Put the machine on the floor, and test the steering levers with the machine running.

3-4.2 To Remove The Steering Lever Assembly

1. Disconnect the linkage rods at the front.

2. Remove the four bolts which hold the mounting clamps to the frame.

3. Remove the retainer collar on the left hand steering lever. Remove the left lever.

4. Hold the limiting bracket (1) and friction bracket (2) together with a locking pliers. Lift the assembly out of the machine (Fig. 3-8).

Assembly is the reverse of disassembly. (Also see Adjustment of the Steering Linkage).

I I

0.0625" --.. + (1,6 mm) ~

Fig. 3-4 Steering Linkage Shaft Adjust.

Fig. 3-6 Steering Linkage

Fig. 3-8 Removing Steering Lever Assembly

-3-7-

Fig. 3-5 Compression Spring Adjustment

8-01616

Fig. 3-7 Pintle Arm Adjustment

700,720,721,722 Loader Service Manual


MAIN FRAME

Paragraph Number

FUEL TANK ......................................... 5-4

GRILL ASSEMBLY ................................... 5-3

LOADER LIFT ARM ASSEMBLy ....................... 5-2

THE BOB-TACH ..................................... 5-1

A WARNING


Page Number

5-3

5-2

5-2

5-1

MAIN FRAME



ELECTRICAL SYSTEM

Paragraph Number

ADJUSTMENT OF ALTERNATOR BELT ................ 6-3

ELECTRICAL CHECKS (700/720) ...................... 6-5

ELECTRICAL CHECKS (721/722) ...................... 6-6

ELECTRICAL CiRCUiTy .............................. 6-1

GENERATOR SERVICE .............................. 6-7

PROBLEM ANALYSIS CHARTS ....................... 6-2

STARTER SERVICE .................................. 6-8

A WARNING


Page Number

6-7

6-8

6-9

6-1

6-9

6-1

6-11

ELECTRICAL SYSTEM



ENGINE SERVICE

Paragraph Number

DEUTZ ENGINE ...................................... 78

FORD ENGINE ....................................... 7C

WISCONSIN ENGINE ................................. 7A

A WARNING


Page Number

78-1

7C-1

7A-1

ENGINE SYSTEM

WISCONSIN (700,720)

DEUTZ (721)

FORD (722)

700,720,721,722 Loader Service Manual


ENGINE SERVICE (WISCONSIN ENGINE - 700, 720)

Paragraph Number

CARBURETOR SERVICE ............................ 7 A-4

ENGINE IGNITION SYSTEM ......................... 7 A-2

ENGINE OVERHAUL ................................ 7A-6

HIGH TEMPERATURE SAFETY SWITCHES ........... 7A-3

LP CARBURETOR SERViCE ......................... 7A-5

TROUBLESHOOTING THE ENGINE .................. 7 A-1

Page Number

7A-4

7A-2

7A-12

7A-3

7A-6

7A-1

WISCONSIN (700, 720)



ENGINE SERVICE (DEUTZ ENGINE - 721)

Paragraph Number

ENGINE SERVICE .................................. 7B-5

FUEL INJECTION NOZZLES ......................... 7B-4

FUEL INJECTION PUMP ............................ 7B-3

FUEL SYSTEM ..................................... 7B-2

TROUBLESHOOTING THE ENGINE .................. 7B-1

Page Number

7B-5

7B-5

7B-3

7B-2

7B-1

DEUTZ (721)



ENGINE SERVICE (FORD ENGINE - 722)

Paragraph Page Number Number

CAMSHAFT & VALVE LIFTERS ..................... 7C-16 7C-23

CAMSHAFT BEARINGS ........................... 7C-26 7C-30

CHECKS & ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . .. 7C-2 7C-2

CONNECTING ROD BEARINGS. . . . . . . . . . . . . . . . . . .. 7C-23 7C-27

CRANKSHAFT ................................... 7C-25 7C-29

CRANKSHAFT REAR OIL SEAL . . . . . . . . . . . . . . . . . . .. 7C-21 7C-26

CYLINDER FRONT COVER, TIMING CHAIN & CRANKSHAFT SPROCKETS ............ 7C-13 7C-21

CYLINDER HEAD .................................. 7C-9 7C-18

CYLINDER HEAD INSTALLED ...................... 7C-11 7C-20

ENGINE DIAGNOSIS & TESTING. . . . . . . . . . . . . . . . . . .. 7C-3 7C-8

ENGINE OVERHAUL ............................... 7C-4 7C-10

FLYWHEEL RING GEAR ........................... 7C-17 7C-25

FRONT OIL SEAL ................................. 7C-14 7C-23

INTAKE MANIFOLD ................................ 7C-8 7C-18

MAIN BEARINGS ................................. 7C-22 7C-26

OIL PAN ......................................... 7C-18 7C-25

OIL PUMP ....................................... 7C-19 7C-26

PISTONS & CONNECTING RODS .................. 7C-24 7C-27

REMOVAL OF ENGINE ............................. 7C-5 7C-16

TIMING CHAIN TIGHTENER ....................... 7C-15 7C-23

TROUBLESHOOTING THE ENGINE ................. 7C-1 7C-1

VALVE PUSH ROD ................................. 7C-7 7C-18

VALVE ROCKER ARM COVER ...................... 7C-6 7C-17

VALVE SPRING, RETAINER & STEM SEAL .......... 7C-10 7C-20

WATER PUMP .................................... 7C-12 7C-21

FORD (722)



TECHNICAL DATA

ENGINE SPECIFICATIONS

Paragraph Number

(700/721 WISCONSIN) ............................... .

ENGINE SPECIFICATIONS (721 DEUTZ) ........................................ .

ENGINE SPECIFICATIONS (722 FORD) ......................................... .

TECHNICAL DATA ..................................... .

A WARNING


Page Number

8A-1

8B-1

8C-1

80-1

TECHNICAL DATA

WISCONSIN (700, 720)

DEUTZ (721)

FORD (722)



TECHNICAL DATA

DECIMAL & MILLIMETER

Paragraph Number

EQUIVALENTS ...................................... .

HYDRAULIC/HYDROSTATIC TRANSMISSION FLUID. . . . . . . . . . . . . . . . . . . . . . . . . .. 80-2

LOADER TORQUE SPECiFiCATIONS ................ 8D-1

SPECIAL TOOLS .................................. 80-3

STANDARD TORQUE SPECIFICATIONS FOR BOLTS ......................................... .

U.S. TO METRIC CONVERSION ......................... .

Page Number

80-2

80-1

80-1

80-1

80-3

8D-2

TECHNICAL DATA



bobcat 700 | 720 | 721 | 722 service manual2-6 2-9 hydraulic system 700, 720, 721, 722 loader...

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