Bobcat 722 Loader Factory Service & Work Shop Manual

7 6556619 (3–87) Printed in U.S.A. © Melroe Company 1987 0 0 7 2 0 7 2 1 7 2 2 Service Manual

MAINTENANCE SAFETY WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0903 Never service the Bobcat Skid- Steer Loader without instructions. Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed. Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame. Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged. Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the loader. Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company. Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention. Use the correct procedure to lift or lower operator cab. Cleaning and maintenance are required daily. Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. MSW01-0805 WRONG B-6590 WRONG B-16102 B-6580 WRONG B-16102 B-6589 WRONG B-15280 WRONG B-15231 WRONG B-11799 B-10731a CORRECT B-12365 CORRECT B-7469 CORRECT Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

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 Page Number ALPHABETICAL INDEX 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTENTS 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.

700, 720, 721, 722 Loader Service Manual

PREVENTIVE MAINTENANCE 700, 720, 721, 722 Loader Service Manual Paragraph Page Number Number ENGINE SERVICE 1–3 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 . . . . . . . . . . . . . . . . . . . . Revised Feb. 82 PREVENTIVE MAINTENANCE 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.

700, 720, 721, 722 Loader Service Manual 700–720–721 Service Manual #6556619 – Contents Section

1 PREVENTIVE MAINTENANCE 1–1 INTRODUCTION 1–1.1 Symbols This notice shows important procedures which must be followed to prevent damage to the loader. IMPORTANT For your safety, warnings are on the loader and in the manual. Failure to follow these warnings can cause injury or death. WARNING 1–1.2 Serial Number Identification It is important to make correct reference to the serial number of the loader when making repairs or ordering parts. It is possible that the present machines do not use all the same parts as earlier machines; or it is possible that different procedures are used for service or repair. 1–1.3 Loader Serial Number The loader serial number plate location is in the front of and below the operators seat (Fig. 1–1). Explanation of serial number: XXXX M XXXX Production Sequence (Series) Plant Location Model, Engine Version 1–1.4 Engine Serial Number 720 Wisconsin: (Fig. 1–2) The engine serial number location is on the engine shroud on the left side of engine. Use all numbers when ordering parts for this engine. 721 Deutz: (Fig. 1–3) The engine serial number location is on the right side of cylinder block. Use all numbers when ordering parts for this engine. Revised Feb. 82 6551915 Fig. 1–1 Loader Serial Number B–02273 700, 720, 721, 722 Loader Service Manual –1–1– B–02249 Fig. 1–3 Engine Serial Number (721) B–02120 Fig. 1–2 Engine Serial Number (720)

722 Ford: (Fig. 1–4) the engine serial number location is on the right side of the valve cover. Use all numbers when ordering parts for this engine. 1–1.5 Pre–Delivery Inspection The purpose of the pre–delivery inspection is to make sure that the loader is in correct condition when it comes to the dealer and before delivery to the customer. The pre–delivery inspection also lets the factory know when something is wrong with the loader so that the problem can be corrected and prevented in the future. All items on the inspection form (Fig. 1–5) must be completed according to specifications in this manual. One copy of the completed form is to be mailed to: *Revised Feb. 82 CLARK EQUIPMENT COMPANY MELROE DIVISION QUALITY CONTROL DEPT. GWINNER, NORTH DAKOTA 58040 The other copy is for the dealer. 1–1.6 30 Hour Inspection The 30 hour inspection must be completed soon after the first 30 hours of operation. The purpose of the 30 hour inspection is: 1. For adjustment and inspection after first work period. 2. To correct wrong maintenance and operating methods. 3. For demonstration of correct service procedures to customer. All items on the 30 hours inspection for (Fig. 1–6) must be completed by the dealer’s mechanic, according to specifications in this manual. When the 30 hour inspection has been completed, the form must be signed by (1) the mechanic that completed the inspection, (2) the dealer, and (3) the owner or operator. One copy of the completed form is to be mailed to: CLARK EQUIPMENT COMPANY MELROE DIVISION – SERVICE DEPARTMENT GWINNER, NORTH DAKOTA 58040 One copy is for the owner and one copy is for the dealer. –1–2– 700, 720, 721, 722 Loader Service Manual B–02796 Fig. 1–4 Engine Serial Number (722) Fig. 1–5 Pre–Delivery Inspection Fig. 1–6 30 Hour Inspection

Bobcat 722 Loader Factory Service & Work Shop Manual

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