Bobcat 974 975 Loader Service Manual 6556214 (6-12) – PDF DOWNLOAD

Description

Bobcat 974 975 Loader Service Manual 6556214 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 974 975 Loader Service Manual 6556214 (6-12) – PDF DOWNLOAD

Language : English
Pages : 322
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 974 975 Loader Service Manual 6556214 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 5
SAFETY INSTRUCTIONS 7
Safety Is Your Responsibility 7
Before You Operate The Bobcat Loader 7
Safe Operation Needs A Qualified Operator 8
FIRE PREVENTION 8
PREVENTIVE MAINTENANCE 9
INTRODUCTION 11
Symbols 11
Serial Number Identification 11
Loader Serial Number 11
Engine Serial Number 11
Pre-Delivery Inspection 11
30 Hour Inspection 12
SERVICE SCHEDULE 13
REAR DOOR AND ENGINE COVER 14
REMOVAL OF SIDE PANEL (FENDER) 14
TILTING THE ROPS (Operator Enclosure) 14
Tilting ROPS Forward 14
To Lower ROPS 15
CONTROL LEVER LOCK 15
TO CLEAN ROPS ANS SKID PLATE AREA 15
To Open The Skid Plate 15
To Close The Skid Plate 16
ENGINE MAINTENANCE 16
Starting The Engine 16
Engine Oil Check 16
Specifications 16
CRANKCASE VENT TUBE 17
REPLACEMENT OF ENGINE OIL AND FILTER 17
ENGINE AIR INLET SYSTEM (Air Cleaner) 17
Air Cleaner Service 17
Air Inlet System Service 18
ENGINE COOLING SYSTEM 18
FLUSHING THE COOLING SYSTEM 18
ADJUSTMENT OF FAN BELT 19
FUEL SYSTEM (General) 20
FUEL SPECIFICATIONS 20
974 FUEL SYSTEM SERVICE 20
CHARGING FUEL SYSTEM 21
975 FUEL SYSTEM SERVICE 21
Fuel Pump 21
Fuel Filter 22
To Charge Fuel System 23
Remove Air From Fuel System 23
REMOVAL OF FUEL TANK 24
ELECTRICAL SYSTEM MAINTENANCE 24
ADJUSTMENT OF CLUTCH/BRAKE 25
Clutch/Brake Spring 27
HYDRAULIC/HYDROSTATIC SYSTEM (General) 28
HYDRAULIC FLUID 28
HYDRAULIC FLUID FILTERS 28
HYDRAULIC RESERVOIR REMOVAL OF WATER OR HYDRAULIC FLUID 29
HYDRAULIC FLUID TO CHECK, ADD OR REPLACE 29
REMOVAL OF HYDRAULIC RESERVOIR 30
TO CHECK FOR HYDRAULIC SYSTEM LEAKS 30
TO CLEAN 100 MESH FILTER SCREEN 30
OIL COOLER 31
HYDROSTATIC TRANSMISSION 31
FINAL DRIVE CHAIN 31
TO TRANSPORT 31
TIRES 32
TIRE MAINTENANCE 33
TIRE ROTATION 33
TIRE REPLACEMENT 33
LUBRICATION 33
WHEEL NUTS 33
BOB-TACH 34
MELROE TRACKS 35
To Install The Tracks (Tandem) 35
Track Adjustment 36
Tires Damaged By Tracks 36
HYDRAULIC SYSTEM 37
HYDRAULIC/HYDROSTATIC SCHEMATICS 39
BASIC OPERATING PRINCIPLE OF THE HYDRAULIC SYSTEM 57
HYDRAULIC CONTROLS 57
Clean Area 57
Air Leaks 57
Tubelines, Hoses, Fittings 57
Straight Thread O-Ring Connections 58
37° Flare Connections 58
Tubelines And Hoses 58
Pipe Thread Connections 58
TROUBLESHOOTING 59
HYDRAULIC FILTER SERVICE 61
HYDRAULIC TESTING 61
To Check Volume Control Relief Valve 61
To Check Lift Circuit Relief Valve 61
HYDRAULIC PUMP 62
Hydraulic Pump Testing 62
Hydraulic Pump Removal 62
Disassembly Of Hydraulic Pump 63
Assembly Of Hydraulic Pump 63
Installation Of Hydraulic Pump 64
HYDRAULIC PUMP (TYRONE) 974-S/N 12818 & Above: 975-S/N 12639 & Above 65
Removal Of The Hydraulic Pump (Tyrone) 65
Disassembly Of The hydraulic Pump (Tyrone) 65
Inspection Of The Hydraulic Pump (Tyrone) 67
Replacement Of The Shaft Seal (Tyrone) 71
Assembly Of The Hydraulic Pump (Tyrone) 68
Installing The Hydraulic Pump (Tyrone) 72
REMOVAL OF CONTROL VALVE 73
Disassembly Of Control Valve 73
CONTROL VALVE SERVICE 73
Control Valve Seal Replacement 73
Self Leveling Section Service 75
CHECK HYDRAULIC LIFT AND TILT CYLINDERS 76
INSPECTION OF HYDRAULIC CYLINDER 77
LIFT CYLINDER SERVICE 77
TILT CYLINDER SERVICE 79
HYDROSTATIC SYSTEM 81
HYDROSTATIC OPERATING PRINCIPLE 83
HYDROSTATIC CIRCUITRY 85
TROUBLESHOOTING 85
ADJUSTMENT OF DIRECTIONAL CONTROL 90
REMOVAL OF CONTROL ASSEMBLY 91
ADJUSTMENT OF PUMP AND MOTOR CONTROL 91
FLUID AND FILTERS 92
Fluid 92
Filters 92
TRANSMISSION STARTING PROCEDURE 92
HYDROSTATIC CHARGE PUMP 93
Description 93
To Check Charge Pressure 93
Removal Of Charge Pump 93
Installation Of Charge Pump 94
DISPLACEMENT CONTROL VALVE 94
Removing Displacement Control Valve 94
Installing Displacement Control Valve 95
Adjustment Of Displacement Control Valve 95
REMOVAL OF CHECK VALVE 97
To Test Check Valves 97
Installation Of Check Valve 97
REMOVAL OF HYDROSTATIC PUMP OR HYDROSTATIC MOTOR 98
Disassembly Of Pump Or Motor 98
Removal Of Seal 98
Installation Of Seal 99
Removal Of End cap 99
Removal Of Valve Plate 100
Removal Of Brass Bearing Plate 100
Removal Of Rear Bearing 100
Removal Of Spring Guide 100
Removal Of Cylinder Block 101
Removal Of Slipper Retainer Guide 101
Removal Of Pistons And Slipper Retainer 101
Removal Of Thrust Plate 101
Removal Of Front Cover 101
Removal Of Drive Shaft 101
Removal Of Swashplate And Trunnion 102
Removal Of Servo Pistons And Sleeves 102
Assembly Procedure 102
Adjustment Of Drive Shaft End Play 103
Assembly Of Servo Pistons 103
Installation Of Servo Pistons 103
Control Link Connections 104
Installation Of Servo Sleeves 104
Installing Swashplate And Trunnions 104
Adjustment Of Neutral Position Of Swashplate 104
Installation Of thrust Plate 105
Installation Of Drive Shaft 105
Installation Of Front Cover And Gasket 105
Assembly Of Cylinder Block 105
Installation Of the Cylinder Block Assembly 106
Installation Of Spring Guide 106
Installation Of Rear Bearing Cone 106
Installation Of Bearing Plate 106
To Place Valve Plate On End Cap 106
Installation Of End Cap 106
Installation Of Motor 107
MANIFOLD BLOCK 107
Motor Manifold Block 107
Removal Of Manifold Bloclk 108
Installation Of Manifold Block 108
OIL COOLER 108
Cleaning 108
Removal Of Oil Cooler 108
Installation Of Oil Cooler 109
Oil Cooler Bypass Valve 109
MECHANICAL DRIVE SYSTEM 111
GENERAL INFORMATION 113
CLUTCH SERVICE 113
Adjustment Of Clutch 113
Clutch Removal 113
Inspection Of Clutch 113
Assembly Of Clutch 113
TRANSFER CHAINCASE SERVICE 114
Removal Of Transfer Chaincase 114
Disassembly Of Transfer Chaincase 114
Inspection Of Transfer Chaincase 115
To Assemble And Install Transfer Chaincase 115
New Transfer Case 115
REDUCTION GEARCASE DESCRIPTION 117
Removal Of Reduction Gearcase 117
Disassembly And Assembly Of The Reduction Gearcase 118
Installation Of The Reduction Gearcase 127
ADJUSTMENT OF FINAL DRIVE CHAIN 127
To Check Final Drive Chain 127
Removal Of Drive Chain 127
AXLES 128
Removal Of Axle Housing 128
Disassembly Of Axle Housing 129
To Check Axle And Sprocket Splines 129
Installation Of Axle Housing 129
Assembly Of Axle And Housing 130
INSTALLATION OF FINAL DRIVE CHAIN 131
FINAL DRIVE CHAIN (With Pivot Bolt) 133
Removal Of The Idler 134
Disassembly Of Idler 134
Assembly And Installation Of Idler 134
FINAL DRIVE IDLER (With Floating Pivot Pin) 134
To Remove The Idler Assembly 134
Disassembly Of Idler 135
Assembly And Installation Of Idler 135
MAIN FRAME 137
ROPS (Operator Enclosure) 139
ROPS TILT CONTROL SERVICE 139
Removal Of Tilt Control Pump 139
Disassembly Of Tilt Control Motor 139
REMOVAL AND INSTALLATION OF ROPS 139
LIFT ARMS 140
Removal Of Lift Arms 140
Installation Of Lift Arms 140
REPLACEMENT OF LIFT ARM PIVOT PIN 140
REPLACEMENT OF LIFT ARM PIVOT BUSHING 140
ELECTRICAL SYSTEM 141
ELECTRICAL SCHEMATICS 144
INSTALLATION OF BATTERY 153
WIRING HARNESS 153
ELECTRICAL CIRCUITRY 153
Wiring Harness (974) 154
Wiring Harness (975) 155
PROBLEM ANALYSIS CHARTS 156
TO CHECK WIRING 156
TO CHECK GENERATOR OUTPUT 158
GENERATOR SERVICE 158
Removal Of Generator 158
Disassembly Of Generator 158
Inspection Of Generator 158
STARTER SERVICE 159
Checking The Starter 159
Removal Of The Starter 159
Disassembly And Inspection Of Starter 159
Assembly Of The Starter 160
SERVICING THE NIPPONDENSO STARTER 160
Checking The Starter 160
Disassembly Of The Starter 161
Inspecting The Starter 161
Assembly Of The Starter 162
ENGINE SERVICE (974 – PERKINS) 163
REMOVAL OF ENGINE 165
INTRODUCTION TO ENGINE REPAIR 165
UNIFIED THREADS 165
ENGINE NUMBER 165
ENGINE DESCRIPTION 165
LUBRICATING OIL PAN 166
CRANKCASE VENTILATION 166
Breather Assembly 166
CYLINDER HEAD 166
Checking Compression 166
Removal Of The Cylinder Head 166
Removal Of Valves 167
To Clean Cylinder Head And Block 169
Valve Guides 169
Valves And Valve Seats 169
Grinding Valves By Hand 169
Valve Seat Inserts (Exhaust Valve) 169
Machining Of Cylinder Head 170
Valve Springs 170
Assembly Of Rocker Shaft 171
Push Rods 171
Valve Stem Oil Seals 171
Assembly Of Cylinder Head 171
Cylinder Head Gasket 171
Installation Of Cylinder Head 172
REMOVAL OF PISTONS AND CONNECTING RODS 175
Removal Of Pistons And Rings From Connecting Rods 175
Assembly Of Pistons To Connecting Rods 175
Installation Of Pistons And Connecting Rods In Cylinder Bore 176
Installation Of New Pistons 176
CYLINDER LINERS 176
Removal of Cylinder Liners (Cast Iron) 177
Installation Of Cylinder Liners 177
CRANKSHAFT AND MAIN BEARINGS 177
Removal Of Main Bearings And Thrust Washers 177
Installation Of Main Bearings And Thrust Washers 177
REMOVAL OF CRANKSHAFT 178
Regrinding Crankshaft 179
Installation Of Crankshaft 179
CRANKSHAFT REAR OIL SEAL 180
BALANCE UNIT 180
Removal Of Balance Unit 180
Disassembly Of Balance Unit 180
Assembly Of Balance Unit 181
BALANCER UNIT (CENTER MOUNTED) 183
Removal And Installation 183
Engine Timing to Balancer Unit 183
Oil Pump Removal And Installation 183
Oil Pump Inspection 184
Oil Pump Relief Valve 184
Disassembly And Assembly 185
Inspection 186
CRANKSHAFT FRONT OIL SEAL 187
REMOVAL OF TIMING CASE COVER 187
Installation Of Timing Case Cover 189
To Check Timing Gear Play 189
Removal Of Idler Gear And Hub 189
Installation Of Idler Gear And Hub 189
Removal Of Camshaft Gear 190
Installation Of Camshaft Gear 190
Removal Of Fuel Pump Gear 190
Installation Of Fuel Pump Gear 190
Removal Of Timing Case 190
Installation Of Timing Case 190
REMOVAL OF CAMSHAFT AND TAPPETS 191
Installation Of Camshaft And Tappets 191
TO CHECK VALVE TIMING 191
LUBRICATION SYSTEM 192
Engine Lubrication System 192
COOLING SYSTEM 192
Removal And Installation Of Water Pump 192
Disassembly Of Water Pump 193
Inspection Of Water Pump 193
Assembly Of Water Pump 193
Removal Of Thermostat 194
To Test Thermostat 195
FUEL SYSTEM 195
To Test Fuel Lift Pump 195
To Clean Fuel Lift Pump 195
Removal Of Fuel Lift Pump 196
Removal Of Fuel Injection Pump 196
Installation Of Fuel Injection Pump 197
Fuel Injection Pump Gear 197
Maximum Speed Setting 197
Adjustment Of Idling Speed 197
To Charge Fuel System 197
HOW THE THERMOSTART UNIT WORKS 198
ENGINE STARTING PROCEDURE 198
HOW TO USE THE THERMOSTART 198
CHARGING THE FUEL LINE 199
FUEL INJECTORS 199
Fuel Injector Problems 199
To Check And Make Adjustments Of Injectors 199
To Check For Injector Failure 199
To Test Injectors (Visual Inspection) 199
To Test Injectors (Using Testing Equipment) 200
REMOVAL OF FLYWHEEL 201
Removal And Installation Of Flywheel Ring Gear 201
Installation Of Flywheel 201
REMOVAL OF FLYWHEEL HOUSING 202
Installation Of Flywheel Housing 202
Installation Of New Housing 202
Installation Of Old Housing (That Was Removed From Engine) 202
FUEL TIMING INJECTION PUMP 203
To Remove The Fuel Injection Pump 203
To Install The Fuel Injection Pump 203
Checking Fuel Injection Pump Timing 203
Timing The Fuel Injection Pump (Using Tming Tool MS 67123) 204
Checking The Timing Mark On The flange Of The Injection Pump 206
SMOKE DIAGNOSIS CHART 207
TROUBLESHOOTING THE PERKINS ENGINE 208
ENGINE SERVICE (975 – JOHN DEERE) 213
GENERAL INFORMATION 215
PRELIMINARY ENGINE TESTING 215
ENGINE TUNE-UP 215
TUNE-UP PROCEDURE 216
DETAILED TUNE-UP PROCEDURES 217
Air Cleaner 217
Exhaust System 218
Crankcase Vent Tube 218
Compression Test 218
REMOVAL OF ENGINE 219
CYLINDER HEAD, VALVES, CAMSHAFT AND TIMING GEAR TRAIN 219
VALVE TRAIN 219
To Check Valve Clearance 219
To Check Valve Lift 220
CYLINDER HEAD AND VALVES 220
To Remove Cylinder Head 220
Valve Springs 220
Valve Face And Stem 221
Valve Rotattors 221
Valve Guides 221
Valve Seats 221
Cylinder Head 221
Rocker Arm 221
Assembly Of Rocker Arm 222
INSTALLATION OF CYLINDER HEAD 222
Torques For Hardware 222
ADJUSTMENT OF VALVE CLEARANCE 222
CAMSHAFT 223
Removal Of Camshaft 223
Inspection And Repair Of Camshaft 223
Installation Of Camshaft 224
To Check Gear Timing 224
TIMING GEAR TRAIN 224
To Remove Timing Gear 224
Inspection And Repair 224
BALANCER SHAFTS 225
Inspection Of Balancer Shaft 225
Front Plate And Timing Gear Cover 226
Assembly And Installation 226
CYLINDER BLOCK, LINERS, PISTONS AND RODS 227
Removal Of Piston 227
Inspection Of Pistons And Rings 228
Inspection Of Piston Pin 228
Inspection Od Connecting Rod 229
Assembly Of Piston And Rod 229
Cylinder Liners 230
Measurements 230
To Deglaze Cylinder Liners 230
To Clean Engine Block 230
Installation Of Liner 231
Replacement Of Liner 231
Installation Of Pistons And Rods 231
CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL 232
To Check End Play Of Crankshaft 232
Removal Of Crankshaft 232
Inspection And Repair Of Crankshaft 232
Crankshaft And Flywheel 232
Front Crankshaft Gear 232
Main Bearings And Crankshaft Journals 233
Rear Crankshaft Oil Seal, Flywheel Housing And Wear Ring 233
Assembly Of Crankshaft 234
LUBRICATION SYSTEM 236
Oil Pump 236
Repair Of Oil Pump 236
Assembly Of Oil Pump 237
Installation Of Oil Pump 237
Engine Oil Cooler 237
Repair Of Engine Oil Cooler 237
Oil Cooler Housing And Core 238
Oil Cooler Bypass Valve 238
Engine Oil And Filter 238
Installation Of Engine Oil Cooler 238
COOLING SYSTEM 238
To Check Radiator And Fan Belt 238
Repair Of Water Pump 239
Removal Of Water Pump 239
Inspection And Repair Of Water Pump 239
Assembly Of Water Pump 239
Repair Of Water Manifold And Thermostat 240
FUEL SYSTEM 240
Fuel Injection Pump 240
Removal Of Injection Pump 240
Injection Pump Drive Shaft 241
Drive Shaft And Gear 241
Repair Of Injection Pump 241
Drive Shaft Shaft And Gear 241
Installation And Timing Of Injection Pump 242
Automatic Speed Advance Adjustment 243
Fuel Injection Nozzles 244
Diagnosising Malfunctions 244
Removal Of Injection Nozzles 244
Repair Of Injection Nozzles 244
Installation Of Injection Nozzles 245
SPECIAL TOOLS 245
TECHNICAL DATA 247
974 LOADER SPECIFICATIONS 249
Operational & Performance 249
Engine 249
Loader Hydraulics 250
Electrical 250
Drive System 250
Capacities 250
Tires 250
TECHNICAL DATA (PERKINS ENGINE) 251
Recommended Torques 251
De-Rating For Altitude 251
Service Wear Limits 251
MANUFACTURING DATA AND DIMENSIONS 252
Cylinder Block 252
Cylinder Liner (Cast Iron) 252
Pistons 252
Piston Rings 252
Piston Pin 252
Connecting Rod 253
Connecting Rod Alignment 253
Crankshaft 253
Main Bearings 253
Connecting Rod Bearings 253
Camshaft 253
Camshaft Thrust Washer 254
Cylinder Head 254
Valve Guides 254
Exhaust Valves 254
Inlet Valves 254
Inner Valve Springs 254
Outer Valve Springs 254
Tappets 254
Rocker Shaft 254
Rocker Levers 254
Valve Clearance 254
Valve Timing 254
TIMING GEARS 255
Camshaft Gears 255
Fuel Pump Gear (Mechanically Goverened Pumps) 255
Idler Gear And Hub 255
Crankshaft Gear 255
Timing Gear Backlash 255
LUBRICATION SYSTEM 255
Sump 255
Oil Pump 255
Relief Valve 255
Lubricating Oil Filter 255
COOLING SYSTEM 255
Type Of Cooling System 255
Thermostat 256
Water Pump 256
BALANCE UNIT 256
Balance Unit (Center Mounted) 256
OIL PUMP (Center Mounted Balancer Unit) 257
Oil Pump, Gear & Relief Valve 257
FUEL SYSTEM 259
Fuel Lift Pump 259
Fuel Filter (Final) 259
Fuel Injection Pump 259
Static Timing Position 259
Injectors 259
PERKINS DIESEL SERVICE TOOLS 259
975 LOADER SPECIFICATIONS 260
Operational & Performance 260
Engine 260
Loader Hydraulics 261
Electrical 261
Drive System 261
Capacities 261
Tires 261
TECHNICAL DATA (JOHN DEERE) 262
Cylinder Head, Valves and Camshaft 262
Cylinder Block, Liners, Pistons And Rods 264
Crankshaft, Mian Bearings And Flywheel 264
Lubrication System 265
Cooling System 265
Fuel System 265
ENGINE BREAK-IN INSTRUCTIONS (After overhaul) 265
LOADER TORQUE SPECIFICATIONS 266
Transfer Chaincase & Clutch Housing 266
Reduction Gearcase 266
Axle Carrier 266
Lift Arm 266
DECIMAL AMD MILLIMETER EQUIVALENTS 267
U S TO METRIC CONVERSION 267
STANDERD TORQUE SPECIFICATIONS FOR BOLTS 268
LOADER SPECIFICATIONS – 974 269
Engine 269
Machine 269
Capacities 269
LOADER SPECIFICATIONS – 975 269
Engine 269
Machine 269
Capacities 269
ALPHABETICAL INDEX 271
SERVICE BULLETINS 277
900-001 277
900-002 279
900-003 281
900-004 283
900-005 285
900-006 287
900-007 289
900-008 291
SERVICE MANUAL REVISIONS 293
974/975-1 293
974/975-2 295
974/975-3 297
974/975-4 299
974/975-5 301
974/975-6 303
974/975-7 305
974/975-8 307
974/975-9 309
974/975-10 311
974/975-11 313
974/975-12 315
974/975-13 317
974/975-14 319
974/975-15 321

DESCRIPTION:

Bobcat 974 975 Loader Service Manual 6556214 (6-12) – PDF DOWNLOAD

FOREWORD:

• This manual provides instruction for proper routine servicing and adjustment of the Bobcat, and detailed overhaul instructions of the power train, 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
undergone service or repair:
1. Check hydraulic fluid level, engine oil level and fuel supply.
2. lnspect for any sign of fuel, oil or hydraulic fluid leaks.
3. Lubricate the machine.
4. lnspect air cleaner system for damage or leaks. Check element and make
replacement, if necessary.
6. Check alternator drive belt for condition and tension.
7. Check for loose drive chains.
8. Check tires for wear and pressure.
9. Check the Bob-Tach attachment for condition. lnspect the wedges for damage or
wear.
10. lnspect safety items for condition (ROPS Guard, Seat Belt, Safety Treads, Lights,
etc.).
11. Make a visual inspection for loose or broken parts or connections.
12. Operate the loader, checking ali functions.
Advise the owner if any of the above items are in need of repair

Need help? Contact: [email protected]

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

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