Bobcat 980 Loader Service Manual 6570341 (6-12) – PDF DOWNLOAD

Description

Bobcat 980 Loader Service Manual 6570341 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 980 Loader Service Manual 6570341 (6-12) – PDF DOWNLOAD

Language : English
Pages : 314
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 980 Loader Service Manual 6570341 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
SAFETY INSTRUCTIONS 9
Safety Is Your Responsibility 9
Before Operating The Bobcat Loader 9
Safe Operation Needs A Qualified Operator 10
FIRE PREVENTION 10
SERIAL NUMBER LOCATIONS 11
Loader Serial Number 11
Engine Serial Number 11
DELIVERY REPORT 11
BOBCAT LOADER IDENTIFICATION 12
PREVENTIVE MAINTENANCE 13
SERVICE SCHEDULE 15
LIFTING AND BLOCKING THE LOADER 16
Procedure 16
TRANSPORTING THE LOADER 17
Procedure 17
TOWING THE LOADER 17
Procedure 17
LIFT ARM STOP 18
Procedure 18
SKID PLATE 18
Removal And Installation 18
OPERATOR CAB 19
Raising The Operator Cab 19
Lowering The Operator cab 19
SEAT BAR SYSTEM 20
Description 20
Seat Bar Inspection 20
Seat Bar Maintenance 20
USING AN EXTRA BATTERY (JUMP STARTING) 21
Procedure 21
HYDRAULIC SYSTEM 23
HYDRAULIC/HYDROSTATIC SCHEMATICS 25
TROUBLESHOOTING 31
HYDRAULIC SYSTEM INFORMATION 32
Flare Connections 32
Straight Thread O-Ring Fitting 32
Tubelines And Hoses 32
LIFT CYLINDER 33
Checking The Lift cylinder 33
Removal And Installation 33
Lift Cylinder Repair 34
TILT CYLINDER 35
Checking The Tilt Cylinder 35
Removal And Installation 35
Repair Of TheTilt cylinder 36
Tilt Cylinder Hoses 36
Tilt Cylinder Tubelines 37
CONTROL VALVE 38
Checking The Tilt Circuit Relief Valve 38
Checking The Lift Circuit Relief Valve 39
Main Relief Valves Removal And Installation 40
Removal And Installation 40
Disassembly And Assembly 42
Quad-Ring Replacement 42
HYDRAULIC PUMP 46
Removal And Installation 46
Disassembly 47
Inspection 51
Assembly 51
Replacement Of The Shaft Seal 56
HYDRAULIC RESERVOIR 58
Removal And Installation 58
Hydraulic Reservoir Filter 58
HYDRAULIC PRIMARY FILTER 60
Replacement Of The Hydraulic Primary Filter 60
Replacement Of The Filter Housing 60
CONTROL PEDALS 61
Removal And Installation 61
Pedal Lock Linkage 63
HYDROSTATIC SYSTEM 65
TROUBLESHOOTING 67
STEERING CONTROLS 68
Adjustment 68
Removal And Installation 69
Disassembly And Assembly 70
HYDROSTATIC PUMP 73
Adjustment Of The Displacement Control Valve 73
Checking Charge Pressure 74
Removal And Installation 74
Inspection 85
Charge Pump 86
HYDROSTATIC MOTOR 88
Removal And Installation 88
Disassembly And Assembly 88
Inspection 95
OIL COOLER 97
Removal And Installation 97
DRIVE SYSTEM 99
BRAKE/CLUTCH 101
Adjustment 101
Removal And Installation Of The Clutch 102
Inspection Of The Clutch 102
TRANSFER CASE 103
Checking Chain Tension 103
Removal And Installation 103
Disassembly 104
Inspection 104
Assembly 105
REDUCTION GEARCASE AND BRAKE 107
Removal And Installation 107
Disassembly And Assembly 107
FINAL DRIVE CHAIN 117
Adjustment 117
Removal 117
Installation 119
PLANETARY AXLE 122
Removal And Installation 122
Disassembly 122
Assembly 126
FINAL DRIVE IDLER 132
Removal And Installation 132
Disassembly And Assembly 132
MAIN FRAME 133
OPERATOR CAB 135
Removal And Installation 135
OPERATOR CAB TILT CONTROL 137
Removal And Installation 137
OPERATOR CAB TILT CONTROL CYLINDER 138
Removal And Installation 138
Disassembly And Assembly 139
REAR DOOR 140
Removal And Installation 140
LIFT ARMS 142
Removal And Installation 142
FUEL TANK 143
Removal And Installation 143
SIDE FENDER 144
Removal And Installation 144
ELECTRICAL SYSTEM 145
ELECTRICAL SCHEMATICS 148
ELECTRICAL SYSTEM INFORMATION 153
Description 153
TROUBLESHOOTING 153
BATTERY 154
Checking The Battery 154
ALTERNATOR 155
Checking The Alternator Output 155
Checking The Alternator Regulator 156
Removal And Installation 157
Disassembly And Assembly 158
STARTER 161
Checking The Starter 161
Removal And Installation 161
Disassembly And Assembly 162
Cleaning And Inspection 162
Replacing The Brushes 163
ENGINE SERVICE 165
TROUBLESHOOTING 169
VALVE CLEARANCE 171
Adjustment 171
FUEL FILTERS 172
Fuel Filter Elements 172
Filter Housing 172
FUEL LINES 173
Removal And Installation 173
REMOVING AIR FROM THE FUEL SYSTEM 174
Procedure 174
FUEL LIFT PUMP 175
Removal And Installation 175
Inspection 175
FUEL INJECTION PUMP 176
Removal 176
Installation 177
Shaft Seal Replacement 179
Shutdown Solenoid Replacement 179
Fuel Inlet Adapter & Sealing Washer Replacement 180
TIMING PIN 181
Timing Pin Replacement 181
Timing Pin Alignment 181
ENGINE COMPRESSION 183
Checking 183
FUEL INJECTORS 184
Removal And Installation 184
Disassembly 184
Inspection 185
Assembly 186
TURBOCHARGER AND EXHAUST MANIFOLD 189
Removal 189
Disassembly 191
Inspection 194
Assembling 195
Installation 200
MUFFLER 204
Removal And Installation 204
RADIATOR 205
Removal And Installation 205
ENGINE 207
Removal And Installation 207
INTAKE MANIFOLD COVER PLATE 210
Removal 210
Installation 210
ROCKER ARM AND PUSH RODS 211
Removal 211
Disassembly 212
Assembly 212
Installation 213
CYLINDER HEAD 215
Removal 215
Checking Cylinder Head For Flatness 215
Installation 215
VALVES, GUIDES AND SPRINGS 217
Removal 217
Cleaning 218
Valve Guide 219
Valve Grinding 219
Seat Grinding 220
Valve Springs 222
Assembly 223
PISTON AND CONNECTING ROD 224
Removal 224
Disassembly 225
Inspection 226
Assembly 228
Installation 231
CRANKSHAFT AND MAIN BEARINGS 233
Removal 233
Inspection 234
Crankshaft Gear 235
Vibration Damper 236
Installation 236
Crankshaft End Play 239
CYLINDER BLOCK 240
Cylinder Block Inspection 240
Cam Bushing Replacement 240
Cylinder Liner Honing 243
Cleaning The Cylinder Block 244
TIMING GEAR COVER 246
Removal 246
Installation 247
FUEL INJECTION PUMP GEAR 249
Removal And Installation 249
Gear Backlash 249
CAMSHAFT AND GEAR 250
Gear Backlash 250
Removal 250
Inspection 251
Gear Replacement 254
Tappet And Push Rod Inspection 255
Installation 255
OIL PAN AND REAR SEAL 257
Removal 257
Rear Seal Installation 258
Oil Pan Installation 259
OIL PUMP 260
Gear Backlash 260
Removal 261
Inspection 261
Installation 263
TIMING GEAR HOUSING 264
Removal 264
Installation 264
OIL COOLER 265
Removal 265
Inspection 265
Pressure Regulating Valve 266
Filter By-Pass Valve 267
Installation 267
FAN HUB 268
Removal And Installation 268
Disassembly 269
Assembly 270
WATER PUMP 271
Removal And Installation 271
Inspection 271
BELT TENSIONER 272
Removal And Installation 272
Disassembly And Assembly 272
THERMOSTAT 273
Removal 273
Inspection 273
Installation 273
ENGINE RUN-IN 274
Procedure 274
BALANCER 275
Checking The Balancer 275
Removing The Balancer 275
Disassembly Of The Balancer 277
Assembly Of The Balancer 279
Installing The Balancer 286
TECHNICAL DATA 291
LOADER SPECIFICATIONS 293
OPERATIONS AND PERFORMANCE 293
ENGINE 293
LOADER HYDRAULICS 294
ELECTRICAL 294
DRIVE SYSTEM 294
CAPACITIES 294
TIRES 294
ENGINE SPECIFICATIONS 295
Cylinder Head 295
Valves 295
Rocker Arm 295
Tappet 295
Piston 295
Connecting Rod 295
Crankshaft 295
Balancer 296
Camshaft 296
Engine Block 296
Fuel Injection Pump 296
Fuel Injectors 296
Turbocharger 296
Exhaust Manifold 296
Oil Pump 296
Oil Cooler 296
Thermostat 296
Engine Torque 297
Blowby Measurement 298
Blowby Conversion Chart 298
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 299
DECIMAL AND MILLIMETER EQUIVALENTS 300
U S TO METRIC CONVERSION 300
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 301
SERVICE MANUAL REVISIONS 303
980-1 303
980-2 305
980-3 307
980-4 309
980-5 311
980-6 313

DESCRIPTION:

Bobcat 980 Loader Service Manual 6570341 (6-12) – PDF DOWNLOAD

(S/N 562215001 & Above)
(S/N 516515001 & Above

FOREWORD:

This manual is for the Bobcat loader mechanic. lt provides necessary servicing and adjustment procedures ‘or the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual ror operating instructions, starting procedure, daily checks, etc.

A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS (lncluding sidescreens) isin good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Melroe approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar and pedal interlocks must be correctly adjusted, clean and lubricated.
5. Machine signs must be legible and in the correct location.
6. Steering levers and foot pedals must return to neutral.
7. Check for correct function of the work lights.
8. The parking brake must function correctly.
9. Enclosure door latches must apen and close freely.
10. Bob-Tach wedges and linkages must function correctly and be in good condition.

Customer Support: [email protected]

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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