Bobcat M 970 (Diesel & Gasoline) Loader Service Manual 6545690 (6-12) – PDF DOWNLOAD

Description

Bobcat M 970 (Diesel & Gasoline) Loader Service Manual 6545690 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat M 970 (Diesel & Gasoline) Loader Service Manual 6545690 (6-12) – PDF DOWNLOAD

Language : English
Pages : 190
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat M 970 (Diesel & Gasoline) Loader Service Manual 6545690 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 2
FOREWORD 4
CONTENTS 6
BOBCAT OPERATION 8
INSTRUMENTATION 8
ENGINE CONTROLS 8
DRIVE CONTROLS 8
LOADER CONTROLS 9
PRE-START CHECK 10
STARTING PROCEDURE 10
COLD WEATHER STARTING 11
OPERATING THE M-970 BOBCAT 11
BREAK-IN 11
LOADER SERVICE AND MAINTENANCE 12
BOB-TACH SYSTEM 14
TRANSPORTING THE M-970 14
TRANSPORTING BY TRUCK OR TRAILER 14
HOISTING THE M-970 14
MAINTENANCE SCHEDULE 15
SERVICE SCHEDULE 16
TIRE MAINTENANCE 18
BELLY PAN 18
OPERATOR ENCLOSURE TILT CONTROL 19
ENCLOSURE TILT CONTROL SERVICE 19
ENCLOSURE REMOVAL AND REINSTALLATION 19
ENCLOSURE LATCHES 20
CONTROL LEVER LOCK 20
LIFT ARM PIVOT REPLACEMENT 20
REWORKING THE LIFT ARM ASSEMBLY 21
SIDE PANEL (FENDER) REMOVAL 21
GRILL REMOVAL 21
FUEL TANK 22
FUEL PICKUP TUBE 22
ENGINE HOOD 22
INTRODUCTION TO ENGINE SERVICE 22
INITIAL 50 HOUR SERVICE 22
AIR CLEANER SERVICE 23
HEAVY DUTY, TWO STAGE, MULTIPLE ELEMENT AIR CLEANER WITH ASPIRATOR 23
FIELD SERVICEING THE AIR CLEANER (DONALDSON ONLY) 23
ENGINE LUBRICATION SERVICE 25
RECOMMENDED OIL SPECIFICATIONS 25
CHANGING ENGINE OIL 25
OIL FILTER REPLACEMENT 25
FUEL SYSTEM SERVICE 26
FUEL SPECIFICATIONS 26
VENTING FUEL SYSTEM (DIESEL) 27
INJECTOR SERVICE (DIESEL ONLY) 28
CYLINDER HEAD RETORQUING (DIESEL ONLY) 28
VALVE CLEARANCE ADJUSTMENT (DIESEL ONLY) 29
COOLING SYSTEM SERVICE 29
RADIATOR COOLING FANS 29
FAN BELT ADJUSTMENT 29
ELECTRICAL SERVICE 30
INSTRUMENT PANELS 32
FUSES 32
WIRING HARNESS 32
ALTRNATOR CHECK 35
REGULATOR CHECKS 35
YACHOMETER TESTING AND CALIBRATION 37
BATTERY INSTALLATION 37
BATTERY PROBLEMS 37
REPLACING HEADLAMPS 37
HYDRAULIC AND HYDROSTATIC SERVICE 39
BASIC OPERATING PRINCIPLE OF HYDRAULIC SYSTEM 41
FILTER SERVICE 41
100 MESH FILTER SCREEN 42
HYDRAULIC TESTING KIT 42
LIFT AND TILT CYLINDER CHECKS 43
HYDRAULIC CYLINDER INSPECTION 43
LIFT CYLINDER SERVICE 44
TILT CYLINDER SERVICE 45
HYDRAULIC CONTROL VALVE BANK REMOVAL 45
CONTROL VALVE SERVICE 46
DISASSEMBLY INSTRUCTIONS 47
SELF LEVELING CONTROL VALVE 48
HYDRAULIC PUMP (IMPLEMENT CIRCUIT) 49
HYDRAULIC PUMP REMOVAL 50
HYDRAULIC PUMP DISASSEMBLY 50
HYDRAULIC PUMP REASSEMBLY 50
HYDRAULIC OPERATING PRINCIPLE 52
HYDROSTATIC CIRCUITRY 54
DIRECTIONAL CONTROL ADJUSTMENT 56
CONTROL ASSEMBLY REMOVAL 56
PUMP AND MOTOR CONTROL ADJUSTMENT 57
HYDROSTATIC CHARGE PUMP 57
CHECKING CHARGE PRESSURE 57
HYDRAULIC FLUID AND 10 MICRON FILTER 58
TRANSMISSION START-UP PROCEDURE 60
CHARGE PUMP REMOVAL 60
CHARGE PUMP REINSTALLATION 61
CHECK VALVE REMOVAL 61
CHECK VALVE REINSTALLATION 61
TESTING CHECK VALVES 61
HYDROSTATIC PUMP REMOVAL 61
PUMP REINSTALLATION 62
MOTOR REMOVAL 62
MOTOR REINSTALLATION 62
PUMP OR MOTOR DISPLACEMENT CONTROL VALVE 63
DISPLACEMENT CONTROL VALVE REMOVAL 63
DISPLACEMENT CONTROL VALVE REINSTALLATION 63
MOTOR MANIFOLD BLOCK 63
MANIFOLD BLOCK REMOVAL 64
MANIFOLD BLOCK REINSTALLATION 64
REMOVAL OF THE SEAL FROM THE PUMP OR MOTOR 65
SEAL REINSTALLATION 65
HYDRAULIC FLUID COOLER 66
COOLER REMOVAL 66
COOLER REINSTALLATION 66
COOLER BYPASS VALVE 66
HYDRAULIC LEAKS 67
COST OF OIL LEAKS 67
37° FLARE SAE CONNECTION 67
SAE STRAIGHT THREAD O-RING SEAL 67
SAE 4 BOLT SPLIT FLANGE CONNECTION 68
OVERHAUL OF HYDROSTATIC PUMP OR MOTOR 69
REMOVAL OF PUMP OR MOTOR FROM VEHICLE 69
DISASSEMBLY PROCEDURE 69
REMOVING CHARGE PUMP 70
REMOVING CHECK VALVES 70
REMOVING END CAP 70
REMOVING VALVE PLATE 71
REMOVING BRASS BEARING PLATE 71
REMOVING REAR BEARING 71
REMOVING SPRING GUIDE 71
REMOVING CYLINDER BLOCK 71
REMOVING SLIPPER RETAINER 72
REMOVING PISTONS AND SLIPPER RETAINER 72
REMOVING THRUST PLATE 72
REMOVING FRONT COVER 72
REMOVING CONTROL VALVE ASSEMBLY 73
REMOVING TRUNNION 73
SERVO SLEEVES 73
REASSEMBLY PROCEDURE 74
SET SHAFT END PLAY 74
ASSEMBLING SERVO PISTONS 75
ATTACHING SERVO PISTON ASSEMBLIES TO SWASH PLATE 75
ATTACHING CONTROL LINK TO SWAH PLATE 76
INSTALLING SWASH PLATE 76
INSTALLING TRUNNIONS 76
INSTALLAING SERVO SLEEVES 76
SETTING NEUTRAL POISTION OF SWASH PLATE 76
INSTALL THE CONTROL ASSEMBLY 77
INSTALLING THE THRUST PLATE 77
INSTALLING THE DRIVE SHAFT 77
INSTALLING FRONT COVER AND GASKET 77
ASSEMBLING THE CYLINDER BLOCK 77
ASSEMBLE THE CYLINDER BLOCK ASSEMBLY INTO THE HOUSING 78
INSTALL THE SPRING GUIDE 78
PRESSING CONE OF REAR BEARING INTO SHAFT 78
INSTALLING BEARING PLATE 78
PLACING VALVE PLATE ON END CAP 78
INSTALLING END CAP 79
INSTALLING CHARGE PUMP 79
INSTALLING SHAFT SEAL 79
TROUBLESHOOTING THE HYDRAULIC SYSTEM 80
TROUBLESHOOTING THE HYDROSTATIC SYSTEM 84
MECHANICAL DRIVE 89
CLUTCH ADJUSTMENT (DIESEL ONLY) 91
CLUTCH REMOVAL 91
POWER TRANSFER CHAIN 91
TRANSFER CHAINCASE REMOVAL 92
CHAINCASE SERVICE 92
REDUCTION GEARCASES 92
GEARCASE MOUNTING 92
GEARCASE REMOVAL 93
DISASSEMBLING A CLARK REDUCTION GEARCASE 94
REASSEMBLING A CLARK REDUCTION GEARCASE 94
DISASSEMBLING A FUNK GEARCASE 95
REASSEMBLING A FUNK GEARCASE 96
FINAL DRIVE CHAIN ADJUSTMENT 97
FINAL DRIVE CHAIN REMOVAL 97
AXLE CARRIER REMOVAL 98
DISASSEMBLING THE AXLE CARRIER 98
REASSEMBLING THE AXLE CARRIER 98
AXLE CARRIER REINSTALLATION 99
FINAL DRIVE CHAIN REINSTALLATION 99
FINAL DRIVE IDLER REPAIR 101
PERKINS ENGINE SERVICE 103
ENGINE REMOVAL 105
INTRODUCTION TO ENGINE REPAIR 105
UNIFIED THREADS 105
ENGINE NUMBER 105
ENGINE DESCRIPTION 106
LUBRICATING OIL SUMP 106
CRANKCASE VENTILATION 106
BREATHER ASSEMBLY 106
TO REMOVE CYLINDER HEAD 106
VALVE REMOVAL 107
CLEANING 107
VALVE GUIDES 107
VALVES AND VALVE SEATS 107
HAND GRINDING 108
VALVE SEAT INSERTS (EXHAUST VALVE) 108
MILLING OF CYLINDER HEAD 109
VALVE SPRINGS 109
ROCKER SHAFT ASSEMBLY 109
PUSH RODS 109
VALVE STEM OIL SEALS 109
TO REASSEMBLE CYLINDER HEAD 109
CYLINDER HEAD GASKET 110
TP REINSTALL CYLINDER HEAD 110
TO REMOVE PISTONS AND CONNECTING ROD ASSEMBLIES 111
TO REMOVE PISTONS AND RINGS FROM CONNECTING ROADS 111
INSPECTION 111
TO ASSEMBLE PISTONS TO CONNECTING RODS 111
TO INSTALL PISTONS AND CONNECTING RODS TO CYLINDER BORE 112
INSTALL NEW PISTONS 112
CYLINDER LINERS 112
TO RENEW CYLINDER LINERS (CAST IRON) 112
CRANKSHAFT AND MAIN BEARINGS 112
MAIN BEARINGS AND THRUST WASHERS REMOVAL 113
INSTALLING MAIN BEARINGS AND THRUST WASHERS 113
REMOVING THE CRANSHAFT 114
REGRINDING THE CRANKSHAFT 114
REINSTALLING THE CRANKSHAFT 114
CRANKSHAFT REAR END OIL SEAL 115
BALANCE UNIT 116
USE OF LOCTITE 116
REASSEMBLING THE UNIT 117
REMOVING TIMING CASE COVER 118
RENEWING THE CRANKSHAFT FRONT OIL SEAL 118
REINSTALLING THE TIMING CASE COVER 118
CHECKING THE TIMING GEAR BACKLASH 119
REMOVING THE IDLER GEAR AND HUB 119
REINSTALLING THE TIMING GEAR AND HUB 119
REMOVING THE CAMSHAFT GEAR 119
REINSTALLING THE CAMSHAFT GEAR 119
REMOVING THE FUEL PUMP GEAR 120
REINSTALLING THE FUEL PUMP GEAR 120
REMOVING THE TIMING CASE 120
REINSTALLING THE TIMING CASE 120
REMOVING THE CAMSHAFT AND TAPPETS 120
REINSTALLING THE CAMSHAFT AND TAPPETS 121
CHECKING VALVE TIMING 121
LUBRICATION SYSTEM 121
DESCRIPTION 121
COOLING SYSTEM 122
REMOVING AND INSTALLING WATER PUMP 122
DISMANTLING THE WATER PUMP 122
INSPECTION 122
REASSEMBLING THE WATER PUMP 123
REMOVING THERMOSTAT 123
TESTING THERMOSTAT 123
FUEL SYSTEM 124
CLEANING HTE PUMP CHAMBER 124
REMOVING THE PUMP 124
DISMANTLING THE FUEL LIFT PUMP 124
INSPECTION OF PARTS 124
REMOVING THE FUEL INJECTION PUMP 125
REINSTALLING THE FUEL INJECTION PUMP 125
FUEL INJECTION PUMP GEAR 125
IDLING SPEED SETTING 126
PRIMING THE FUEL SYSTEM 126
THROTTLE LINKAGE AND FUEL SHUT-OFF CONTROL 126
COLD WEATHER STARTING AID 127
INJECTORS 127
FUEL PIPES 128
REMOVING THE FLYWHEEL 128
RENEWING FLYWHEEL AND RING GEAR 129
REINSTALLING THE FLYWHEEL 129
REMOVING THE FLYWHEEL HOUSING 129
REINSTALLING THE FLYWHEEL HOUSING 129
SMOKE DIAGNOSIS CHART 130
TROUBLESHOOTING PERKINS 131
CONTINENTAL ENGINE SECTION 137
INFORMATION FOR ORDERING PARTS 139
DESCRIPTION OF ENGINE 139
LUBRICATION SYSTEM 140
OIL PUMP 140
OIL FILTER 140
COOLING SYSTEM 140
CLEANING COOLING SYSTEM 140
RADIATOR PRESSURE CAP 141
WATER PUMP REMOVAL 141
WATER PUMP DISASSEMBLY 141
WATER PUMP 142
TESTING THERMOSTAT 142
COOLANT 142
FUEL SYSTEM 143
CARBURETOR REMOVAL 143
DISASSEMBLY OF THE FUEL BOWL BODY 143
CLEANING THE CARBURETOR 143
DISASSEMBLY OF THE THROTTLE BODY 143
CARBURETOR REINSTALLATION 144
FUEL PUMP SERVICE 144
IGNITION SYSTEM 145
IGNITION COIL 145
DISTRIBUTOR 145
DISTRIBUTOR MAINTENANCE 146
SPARK PLUGS 147
GAPPING THE SPARK PLUG 147
COLD, NORMAL, HOT SPARK PLUGS 147
IGNITION TIMING 148
ENGINE REMOVAL 149
ENGINE REPAIR AND OVERHAUL 149
CYLINDER HEAD 149
CYLINDER BLOCK 150
VALVE GUIDES 150
VALVE SEAT INSERTS 150
VALVES 151
VALVE SPRINGS 151
PREPARING CYLINDER WALLS FOR REGRINDING OR REBORING 151
PISTONS 152
PISTON PINS 153
CONNECTING ROD 153
PISTON AND CONNECTING ROD ASSEMBLY 153
PISTON RINGS 154
RECOMMENDED METHOD OF INSTALLING PISTON RINGS 154
CRANKSHAFT AND MAIN BEARINGS 155
BEARINGS 155
CAMSHAFT 156
TAPPETS 157
LIMITS AND CLEARANCE 157
TIMING GEARS 157
CRANKSHAFT END PLAY 157
ASSEMBLING OIL SEALS IN FILLER BLOCK AND OIL GUARD 158
JUTE TYPE OIL SEALS 158
NEOPRENE OIL SEAL 158
OIL PUMPS 159
FLYWHEEL AND FLYWHEEL HOUSING 160
REASSEMBLING ENGINE 160
TROUBLESHOOTING THE ENGINE 161
TECHNICAL DATA, LIMITS AND CLEARANCES 167
TECHNICAL DATA (PERKINS) 169
Recommended Torques 169
De-Rating For Altitude 169
Service Wear Limits 169
MANUFACTURING DATA AND DIMENSIONS 170
Cylinder Block 170
Cylinder Liners Cast Iron 170
Pistons 170
Piston Rings 170
Piston Pin 170
Piston Pin Bushing 171
Connecting Rod 171
Connecting Rod Alignment 171
Crankshaft 171
Main Bearings 171
Connecting Rod Bearings 171
Camshaft 171
Canshaft Thrust Washer 172
Cylinder Head 172
Valve Guides 172
Exhaust Valves 172
Inlet Valves 172
Inner Valce Springs 172
Outer Valve Springs 172
Tappets 172
Rocker Shaft 172
Rocker Levers 172
Valve Clearance 172
Valve Timing 172
TIMING GEARS 173
Camshaft Gear 173
Fuel Pump Gear 173
Idler Gear And Hub 173
Crankshaft Gear 173
Timing Gear Backlash 173
LUBRICATION SYSTEM 173
Sump 173
Oil Pump 173
Relief Valve 173
Lubricating Oil Filter 173
COOLING SYSTEM 173
Type Of Cooling System 173
Thermostat 174
Water Pump 174
BALANCE UNIT 174
FUEL SYSTEM 174
Fuel Lift Pump 174
Fuel Filter (Final) 174
Fuel Injection Pump 175
Static Timing Position 175
Injectors 175
PERKINS DIESEL SERVICE TOOLS 175
TECHNICAL DATA (CONTINENTAL) 176
VALVE GUIDE 176
VALVES, INTAKE 176
VALVES, EXHAUST 176
VALVES SPRINGS 176
CAMSHAFT 176
MAIN BEARINGS 176
REAR FLANGE BEARING 176
PISTON PIN 176
PISTONS 176
PISTON RINGS 176
RECOMMENDED TORQUES (CONTINENTAL) 177
LOADER TORQUES SPECIFICATIONS 178
TIME REQUIRED FOR SERVICE 179
FORMS 181
50-HOUR CHECK 181
CUSTOMER RESPONSIBILITY 181
DELIVERY REPORT 182
PRE-DELIVERY CHECK LIST 182
M-970 DIESEL LOADER SPECIFICATIONS 183
OPERATIONAL & PERFORMANCE 183
ENGINE 183
LOADER HYDRAULICS 183
ELECTRICAL 183
POWER TRAIN 183
CAPACITIES 183
TIRES 183
MACHINE WEIGHT 183
M-970 GASOLINE LOADER SPECIFICATIONS 184
OPERATIONAL & PERFORMANCE 184
ENGINE 184
LOADER HYDRAULICS 184
ELECTRICAL 184
POWER TRAIN 184
CAPACITIES 184
TIRES 184
MACHINE WEIGHT 184
SERVICE BULLETINS 185
76-27 185
SERVICE MANUAL REVISIONS 187
970-1 187
970-2 189

DESCRIPTION:

Bobcat M 970 (Diesel & Gasoline) Loader Service Manual 6545690 (6-12) – PDF DOWNLOAD

FOREWORD:

• This manual has been written as a guide to the performance of Dealer Service on the Melroe
  Bobcat Loader. Read the instructions carefully and follow them.
• Refer to the applicable Bobcat Owner’s Manual for routine service and adjustments.
• When performing service on any Bobcat Loader, be sure to note the machine and engine
  serial numbers. They are necessary in obtaining prompt parts and service information.
• Certain information and illustrations are contained in this publication through the courtesy
  of the following: Aeroquip Corporation, Continental Motors, Perkins Motors, Sundstrand
  Corporation.

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