Bobcat Loader M970 Service Manual 6545690

MAINTENANCE SAFETY
FOREWORD
CONTENTS
BOBCAT OPERATION
– INSTRUMENTATION
– ENGINE CONTROLS
– DRIVE CONTROLS
– LOADER CONTROLS
– PRESTART CHECK
– STARTING PROCEDURE
– COLD WEATHER STARTING
– OPERATING THE M970 BOBCAT
– BREAKIN
LOADER SERVICE AND MAINTENANCE
– BOBTACH SYSTEM
– TRANSPORTING THE M970
– TRANSPORTING BY TRUCK OR TRAILER
– HOISTING THE M970
– MAINTENANCE SCHEDULE
– SERVICE SCHEDULE
– TIRE MAINTENANCE
– BELLY PAN
– OPERATOR ENCLOSURE TILT CONTROL
– ENCLOSURE TILT CONTROL SERVICE
– ENCLOSURE REMOVAL AND REINSTALLATION
– ENCLOSURE LATCHES
– CONTROL LEVER LOCK
– LIFT ARM PIVOT REPLACEMENT
– REWORKING THE LIFT ARM ASSEMBLY
– SIDE PANEL FENDER REMOVAL
– GRILL REMOVAL
– FUEL TANK
– FUEL PICKUP TUBE
– ENGINE HOOD
– INTRODUCTION TO ENGINE SERVICE
– INITIAL 50 HOUR SERVICE
– AIR CLEANER SERVICE
– HEAVY DUTY, TWO STAGE, MULTIPLE ELEMENT AIR CLEANER WITH ASPIRATOR
– FIELD SERVICEING THE AIR CLEANER DONALDSON ONLY
– ENGINE LUBRICATION SERVICE
– RECOMMENDED OIL SPECIFICATIONS
– CHANGING ENGINE OIL
– OIL FILTER REPLACEMENT
– FUEL SYSTEM SERVICE
– FUEL SPECIFICATIONS
– VENTING FUEL SYSTEM DIESEL
– INJECTOR SERVICE DIESEL ONLY
– CYLINDER HEAD RETORQUING DIESEL ONLY
– VALVE CLEARANCE ADJUSTMENT DIESEL ONLY
– COOLING SYSTEM SERVICE
– RADIATOR COOLING FANS
– FAN BELT ADJUSTMENT
ELECTRICAL SERVICE
– INSTRUMENT PANELS
– FUSES
– WIRING HARNESS
– ALTRNATOR CHECK
– REGULATOR CHECKS
– YACHOMETER TESTING AND CALIBRATION
– BATTERY INSTALLATION
– BATTERY PROBLEMS
– REPLACING HEADLAMPS
HYDRAULIC AND HYDROSTATIC SERVICE
– BASIC OPERATING PRINCIPLE OF HYDRAULIC SYSTEM
– FILTER SERVICE
– 100 MESH FILTER SCREEN
– HYDRAULIC TESTING KIT
– LIFT AND TILT CYLINDER CHECKS
– HYDRAULIC CYLINDER INSPECTION
– LIFT CYLINDER SERVICE
– TILT CYLINDER SERVICE
– HYDRAULIC CONTROL VALVE BANK REMOVAL
– CONTROL VALVE SERVICE
– DISASSEMBLY INSTRUCTIONS
– SELF LEVELING CONTROL VALVE
– HYDRAULIC PUMP IMPLEMENT CIRCUIT
– HYDRAULIC PUMP REMOVAL
– HYDRAULIC PUMP DISASSEMBLY
– HYDRAULIC PUMP REASSEMBLY
– HYDRAULIC OPERATING PRINCIPLE
– HYDROSTATIC CIRCUITRY
– DIRECTIONAL CONTROL ADJUSTMENT
– CONTROL ASSEMBLY REMOVAL
– PUMP AND MOTOR CONTROL ADJUSTMENT
– HYDROSTATIC CHARGE PUMP
– CHECKING CHARGE PRESSURE
– HYDRAULIC FLUID AND 10 MICRON FILTER
– TRANSMISSION STARTUP PROCEDURE
– CHARGE PUMP REMOVAL
– CHARGE PUMP REINSTALLATION
– CHECK VALVE REMOVAL
– CHECK VALVE REINSTALLATION
– TESTING CHECK VALVES
– HYDROSTATIC PUMP REMOVAL
– PUMP REINSTALLATION
– MOTOR REMOVAL
– MOTOR REINSTALLATION
– PUMP OR MOTOR DISPLACEMENT CONTROL VALVE
– DISPLACEMENT CONTROL VALVE REMOVAL
– DISPLACEMENT CONTROL VALVE REINSTALLATION
– MOTOR MANIFOLD BLOCK
– MANIFOLD BLOCK REMOVAL
– MANIFOLD BLOCK REINSTALLATION
– REMOVAL OF THE SEAL FROM THE PUMP OR MOTOR
– SEAL REINSTALLATION
– HYDRAULIC FLUID COOLER
– COOLER REMOVAL
– COOLER REINSTALLATION
– COOLER BYPASS VALVE
– HYDRAULIC LEAKS
– COST OF OIL LEAKS
– 37 FLARE SAE CONNECTION
– SAE STRAIGHT THREAD ORING SEAL
– SAE 4 BOLT SPLIT FLANGE CONNECTION
– OVERHAUL OF HYDROSTATIC PUMP OR MOTOR
– REMOVAL OF PUMP OR MOTOR FROM VEHICLE
– DISASSEMBLY PROCEDURE
– REMOVING CHARGE PUMP
– REMOVING CHECK VALVES
– REMOVING END CAP
– REMOVING VALVE PLATE
– REMOVING BRASS BEARING PLATE
– REMOVING REAR BEARING
– REMOVING SPRING GUIDE
– REMOVING CYLINDER BLOCK
– REMOVING SLIPPER RETAINER
– REMOVING PISTONS AND SLIPPER RETAINER
– REMOVING THRUST PLATE
– REMOVING FRONT COVER
– REMOVING CONTROL VALVE ASSEMBLY
– REMOVING TRUNNION
– SERVO SLEEVES
– REASSEMBLY PROCEDURE
– SET SHAFT END PLAY
– ASSEMBLING SERVO PISTONS
– ATTACHING SERVO PISTON ASSEMBLIES TO SWASH PLATE
– ATTACHING CONTROL LINK TO SWAH PLATE
– INSTALLING SWASH PLATE
– INSTALLING TRUNNIONS
– INSTALLAING SERVO SLEEVES
– SETTING NEUTRAL POISTION OF SWASH PLATE
– INSTALL THE CONTROL ASSEMBLY
– INSTALLING THE THRUST PLATE
– INSTALLING THE DRIVE SHAFT
– INSTALLING FRONT COVER AND GASKET
– ASSEMBLING THE CYLINDER BLOCK
– ASSEMBLE THE CYLINDER BLOCK ASSEMBLY INTO THE HOUSING
– INSTALL THE SPRING GUIDE
– PRESSING CONE OF REAR BEARING INTO SHAFT
– INSTALLING BEARING PLATE
– PLACING VALVE PLATE ON END CAP
– INSTALLING END CAP
– INSTALLING CHARGE PUMP
– INSTALLING SHAFT SEAL
– TROUBLESHOOTING THE HYDRAULIC SYSTEM
– TROUBLESHOOTING THE HYDROSTATIC SYSTEM
MECHANICAL DRIVE
– CLUTCH ADJUSTMENT DIESEL ONLY
– CLUTCH REMOVAL
– POWER TRANSFER CHAIN
– TRANSFER CHAINCASE REMOVAL
– CHAINCASE SERVICE
– REDUCTION GEARCASES
– GEARCASE MOUNTING
– GEARCASE REMOVAL
– DISASSEMBLING A CLARK REDUCTION GEARCASE
– REASSEMBLING A CLARK REDUCTION GEARCASE
– DISASSEMBLING A FUNK GEARCASE
– REASSEMBLING A FUNK GEARCASE
– FINAL DRIVE CHAIN ADJUSTMENT
– FINAL DRIVE CHAIN REMOVAL
– AXLE CARRIER REMOVAL
– DISASSEMBLING THE AXLE CARRIER
– REASSEMBLING THE AXLE CARRIER
– AXLE CARRIER REINSTALLATION
– FINAL DRIVE CHAIN REINSTALLATION
– FINAL DRIVE IDLER REPAIR
PERKINS ENGINE SERVICE
– ENGINE REMOVAL
– INTRODUCTION TO ENGINE REPAIR
– UNIFIED THREADS
– ENGINE NUMBER
– ENGINE DESCRIPTION
– LUBRICATING OIL SUMP
– CRANKCASE VENTILATION
– BREATHER ASSEMBLY
– TO REMOVE CYLINDER HEAD
– VALVE REMOVAL
– CLEANING
– VALVE GUIDES
– VALVES AND VALVE SEATS
– HAND GRINDING
– VALVE SEAT INSERTS EXHAUST VALVE
– MILLING OF CYLINDER HEAD
– VALVE SPRINGS
– ROCKER SHAFT ASSEMBLY
– PUSH RODS
– VALVE STEM OIL SEALS
– TO REASSEMBLE CYLINDER HEAD
– CYLINDER HEAD GASKET
– TP REINSTALL CYLINDER HEAD
– TO REMOVE PISTONS AND CONNECTING ROD ASSEMBLIES
– TO REMOVE PISTONS AND RINGS FROM CONNECTING ROADS
– INSPECTION
– TO ASSEMBLE PISTONS TO CONNECTING RODS
– TO INSTALL PISTONS AND CONNECTING RODS TO CYLINDER BORE
– INSTALL NEW PISTONS
– CYLINDER LINERS
– TO RENEW CYLINDER LINERS CAST IRON
– CRANKSHAFT AND MAIN BEARINGS
– MAIN BEARINGS AND THRUST WASHERS REMOVAL
– INSTALLING MAIN BEARINGS AND THRUST WASHERS
– REMOVING THE CRANSHAFT
– REGRINDING THE CRANKSHAFT
– REINSTALLING THE CRANKSHAFT
– CRANKSHAFT REAR END OIL SEAL
– BALANCE UNIT
– USE OF LOCTITE
– REASSEMBLING THE UNIT
– REMOVING TIMING CASE COVER
– RENEWING THE CRANKSHAFT FRONT OIL SEAL
– REINSTALLING THE TIMING CASE COVER
– CHECKING THE TIMING GEAR BACKLASH
– REMOVING THE IDLER GEAR AND HUB
– REINSTALLING THE TIMING GEAR AND HUB
– REMOVING THE CAMSHAFT GEAR
– REINSTALLING THE CAMSHAFT GEAR
– REMOVING THE FUEL PUMP GEAR
– REINSTALLING THE FUEL PUMP GEAR
– REMOVING THE TIMING CASE
– REINSTALLING THE TIMING CASE
– REMOVING THE CAMSHAFT AND TAPPETS
– REINSTALLING THE CAMSHAFT AND TAPPETS
– CHECKING VALVE TIMING
– LUBRICATION SYSTEM
– DESCRIPTION
– COOLING SYSTEM
– REMOVING AND INSTALLING WATER PUMP
– DISMANTLING THE WATER PUMP
– INSPECTION
– REASSEMBLING THE WATER PUMP
– REMOVING THERMOSTAT
– TESTING THERMOSTAT
– FUEL SYSTEM
– CLEANING HTE PUMP CHAMBER
– REMOVING THE PUMP
– DISMANTLING THE FUEL LIFT PUMP
– INSPECTION OF PARTS
– REMOVING THE FUEL INJECTION PUMP
– REINSTALLING THE FUEL INJECTION PUMP
– FUEL INJECTION PUMP GEAR
– IDLING SPEED SETTING
– PRIMING THE FUEL SYSTEM
– THROTTLE LINKAGE AND FUEL SHUTOFF CONTROL
– COLD WEATHER STARTING AID
– INJECTORS
– FUEL PIPES
– REMOVING THE FLYWHEEL
– RENEWING FLYWHEEL AND RING GEAR
– REINSTALLING THE FLYWHEEL
– REMOVING THE FLYWHEEL HOUSING
– REINSTALLING THE FLYWHEEL HOUSING
– SMOKE DIAGNOSIS CHART
– TROUBLESHOOTING PERKINS
CONTINENTAL ENGINE SECTION
– INFORMATION FOR ORDERING PARTS
– DESCRIPTION OF ENGINE
– LUBRICATION SYSTEM
– OIL PUMP
– OIL FILTER
– COOLING SYSTEM
– CLEANING COOLING SYSTEM
– RADIATOR PRESSURE CAP
– WATER PUMP REMOVAL
– WATER PUMP DISASSEMBLY
– WATER PUMP
– TESTING THERMOSTAT
– COOLANT
– FUEL SYSTEM
– CARBURETOR REMOVAL
– DISASSEMBLY OF THE FUEL BOWL BODY
– CLEANING THE CARBURETOR
– DISASSEMBLY OF THE THROTTLE BODY
– CARBURETOR REINSTALLATION
– FUEL PUMP SERVICE
– IGNITION SYSTEM
– IGNITION COIL
– DISTRIBUTOR
– DISTRIBUTOR MAINTENANCE
– SPARK PLUGS
– GAPPING THE SPARK PLUG
– COLD, NORMAL, HOT SPARK PLUGS
– IGNITION TIMING
– ENGINE REMOVAL
– ENGINE REPAIR AND OVERHAUL
– CYLINDER HEAD
– CYLINDER BLOCK
– VALVE GUIDES
– VALVE SEAT INSERTS
– VALVES
– VALVE SPRINGS
– PREPARING CYLINDER WALLS FOR REGRINDING OR REBORING
– PISTONS
– PISTON PINS
– CONNECTING ROD
– PISTON AND CONNECTING ROD ASSEMBLY
– PISTON RINGS
– RECOMMENDED METHOD OF INSTALLING PISTON RINGS
– CRANKSHAFT AND MAIN BEARINGS
– BEARINGS
– CAMSHAFT
– TAPPETS
– LIMITS AND CLEARANCE
– TIMING GEARS
– CRANKSHAFT END PLAY
– ASSEMBLING OIL SEALS IN FILLER BLOCK AND OIL GUARD
– JUTE TYPE OIL SEALS
– NEOPRENE OIL SEAL
– OIL PUMPS
– FLYWHEEL AND FLYWHEEL HOUSING
– REASSEMBLING ENGINE
– TROUBLESHOOTING THE ENGINE
TECHNICAL DATA, LIMITS AND CLEARANCES
– TECHNICAL DATA PERKINS
– TECHNICAL DATA CONTINENTAL
– LOADER TORQUES SPECIFICATIONS
– TIME REQUIRED FOR SERVICE
– FORMS
– M970 DIESEL LOADER SPECIFICATIONS
– M970 GASOLINE LOADER SPECIFICATIONS
SERVICE BULLETINS
– 7627
SERVICE MANUAL REVISIONS
– 9701
– 9702