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This workshop repair service manual PDF download for the 974 / 975 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
Bobcat Loader 974
Bobcat Loader 975
TABLE OF CONTENTS :
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
MECHANICAL TRANSMISSION
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE (974 Perkins)
ENGINE SERVICE {975 John Deere)
TECHNICAL DATA
ALPHABETICAL INDEX
SERVICE BULLETINS
SERVICE MANUAL REVISIONS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6556214 (11-85)
Total Pages : 320
This 974/975 Bobcat Loader Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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MAINTENANCE SAFETY
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
Safety Is Your Responsibility
Before You Operate The Bobcat Loader
Safe Operation Needs A Qualified Operator
FIRE PREVENTION
PREVENTIVE MAINTENANCE
INTRODUCTION
Symbols
Serial Number Identification
Loader Serial Number
Engine Serial Number
Pre-Delivery Inspection
30 Hour Inspection
SERVICE SCHEDULE
REAR DOOR AND ENGINE COVER
REMOVAL OF SIDE PANEL (FENDER)
TILTING THE ROPS (Operator Enclosure)
Tilting ROPS Forward
To Lower ROPS
CONTROL LEVER LOCK
TO CLEAN ROPS ANS SKID PLATE AREA
To Open The Skid Plate
To Close The Skid Plate
ENGINE MAINTENANCE
Starting The Engine
Engine Oil Check
Specifications
CRANKCASE VENT TUBE
REPLACEMENT OF ENGINE OIL AND FILTER
ENGINE AIR INLET SYSTEM (Air Cleaner)
Air Cleaner Service
Air Inlet System Service
ENGINE COOLING SYSTEM
FLUSHING THE COOLING SYSTEM
ADJUSTMENT OF FAN BELT
FUEL SYSTEM (General)
FUEL SPECIFICATIONS
974 FUEL SYSTEM SERVICE
CHARGING FUEL SYSTEM
975 FUEL SYSTEM SERVICE
Fuel Pump
Fuel Filter
To Charge Fuel System
Remove Air From Fuel System
REMOVAL OF FUEL TANK
ELECTRICAL SYSTEM MAINTENANCE
ADJUSTMENT OF CLUTCH/BRAKE
Clutch/Brake Spring
HYDRAULIC/HYDROSTATIC SYSTEM (General)
HYDRAULIC FLUID
HYDRAULIC FLUID FILTERS
HYDRAULIC RESERVOIR REMOVAL OF WATER OR HYDRAULIC FLUID
HYDRAULIC FLUID TO CHECK, ADD OR REPLACE
REMOVAL OF HYDRAULIC RESERVOIR
TO CHECK FOR HYDRAULIC SYSTEM LEAKS
TO CLEAN 100 MESH FILTER SCREEN
OIL COOLER
HYDROSTATIC TRANSMISSION
FINAL DRIVE CHAIN
TO TRANSPORT
TIRES
TIRE MAINTENANCE
TIRE ROTATION
TIRE REPLACEMENT
LUBRICATION
WHEEL NUTS
BOB-TACH
MELROE TRACKS
To Install The Tracks (Tandem)
Track Adjustment
Tires Damaged By Tracks
HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
BASIC OPERATING PRINCIPLE OF THE HYDRAULIC SYSTEM
HYDRAULIC CONTROLS
Clean Area
Air Leaks
Tubelines, Hoses, Fittings
Straight Thread O-Ring Connections
37° Flare Connections
Tubelines And Hoses
Pipe Thread Connections
TROUBLESHOOTING
HYDRAULIC FILTER SERVICE
HYDRAULIC TESTING
To Check Volume Control Relief Valve
To Check Lift Circuit Relief Valve
HYDRAULIC PUMP
Hydraulic Pump Testing
Hydraulic Pump Removal
Disassembly Of Hydraulic Pump
Assembly Of Hydraulic Pump
Installation Of Hydraulic Pump
HYDRAULIC PUMP (TYRONE) 974-S/N 12818 & Above: 975-S/N 12639 & Above
Removal Of The Hydraulic Pump (Tyrone)
Disassembly Of The hydraulic Pump (Tyrone)
Inspection Of The Hydraulic Pump (Tyrone)
Replacement Of The Shaft Seal (Tyrone)
Assembly Of The Hydraulic Pump (Tyrone)
Installing The Hydraulic Pump (Tyrone)
REMOVAL OF CONTROL VALVE
Disassembly Of Control Valve
CONTROL VALVE SERVICE
Control Valve Seal Replacement
Self Leveling Section Service
CHECK HYDRAULIC LIFT AND TILT CYLINDERS
INSPECTION OF HYDRAULIC CYLINDER
LIFT CYLINDER SERVICE
TILT CYLINDER SERVICE
HYDROSTATIC SYSTEM
HYDROSTATIC OPERATING PRINCIPLE
HYDROSTATIC CIRCUITRY
TROUBLESHOOTING
ADJUSTMENT OF DIRECTIONAL CONTROL
REMOVAL OF CONTROL ASSEMBLY
ADJUSTMENT OF PUMP AND MOTOR CONTROL
FLUID AND FILTERS
Fluid
Filters
TRANSMISSION STARTING PROCEDURE
HYDROSTATIC CHARGE PUMP
Description
To Check Charge Pressure
Removal Of Charge Pump
Installation Of Charge Pump
DISPLACEMENT CONTROL VALVE
Removing Displacement Control Valve
Installing Displacement Control Valve
Adjustment Of Displacement Control Valve
REMOVAL OF CHECK VALVE
To Test Check Valves
Installation Of Check Valve
REMOVAL OF HYDROSTATIC PUMP OR HYDROSTATIC MOTOR
Disassembly Of Pump Or Motor
Removal Of Seal
Installation Of Seal
Removal Of End cap
Removal Of Valve Plate
Removal Of Brass Bearing Plate
Removal Of Rear Bearing
Removal Of Spring Guide
Removal Of Cylinder Block
Removal Of Slipper Retainer Guide
Removal Of Pistons And Slipper Retainer
Removal Of Thrust Plate
Removal Of Front Cover
Removal Of Drive Shaft
Removal Of Swashplate And Trunnion
Removal Of Servo Pistons And Sleeves
Assembly Procedure
Adjustment Of Drive Shaft End Play
Assembly Of Servo Pistons
Installation Of Servo Pistons
Control Link Connections
Installation Of Servo Sleeves
Installing Swashplate And Trunnions
Adjustment Of Neutral Position Of Swashplate
Installation Of thrust Plate
Installation Of Drive Shaft
Installation Of Front Cover And Gasket
Assembly Of Cylinder Block
Installation Of the Cylinder Block Assembly
Installation Of Spring Guide
Installation Of Rear Bearing Cone
Installation Of Bearing Plate
To Place Valve Plate On End Cap
Installation Of End Cap
Installation Of Motor
MANIFOLD BLOCK
Motor Manifold Block
Removal Of Manifold Bloclk
Installation Of Manifold Block
OIL COOLER
Cleaning
Removal Of Oil Cooler
Installation Of Oil Cooler
Oil Cooler Bypass Valve
MECHANICAL DRIVE SYSTEM
GENERAL INFORMATION
CLUTCH SERVICE
Adjustment Of Clutch
Clutch Removal
Inspection Of Clutch
Assembly Of Clutch
TRANSFER CHAINCASE SERVICE
Removal Of Transfer Chaincase
Disassembly Of Transfer Chaincase
Inspection Of Transfer Chaincase
To Assemble And Install Transfer Chaincase
New Transfer Case
REDUCTION GEARCASE DESCRIPTION
Removal Of Reduction Gearcase
Disassembly And Assembly Of The Reduction Gearcase
Installation Of The Reduction Gearcase
ADJUSTMENT OF FINAL DRIVE CHAIN
To Check Final Drive Chain
Removal Of Drive Chain
AXLES
Removal Of Axle Housing
Disassembly Of Axle Housing
To Check Axle And Sprocket Splines
Installation Of Axle Housing
Assembly Of Axle And Housing
INSTALLATION OF FINAL DRIVE CHAIN
FINAL DRIVE CHAIN (With Pivot Bolt)
Removal Of The Idler
Disassembly Of Idler
Assembly And Installation Of Idler
FINAL DRIVE IDLER (With Floating Pivot Pin)
To Remove The Idler Assembly
Disassembly Of Idler
Assembly And Installation Of Idler
MAIN FRAME
ROPS (Operator Enclosure)
ROPS TILT CONTROL SERVICE
Removal Of Tilt Control Pump
Disassembly Of Tilt Control Motor
REMOVAL AND INSTALLATION OF ROPS
LIFT ARMS
Removal Of Lift Arms
Installation Of Lift Arms
REPLACEMENT OF LIFT ARM PIVOT PIN
REPLACEMENT OF LIFT ARM PIVOT BUSHING
ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
INSTALLATION OF BATTERY
WIRING HARNESS
ELECTRICAL CIRCUITRY
Wiring Harness (974)
Wiring Harness (975)
PROBLEM ANALYSIS CHARTS
TO CHECK WIRING
TO CHECK GENERATOR OUTPUT
GENERATOR SERVICE
Removal Of Generator
Disassembly Of Generator
Inspection Of Generator
STARTER SERVICE
Checking The Starter
Removal Of The Starter
Disassembly And Inspection Of Starter
Assembly Of The Starter
SERVICING THE NIPPONDENSO STARTER
Checking The Starter
Disassembly Of The Starter
Inspecting The Starter
Assembly Of The Starter
ENGINE SERVICE (974 - PERKINS)
REMOVAL OF ENGINE
INTRODUCTION TO ENGINE REPAIR
UNIFIED THREADS
ENGINE NUMBER
ENGINE DESCRIPTION
LUBRICATING OIL PAN
CRANKCASE VENTILATION
Breather Assembly
CYLINDER HEAD
Checking Compression
Removal Of The Cylinder Head
Removal Of Valves
To Clean Cylinder Head And Block
Valve Guides
Valves And Valve Seats
Grinding Valves By Hand
Valve Seat Inserts (Exhaust Valve)
Machining Of Cylinder Head
Valve Springs
Assembly Of Rocker Shaft
Push Rods
Valve Stem Oil Seals
Assembly Of Cylinder Head
Cylinder Head Gasket
Installation Of Cylinder Head
REMOVAL OF PISTONS AND CONNECTING RODS
Removal Of Pistons And Rings From Connecting Rods
Assembly Of Pistons To Connecting Rods
Installation Of Pistons And Connecting Rods In Cylinder Bore
Installation Of New Pistons
CYLINDER LINERS
Removal of Cylinder Liners (Cast Iron)
Installation Of Cylinder Liners
CRANKSHAFT AND MAIN BEARINGS
Removal Of Main Bearings And Thrust Washers
Installation Of Main Bearings And Thrust Washers
REMOVAL OF CRANKSHAFT
Regrinding Crankshaft
Installation Of Crankshaft
CRANKSHAFT REAR OIL SEAL
BALANCE UNIT
Removal Of Balance Unit
Disassembly Of Balance Unit
Assembly Of Balance Unit
BALANCER UNIT (CENTER MOUNTED)
Removal And Installation
Engine Timing to Balancer Unit
Oil Pump Removal And Installation
Oil Pump Inspection
Oil Pump Relief Valve
Disassembly And Assembly
Inspection
CRANKSHAFT FRONT OIL SEAL
REMOVAL OF TIMING CASE COVER
Installation Of Timing Case Cover
To Check Timing Gear Play
Removal Of Idler Gear And Hub
Installation Of Idler Gear And Hub
Removal Of Camshaft Gear
Installation Of Camshaft Gear
Removal Of Fuel Pump Gear
Installation Of Fuel Pump Gear
Removal Of Timing Case
Installation Of Timing Case
REMOVAL OF CAMSHAFT AND TAPPETS
Installation Of Camshaft And Tappets
TO CHECK VALVE TIMING
LUBRICATION SYSTEM
Engine Lubrication System
COOLING SYSTEM
Removal And Installation Of Water Pump
Disassembly Of Water Pump
Inspection Of Water Pump
Assembly Of Water Pump
Removal Of Thermostat
To Test Thermostat
FUEL SYSTEM
To Test Fuel Lift Pump
To Clean Fuel Lift Pump
Removal Of Fuel Lift Pump
Removal Of Fuel Injection Pump
Installation Of Fuel Injection Pump
Fuel Injection Pump Gear
Maximum Speed Setting
Adjustment Of Idling Speed
To Charge Fuel System
HOW THE THERMOSTART UNIT WORKS
ENGINE STARTING PROCEDURE
HOW TO USE THE THERMOSTART
CHARGING THE FUEL LINE
FUEL INJECTORS
Fuel Injector Problems
To Check And Make Adjustments Of Injectors
To Check For Injector Failure
To Test Injectors (Visual Inspection)
To Test Injectors (Using Testing Equipment)
REMOVAL OF FLYWHEEL
Removal And Installation Of Flywheel Ring Gear
Installation Of Flywheel
REMOVAL OF FLYWHEEL HOUSING
Installation Of Flywheel Housing
Installation Of New Housing
Installation Of Old Housing (That Was Removed From Engine)
FUEL TIMING INJECTION PUMP
To Remove The Fuel Injection Pump
To Install The Fuel Injection Pump
Checking Fuel Injection Pump Timing
Timing The Fuel Injection Pump (Using Tming Tool MS 67123)
Checking The Timing Mark On The flange Of The Injection Pump
SMOKE DIAGNOSIS CHART
TROUBLESHOOTING THE PERKINS ENGINE
ENGINE SERVICE (975 - JOHN DEERE)
GENERAL INFORMATION
PRELIMINARY ENGINE TESTING
ENGINE TUNE-UP
TUNE-UP PROCEDURE
DETAILED TUNE-UP PROCEDURES
Air Cleaner
Exhaust System
Crankcase Vent Tube
Compression Test
REMOVAL OF ENGINE
CYLINDER HEAD, VALVES, CAMSHAFT AND TIMING GEAR TRAIN
VALVE TRAIN
To Check Valve Clearance
To Check Valve Lift
CYLINDER HEAD AND VALVES
To Remove Cylinder Head
Valve Springs
Valve Face And Stem
Valve Rotattors
Valve Guides
Valve Seats
Cylinder Head
Rocker Arm
Assembly Of Rocker Arm
INSTALLATION OF CYLINDER HEAD
Torques For Hardware
ADJUSTMENT OF VALVE CLEARANCE
CAMSHAFT
Removal Of Camshaft
Inspection And Repair Of Camshaft
Installation Of Camshaft
To Check Gear Timing
TIMING GEAR TRAIN
To Remove Timing Gear
Inspection And Repair
BALANCER SHAFTS
Inspection Of Balancer Shaft
Front Plate And Timing Gear Cover
Assembly And Installation
CYLINDER BLOCK, LINERS, PISTONS AND RODS
Removal Of Piston
Inspection Of Pistons And Rings
Inspection Of Piston Pin
Inspection Od Connecting Rod
Assembly Of Piston And Rod
Cylinder Liners
Measurements
To Deglaze Cylinder Liners
To Clean Engine Block
Installation Of Liner
Replacement Of Liner
Installation Of Pistons And Rods
CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL
To Check End Play Of Crankshaft
Removal Of Crankshaft
Inspection And Repair Of Crankshaft
Crankshaft And Flywheel
Front Crankshaft Gear
Main Bearings And Crankshaft Journals
Rear Crankshaft Oil Seal, Flywheel Housing And Wear Ring
Assembly Of Crankshaft
LUBRICATION SYSTEM
Oil Pump
Repair Of Oil Pump
Assembly Of Oil Pump
Installation Of Oil Pump
Engine Oil Cooler
Repair Of Engine Oil Cooler
Oil Cooler Housing And Core
Oil Cooler Bypass Valve
Engine Oil And Filter
Installation Of Engine Oil Cooler
COOLING SYSTEM
To Check Radiator And Fan Belt
Repair Of Water Pump
Removal Of Water Pump
Inspection And Repair Of Water Pump
Assembly Of Water Pump
Repair Of Water Manifold And Thermostat
FUEL SYSTEM
Fuel Injection Pump
Removal Of Injection Pump
Injection Pump Drive Shaft
Drive Shaft And Gear
Repair Of Injection Pump
Drive Shaft Shaft And Gear
Installation And Timing Of Injection Pump
Automatic Speed Advance Adjustment
Fuel Injection Nozzles
Diagnosising Malfunctions
Removal Of Injection Nozzles
Repair Of Injection Nozzles
Installation Of Injection Nozzles
SPECIAL TOOLS
TECHNICAL DATA
974 LOADER SPECIFICATIONS
Operational & Performance
Engine
Loader Hydraulics
Electrical
Drive System
Capacities
Tires
TECHNICAL DATA (PERKINS ENGINE)
Recommended Torques
De-Rating For Altitude
Service Wear Limits
MANUFACTURING DATA AND DIMENSIONS
Cylinder Block
Cylinder Liner (Cast Iron)
Pistons
Piston Rings
Piston Pin
Connecting Rod
Connecting Rod Alignment
Crankshaft
Main Bearings
Connecting Rod Bearings
Camshaft
Camshaft Thrust Washer
Cylinder Head
Valve Guides
Exhaust Valves
Inlet Valves
Inner Valve Springs
Outer Valve Springs
Tappets
Rocker Shaft
Rocker Levers
Valve Clearance
Valve Timing
TIMING GEARS
Camshaft Gears
Fuel Pump Gear (Mechanically Goverened Pumps)
Idler Gear And Hub
Crankshaft Gear
Timing Gear Backlash
LUBRICATION SYSTEM
Sump
Oil Pump
Relief Valve
Lubricating Oil Filter
COOLING SYSTEM
Type Of Cooling System
Thermostat
Water Pump
BALANCE UNIT
Balance Unit (Center Mounted)
OIL PUMP (Center Mounted Balancer Unit)
Oil Pump, Gear & Relief Valve
FUEL SYSTEM
Fuel Lift Pump
Fuel Filter (Final)
Fuel Injection Pump
Static Timing Position
Injectors
PERKINS DIESEL SERVICE TOOLS
975 LOADER SPECIFICATIONS
Operational & Performance
Engine
Loader Hydraulics
Electrical
Drive System
Capacities
Tires
TECHNICAL DATA (JOHN DEERE)
Cylinder Head, Valves and Camshaft
Cylinder Block, Liners, Pistons And Rods
Crankshaft, Mian Bearings And Flywheel
Lubrication System
Cooling System
Fuel System
ENGINE BREAK-IN INSTRUCTIONS (After overhaul)
LOADER TORQUE SPECIFICATIONS
Transfer Chaincase & Clutch Housing
Reduction Gearcase
Axle Carrier
Lift Arm
DECIMAL AMD MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION
STANDERD TORQUE SPECIFICATIONS FOR BOLTS
LOADER SPECIFICATIONS - 974
Engine
Machine
Capacities
LOADER SPECIFICATIONS - 975
Engine
Machine
Capacities
ALPHABETICAL INDEX
SERVICE BULLETINS
900-001
900-002
900-003
900-004
900-005
900-006
900-007
900-008
SERVICE MANUAL REVISIONS
974/975-1
974/975-2
974/975-3
974/975-4
974/975-5
974/975-6
974/975-7
974/975-8
974/975-9
974/975-10
974/975-11
974/975-12
974/975-13
974/975-14
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Bobcat 974, 975 Skid-Steer Loader Repair Service Manual - 6556214.pdf
Source : Sitelux.com