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Bobcat 974, 975 Skid Steer Loader Service Manual

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Language: English
Manufacturer: Komatsu
Models Covered: 974, 975
Serial Numbers Covered: nan
Manual Type: Service Manual
Manufacturer Part Number: 6556214_11_85
Pages: 320
Format: PDF Instant View+Download

SKU: 6556214_11_85 Category:

Description

Bobcat 974, 975 Skid Steer Loader Service Manual



Condition: Brand New
Language: English
Manufacturer: Bobcat
Models Covered: 974, 975
Serial Numbers Covered: nan
Manual Type: Service Manual
Manufacturer Part Number: 6556214_11_85
Pages: 320
Format: PDF Instant View+Download

A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams
and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

A Parts Catalog is often large and broken down in to sections for
different parts of your
equipment. Parts Catalogs cover absolutely every aspect of your machine unless
mentioned
otherwise. Sometimes, the engine is covered in a separate parts catalog that is
written
specifically for the engine. Most of the time though, it’s included in the main
parts
catalog. A parts catalog will arm you with the same exact information that your
local
service center has and includes exploded views of assemblies that are a great
help with
disassembly and re-assembly. Parts catalogs also include all part numbers for
every part
of your machine which makes for easy ordering of parts.

PDF Contents:

  • 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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