Bobcat 974, 975 Skid-Steer Loader Repair Service Manual - 6556214

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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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