Bobcat M-970 Skid-Steer Loader Repair Service Manual – 6545690

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This workshop repair service manual PDF download for the M-970 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 M-970
(Diesel and Gasoline)

TABLE OF CONTENTS :

BOBCAT OPERATION
LOADER SERVICE AND MAINTENANCE
ELECTRICAL SERVICE
HYDRAULIC AND HYDROSTATIC SERVICE
MECHANICAL DRIVE
PERKINS ENGINE SERVICE
CONTINENTAL ENGINE SERVICE
TECHNICAL DATA, LIMITS AND CLEARANCES
SERVICE BULLETINS
SERVICE MANUAL REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : 6545690 (6-81) Revised (5-85)
Total Pages : 188

This M-970 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
FOREWORD
CONTENTS

BOBCAT OPERATION
INSTRUMENTATION
ENGINE CONTROLS
DRIVE CONTROLS
LOADER CONTROLS
PRE-START CHECK
STARTING PROCEDURE
COLD WEATHER STARTING
OPERATING THE M-970 BOBCAT
BREAK-IN

LOADER SERVICE AND MAINTENANCE
BOB-TACH SYSTEM
TRANSPORTING THE M-970
TRANSPORTING BY TRUCK OR TRAILER
HOISTING THE M-970
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 START-UP 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 O-RING 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 SHUT-OFF 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)
Recommended Torques
De-Rating For Altitude
Service Wear Limits
MANUFACTURING DATA AND DIMENSIONS
Cylinder Block
Cylinder Liners Cast Iron
Pistons
Piston Rings
Piston Pin
Piston Pin Bushing
Connecting Rod
Connecting Rod Alignment
Crankshaft
Main Bearings
Connecting Rod Bearings
Camshaft
Canshaft Thrust Washer
Cylinder Head
Valve Guides
Exhaust Valves
Inlet Valves
Inner Valce Springs
Outer Valve Springs
Tappets
Rocker Shaft
Rocker Levers
Valve Clearance
Valve Timing
TIMING GEARS
Camshaft Gear
Fuel Pump Gear
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
FUEL SYSTEM
Fuel Lift Pump
Fuel Filter (Final)
Fuel Injection Pump
Static Timing Position
Injectors
PERKINS DIESEL SERVICE TOOLS
TECHNICAL DATA (CONTINENTAL)
VALVE GUIDE
VALVES, INTAKE
VALVES, EXHAUST
VALVES SPRINGS
CAMSHAFT
MAIN BEARINGS
REAR FLANGE BEARING
PISTON PIN
PISTONS
PISTON RINGS
RECOMMENDED TORQUES (CONTINENTAL)
LOADER TORQUES SPECIFICATIONS
TIME REQUIRED FOR SERVICE
FORMS
50-HOUR CHECK
CUSTOMER RESPONSIBILITY
DELIVERY REPORT
PRE-DELIVERY CHECK LIST
M-970 DIESEL LOADER SPECIFICATIONS
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
POWER TRAIN
CAPACITIES
TIRES
MACHINE WEIGHT
M-970 GASOLINE LOADER SPECIFICATIONS
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
POWER TRAIN
CAPACITIES
TIRES
MACHINE WEIGHT

SERVICE BULLETINS
76-27

SERVICE MANUAL REVISIONS
970-1

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