Complete workshop repair service manual with electrical wiring diagrams for Bobcat M970 Loader. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Bobcat M970 Loaderservice & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

6545690 - M970 (Gasoline & Diesel) Service Manual.pdf

EXCERPT:
SEAT BAR (Cont’d)
Removal And Installation (Cont’d)
Disconnect the wiring harness connector (Item 1) [A] (left side).
Remove the seat bar mounting bolt (Item 2) [A] (both sides).
Remove the sensor mounting bolt (Item 3) [A] (left side).
Installation: Make sure the two tabs (Item 1) [B] are located in the slot on the operator cab.
Installation: Tighten the mounting bolt and nut (Item 1) [C] to 180 – 200 in.–lbs. (21 – 23 Nm) torque.
To protect the paint on the operator cab from getting scratched, install cardboard (Item 1) [D] on the right side.
Wrap tape around the left pivot end (Item 2) [D] of the seat bar.
Wrap tape around the cab grab handle (Item 3) [D] and the front edge of the cab (Item 4) [D].
…

MAINTENANCE SAFETY...2
FOREWORD...4
CONTENTS...6
BOBCAT OPERATION...8
  INSTRUMENTATION...8
  ENGINE CONTROLS...8
  DRIVE CONTROLS...8
  LOADER CONTROLS...9
  PRE-START CHECK...10
  STARTING PROCEDURE...10
  COLD WEATHER STARTING...11
  OPERATING THE M-970 BOBCAT...11
  BREAK-IN...11
LOADER SERVICE AND MAINTENANCE...12
  BOB-TACH SYSTEM...14
  TRANSPORTING THE M-970...14
  TRANSPORTING BY TRUCK OR TRAILER...14
  HOISTING THE M-970...14
  MAINTENANCE SCHEDULE...15
  SERVICE SCHEDULE...16
  TIRE MAINTENANCE...18
  BELLY PAN...18
  OPERATOR ENCLOSURE TILT CONTROL...19
  ENCLOSURE TILT CONTROL SERVICE...19
  ENCLOSURE REMOVAL AND REINSTALLATION...19
  ENCLOSURE LATCHES...20
  CONTROL LEVER LOCK...20
  LIFT ARM PIVOT REPLACEMENT...20
  REWORKING THE LIFT ARM ASSEMBLY...21
  SIDE PANEL (FENDER) REMOVAL...21
  GRILL REMOVAL...21
  FUEL TANK...22
  FUEL PICKUP TUBE...22
  ENGINE HOOD...22
  INTRODUCTION TO ENGINE SERVICE...22
  INITIAL 50 HOUR SERVICE...22
  AIR CLEANER SERVICE...23
  HEAVY DUTY, TWO STAGE, MULTIPLE ELEMENT AIR CLEANER WITH ASPIRATOR...23
  FIELD SERVICEING THE AIR CLEANER (DONALDSON ONLY) ...23
  ENGINE LUBRICATION SERVICE...25
  RECOMMENDED OIL SPECIFICATIONS...25
  CHANGING ENGINE OIL...25
  OIL FILTER REPLACEMENT...25
  FUEL SYSTEM SERVICE...26
  FUEL SPECIFICATIONS...26
  VENTING FUEL SYSTEM (DIESEL)...27
  INJECTOR SERVICE (DIESEL ONLY)...28
  CYLINDER HEAD RETORQUING (DIESEL ONLY)...28
  VALVE CLEARANCE ADJUSTMENT (DIESEL ONLY)...29
  COOLING SYSTEM SERVICE...29
  RADIATOR COOLING FANS...29
  FAN BELT ADJUSTMENT...29
ELECTRICAL SERVICE...30
  INSTRUMENT PANELS...32
  FUSES...32
  WIRING HARNESS...32
  ALTRNATOR CHECK...35
  REGULATOR CHECKS...35
  YACHOMETER TESTING AND CALIBRATION...37
  BATTERY INSTALLATION...37
  BATTERY PROBLEMS...37
  REPLACING HEADLAMPS...37
HYDRAULIC AND HYDROSTATIC SERVICE...39
  BASIC OPERATING PRINCIPLE OF HYDRAULIC SYSTEM...41
  FILTER SERVICE...41
  100 MESH FILTER SCREEN...42
  HYDRAULIC TESTING KIT...42
  LIFT AND TILT CYLINDER CHECKS...43
  HYDRAULIC CYLINDER INSPECTION...43
  LIFT CYLINDER SERVICE...44
  TILT CYLINDER SERVICE...45
  HYDRAULIC CONTROL VALVE BANK REMOVAL...45
  CONTROL VALVE SERVICE...46
  DISASSEMBLY INSTRUCTIONS...47
  SELF LEVELING CONTROL VALVE...48
  HYDRAULIC PUMP (IMPLEMENT CIRCUIT)...49
  HYDRAULIC PUMP REMOVAL...50
  HYDRAULIC PUMP DISASSEMBLY...50
  HYDRAULIC PUMP REASSEMBLY...50
  HYDRAULIC OPERATING PRINCIPLE...52
  HYDROSTATIC CIRCUITRY...54
  DIRECTIONAL CONTROL ADJUSTMENT...56
  CONTROL ASSEMBLY REMOVAL...56
  PUMP AND MOTOR CONTROL ADJUSTMENT...57
  HYDROSTATIC CHARGE PUMP...57
  CHECKING CHARGE PRESSURE...57
  HYDRAULIC FLUID AND 10 MICRON FILTER...58
  TRANSMISSION START-UP PROCEDURE...60
  CHARGE PUMP REMOVAL...60
  CHARGE PUMP REINSTALLATION...61
  CHECK VALVE REMOVAL...61
  CHECK VALVE REINSTALLATION...61
  TESTING CHECK VALVES...61
  HYDROSTATIC PUMP REMOVAL...61
  PUMP REINSTALLATION...62
  MOTOR REMOVAL...62
  MOTOR REINSTALLATION...62
  PUMP OR MOTOR DISPLACEMENT CONTROL VALVE...63
  DISPLACEMENT CONTROL VALVE REMOVAL...63
  DISPLACEMENT CONTROL VALVE REINSTALLATION...63
  MOTOR MANIFOLD BLOCK...63
  MANIFOLD BLOCK REMOVAL...64
  MANIFOLD BLOCK REINSTALLATION...64
  REMOVAL OF THE SEAL FROM THE PUMP OR MOTOR...65
  SEAL REINSTALLATION...65
  HYDRAULIC FLUID COOLER...66
  COOLER REMOVAL...66
  COOLER REINSTALLATION...66
  COOLER BYPASS VALVE...66
  HYDRAULIC LEAKS...67
  COST OF OIL LEAKS...67
  37° FLARE SAE CONNECTION...67
  SAE STRAIGHT THREAD O-RING SEAL...67
  SAE 4 BOLT SPLIT FLANGE CONNECTION...68
  OVERHAUL OF HYDROSTATIC PUMP OR MOTOR...69
  REMOVAL OF PUMP OR MOTOR FROM VEHICLE...69
  DISASSEMBLY PROCEDURE...69
  REMOVING CHARGE PUMP...70
  REMOVING CHECK VALVES...70
  REMOVING END CAP...70
  REMOVING VALVE PLATE...71
  REMOVING BRASS BEARING PLATE...71
  REMOVING REAR BEARING...71
  REMOVING SPRING GUIDE...71
  REMOVING CYLINDER BLOCK...71
  REMOVING SLIPPER RETAINER...72
  REMOVING PISTONS AND SLIPPER RETAINER...72
  REMOVING THRUST PLATE...72
  REMOVING FRONT COVER...72
  REMOVING CONTROL VALVE ASSEMBLY...73
  REMOVING TRUNNION...73
  SERVO SLEEVES...73
  REASSEMBLY PROCEDURE...74
  SET SHAFT END PLAY...74
  ASSEMBLING SERVO PISTONS...75
  ATTACHING SERVO PISTON ASSEMBLIES TO SWASH PLATE...75
  ATTACHING CONTROL LINK TO SWAH PLATE...76
  INSTALLING SWASH PLATE...76
  INSTALLING TRUNNIONS...76
  INSTALLAING SERVO SLEEVES...76
  SETTING NEUTRAL POISTION OF SWASH PLATE...76
  INSTALL THE CONTROL ASSEMBLY...77
  INSTALLING THE THRUST PLATE...77
  INSTALLING THE DRIVE SHAFT...77
  INSTALLING FRONT COVER AND GASKET...77
  ASSEMBLING THE CYLINDER BLOCK...77
  ASSEMBLE THE CYLINDER BLOCK ASSEMBLY INTO THE HOUSING...78
  INSTALL THE SPRING GUIDE...78
  PRESSING CONE OF REAR BEARING INTO SHAFT...78
  INSTALLING BEARING PLATE...78
  PLACING VALVE PLATE ON END CAP...78
  INSTALLING END CAP...79
  INSTALLING CHARGE PUMP...79
  INSTALLING SHAFT SEAL...79
  TROUBLESHOOTING THE HYDRAULIC SYSTEM...80
  TROUBLESHOOTING THE HYDROSTATIC SYSTEM...84
MECHANICAL DRIVE...89
  CLUTCH ADJUSTMENT (DIESEL ONLY)...91
  CLUTCH REMOVAL...91
  POWER TRANSFER CHAIN...91
  TRANSFER CHAINCASE REMOVAL...92
  CHAINCASE SERVICE...92
  REDUCTION GEARCASES...92
  GEARCASE MOUNTING...92
  GEARCASE REMOVAL...93
  DISASSEMBLING A CLARK REDUCTION GEARCASE...94
  REASSEMBLING A CLARK REDUCTION GEARCASE...94
  DISASSEMBLING A FUNK GEARCASE...95
  REASSEMBLING A FUNK GEARCASE...96
  FINAL DRIVE CHAIN ADJUSTMENT...97
  FINAL DRIVE CHAIN REMOVAL...97
  AXLE CARRIER REMOVAL...98
  DISASSEMBLING THE AXLE CARRIER...98
  REASSEMBLING THE AXLE CARRIER...98
  AXLE CARRIER REINSTALLATION...99
  FINAL DRIVE CHAIN REINSTALLATION...99
  FINAL DRIVE IDLER REPAIR...101
PERKINS ENGINE SERVICE...103
  ENGINE REMOVAL...105
  INTRODUCTION TO ENGINE REPAIR...105
  UNIFIED THREADS...105
  ENGINE NUMBER...105
  ENGINE DESCRIPTION...106
  LUBRICATING OIL SUMP...106
  CRANKCASE VENTILATION...106
  BREATHER ASSEMBLY...106
  TO REMOVE CYLINDER HEAD...106
  VALVE REMOVAL...107
  CLEANING...107
  VALVE GUIDES...107
  VALVES AND VALVE SEATS...107
  HAND GRINDING...108
  VALVE SEAT INSERTS (EXHAUST VALVE)...108
  MILLING OF CYLINDER HEAD...109
  VALVE SPRINGS...109
  ROCKER SHAFT ASSEMBLY...109
  PUSH RODS...109
  VALVE STEM OIL SEALS...109
  TO REASSEMBLE CYLINDER HEAD...109
  CYLINDER HEAD GASKET...110
  TP REINSTALL CYLINDER HEAD...110
  TO REMOVE PISTONS AND CONNECTING ROD ASSEMBLIES...111
  TO REMOVE PISTONS AND RINGS FROM CONNECTING ROADS...111
  INSPECTION...111
  TO ASSEMBLE PISTONS TO CONNECTING RODS...111
  TO INSTALL PISTONS AND CONNECTING RODS TO CYLINDER BORE...112
  INSTALL NEW PISTONS...112
  CYLINDER LINERS...112
  TO RENEW CYLINDER LINERS (CAST IRON)...112
  CRANKSHAFT AND MAIN BEARINGS...112
  MAIN BEARINGS AND THRUST WASHERS REMOVAL...113
  INSTALLING MAIN BEARINGS AND THRUST WASHERS...113
  REMOVING THE CRANSHAFT...114
  REGRINDING THE CRANKSHAFT...114
  REINSTALLING THE CRANKSHAFT...114
  CRANKSHAFT REAR END OIL SEAL...115
  BALANCE UNIT...116
  USE OF LOCTITE...116
  REASSEMBLING THE UNIT...117
  REMOVING TIMING CASE COVER...118
  RENEWING THE CRANKSHAFT FRONT OIL SEAL...118
  REINSTALLING THE TIMING CASE COVER...118
  CHECKING THE TIMING GEAR BACKLASH...119
  REMOVING THE IDLER GEAR AND HUB...119
  REINSTALLING THE TIMING GEAR AND HUB...119
  REMOVING THE CAMSHAFT GEAR...119
  REINSTALLING THE CAMSHAFT GEAR...119
  REMOVING THE FUEL PUMP GEAR...120
  REINSTALLING THE FUEL PUMP GEAR...120
  REMOVING THE TIMING CASE...120
  REINSTALLING THE TIMING CASE...120
  REMOVING THE CAMSHAFT AND TAPPETS...120
  REINSTALLING THE CAMSHAFT AND TAPPETS...121
  CHECKING VALVE TIMING...121
  LUBRICATION SYSTEM...121
  DESCRIPTION...121
  COOLING SYSTEM...122
  REMOVING AND INSTALLING WATER PUMP...122
  DISMANTLING THE WATER PUMP...122
  INSPECTION...122
  REASSEMBLING THE WATER PUMP...123
  REMOVING THERMOSTAT...123
  TESTING THERMOSTAT...123
  FUEL SYSTEM...124
  CLEANING HTE PUMP CHAMBER...124
  REMOVING THE PUMP...124
  DISMANTLING THE FUEL LIFT PUMP...124
  INSPECTION OF PARTS...124
  REMOVING THE FUEL INJECTION PUMP...125
  REINSTALLING THE FUEL INJECTION PUMP...125
  FUEL INJECTION PUMP GEAR...125
  IDLING SPEED SETTING...126
  PRIMING THE FUEL SYSTEM...126
  THROTTLE LINKAGE AND FUEL SHUT-OFF CONTROL...126
  COLD WEATHER STARTING AID...127
  INJECTORS...127
  FUEL PIPES...128
  REMOVING THE FLYWHEEL...128
  RENEWING FLYWHEEL AND RING GEAR...129
  REINSTALLING THE FLYWHEEL...129
  REMOVING THE FLYWHEEL HOUSING...129
  REINSTALLING THE FLYWHEEL HOUSING...129
  SMOKE DIAGNOSIS CHART...130
  TROUBLESHOOTING PERKINS...131
CONTINENTAL ENGINE SECTION...137
  INFORMATION FOR ORDERING PARTS...139
  DESCRIPTION OF ENGINE...139
  LUBRICATION SYSTEM...140
  OIL PUMP...140
  OIL FILTER...140
  COOLING SYSTEM...140
  CLEANING COOLING SYSTEM...140
  RADIATOR PRESSURE CAP...141
  WATER PUMP REMOVAL...141
  WATER PUMP DISASSEMBLY...141
  WATER PUMP...142
  TESTING THERMOSTAT...142
  COOLANT...142
  FUEL SYSTEM...143
  CARBURETOR REMOVAL...143
  DISASSEMBLY OF THE FUEL BOWL BODY...143
  CLEANING THE CARBURETOR...143
  DISASSEMBLY OF THE THROTTLE BODY...143
  CARBURETOR REINSTALLATION...144
  FUEL PUMP SERVICE...144
  IGNITION SYSTEM...145
  IGNITION COIL...145
  DISTRIBUTOR...145
  DISTRIBUTOR MAINTENANCE...146
  SPARK PLUGS...147
  GAPPING THE SPARK PLUG...147
  COLD, NORMAL, HOT SPARK PLUGS...147
  IGNITION TIMING...148
  ENGINE REMOVAL...149
  ENGINE REPAIR AND OVERHAUL...149
  CYLINDER HEAD...149
  CYLINDER BLOCK...150
  VALVE GUIDES...150
  VALVE SEAT INSERTS...150
  VALVES...151
  VALVE SPRINGS...151
  PREPARING CYLINDER WALLS FOR REGRINDING OR REBORING...151
  PISTONS...152
  PISTON PINS...153
  CONNECTING ROD...153
  PISTON AND CONNECTING ROD ASSEMBLY...153
  PISTON RINGS...154
  RECOMMENDED METHOD OF INSTALLING PISTON RINGS...154
  CRANKSHAFT AND MAIN BEARINGS...155
  BEARINGS...155
  CAMSHAFT...156
  TAPPETS...157
  LIMITS AND CLEARANCE...157
  TIMING GEARS...157
  CRANKSHAFT END PLAY...157
  ASSEMBLING OIL SEALS IN FILLER BLOCK AND OIL GUARD...158
  JUTE TYPE OIL SEALS...158
  NEOPRENE OIL SEAL...158
  OIL PUMPS...159
  FLYWHEEL AND FLYWHEEL HOUSING...160
  REASSEMBLING ENGINE...160
  TROUBLESHOOTING THE ENGINE...161
TECHNICAL DATA, LIMITS AND CLEARANCES...167
  TECHNICAL DATA (PERKINS)...169
    Recommended Torques...169
    De-Rating For Altitude...169
    Service Wear Limits...169
    MANUFACTURING DATA AND DIMENSIONS...170
      Cylinder Block...170
      Cylinder Liners Cast Iron...170
      Pistons...170
      Piston Rings...170
      Piston Pin...170
      Piston Pin Bushing...171
      Connecting Rod...171
      Connecting Rod Alignment...171
      Crankshaft...171
      Main Bearings...171
      Connecting Rod Bearings...171
      Camshaft...171
      Canshaft Thrust Washer...172
      Cylinder Head...172
      Valve Guides...172
      Exhaust Valves...172
      Inlet Valves...172
      Inner Valce Springs...172
      Outer Valve Springs...172
      Tappets...172
      Rocker Shaft...172
      Rocker Levers...172
      Valve Clearance...172
      Valve Timing...172
    TIMING GEARS...173
      Camshaft Gear...173
      Fuel Pump Gear...173
      Idler Gear And Hub...173
      Crankshaft Gear...173
      Timing Gear Backlash...173
    LUBRICATION SYSTEM...173
      Sump...173
      Oil Pump...173
      Relief Valve...173
      Lubricating Oil Filter...173
    COOLING SYSTEM...173
      Type Of Cooling System...173
      Thermostat...174
      Water Pump...174
    BALANCE UNIT...174
    FUEL SYSTEM...174
      Fuel Lift Pump...174
      Fuel Filter (Final)...174
      Fuel Injection Pump...175
      Static Timing Position...175
      Injectors...175
    PERKINS DIESEL SERVICE TOOLS...175
  TECHNICAL DATA (CONTINENTAL)...176
    VALVE GUIDE...176
    VALVES, INTAKE...176
    VALVES, EXHAUST...176
    VALVES SPRINGS...176
    CAMSHAFT...176
    MAIN BEARINGS...176
    REAR FLANGE BEARING...176
    PISTON PIN...176
    PISTONS...176
    PISTON RINGS...176
    RECOMMENDED TORQUES (CONTINENTAL)...177
  LOADER TORQUES SPECIFICATIONS...178
  TIME REQUIRED FOR SERVICE...179
  FORMS...181
    50-HOUR CHECK...181
    CUSTOMER RESPONSIBILITY...181
    DELIVERY REPORT...182
    PRE-DELIVERY CHECK LIST...182
  M-970 DIESEL LOADER SPECIFICATIONS...183
    OPERATIONAL & PERFORMANCE...183
    ENGINE...183
    LOADER HYDRAULICS...183
    ELECTRICAL...183
    POWER TRAIN...183
    CAPACITIES...183
    TIRES...183
    MACHINE WEIGHT...183
  M-970 GASOLINE LOADER SPECIFICATIONS...184
    OPERATIONAL & PERFORMANCE...184
    ENGINE...184
    LOADER HYDRAULICS...184
    ELECTRICAL...184
    POWER TRAIN...184
    CAPACITIES...184
    TIRES...184
    MACHINE WEIGHT...184
SERVICE BULLETINS...185
  76-27...185
SERVICE MANUAL REVISIONS...187
  970-1...187
  970-2...189