Bobcat 2000 RTF Wheel Loader Repair Service Manual – 6566662

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This workshop repair service manual PDF download for the 2000 RTF Bobcat Wheel 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 RTF 2000
Rough Terrain Forklift

TABLE OF CONTENTS :

PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
TECHNICAL DATA
ALPHABETICAL INDEX

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6566662 (11-88)-1C
Total Pages : 252

This Bobcat Service / Repair / Workshop 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 !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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WARNINGS
SAFETY NSTRUCTIONS
Safety Is Your Responsibility
Safe Operation Needs A Qualified Operator
CONTENTS
FOREWORD

PREVENTIVE MAINTENANCE
FRAME LOCK
LIFTING AND BLOCKING THE BOBCAT FORKLIFT
SERIAL NUMBER LOCATIONS
Machine Serial Number
Engine Serial Number
Vertical Mast Serial Number
Axle Serial Numbers
DELIVERY REPORT
SERVICE SCHEDULE
ENGINE SERICE
ADJUSTING THE DOOR LATCH
AIR CLEANER SERVICE
FUEL SYSTEM
Removing Air From The Fuel System
Fuel System Service
Fuel Filter
ENGINE LUBRICATION SYSTEM
Replacement Of Engine Oil And Filter
ENGINE COOLING SYSTEM
Coolant Level
Removing Coolant From The Cooling System
ALTERNATOR BELT
ELECTRICAL SYSTEM
Operator Guard Electrical Circuitry
Engine Electrical Circuitry
Using An Extra Battery (Booster Starting)
New Battery Installation
HYDRAULIC/HYDROSTATIC SYSTEM
Hydraulic/Hydrostatic Fluid Reservoir
Checking And Adding Hydraulic/Hydrostatic Fluid
Replacement Of The Hydraulic/Hydrostatic Filter
FRONT & REAR AXLE
U-JOINTS
TIRE MAINTENANCE
Tire Rotation
Wheel Nuts
LUBRICATION OF THE BOBCAT ROUGH TERRAING FORKLIFT
SPARK ARRESTOR MUFFLER
BACK-UP ALARM
VERTICAL MAST
OPERATOR CAB

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM OPERATIONS
Description
Flow Chart
TROUBLESHOOTING
HYDRAULIC SYSTEM OPERATION
37° Flare Connections
Straight Thread O-Ring Fitting
Tubelines And Hoses
HYDRAULIC SYSTEM SERVICE
Checking And Adding Hydraulic Fluid
Replacing The Hydraulic Fluid
Replacing The Hydraulic Fluid Filters
Replacing The Bronze (40 Micron) Filter
Replacing The Neutral By-Pass Valve
Replacing The Cold Weather By-Pass Valve
OIL RESERVOIR
Removing The Oil Reservoir
Installing The Oil Reservoir
HYDRAULIC CONTROL VALVE
Description Of The Control Valve
Removing The Hydraulic Control Valve
Disassembly Of The Control Valve
Inspection Of The Control Valve
Reassembly Of The Control Valve
Installing The Control Valve
HYDRAULIC MAIN RELIEF VALVE
Checking The Hydraulic Main Relief Valve
Replacing The Hydraulic Main Relief Valve
HYDRAULIC PUMP
Checking The Hydraulic Pump Pressure
Removing The Hydraulic Pump
Disassembly Of The Hydraulic Pump
Inspection Of The Hydraulic Pump
Assembly Of The Hydraulic Pump
Installing The Hydraulic Pump
Checking Steering Relief Pressure
COUNTERBALANCE VALVE
HYDRAULIC CYLINDERS
Checking The Lift Cylinder Seals
Checking The Tilt Cylinder Seals
Checking The Steering Cylinder Seals
Removing The Lift Cylinder
Inspecting The Lift Cylinder
Installing The Lift Cylinder
Removing The Tilt Cylinders
Installing The Tilt Cylinders
Removing The Steering Cylinder
Installing The Steering Cylinder
Disassembly Of The Hydrailic Cylinder
Assembly Of The Hydraulic Cylinder
STEERING CONTROL VALVE
Removing The Steering Control Valve
Disassembly Of The Steering Control Valve
Inspection Of The Steering Control Valve
Assembly Of The Steering Control Valve
Installing The Steering Control Valve

HYDROSTATIC SYSTEM
SYSTEM OPERATIONS DESCRIPTION
TROUBLESHOOTING
SERVO CONTROL
Neutral Adjustment For Servo Control
Removing The Servo Control
Disassembly Of The Servo Control
Assembly Of The Servo Control
Installing The Servo Control
FOOT PEDAL AND CENTERING MECHANISM
Removing The Centering Mechanism
Adjusting The Springs In The Centering Mechanism
Replacing The Springs On The Centering Mechanism
Installing The Centering Mechanism
Adjusting The Neutral Safety Start Switch
CHARGE PRESSURE AND REPLENISHING VALVES
Checking The Charge Pressure
Checking Orifice In Charge Tubeline
Replenishing Valves
HYDROSTATIC PUMP
Removing The Hydrostatic Pump
Disassembly Of The Hydrostaic Pumps
Hydrostatic Pump Inspection
Assembly Of The Hydrostatic Pump
Installing Pumps To The Manifold Block
Hydrostatic Pump Installation
Hydrostatic Pump Start-Up Procedure
HYDROSTATIC MOTOR
Hydrostatic Motor Removal
Hydrostatic Motor Disassembly
Inspection Of The Hydrostatic Motor
Assembling The The Hydrostatic Motor
Manifold Block Disassembly
Manifold Block Assembly
Hydrostatic Motor Installation
Hydrostatic Motor Start-Up
Tow Valves

DRIVE SYSTEM
DESCRIPTION
DIFFERENTIAL OIL LEVEL
LUBRICATING THE U-JOINTS
DRIVE SHAFT
Removing The Drive Shaft
Installing The Drive Shaft
REAR AXLE
Description
Removing The Rear Axle
Installing The Rear Axle
FRONT AXLE
Description
Removing The Front Axle
Installing The Front Axle
DISASSEMBLING AND ASSEMBLING AXLES
Removing Hubs
Installing Hubs
Removing The Differential Assembly
Removing The Ring Gear
Installing The Ring Gear
Removing Clutch Plates
Installing Clutch Plates
Explanation Of Assembly Procedure
Removing The Drop Gear And Pinion Shaft
Checking Differential Assembly End Play (WITHOUT Pinion Shaft Installed)
Installing The Pinion Shaft Bearings
Installing The Pinion Shaft
Setting Pinion Shaft position (Using Tool – Pinion Shaft NOT Installed)
Setting Pinion Bearing Pre-Load
Installing Differential Assembly & Checking end Play (Pinion Shaft Installed)
Checking Gear Backlash
PARKING BRAKE
Description
Adjusting The Parking Brake
Removing The Parking Brake Cable
Installing The Parking Brake Cable
Removing The Parking Brake Assembly From The Hydrostatic Motor
Installing The Parking Brake Assembly On The Hydrostatic Motor Housing

MAIN FRAME
OPERATOR CAB
REAR GRILL
Removing The Rear Grill
Installing The Rear Grill
FLOORPANELS
Removing The Floorpanels
Installing The Floorpanels
SEAT AND SEAT PLATE
Removing The Seat And Seat Plate
Installing The Seat And Seat Plate
FUEL TANK
Removing The Fuel Tank
Installing The Fuel Tank
DOORS
Removing The Rear door
Installing The Rear Door
Removing The Side Doors
Installing The Side Doors
DISASSEMBLING THE BOBCAT FORKLIFT
Seperating The Sections
Ball Stud & Race Assembly
Removing The Oscillating Link
ASSEMBLING THE BOBCAT FORKLIFT

VERTICAL MAST
TROUBLESHOOTING THE VERTICAL MAST
REMOVING THE VERTICAL MAST
INSTALLING THE VERTICAL MAST
INSPECTING THE VERTICAL MAST
REPLACING THE BRONZE BUSHING
REMOVING THE MOUNTING FRAME
INSTALLING THE MOUNTING FRAME
REMOVING THE CARRIAGE CHAINS
INSTALLING THE CARRIAGE CHAINS
ADJUSTING THE LIFT CARRIAGE
REMOVING THE LIFT CARRIAGE
INSTALLING THE LIFT CARRIAGE
ADJUSTING THE CARRIAGE ROLLERS
PALLET FORKS
Installing The Pallet Forks
Removing The Pallet Forks
Adjusting The Pallet Forks

ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
DESCRIPTION
Dash Panel
Wiring Diagrams
SERVICING THE ELECTRICAL SYSTEM
Cautions To Be Taken In Use Of The Alternator
General Servicing
Charging The Batteries
TROUBLESHOOTING THE ELECTRICAL SYSTEM
CHECKING THE BATTERIES
REPLACING THE BATTERIES
WIRING HARNESS DIODES
Description
Checking The Diodes
Replacing The Diodes
NEUTRAL START SAFETY SWITCH
Checking The Neutral Start Safety Switch
ALTERNATOR
Description
Adjusting Or Replacing The Alternator Belt
Checking Alternator Wiring
Checking Alternator Output
Checking The Regulator
Removing The Alternator
Disassembling The Alternator
Checking The Rotor
Checking The Stator
Checking Diode Trio
Checking Rectifier
Assembling And Installing The Alternator
STARTER
Description
Checking Starter
Removing Starter
Disassembling The Starter
Cleaning And Inspecting The Starter
Replacing The Brushes
Assembling The Starter
BACK-UP ALARM

ENGINE SERVICE
TROUBLESHOOTING
CHECKS & ADJUSTMENTS
Oil Pressure
Valve Clearance
Check Engine Compression
FUEL SYSTEM AND TIMING
Fuel Injection Pump
Removing The Fuel Injection Pump
Installing The Fuel Injection Pump
Timing The Fuel Injection Pump
Fuel Injector Nozzles
Removing Fuel Injector Nozzles
Checking The Fuel Injector Nozzles
Installing The Fuel Injector Nozzles
High Pressure Fuel Lines
Glow Plugs
ENGINE AND ATTACHING PARTS
Removing The Engine
Installing The Engine
Blower Housing Shield
Removal
Installation
Engine Coolant Radiator
Removal
Installation
Engine Blower Housing
Removal
Installation
Engine Muffler
Removal
Installation
Oil Cooler
Installing The Oil Cooler
Removing The Oil Cooler
CYLINDER HEAD
Removing The Cylinder Head
Removal Of The Valves
Reconditioning The Valves And Valve Seats
Installing Valve Guides
Checking Valve Springs
Combustion Chamber Inserts
Cylinder Head Inspection
Installation Of The Valves
Reconditioning The Rocker Arms
Disassembly
Checking
Assembly
Installing The Cylinder Head
RECONDITIONING THE ENGINE
Pistons And Connecting Rods
Removal
Disassembly
Inspection
Installation Of Piston To Connecting Rod
Installation Of Rings On The Piston
Installing Piston Assembly In The Engine Block
Cylinder Liners
Checking
Installation
Main Bearings
Removal
Installation
Crankshaft End Play
Crankshaft
Removal
Checking
Installation
Rear Main Bearing Oil Seal
TIMING CASE AND GEARS
Timing Case Cover
Removal
Installation
Front Seal
Removal
Installation
Idler Gear And Hub
Removal
Inspection
Installation
Camshaft Gear
Removal
Installation
Fuel Injection Pump Gear
Removal
Installation
Crankshaft Gear
Timing Case
Removal
Installation
Camshaft And Tappets
Removal
Inspection
Installation
LUBRICATION SYSTEM
Description Of The Lubrication System
Oil Pan
Removal
Installation
Oil Pump
Removal
Disassembly
Checking
Assembly
Installation
Oil Filter And Adapter Housing
Removal
Installation
COOLING SYSTEM
Alternator And Water Pump Belt
Water Pump
Removal
Installation
Thermostat
Removal
Testing The Thermostat
Installation
FLYWHEEL
Removal Of The Flywheel
Replace The Flywheel Ring Gear
Installation Of The Flywheel

TECHNICAL DATA
FORKLIFT SPECIFICATIONS
Specifications
Vertical Mast
Engine
Hydraulics
Electrical
Drive System
Capacities
Tires
ENGINE SPECIFICATIONS
Cylinder Head Dimensions
Pistons And Connecting Rod Dimensions
Cylinder Block And Liner Dimensions
Crankshaft And Main Bearing Dimensions
Timing Case, Camshaft And Drive Dimensions
Oil Pump Dimensions
Cooling System And Water Pump Dimensions
Fuel System Specifications
De-Rating For Altitude
Engine Torque
Grinding Specifications For Crankshaft
Crankshaft Regrind Data
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION
STANDARD TORQUE SPECIFICATIONS FOR BOLTS

ALPHABETICAL INDEX

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