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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