Bobcat 2000 Wheel Loader Repair Service Manual - 6566180

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This workshop repair service manual PDF download for the 2000 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 Loader 2000


TABLE OF CONTENTS :

SAFETY INSTRUCTIONS 
FIRE PREVENTION 
SERIAL NUMBER LOCATIONS 
ARRIVAL CONDITION REPORT 
DELIVERY REPORT 
BOBCAT LOADER IDENTIFICATION 
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
MAIN FRAME 
ELECTRICAL SYSTEM 
ENGINE SERVICE 
SPECIFICATIONS 
TECHNICAL DATA 
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6566180 (4-85)
Total Pages : 352


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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Bobcat 2000 (1983-1987) Wheel Loader
Bobcat 2000 Articulated

MAINTENANCE SAFETY
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
        Safety Is your Responsibility
        Before You Operate The Bobcat Loader
        Safe Operation needs A Qualified Operator
    FIRE PREVENTION
    SERIAL NUMBER LOCATIONS
        Loader Serial Number
        Engine Serial Number Locations
    ARRIVAL CONDITION REPORT
    DELIVERY REPORT
    BOBCAT LOADER IDENTIFICATION
    
PREVENTIVE MAINTENANCE
    SERVICE SCHEDULE
    LIFT ARM STOP
    FRAME LOCK
    LIFTING AND BLOCKING THE LOADER
    REAR DOOR
        Door Latch Adjustment
    AIR CLEANER
    FUEL SYSTEM
        Filling The Fuel Tank
        Fuel Filter
        Removing Air From The Fuel System
    ENGINE LUBRICATION SYSTEM
        Engine Oil And Filter Replacement
    ENGINE COOLING SYSTEM
        Coolant Level
        Coolant Replacement
    ALTERNATOR BELT ADJUSTMENT
    ELECTRICAL SYSTEM
        Electrical System Service
        Using An Extra Battery (Jump Starting)
        Battery Replacement
    HYDRAULIC / HYDROSTATIC SYSTEM
        Hydraulic/Hydrostatic Fluid Reservoir
        Checking And Adding Fluid
        Hydraulic Fluid Replacement
        Hydraulic / Hydrostatic Filter Replacement
    SPARK ARRESTOR MUFFLER
    FRONT & REAR AXLES
    U-JOINTS
    TIRE MAINTENANCE
        Wheel Nuts
    LOADER LUBRICATION
    BACK-UP ALARM
    OPERATOR CAB
    
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    TROUBLESHOOTING
    HYDRAULIC SYSTEM INFORMATION
        37° Flare Connections
        Straight Thread O-Ring Fitting
        Tubelines And Hoses
    PORT BLOCK SERVICE
        Bronze (40 Micron) Filter Replacement
        Neutral By-Pass Valve Replacement
        Cold Oil By-Pass Valve Replacement
    OIL RESERVOIR
        Oil Reservoir Removal
        Oil Reservoir Installation
    HYDRAULIC CONTROL VALVE (S/N 12999 & BELOW)
        Hydraulic Control Valve Removal
        Hydraulic Control Valve Disassembly
        Inlet Section
        Tilt Section
        Lift Section
        Auxiliary Section (For Older Style Control Valves)
        Auxiliary Section (For Control Valves Equipped With Adjustable Detent)
        Auxiliary Detent Adjustment
        Hydraulic Control Valve Assembling
        Hydraulic Control Valve Installation
    HYDRAULIC CONTROL VALVE (S/N 13001 & ABOVE - MELROE VALVE)
        Hydraulic Control Valve Removal
        Hydraulic Control Valve Disassembly
        Hydraulic Control Valve Inspection
        Hydraulic Control Valve Assembling
        Hydraulic Control Valve Installation
    HYDRAULIC MAIN RELIEF VALVE
        Hydraulic Main Relief Valve Testing
        Hydraulic Main Relief Valve Replacement
        Hydraulic Main Relief Valve Adjustment (S/N 12999 & Below)
        Hydraulic Main Relief Valve Cleaning (S/N 13001 & Above)
        Hydraulic Main Relief Valve Adjustment (S/N 13001 & Above)
    HYDRAULIC PUMP
        Checking Hydraulic Pump Pressure
        Hydraulic Pump Removal
        Hydraulic Pump Disassembly
        Hydraulic Pump Inspection
        Hydraulic Pump Assembling
        Hydraulic Pump Installation
        Checking Steering Relief Pressure
    HYDRAULIC CYLINDERS
        Checking Lift And Tilt Cylinder Seals
        Checking Steering Cylinder Seals
        Lift Cylinder Removal
        Lift Cylinder Installation
        Tilt Cylinder Removal
        Tilt Cylinder Installation
        Steering Cylinder Removal
        Steering Cylinder Installation
        Hydraulic Cylinder Disassembly
        Hydraulic Cylinder Assembly
    STEERING CONTROL VALVE
        Steering Control Valve Removal
        Steering Control Valve Disassembly
        Steering Control Valve Inspection
        Steering Control Valve Assembling
        Steering Control Valve Installation
        
HYDROSTATIC SYSTEM
    TROUBLESHOOTING
    SERVO CONTROL
        Servo Control Neutral Adjustment
        Servo Control Removal
        Servo Control Disassembly
        Servo Control Assembling
        Servo Control Installation (S/N 13033 & Below)
        Servo Control Installation (S/N 13034 & Above)
    FOOT PEDAL, PEDAL LOCK SYSTEM AND CENTERING MECHANISM
        Foot Pedal Angle Adjustment
        Seat Bar Assembly (S/N 13092 & Above)
        Pedal Lock Cable
        Centering Mechanism Removal
        Centering Mechanism Spring Adjustment
            S/N 13091 & Below
            S/N 13092 & Above
        Centering Mechanism Spring Replacement
            S/N 13091 & Below
            S/N 13092 & Above
        Centering Mechanism Installation
        Checking The Neutral Safety Switch
        Neutral Safety Switch Adjustment
        Micro Switch Adjustment
    CHARGE PRESSURE AND REPLENISHING VALVES
        Checking Charge Pressure
        Checking Orifice In Charge Tubeline
        Replenishing Valves
    HYDROSTATIC PUMP
        Hydrostatic Pump Removal
        Hydrostatic Pump Disassembly
        Hydrostatic Pump Inspection
        Hydrostatic Pump Assembling
        Hydrostatic Pump Installation On The Manifold Block
        Hydrostatic Pump Installation
        Hydrostatic Pump Start-Up Procedure
    HYDROSTATIC MOTOR
        Hydrostatic Motor Removal
        Hydrostatic Motor Disassembly
        Hydrostatic Motor Inspection
        Hydrostatic Motor Assembly
        Manifold block Disassembly
        Manifold Block Assembling
        Hydrostatic Motor Installation
        Hydrostatic Motor Start-Up
        Emergency Tow Valve
        
DRIVE SYSTEM
    TROUBLESHOOTING THE DRIVE SYSTEM
    DRIVE SHAFT
        Drive Shaft Removal
        Drive Shaft Installation
    REAR AXLE
        Rear Axle Removal
        Rear Axle Installation
    FRONT AXLE
        Front Axle Removal
        Front Axle Installation
    AXLE AND DIFFERENTIAL DISASSEMBLY AND ASSEMBLY
        Hub Removal
        Hub Installation
        Differential Assembly Removal
        Ring Gear Removal
        Ring Gear Installation
        Clutch Plate Removal
        Clutch Plate Installation
        Drop Gear And Pinion Shaft Removal
        Assembling Procedure Explanation
        Checking Differential Assembly End Play (WITHOUT Pinion Shaft Installed)
        Pinion Shaft Bearing Installation
        Pinion Shaft Installation
        Setting Pinion Shaft Position (Using Tool - Pinion Shaft NOT Installaed)
        Setting Pinion Bearing Pre-Load
        Differential Assembly Installation & Checking End Play (Pinion Shaft Installed)
            Checking Gear Backlash
    PARKING BRAKE (S/N 13060 & BELOW)
        Description
        Parking Brake Adjustment
        Parking Brake Cable Removal
        Parking Brake Cale Installation
        Parking Brake Removal Fromm The Hydrostatic Motor
        Parking Brake Installation On The Hydrostatic Motor
    HYDRAULIC BRAKE (DUSCO) (S/N 13061 & ABOVE)
        Description
        Brake Removal (Dusco)
        Brake Servicing (Dusco)
        Brake Installation (Dusco)
        Removing Air From The Brake System (Dusco)
        Brake Valve Removal
        Brake Valve Service
        Brake Valve Installation
    BRAKE (SY*TEC)
        Removal And Installation
        Disassembly And Assembly
        
MAIN FRAME
    OPERATOR CAB
        Operator Cab Removal
        Operator Cab Installation
    BOB-TACH
        Checking Bob-Tach Wedges
        Bob-Tach Removal
        Bob-Tach Installation
    FLOORPANEL
        Floorpanel Removal
        Floorpanel Installation
    SEAT AND SEAT PLATE
        Seat And Seat Plate Removal
        Seat And Seat Plate Installation
    FUEL TANK
        Fuel Tank Removal
        Fuel Tank Installation
    DOORS
        Rear Door Removal
        Rear Door Installation
        Side Door Removal
        Side Door Installation
    LOADER DISASSEMBLY AND ASSEMBLY
        Seperating The Sections
        Connecting The Sections
    LIFT ARMS
        Lift Arm Removal
        Lift Arm Installation
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM
        Description
    TROUBLESHOOTING
    BATTERIES
        Checking The Batteries
        Battery Safety Procedures
    DIODES
        Checking The Diodes
        Diode Replacement
    ALTERNATOR
        Checking The Alternator
        Alternator Removal
        Alternator Service
        Alternator Installation
    STARTER
        Checking The Starter
        Starter Removal
        Starter Service
        Starter Installation
        
ENGINE SERVICE
    ENGINE SERVICE (S/N 12999 & BELOW)
        TROUBLESHOOTING
        CHECKS AND ADJUSTMENTS
            Oil Pressure
            Valve Clearance
            Engine Compression
            Servicing The Air Cleaner
            Throttle Linkage Adjustment
        FUEL SYSTEM AND TIMING
        FUEL FILTERS
            Replacing The Final Fuel Filter Element
            Cleaning The Water Filter Trap
        REMOVING AIR FROM THE FUEL SYSTEM
        FUEL LIFT PUMP
            Checking The Lift Pump
            Removing The Lift Pump
            Installing The Lift Pump
        FUEL INJECTION PUMP
            Removing The Fuel Injection Pump
            Installing The Fuel Injection Pump
            Timing The Fuel Injection Pump (Using Dial Indicator)
            Timing The Fuel Injection Pump (Using The Timing Tool)
            Checking The Timing Mark On The Flange Injection Pump
        FUEL INJECTOR NOZZLES
            Removing Fuel Injector Nozzles
            Checking Fuel Injector Nozzles
            Installing Fuel Injector Nozzles
        ENGINE
            Removing The Engine
            Installing The Engine
        BLOWER HOUSING SHIELD
            Removing The Blower Housing Shield
            Installing The Blower Housing Shield
        RADIATOR AND OIL COOLER ASSEMBLY
            Cleaning Radiator And Oil Cooler Assembly
            Removing Radiator And Oil Cooler Assembly
            Installing Radiator And Oil Cooler Assembly
        ENGINE BLOWER HOUSING
            Installing The Engine Blower Housing
        SPARK ARRESTOR MUFFLER
            Cleaning The Muffler
            Removing The Muffler
            Installing The Muffler
        CYLINDER HEAD
            Removing The Cylinder Head
            Removing Valves
            Reconditioning The Valves And Valve SEATS
            Installing Valve Guides
            Checking Valve Springs
            Combustion Chamber Inserts
            Aligning Cylinder Head Surfaces
            Installing Valves
            Disassembling The Rocker Arms
            Checking The Rocker Arms
            Assembling The Rocker Arms
            Installing The Cylinder Head
        RECONDITIONING THE ENGINE
        PISTONS AND CONNECTING RODS
            Removing Pistons
            Disassembling Pistons
            Inspecting The Pistons
            Installing Pistons To Connecting Rod
            Installing Piston Assembly In The Engine Block
            Installing New Pistons
        CYLINDER LINERS
            Checking Liners
            Installing Liners
        MAIN BEARINGS
            Removing The Main Bearings
            Installing The Main Bearings
            Crankshaft End Play
        CRANKSHAFT
            Removing The Crankshaft
            Checking The Crankshaft
            Installing The Crankshaft
        REAR MAIN BEARING OIL SEAL
            Installing The Oil Seal
        TIMING CASE AND GEARS
            Removing The Timing Case Cover
            Installing The Timing Case Cover
            Removing The Front Seal
            Installing The Front Seal
            Removing The Idler Gear and Hub
            Inspecting The Idler Gear And Hub
            Installing The Idler Gear And Hub
            Removing The Camshaft Gear
            Installing The Camshaft Gear
            Removing The Fuel Injection Pump
            Installing The Fuel Injection Pump
            Removing The Crankshaft Gear
            Removing The Timing Case
            Installing The Timing Case
            Removing Camshaft And Tappets
            Inspecting Camshaft And Tappets
            Installing Camshaft And Tappets
        LUBRICATION SYSTEM
            Description Of The Lubrication System
            Checking Engine Oil
            Replacing Engine Oil And Filter
        OIL PAN
            Removing The Oil Pan
            Installing The Oil Pan
        OIL PUMP
            Removing The Oil Pump
            Disassembling The Oil Pump
            Checking The Oil Pump
            Assembling The Oil Pump
            Installing The Oil Pump
        OIL FILTER
            Removing The Oil Filter
            Disassembling The Oil Filter
        COOLING SYSTEM
            Belt For The Alternator And Water Pump
            Coolant Level
            Removing Coolant From The Cooling System
        WATER PUMP
            Removing The Water Pump
            Disassembling The Water Pump
            Checking The Water Pump
            Assembling The Water Pump
            Installing The Water Pump
        THERMOSTAT
            Removing The Thermostat
            Checking The Thermostat
            Installing The Thermostat
        FLYWHEEL
            Removing The Flywheel
            Replacing The Flywheel Ring Gear
            Installing The Flywheel
    ENGINE SERVICE (S/N 13001 & ABOVE)
        TROUBLSHOOTING
        CHECKS AND ADJUSTMENTS
            Serial Number
            Oil Pressure
            Valve Clearance
            Check Engine Compression
        FUEL SYSTEM AND TIMING
            Fuel Filter
            Removing Air From The Fuel System
            Fuel Injection Pump
            Removing The Fuel Injection Pump
            Installing The Fuel Injection Pump
            Timing The Fuel Injection Pump
            Fuel Injector Nozzles
            Removing The 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
                Removing The Oil Cooler
                Installing The Oil cooler
        CYLINDER HEAD
            Removing The Cylinder Head
            Removal Of The Valves
            Reconditioning The Valves And Valve Seats
            Installing The 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
            Replacement Of The Flywheel Ring Gear
            Installation Of The Flywheel
            
TECHNICAL DATA (S/N 12999 & BELOW)
    LOADER SPECIFICATIONS
        Specifications
        Engine
        Loader Hydraulics
        Electrical
        Drive System
        Capacities
        Tires
    ENGINE SPECIFICATIONS
        Cylinder Head Dimensions
        pistons And Connecting Rod Dimensions
        Cylinder Block And Liners Dimensions
        Crankshaft And Main Bearings Dimesions
        Timing Cse, Camshaft And Drive Dimensions
        Oil Pump Dimensions
        Cooling System And Water Pump Dimensions
        Fuel System Specifications
        De-Rating For Altitude
        Engine Bolt Torque
        Grinding Specifications For Crankshaft
        Crankshaft Regrinding Data
    HYDRAULIC SYSTEM
    HYDROSTATIC SYSTEM
    DECIMAL AND MILLIMETER EQUIVALENTS
    U.S. TO METRIC CONVERSION
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS
    
TECHNICAL DATA (S/N 13001 & ABOVE)
    LOADER SPECIFICATIONS
        Specifications
        Engine
        Loader 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
        
ALPHABETICAL INDEX

SERVICE MANUAL REVISIONS
    2000-1
    2000-2
    2000-3
    
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