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This 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
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 !!!!
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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
Bobcat 2000 Wheel Loader Service Manual - 6566180.pdf