Bobcat 2000 Loader Service Manual 6566180(6-12) – PDF DOWNLOAD
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Bobcat 2000 Loader Service Manual 6566180(6-12) – PDF DOWNLOAD
Language : English
Pages : 354
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat 2000 Loader Service Manual 6566180(6-12) – PDF DOWNLOAD
FOREWORD:
This manual gives instruction for correct servicing and adjustment of the Bobcat loader
and overhaul instructions of the drive system, loader hydraulic/hydrostatic system and
general main frame parts.
Refer to the Operator’s Manual for operating instructions (Starting Procedure, Daily
Checks, Bucket Operation, etc.).
A general inspection of the following items must be made whenever the loader has
had service or repair:
1. Check hydrulic fluid level, engine oil level and fuel supply.
2. lnspect for any sign of fuel, oil or hydraulic fluid leaks.
3. Lubricate the loader.
4. Check battery condition and cables.
5. lnspect air cleaner for damage or leaks. Check element and replace as needed.
6. Check electrical charging system.
7. Check the warning lights.
8. Check tires for wear and pressure.
9. Check the Bob-Tach attachment for condition. lnspect the wedges for damage or
wear.
10. lnspect Operator Cab, Seat Belt, Seat Bar, Safety Treads, Lights, Horn, Safety Signs
(Decals), Brake, etc.
11. lnspect for loose or broken parts or connections.
12. Operate the loader and check all functions.
13. lnform the Owner/Operator of any items that need service.
TABLE OF CONTENTS:
Bobcat 2000 Loader Service Manual 6566180(6-12) – PDF DOWNLOAD
MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 5
SAFETY INSTRUCTIONS 7
Safety Is your Responsibility 7
Before You Operate The Bobcat Loader 7
Safe Operation needs A Qualified Operator 8
FIRE PREVENTION 8
SERIAL NUMBER LOCATIONS 9
Loader Serial Number 9
Engine Serial Number Locations 9
ARRIVAL CONDITION REPORT 9
DELIVERY REPORT 9
BOBCAT LOADER IDENTIFICATION 10
PREVENTIVE MAINTENANCE 11
SERVICE SCHEDULE 13
LIFT ARM STOP 14
FRAME LOCK 14
LIFTING AND BLOCKING THE LOADER 14
REAR DOOR 15
Door Latch Adjustment 15
AIR CLEANER 15
FUEL SYSTEM 16
Filling The Fuel Tank 16
Fuel Filter 17
Removing Air From The Fuel System 18
ENGINE LUBRICATION SYSTEM 18
Engine Oil And Filter Replacement 19
ENGINE COOLING SYSTEM 20
Coolant Level 20
Coolant Replacement 20
ALTERNATOR BELT ADJUSTMENT 20
ELECTRICAL SYSTEM 20
Electrical System Service 21
Using An Extra Battery (Jump Starting) 21
Battery Replacement 23
HYDRAULIC / HYDROSTATIC SYSTEM 23
Hydraulic/Hydrostatic Fluid Reservoir 23
Checking And Adding Fluid 23
Hydraulic Fluid Replacement 24
Hydraulic / Hydrostatic Filter Replacement 24
SPARK ARRESTOR MUFFLER 25
FRONT & REAR AXLES 26
U-JOINTS 27
TIRE MAINTENANCE 27
Wheel Nuts 27
LOADER LUBRICATION 28
BACK-UP ALARM 29
OPERATOR CAB 29
HYDRAULIC SYSTEM 31
HYDRAULIC / HYDROSTATIC SCHEMATICS 34
TROUBLESHOOTING 55
HYDRAULIC SYSTEM INFORMATION 56
37° Flare Connections 56
Straight Thread O-Ring Fitting 56
Tubelines And Hoses 56
PORT BLOCK SERVICE 57
Bronze (40 Micron) Filter Replacement 57
Neutral By-Pass Valve Replacement 58
Cold Oil By-Pass Valve Replacement 58
OIL RESERVOIR 58
Oil Reservoir Removal 58
Oil Reservoir Installation 59
HYDRAULIC CONTROL VALVE (S/N 12999 & BELOW) 59
Hydraulic Control Valve Removal 59
Hydraulic Control Valve Disassembly 60
Inlet Section 61
Tilt Section 61
Lift Section 63
Auxiliary Section (For Older Style Control Valves) 66
Auxiliary Section (For Control Valves Equipped With Adjustable Detent) 68
Auxiliary Detent Adjustment 70
Hydraulic Control Valve Assembling 71
Hydraulic Control Valve Installation 71
HYDRAULIC CONTROL VALVE (S/N 13001 & ABOVE – MELROE VALVE) 72
Hydraulic Control Valve Removal 72
Hydraulic Control Valve Disassembly 73
Hydraulic Control Valve Inspection 76
Hydraulic Control Valve Assembling 76
Hydraulic Control Valve Installation 78
HYDRAULIC MAIN RELIEF VALVE 78
Hydraulic Main Relief Valve Testing 78
Hydraulic Main Relief Valve Replacement 79
Hydraulic Main Relief Valve Adjustment (S/N 12999 & Below) 80
Hydraulic Main Relief Valve Cleaning (S/N 13001 & Above) 80
Hydraulic Main Relief Valve Adjustment (S/N 13001 & Above) 80
HYDRAULIC PUMP 81
Checking Hydraulic Pump Pressure 81
Hydraulic Pump Removal 82
Hydraulic Pump Disassembly 82
Hydraulic Pump Inspection 83
Hydraulic Pump Assembling 83
Hydraulic Pump Installation 84
Checking Steering Relief Pressure 84
HYDRAULIC CYLINDERS 85
Checking Lift And Tilt Cylinder Seals 85
Checking Steering Cylinder Seals 86
Lift Cylinder Removal 86
Lift Cylinder Installation 87
Tilt Cylinder Removal 87
Tilt Cylinder Installation 88
Steering Cylinder Removal 88
Steering Cylinder Installation 89
Hydraulic Cylinder Disassembly 89
Hydraulic Cylinder Assembly 92
STEERING CONTROL VALVE 94
Steering Control Valve Removal 94
Steering Control Valve Disassembly 95
Steering Control Valve Inspection 97
Steering Control Valve Assembling 98
Steering Control Valve Installation 102
HYDROSTATIC SYSTEM 103
TROUBLESHOOTING 105
SERVO CONTROL 107
Servo Control Neutral Adjustment 107
Servo Control Removal 108
Servo Control Disassembly 109
Servo Control Assembling 110
Servo Control Installation (S/N 13033 & Below) 110
Servo Control Installation (S/N 13034 & Above) 111
FOOT PEDAL, PEDAL LOCK SYSTEM AND CENTERING MECHANISM 112
Foot Pedal Angle Adjustment 112
Seat Bar Assembly (S/N 13092 & Above) 113
Pedal Lock Cable 113
Centering Mechanism Removal 114
Centering Mechanism Spring Adjustment 115
S/N 13091 & Below 115
S/N 13092 & Above 115
Centering Mechanism Spring Replacement 116
S/N 13091 & Below 116
S/N 13092 & Above 117
Centering Mechanism Installation 118
Checking The Neutral Safety Switch 118
Neutral Safety Switch Adjustment 119
Micro Switch Adjustment 120
CHARGE PRESSURE AND REPLENISHING VALVES 122
Checking Charge Pressure 122
Checking Orifice In Charge Tubeline 122
Replenishing Valves 123
HYDROSTATIC PUMP 124
Hydrostatic Pump Removal 124
Hydrostatic Pump Disassembly 126
Hydrostatic Pump Inspection 129
Hydrostatic Pump Assembling 131
Hydrostatic Pump Installation On The Manifold Block 136
Hydrostatic Pump Installation 137
Hydrostatic Pump Start-Up Procedure 139
HYDROSTATIC MOTOR 140
Hydrostatic Motor Removal 140
Hydrostatic Motor Disassembly 141
Hydrostatic Motor Inspection 144
Hydrostatic Motor Assembly 145
Manifold block Disassembly 148
Manifold Block Assembling 148
Hydrostatic Motor Installation 148
Hydrostatic Motor Start-Up 149
Emergency Tow Valve 150
DRIVE SYSTEM 151
TROUBLESHOOTING THE DRIVE SYSTEM 153
DRIVE SHAFT 153
Drive Shaft Removal 153
Drive Shaft Installation 154
REAR AXLE 154
Rear Axle Removal 154
Rear Axle Installation 154
FRONT AXLE 155
Front Axle Removal 155
Front Axle Installation 155
AXLE AND DIFFERENTIAL DISASSEMBLY AND ASSEMBLY 156
Hub Removal 156
Hub Installation 157
Differential Assembly Removal 160
Ring Gear Removal 161
Ring Gear Installation 163
Clutch Plate Removal 163
Clutch Plate Installation 164
Drop Gear And Pinion Shaft Removal 165
Assembling Procedure Explanation 166
Checking Differential Assembly End Play (WITHOUT Pinion Shaft Installed) 167
Pinion Shaft Bearing Installation 168
Pinion Shaft Installation 169
Setting Pinion Shaft Position (Using Tool – Pinion Shaft NOT Installaed) 170
Setting Pinion Bearing Pre-Load 171
Differential Assembly Installation & Checking End Play (Pinion Shaft Installed) 173
Checking Gear Backlash 176
PARKING BRAKE (S/N 13060 & BELOW) 177
Description 177
Parking Brake Adjustment 177
Parking Brake Cable Removal 178
Parking Brake Cale Installation 178
Parking Brake Removal Fromm The Hydrostatic Motor 178
Parking Brake Installation On The Hydrostatic Motor 179
HYDRAULIC BRAKE (DUSCO) (S/N 13061 & ABOVE) 179
Description 179
Brake Removal (Dusco) 179
Brake Servicing (Dusco) 179
Brake Installation (Dusco) 181
Removing Air From The Brake System (Dusco) 182
Brake Valve Removal 182
Brake Valve Service 182
Brake Valve Installation 183
BRAKE (SY*TEC) 183
Removal And Installation 183
Disassembly And Assembly 183
MAIN FRAME 187
OPERATOR CAB 189
Operator Cab Removal 189
Operator Cab Installation 190
BOB-TACH 190
Checking Bob-Tach Wedges 191
Bob-Tach Removal 191
Bob-Tach Installation 192
FLOORPANEL 193
Floorpanel Removal 193
Floorpanel Installation 193
SEAT AND SEAT PLATE 193
Seat And Seat Plate Removal 193
Seat And Seat Plate Installation 194
FUEL TANK 194
Fuel Tank Removal 194
Fuel Tank Installation 195
DOORS 195
Rear Door Removal 195
Rear Door Installation 195
Side Door Removal 195
Side Door Installation 195
LOADER DISASSEMBLY AND ASSEMBLY 196
Seperating The Sections 196
Connecting The Sections 198
LIFT ARMS 199
Lift Arm Removal 199
Lift Arm Installation 199
ELECTRICAL SYSTEM 201
ELECTRICAL SCHEMATICS 203
ELECTRICAL SYSTEM 211
Description 211
TROUBLESHOOTING 211
BATTERIES 212
Checking The Batteries 212
Battery Safety Procedures 212
DIODES 213
Checking The Diodes 213
Diode Replacement 214
ALTERNATOR 214
Checking The Alternator 214
Alternator Removal 215
Alternator Service 216
Alternator Installation 217
STARTER 217
Checking The Starter 217
Starter Removal 218
Starter Service 218
Starter Installation 220
ENGINE SERVICE 221
ENGINE SERVICE (S/N 12999 & BELOW) 223
TROUBLESHOOTING 225
CHECKS AND ADJUSTMENTS 226
Oil Pressure 226
Valve Clearance 227
Engine Compression 227
Servicing The Air Cleaner 227
Throttle Linkage Adjustment 228
FUEL SYSTEM AND TIMING 228
FUEL FILTERS 229
Replacing The Final Fuel Filter Element 229
Cleaning The Water Filter Trap 229
REMOVING AIR FROM THE FUEL SYSTEM 229
FUEL LIFT PUMP 230
Checking The Lift Pump 230
Removing The Lift Pump 230
Installing The Lift Pump 230
FUEL INJECTION PUMP 230
Removing The Fuel Injection Pump 231
Installing The Fuel Injection Pump 231
Timing The Fuel Injection Pump (Using Dial Indicator) 231
Timing The Fuel Injection Pump (Using The Timing Tool) 232
Checking The Timing Mark On The Flange Injection Pump 233
FUEL INJECTOR NOZZLES 234
Removing Fuel Injector Nozzles 234
Checking Fuel Injector Nozzles 234
Installing Fuel Injector Nozzles 235
ENGINE 236
Removing The Engine 236
Installing The Engine 237
BLOWER HOUSING SHIELD 238
Removing The Blower Housing Shield 238
Installing The Blower Housing Shield 238
RADIATOR AND OIL COOLER ASSEMBLY 238
Cleaning Radiator And Oil Cooler Assembly 238
Removing Radiator And Oil Cooler Assembly 238
Installing Radiator And Oil Cooler Assembly 238
ENGINE BLOWER HOUSING 239
Installing The Engine Blower Housing 239
SPARK ARRESTOR MUFFLER 239
Cleaning The Muffler 239
Removing The Muffler 240
Installing The Muffler 240
CYLINDER HEAD 240
Removing The Cylinder Head 240
Removing Valves 241
Reconditioning The Valves And Valve SEATS 241
Installing Valve Guides 241
Checking Valve Springs 242
Combustion Chamber Inserts 243
Aligning Cylinder Head Surfaces 243
Installing Valves 243
Disassembling The Rocker Arms 244
Checking The Rocker Arms 245
Assembling The Rocker Arms 245
Installing The Cylinder Head 245
RECONDITIONING THE ENGINE 246
PISTONS AND CONNECTING RODS 246
Removing Pistons 246
Disassembling Pistons 247
Inspecting The Pistons 247
Installing Pistons To Connecting Rod 248
Installing Piston Assembly In The Engine Block 249
Installing New Pistons 249
CYLINDER LINERS 250
Checking Liners 250
Installing Liners 250
MAIN BEARINGS 251
Removing The Main Bearings 251
Installing The Main Bearings 251
Crankshaft End Play 252
CRANKSHAFT 252
Removing The Crankshaft 252
Checking The Crankshaft 253
Installing The Crankshaft 253
REAR MAIN BEARING OIL SEAL 254
Installing The Oil Seal 254
TIMING CASE AND GEARS 255
Removing The Timing Case Cover 255
Installing The Timing Case Cover 255
Removing The Front Seal 255
Installing The Front Seal 255
Removing The Idler Gear and Hub 256
Inspecting The Idler Gear And Hub 256
Installing The Idler Gear And Hub 256
Removing The Camshaft Gear 257
Installing The Camshaft Gear 257
Removing The Fuel Injection Pump 258
Installing The Fuel Injection Pump 258
Removing The Crankshaft Gear 258
Removing The Timing Case 258
Installing The Timing Case 258
Removing Camshaft And Tappets 259
Inspecting Camshaft And Tappets 259
Installing Camshaft And Tappets 260
LUBRICATION SYSTEM 260
Description Of The Lubrication System 260
Checking Engine Oil 261
Replacing Engine Oil And Filter 261
OIL PAN 261
Removing The Oil Pan 262
Installing The Oil Pan 262
OIL PUMP 262
Removing The Oil Pump 262
Disassembling The Oil Pump 262
Checking The Oil Pump 263
Assembling The Oil Pump 263
Installing The Oil Pump 263
OIL FILTER 264
Removing The Oil Filter 264
Disassembling The Oil Filter 264
COOLING SYSTEM 264
Belt For The Alternator And Water Pump 264
Coolant Level 264
Removing Coolant From The Cooling System 264
WATER PUMP 265
Removing The Water Pump 265
Disassembling The Water Pump 265
Checking The Water Pump 265
Assembling The Water Pump 265
Installing The Water Pump 266
THERMOSTAT 266
Removing The Thermostat 266
Checking The Thermostat 266
Installing The Thermostat 266
FLYWHEEL 267
Removing The Flywheel 267
Replacing The Flywheel Ring Gear 267
Installing The Flywheel 267
ENGINE SERVICE (S/N 13001 & ABOVE) 269
TROUBLSHOOTING 271
CHECKS AND ADJUSTMENTS 273
Serial Number 273
Oil Pressure 273
Valve Clearance 273
Check Engine Compression 273
FUEL SYSTEM AND TIMING 274
Fuel Filter 274
Removing Air From The Fuel System 274
Fuel Injection Pump 275
Removing The Fuel Injection Pump 275
Installing The Fuel Injection Pump 276
Timing The Fuel Injection Pump 277
Fuel Injector Nozzles 278
Removing The Fuel Injector Nozzles 279
Checking The Fuel Injector Nozzles 279
Installing The Fuel Injector Nozzles 280
High Pressure Fuel Lines 280
Glow Plugs 281
ENGINE AND ATTACHING PARTS 282
Removing The Engine 282
Installing The Engine 283
Blower Housing Shield 284
Removal 284
Installation 284
Engine Coolant Radiator 284
Removal 284
Installation 285
Engine Blower Housing 285
Removal 285
Installation 285
Engine Muffler 286
Removal 286
Installation 286
Oil Cooler 286
Removing The Oil Cooler 286
Installing The Oil cooler 286
CYLINDER HEAD 287
Removing The Cylinder Head 287
Removal Of The Valves 287
Reconditioning The Valves And Valve Seats 288
Installing The Valve Guides 288
Checking Valve Springs 289
Combustion Chamber Inserts 290
Cylinder Head Inspection 290
Installation Of The Valves 291
Reconditioning The Rocker Arms 291
Disassembly 291
Checking 292
Assembly 292
Installing The Cylinder Head 292
RECONDITIONING THE ENGINE 294
Pistons And Connecting Rods 294
Removal 294
Disassembly 295
Inspection 295
Installation Of Piston To Connecting Rod 296
Installation Of Rings On The Piston 296
Installing Piston Assembly In The Engine Block 297
Cylinder Liners 297
Checking 297
Installation 298
Main Bearings 299
Removal 299
Installation 300
Crankshaft End Play 300
Crankshaft 300
Removal 300
Checking 301
Installation 302
Rear Main Bearing Oil Seal 302
TIMING CASE AND GEARS 303
Timing Case Cover 303
Removal 303
Installation 303
Front Seal 304
Removal 304
Installation 304
Idler Gear And Hub 304
Removal 304
Inspection 305
Installation 305
Camshaft Gear 305
Removal 306
Installation 306
Fuel Injection Pump Gear 306
Removal 306
Installation 306
Crankshaft Gear 307
Timing Case 307
Removal 307
Installation 307
Camshaft And Tappets 308
Removal 308
Inspection 309
Installation 309
LUBRICATION SYSTEM 309
Description Of The Lubrication System 309
Oil Pan 310
Removal 310
Installation 310
Oil Pump 311
Removal 311
Disassembly 311
Checking 312
Assembly 313
Installation 313
Oil Filter And Adapter Housing 314
Removal 314
Installation 314
COOLING SYSTEM 314
Alternator And Water Pump Belt 314
Water Pump 314
Removal 314
Installation 315
Thermostat 315
Removal 315
Testing The Thermostat 315
Installation 315
FLYWHEEL 316
Removal Of The Flywheel 316
Replacement Of The Flywheel Ring Gear 316
Installation Of The Flywheel 316
TECHNICAL DATA (S/N 12999 & BELOW) 317
LOADER SPECIFICATIONS 319
Specifications 319
Engine 319
Loader Hydraulics 320
Electrical 320
Drive System 320
Capacities 320
Tires 320
ENGINE SPECIFICATIONS 321
Cylinder Head Dimensions 321
pistons And Connecting Rod Dimensions 322
Cylinder Block And Liners Dimensions 323
Crankshaft And Main Bearings Dimesions 323
Timing Cse, Camshaft And Drive Dimensions 324
Oil Pump Dimensions 325
Cooling System And Water Pump Dimensions 326
Fuel System Specifications 326
De-Rating For Altitude 327
Engine Bolt Torque 327
Grinding Specifications For Crankshaft 328
Crankshaft Regrinding Data 328
HYDRAULIC SYSTEM 329
HYDROSTATIC SYSTEM 329
DECIMAL AND MILLIMETER EQUIVALENTS 330
U S TO METRIC CONVERSION 330
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 331
TECHNICAL DATA (S/N 13001 & ABOVE) 333
LOADER SPECIFICATIONS 335
Specifications 335
Engine 335
Loader Hydraulics 336
Electrical 336
Drive System 336
Capacities 336
Tires 336
ENGINE SPECIFICATIONS 337
Cylinder Head Dimensions 337
Pistons And Connecting Rod Dimensions 337
Cylinder Block And Liner Dimensions 338
Crankshaft And Main Bearing Dimensions 339
Timing Case, Camshaft And Drive Dimensions 339
Oil Pump Dimensions 339
Cooling System And Water Pump Dimensions 340
Fuel System Specifications 340
De-Rating For Altitude 340
Engine Torque 341
Grinding Specifications For Crankshaft 342
Crankshaft Regrind Data 342
ALPHABETICAL INDEX 343
SERVICE MANUAL REVISIONS 347
2000-1 347
2000-2 349
2000-3 351
2000-4 353
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