Bobcat 2000 RTF Loader Service Manual 6566662 – PDF DOWNLOAD

Description

Bobcat 2000 RTF Loader Service Manual 6566662 – PDF DOWNLOAD

FILE DETAILS:

Bobcat 2000 RTF Loader Service Manual 6566662 – PDF DOWNLOAD

Language : English
Pages : 252
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Bobcat 2000 RTF Loader Service Manual 6566662 – PDF DOWNLOAD

The Rough Terrain Forklift is a highly maneuverable and compact machine. In operation, it is rugged and useful under a wide variety of conditions. This presents an operator with hazards which are common for off-highway, rough-terrain applications but are not unique for use of the Bobcat Forklifts.

• The machine has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill so the machine must be used with adequate ventilation. The machine must not be used in space with explosive dusts or gases or so that the engine exhaust contacts flammable material.
• The machine has a spark arrestor muffler which is required for operation in certain areas. For machine applications, the dealer recommends the capabilities and restrictions of the machine and attachments for each application use. The dealer demonstrates the safe operation of the machine according to the manufacturer’s instructional materials which are also available to all operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for rated capacity and secure fastening to the machine. For each model machine, the user must check with the dealer or manufacturer’s literature to identify each bucket or attachment for safe loads of materials of specified densities.

The following publications provide information on the safe use of the machine and attachments:

The dealer and owner/operator review the recommended uses of the machine and attachments at the time of delivery of the machine. If change of the use of the machine occurs in the future, the owner/operator must remember to ask the dealer for recommendations on the new use of the machine.

TABLE OF CONTENTS:

Bobcat 2000 RTF Loader Service Manual 6566662 – PDF DOWNLOAD

WARNINGS 2
SAFETY NSTRUCTIONS 3
Safety Is Your Responsibility 3
Safe Operation Needs A Qualified Operator 4
CONTENTS 5
FOREWORD 5
PREVENTIVE MAINTENANCE 7
FRAME LOCK 9
LIFTING AND BLOCKING THE BOBCAT FORKLIFT 9
SERIAL NUMBER LOCATIONS 10
Machine Serial Number 10
Engine Serial Number 10
Vertical Mast Serial Number 10
Axle Serial Numbers 10
DELIVERY REPORT 10
SERVICE SCHEDULE 11
ENGINE SERICE 12
ADJUSTING THE DOOR LATCH 12
AIR CLEANER SERVICE 12
FUEL SYSTEM 13
Removing Air From The Fuel System 14
Fuel System Service 13
Fuel Filter 14
ENGINE LUBRICATION SYSTEM 15
Replacement Of Engine Oil And Filter 16
ENGINE COOLING SYSTEM 17
Coolant Level 17
Removing Coolant From The Cooling System 17
ALTERNATOR BELT 17
ELECTRICAL SYSTEM 17
Operator Guard Electrical Circuitry 18
Engine Electrical Circuitry 19
Using An Extra Battery (Booster Starting) 20
New Battery Installation 21
HYDRAULIC/HYDROSTATIC SYSTEM 22
Hydraulic/Hydrostatic Fluid Reservoir 22
Checking And Adding Hydraulic/Hydrostatic Fluid 24
Replacement Of The Hydraulic/Hydrostatic Filter 24
FRONT & REAR AXLE 25
U-JOINTS 25
TIRE MAINTENANCE 26
Tire Rotation 26
Wheel Nuts 26
LUBRICATION OF THE BOBCAT ROUGH TERRAING FORKLIFT 27
SPARK ARRESTOR MUFFLER 28
BACK-UP ALARM 29
VERTICAL MAST 29
OPERATOR CAB 29
HYDRAULIC SYSTEM 31
HYDRAULIC/HYDROSTATIC SCHEMATICS 33
HYDRAULIC SYSTEM OPERATIONS 41
Description 41
Flow Chart 41
TROUBLESHOOTING 42
HYDRAULIC SYSTEM OPERATION 43
37° Flare Connections 43
Straight Thread O-Ring Fitting 43
Tubelines And Hoses 43
HYDRAULIC SYSTEM SERVICE 44
Checking And Adding Hydraulic Fluid 44
Replacing The Hydraulic Fluid 44
Replacing The Hydraulic Fluid Filters 45
Replacing The Bronze (40 Micron) Filter 45
Replacing The Neutral By-Pass Valve 46
Replacing The Cold Weather By-Pass Valve 47
OIL RESERVOIR 47
Removing The Oil Reservoir 47
Installing The Oil Reservoir 47
HYDRAULIC CONTROL VALVE 48
Description Of The Control Valve 48
Removing The Hydraulic Control Valve 49
Disassembly Of The Control Valve 50
Inspection Of The Control Valve 52
Reassembly Of The Control Valve 52
Installing The Control Valve 53
HYDRAULIC MAIN RELIEF VALVE 53
Checking The Hydraulic Main Relief Valve 53
Replacing The Hydraulic Main Relief Valve 55
HYDRAULIC PUMP 55
Checking The Hydraulic Pump Pressure 55
Removing The Hydraulic Pump 56
Disassembly Of The Hydraulic Pump 57
Inspection Of The Hydraulic Pump 58
Assembly Of The Hydraulic Pump 58
Installing The Hydraulic Pump 59
Checking Steering Relief Pressure 59
COUNTERBALANCE VALVE 60
HYDRAULIC CYLINDERS 60
Checking The Lift Cylinder Seals 60
Checking The Tilt Cylinder Seals 61
Checking The Steering Cylinder Seals 62
Removing The Lift Cylinder 62
Inspecting The Lift Cylinder 64
Installing The Lift Cylinder 64
Removing The Tilt Cylinders 64
Installing The Tilt Cylinders 65
Removing The Steering Cylinder 66
Installing The Steering Cylinder 66
Disassembly Of The Hydrailic Cylinder 66
Assembly Of The Hydraulic Cylinder 69
STEERING CONTROL VALVE 70
Removing The Steering Control Valve 71
Disassembly Of The Steering Control Valve 71
Inspection Of The Steering Control Valve 74
Assembly Of The Steering Control Valve 75
Installing The Steering Control Valve 79
HYDROSTATIC SYSTEM 81
SYSTEM OPERATIONS DESCRIPTION 83
TROUBLESHOOTING 84
SERVO CONTROL 86
Neutral Adjustment For Servo Control 86
Removing The Servo Control 87
Disassembly Of The Servo Control 87
Assembly Of The Servo Control 88
Installing The Servo Control 88
FOOT PEDAL AND CENTERING MECHANISM 89
Removing The Centering Mechanism 89
Adjusting The Springs In The Centering Mechanism 89
Replacing The Springs On The Centering Mechanism 90
Installing The Centering Mechanism 91
Adjusting The Neutral Safety Start Switch 91
CHARGE PRESSURE AND REPLENISHING VALVES 92
Checking The Charge Pressure 92
Checking Orifice In Charge Tubeline 92
Replenishing Valves 93
HYDROSTATIC PUMP 94
Removing The Hydrostatic Pump 94
Disassembly Of The Hydrostaic Pumps 96
Hydrostatic Pump Inspection 99
Assembly Of The Hydrostatic Pump 101
Installing Pumps To The Manifold Block 105
Hydrostatic Pump Installation 106
Hydrostatic Pump Start-Up Procedure 108
HYDROSTATIC MOTOR 108
Hydrostatic Motor Removal 109
Hydrostatic Motor Disassembly 109
Inspection Of The Hydrostatic Motor 112
Assembling The The Hydrostatic Motor 113
Manifold Block Disassembly 117
Manifold Block Assembly 117
Hydrostatic Motor Installation 117
Hydrostatic Motor Start-Up 118
Tow Valves 118
DRIVE SYSTEM 119
DESCRIPTION 121
DIFFERENTIAL OIL LEVEL 121
LUBRICATING THE U-JOINTS 121
DRIVE SHAFT 121
Removing The Drive Shaft 121
Installing The Drive Shaft 122
REAR AXLE 122
Description 122
Removing The Rear Axle 122
Installing The Rear Axle 123
FRONT AXLE 123
Description 123
Removing The Front Axle 123
Installing The Front Axle 123
DISASSEMBLING AND ASSEMBLING AXLES 124
Removing Hubs 124
Installing Hubs 125
Removing The Differential Assembly 127
Removing The Ring Gear 128
Installing The Ring Gear 129
Removing Clutch Plates 130
Installing Clutch Plates 131
Explanation Of Assembly Procedure 132
Removing The Drop Gear And Pinion Shaft 131
Checking Differential Assembly End Play (WITHOUT Pinion Shaft Installed) 133
Installing The Pinion Shaft Bearings 134
Installing The Pinion Shaft 134
Setting Pinion Shaft position (Using Tool – Pinion Shaft NOT Installed) 135
Setting Pinion Bearing Pre-Load 136
Installing Differential Assembly & Checking end Play (Pinion Shaft Installed) 138
Checking Gear Backlash 141
PARKING BRAKE 142
Description 142
Adjusting The Parking Brake 142
Removing The Parking Brake Cable 143
Installing The Parking Brake Cable 143
Removing The Parking Brake Assembly From The Hydrostatic Motor 143
Installing The Parking Brake Assembly On The Hydrostatic Motor Housing 144
MAIN FRAME 145
OPERATOR CAB 147
REAR GRILL 147
Removing The Rear Grill 147
Installing The Rear Grill 147
FLOORPANELS 147
Removing The Floorpanels 147
Installing The Floorpanels 147
SEAT AND SEAT PLATE 148
Removing The Seat And Seat Plate 148
Installing The Seat And Seat Plate 148
FUEL TANK 149
Removing The Fuel Tank 149
Installing The Fuel Tank 149
DOORS 149
Removing The Rear door 149
Installing The Rear Door 149
Removing The Side Doors 150
Installing The Side Doors 150
DISASSEMBLING THE BOBCAT FORKLIFT 150
Seperating The Sections 150
Ball Stud & Race Assembly 151
Removing The Oscillating Link 151
ASSEMBLING THE BOBCAT FORKLIFT 152
VERTICAL MAST 153
TROUBLESHOOTING THE VERTICAL MAST 155
REMOVING THE VERTICAL MAST 155
INSTALLING THE VERTICAL MAST 156
INSPECTING THE VERTICAL MAST 157
REPLACING THE BRONZE BUSHING 158
REMOVING THE MOUNTING FRAME 158
INSTALLING THE MOUNTING FRAME 159
REMOVING THE CARRIAGE CHAINS 159
INSTALLING THE CARRIAGE CHAINS 159
ADJUSTING THE LIFT CARRIAGE 160
REMOVING THE LIFT CARRIAGE 160
INSTALLING THE LIFT CARRIAGE 161
ADJUSTING THE CARRIAGE ROLLERS 161
PALLET FORKS 164
Installing The Pallet Forks 164
Removing The Pallet Forks 164
Adjusting The Pallet Forks 164
ELECTRICAL SYSTEM 165
ELECTRICAL SCHEMATICS 167
DESCRIPTION 175
Dash Panel 175
Wiring Diagrams 175
SERVICING THE ELECTRICAL SYSTEM 176
Cautions To Be Taken In Use Of The Alternator 176
General Servicing 176
Charging The Batteries 176
TROUBLESHOOTING THE ELECTRICAL SYSTEM 177
CHECKING THE BATTERIES 177
REPLACING THE BATTERIES 177
WIRING HARNESS DIODES 178
Description 178
Checking The Diodes 178
Replacing The Diodes 178
NEUTRAL START SAFETY SWITCH 178
Checking The Neutral Start Safety Switch 178
ALTERNATOR 179
Description 179
Adjusting Or Replacing The Alternator Belt 179
Checking Alternator Wiring 179
Checking Alternator Output 180
Checking The Regulator 180
Removing The Alternator 180
Disassembling The Alternator 180
Checking The Rotor 181
Checking The Stator 181
Checking Diode Trio 182
Checking Rectifier 182
Assembling And Installing The Alternator 182
STARTER 182
Description 182
Checking Starter 183
Removing Starter 183
Disassembling The Starter 183
Cleaning And Inspecting The Starter 184
Replacing The Brushes 184
Assembling The Starter 184
BACK-UP ALARM 185
ENGINE SERVICE 187
TROUBLESHOOTING 189
CHECKS & ADJUSTMENTS 191
Oil Pressure 191
Valve Clearance 191
Check Engine Compression 191
FUEL SYSTEM AND TIMING 192
Fuel Injection Pump 192
Removing The Fuel Injection Pump 192
Installing The Fuel Injection Pump 193
Timing The Fuel Injection Pump 194
Fuel Injector Nozzles 195
Removing Fuel Injector Nozzles 196
Checking The Fuel Injector Nozzles 196
Installing The Fuel Injector Nozzles 197
High Pressure Fuel Lines 197
Glow Plugs 198
ENGINE AND ATTACHING PARTS 199
Removing The Engine 199
Installing The Engine 200
Blower Housing Shield 201
Removal 201
Installation 201
Engine Coolant Radiator 201
Removal 201
Installation 202
Engine Blower Housing 202
Removal 202
Installation 202
Engine Muffler 203
Removal 203
Installation 203
Oil Cooler 203
Installing The Oil Cooler 203
Removing The Oil Cooler 203
CYLINDER HEAD 204
Removing The Cylinder Head 204
Removal Of The Valves 204
Reconditioning The Valves And Valve Seats 205
Installing Valve Guides 205
Checking Valve Springs 206
Combustion Chamber Inserts 207
Cylinder Head Inspection 207
Installation Of The Valves 208
Reconditioning The Rocker Arms 208
Disassembly 208
Checking 209
Assembly 209
Installing The Cylinder Head 209
RECONDITIONING THE ENGINE 211
Pistons And Connecting Rods 211
Removal 211
Disassembly 212
Inspection 212
Installation Of Piston To Connecting Rod 213
Installation Of Rings On The Piston 213
Installing Piston Assembly In The Engine Block 214
Cylinder Liners 214
Checking 214
Installation 215
Main Bearings 216
Removal 216
Installation 217
Crankshaft End Play 217
Crankshaft 217
Removal 217
Checking 218
Installation 219
Rear Main Bearing Oil Seal 219
TIMING CASE AND GEARS 220
Timing Case Cover 220
Removal 220
Installation 220
Front Seal 221
Removal 221
Installation 221
Idler Gear And Hub 221
Removal 221
Inspection 222
Installation 222
Camshaft Gear 222
Removal 223
Installation 223
Fuel Injection Pump Gear 223
Removal 223
Installation 223
Crankshaft Gear 224
Timing Case 224
Removal 224
Installation 224
Camshaft And Tappets 225
Removal 225
Inspection 226
Installation 226
LUBRICATION SYSTEM 226
Description Of The Lubrication System 226
Oil Pan 227
Removal 227
Installation 227
Oil Pump 228
Removal 228
Disassembly 228
Checking 229
Assembly 230
Installation 230
Oil Filter And Adapter Housing 231
Removal 231
Installation 231
COOLING SYSTEM 231
Alternator And Water Pump Belt 231
Water Pump 231
Removal 231
Installation 232
Thermostat 232
Removal 232
Testing The Thermostat 232
Installation 232
FLYWHEEL 233
Removal Of The Flywheel 233
Replace The Flywheel Ring Gear 233
Installation Of The Flywheel 233
TECHNICAL DATA 235
FORKLIFT SPECIFICATIONS 237
Specifications 237
Vertical Mast 237
Engine 237
Hydraulics 238
Electrical 238
Drive System 238
Capacities 238
Tires 238
ENGINE SPECIFICATIONS 239
Cylinder Head Dimensions 239
Pistons And Connecting Rod Dimensions 239
Cylinder Block And Liner Dimensions 240
Crankshaft And Main Bearing Dimensions 240
Timing Case, Camshaft And Drive Dimensions 241
Oil Pump Dimensions 241
Cooling System And Water Pump Dimensions 241
Fuel System Specifications 242
De-Rating For Altitude 242
Engine Torque 242
Grinding Specifications For Crankshaft 243
Crankshaft Regrind Data 243
HYDRAULIC SYSTEM 244
HYDROSTATIC SYSTEM 244
DECIMAL AND MILLIMETER EQUIVALENTS 245
U S TO METRIC CONVERSION 245
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 246
ALPHABETICAL INDEX 247

Contact us: [email protected]

https://vimeo.com/842744637?share=copy

PLEASE NOTE:

• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
• No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
• Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
• So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com

S.V