102397615, M&S, 2004 -2007, Bobcat 2200 Service Manual

102397615, M&S, 2004 -2007, Bobcat 2200 Service Manual

 

102397615, M&S, 2004 -2007, Bobcat 2200 Service Manual SN 235311001-D to 235312999-D, SN 235211001-G to 235212999-G, 588 Pages, $99.95

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SECTION 1 – SAFETY
General Warning
SECTION 2 – VEHICLE SPECIFICATIONS
SECTION 3 – GENERAL INFORMATION
General Information
Model Identification
Storage
Preparing the Vehicle for Extended Storage
Returning the Stored Vehicle to Service
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle
Seat Cleaning
Front Body Repair
Abrasions and Haze
Light Scratches
Large Scratches and Abrasions
Front Body Components
Instrument Panel Removal
Instrument Panel Installation
Dashboard Removal
Dashboard Installation
Front Body Removal
Front Body Installation
Front Fender Removal
Front Fender Installation
Roll-Over Protective Structure (ROPS)
ROPS Removal
ROPS Installation
Page iv Bobcat 2200 Service Manual
Seat
Seat Removal
Seat Adjustment
Seat Installation
Seat Frame Removal
Seat Frame Installation
Safety Belts
Safety Belt Removal
Safety Belt Installation
Cargo Bed With Electric Lift
Testing the Bed Lift Motor
Bed Lift Motor Removal
Bed Lift Motor Installation
Cargo Bed Removal
Cargo Bed Installation
Rear Fender
Rear Fender Removal
Rear Fender Installation
Floor Mat
Floor Mat Removal
Floor Mat Installation
SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES
Accelerator Pedal
Accelerator Pedal Removal
Accelerator Pedal Installation
Accelerator Pedal and RPM Adjustment
Brake Pedal
Brake Pedal Removal
Brake Pedal Installation
Brake Pedal Adjustment
Park Brake Pedal
Park Brake Pedal Removal
Park Brake Pedal Installation
Park Brake Cable Installation
Park Brake Cable Adjustment
SECTION 6 – HYDRAULIC AND PARK BRAKE SYSTEMS
Brake System Inspection
Brake System Troubleshooting
Bobcat 2200 Service Manual Page v
Brake Pads and Caliper
Front Brake Pad and Caliper Removal
Front Brake Pad and Caliper Installation
Rear Brake Pad and Caliper Removal
Rear Brake Pad and Caliper Installation
Brake Disc and Hub
Front Wheel Disc and Hub Removal
Front Wheel Disc and Hub Installation
Rear Wheel Disc Removal
Rear Wheel Disc Installation
Front Brake Line Removal
Front Brake Line Installation
Rear Brake Line Removal
Rear Brake Line Installation
Filling the Hydraulic System
Reservoir Removal
Reservoir Installation
Master Cylinder Removal
Master Cylinder Installation
Bleeding the Hydraulic Brake System
Purging the Hydraulic System
Park Brake System
Park Brake Adjustment
Park Brake Cable Adjustment
Park Brake Wheel Cables
Front Park Brake Cable Removal
Front Park Brake Cable Installation
SECTION 7 – STEERING AND FRONT SUSPENSION
Steering Wheel
Steering Wheel Removal
Steering Wheel Installation
Steering Column
Steering Column Removal
Steering Column Installation
Rack and Pinion
Rack and Pinion Removal
Rack and Pinion Installation
Rack and Pinion Disassembly
Rack and Pinion Assembly
Wheel Alignment
Page vi Bobcat 2200 Service Manual
Front Suspension Components
Steering Upright Removal
Upper A-Arm Removal
Upper A-Arm Installation
Lower A-Arm Removal
Lower A-Arm Installation
Front Coil-Over Shock Absorber Removal
Front Coil-Over Shock Absorber Installation
Steering Upright Installation
SECTION 8 – WHEELS AND TIRES
General Information
Wheels
Wheel Removal
Wheel Installation
Tires
Tire Removal
Tire Installation
SECTION 9 – REAR SUSPENSION
Rear Coil-Over Shock Absorber
Swing Arms
Swing Arm Removal
Swing Arm Installation
SECTION 10 – PERIODIC MAINTENANCE
Periodic Service Schedule
Brake Fluid Reservoir
Brake Fluid
Engine Oil
Oil Pressure – Gasoline Engine
Engine Oil Level Check
Engine Oil and Filter Change
Oil Viscosity
Gearcase Lubrication
Lubrication Level Check for Front Differential, Transmission, and Rear Differential
Lubrication Change for Front Differential, Transmission, and Rear Differential
Engine Coolant – Diesel Vehicles
Engine Coolant Level Check
Bobcat 2200 Service Manual Page vii
Fueling Instructions
Draining Water from Fuel Filter
Battery
SECTION 11A – TROUBLESHOOTING AND ELECTRICAL SYSTEM: GASOLINE VEHICLES
Troubleshooting Guide
Wiring Diagram
Test Procedures
Index of Test Procedures
SECTION 11B – TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES
Troubleshooting Guide
Wiring Diagram
Test Procedures
Index of Test Procedures
SECTION 12A – ELECTRICAL COMPONENTS: GASOLINE VEHICLES
Starter and Starter Solenoid
Relays
Neutral Switch
Carburetor Solenoid
Voltage Regulator
Instrument Panel
Key Switch
Fuse
Reverse Warning Buzzer
Reverse Warning Buzzer Limit Switch
Low Oil Warning Light
Fuel Gauge/Hour Meter
Fuel Level Sending Unit
Ignition Coil and Charge Coil
Charge Coil
Oil Pressure Sensor
Light Switch
Wire Harness Diodes
Bed Lift Switch
Bed Lift Circuit Breaker
General Information
Page viii Bobcat 2200 Service Manual
SECTION 12B – ELECTRICAL COMPONENTS: DIESEL VEHICLES
Starter and Starter Solenoid
Relays
Neutral Switch
Fuel Solenoid
50-Amp Circuit Breaker
Instrument Panel
Key Switch
Fuse
Reverse Warning Buzzer
Low Oil Warning Light
Fuel Gauge/Hour Meter
Electric Fuel Pump
Fuel Level Sending Unit
Alternator
Headlights
Light Switch
Thermostat Switch
Fan Motor
Wire Harness Diodes
Bed Lift Switch
Bed Lift Circuit Breaker
Battery
General Information
SECTION 13A – GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES
Gasoline Engine
Engine Removal
Engine Installation
Exhaust System
Muffler Removal
Intermediate Pipe Removal
Intermediate Pipe Installation
Muffler Installation
Bobcat 2200 Service Manual Page ix
Fuel System
Carburetor
Main Jet Elevation/Size Chart
Fuel Filter
Fuel Pump
Fuel Level Sending Unit
Fuel Tank
Fuel Lines
Fuel Shut-Off Valve
Oil Filter Hoses
Engine Control Linkages
Accelerator Cable
Governor Guard
Governor Cable
Cable Retention Clip Adjustment
Ground Speed (Transmission) Governor Arm Adjustment
Engine Governor Arm
Engine RPM Adjustment
Choke and Air Intake System
Air Filter Replacement
Choke Cable Removal
Choke Cable Installation
Air Canister Removal
Air Canister Installation
Air Filter Intake Hose Removal
Air Filter Intake Hose Installation
Air Filter Outlet Hose Removal
Air Filter Outlet Hose Installation
Clutches
Clutch Troubleshooting
Drive Belt
Drive Clutch
Driven Clutch
Clutch Cover
SECTION 13B – DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES
Diesel Engine
Engine Removal
Engine Installation
Page x Bobcat 2200 Service Manual
Exhaust System
Muffler Removal
Intermediate Pipe Removal
Manifold Pipe Removal
Manifold Pipe Installation
Intermediate Pipe Installation
Muffler Installation
Fuel System
Fuel Line Hose Replacement
Fuel Filter Replacement
Draining Water from the Secondary Fuel Filter
Electric Fuel Pump
Fuel Level Sending Unit
Fuel Tank
Fuel Lines
Engine Control Linkages
Accelerator Cable
Engine RPM Adjustment
Air Intake System
Air Filter Replacement
Air Canister Removal
Air Canister Installation
Air Filter Intake Hose Removal
Air Filter Intake Hose Installation
Air Filter Outlet Hose Removal
Air Filter Outlet Hose Installation
Clutches
Clutch Troubleshooting
Drive Belt
Drive Clutch
Driven Clutch
Clutch Cover
SECTION 14 – DRIVETRAIN COMPONENTS
Half Shafts
Half Shaft Removal
Half Shaft Installation
Front Differential
Front Differential Removal
Front Differential Installation
Bobcat 2200 Service Manual Page xi
Front Driveshaft
Front Driveshaft Removal
Front Driveshaft Installation
Rear Receiver Hitch
Rear Receiver Hitch Removal
Rear Receiver Hitch Installation
Rear Axle
Rear Axle Removal
Rear Axle Installation
Rear Driveshaft
Rear Driveshaft Removal
Rear Driveshaft Installation
Transmission
Troubleshooting
Transmission Removal
Transmission Installation
Forward/Reverse Shifter Cable
Forward/Reverse Shifter Handle
Rear Differential and Axles
Rear Differential Removal
Rear Axle Shafts and Wheel Bearings
Rear Differential Installation
SECTION 15 – RADIATOR AND COOLANT SYSTEM (DIESEL)
General Information
Engine Coolant Check
Engine Coolant Change
Coolant Reservoir Removal
Coolant Reservoir Installation
Radiator
Radiator Removal
Radiator Installation
Coolant Pipe Weldment (Steel)
Coolant Pipe Weldment Removal
Coolant Pipe Weldment Installation
SECTION 16 – TRANSMISSION MODELS 420317 AND 420682
General Information
Model Identification
Service Fixture
Page xii Bobcat 2200 Service Manual
Transmission Removal
Transmission Disassembly
Input Shaft Disassembly
Input Shaft Assembly
Intermediate Shaft Disassembly
Output Shaft Disassembly
Shifter Shaft Removal
Shifter Shaft Installation
Case Inspection
Shaft Seal Removal
Shaft Seal Installation
Output Shaft Assembly
Intermediate Shaft Assembly
Intermediate and Output Shaft Assembly
Transmission Assembly
Transmission Installation
SECTION 17 – FRONT DIFFERENTIAL MODELS 6203-01-139-S AND 6203-01-189-S
General Information
Axle Half Shaft Removal
Front Differential Removal
Tools Required For This Section
Front Differential Coil And Output Cover
Coil and Output Cover Removal
Coil and Output Cover Installation
Front Differential
Front Differential Disassembly
Front Differential Assembly
Front Differential Installation
Axle Half Shaft Installation
SECTION 18 – REAR DIFFERENTIAL MODELS 420366 AND 420851
General Information
Rear Differential Disassembly
Pinion Gear Removal
Ring Gear Removal
Clutch Carrier Assembly
Ring Gear Installation
Pinion Gear Installation
Rear Differential Assembly
Bobcat 2200 Service Manual Page xiii
Axle Shafts and Differential Installation
SECTION 19 – KUBOTA D722 DIESEL ENGINE MANUAL
SECTION 20 – HONDA GX 620 GASOLINE ENGINE MANUAL

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