Bobcat Utility 2200 Service Manual-21416B320178.pdf -Bookmark created by https://wimanual.com TOC 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 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 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 Hydraulic Line Replacement Front Brake Line Removal Front Brake Line Installation Rear Brake Line Removal Rear Brake Line Installation Master Cylinder and Reservoir 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 Front Suspension Wheel Alignment 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 Periodic Lubrication 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 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 Fuel Level Sending Unit Ignition Coil and Charge Coil Charge Coil Oil Pressure Sensor Headlights Light Switch Wire Harness Diodes Bed Lift Switch Bed Lift Circuit Breaker Battery General Information 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 Reverse Warning Buzzer Limit Switch Low Oil Warning Light Fuel Gauge Electric Fuel Pump Fuel Level Sending Unit Alternator Oil Pressure Sensor 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 Fuel System Carburetor Main Jet Elevation 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 Accelerator 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 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 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 Forward 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 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 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 Axle Shafts and Differential Removal Rear Differential Disassembly Pinion Gear Removal Ring Gear Removal Clutch Carrier Assembly Ring Gear Installation Pinion Gear Installation Rear Differential Assembly Axle Shafts and Differential Installation Section 19 - Kubota D722 Diesel Engine Manual Section 20 - Honda GX 620 Gasoline Engine Manual GX620K1_(GCAD-2000001-FORWARD).pdf NAVIGATION QUICKTIPS SPECIFICATIONS SPECIFICATIONS DIMENSIONS AND WEIGHTS PERFORMANCE CURVES DIMENSIONAL DRAWINGS SNORKEL AIR CLEANER EQUIPPED TYPE P.T.O. DIMENSIONAL DRAWINGS WIRING DIAGRAMS SERVICE INFORMATION GENERAL SAFETY SERIAL NUMBER LOCATION SERVICE RULES MAINTENANCE STANDARDS ENGINE ELECTRICAL VALVES CONNECTING ROD CYLINDER TORQUE VALUES SPECIAL TOOLS TROUBLESHOOTING GENERAL SYMPTOMS AND POSSIBLE CAUSES HARD STARTING OIL ALERT SYSTEM IGNITION SYSTEM STARTER MOTOR HARNESS ROUTING MAINTENANCE MAINTENANCE SCHEDULE ENGINE OIL OIL FILTER AIR CLEANER SNORKEL TYPE VALVE CLEARANCE SPARK PLUG CARBURETOR GOVERNOR FUEL FILTER SPARK ARRESTER DISASSEMBLY AIR CLEANER RECOIL STARTER REMOVAL RECOIL STARTER ASSEMBLY FAN COVER REMOVAL INSTALLATION CONTROL BOX DISASSEMBLY INSPECTION GOVERNOR ARM DISASSEMBLY INSTALLATION FUEL PUMP CARBURETOR REMOVAL DISASSEMBLY INSPECTION ADJUSTMENT STARTER MOTOR REMOVAL DISASSEMBLY INSPECTION INSTALLATION COOLING FAN DISASSEMBLY INSPECTION ADJUSTMENT CYLINDER HEAD REMOVAL DISASSEMBLY INSPECTION VALVE GUIDE REPLACEMENT VALVE SEAT RECONDITIONING INSTALLATION CRANKCASE COVER REMOVAL DISASSEMBLY INSPECTION CRANKSHAFT DISASSEMBLY INSPECTION PISTON DISASSEMBLY INSPECTION PISTON ASSEMBLY VALVE LIFTER ASSEMBLY DISASSEMBLY INSPECTION INSTALLATION HIGH MOUNT MUFFLER A Index A a-arm, lower a-arm, upper accelerator air canister (diesel vehicles) air canister (gasoline vehicles) air filter (diesel vehicles) air filter (gasoline vehicles) alternator (diesel vehicles) antifreeze axle half shaft axle shaft and differential axle, rear B ball joint, lower ball joint, upper battery (diesel vehicles) 12b-20 battery (gasoline vehicles) 12a-16 bed lift circuit breaker (gasoline vehicles) bed lift motor bed lift motor (gasoline vehicles) bed lift switch (gasoline vehicles) bed, cargo belt, drive belt, seat body, front box bed brakes C cable, accelerator cable, forward cable, governor cable, park brake camber carburetor (diesel vehicles) carburetor (gasoline vehicles) carburetor solenoid (gasoline vehicles) cargo bed CAUTION charge coil (gasoline vehicles) 12a-11 choke cable (gasoline vehicles) circuit breaker (diesel vehicles) circuit breaker, bed lift (gasoline vehicles) cleaning clutch and ring gear clutch carrier clutch inner cover (diesel vehicles) clutch inner cover (gasoline vehicles) clutch outer cover (diesel vehicles) clutch outer cover (gasoline vehicles) clutch, drive clutch, driven coil and output cover coil, charge (gasoline vehicles) 12a-11 coil, ignition (gasoline vehicles) 12a-11 column, steering coolant reservoir (diesel vehicles) coolant, engine (diesel vehicles) D DANGER dashboard differential relay (diesel vehicles) differential relay (gasoline vehicles) differential, front differential, rear diode, wire harness (diesel vehicles) diode, wire harness (gasoline vehicles) drive belt (diesel vehicles) drive belt (gasoline vehicles) drive clutch (diesel vehicles) 13b-28 drive clutch (gasoline vehicles) 13a-31 driven clutch (diesel vehicles) 13b-28 driven clutch (gasoline vehicles) 13a-31 driveshaft, front driveshaft, rear E engine (diesel vehicles) engine (gasoline vehicles) engine governor arm engine oil exhaust system (diesel vehicles) exhaust system (gasoline vehicles) F fan motor (diesel vehicles) fan relay (diesel vehicles) fender, front fender, rear floor mat fluid, brake 10-6 forward forward front body front differential front drive gearcase coil (diesel vehicles) front drive gearcase coil (gasoline vehicles) front driveshaft fuel filter (gasoline vehicles) 13a-8 fuel filter, primary (diesel vehicles) fuel filter, secondary (diesel vehicles) fuel gauge fuel gauge fuel level sending unit (diesel vehicles) fuel level sending unit (gasoline vehicles) fuel pump (diesel vehicles) fuel pump (gasoline vehicles) 13a-8 fuel shut-off valve (gasoline vehicles) 13a-16 fuel solenoid (diesel vehicles) fuel system (diesel vehicles) 13b-9 fuel system (gasoline vehicles) 13a-7 fuel tank (diesel vehicles) fuel tank (gasoline vehicles) fueling instructions 10-13 fuse (diesel vehicles) fuse (gasoline vehicles) G gearcase gearcase coil glow plug circuit (diesel vehicles) governor arm, engine (gasoline vehicles) governor arm, transmission (gasoline vehicles) governor cable (gasoline vehicles) governor guard (gasoline vehicles) ground cables (diesel vehicles) ground cables (gasoline vehicles) H half shaft handle, forward headlight (diesel vehicles) headlight (gasoline vehicles) high-temperature light circuit (diesel vehicles) hitch, receiver hydrometer test (diesel vehicles) 11b-9 hydrometer test (gasoline vehicles) 11a-9 I ignition (gasoline vehicles) ignition coil (gasoline vehicles) 12a-11 input shaft input shaft seal inspection instrument panel (diesel vehicles) instrument panel (gasoline vehicles) intake hose, air (diesel vehicles) intake hose, air (gasoline vehicles) intermediate and output shaft intermediate shaft J jetting, carburetor (gasoline vehicles) 13a-7 K key switch (diesel vehicles) key switch (gasoline vehicles) kill circuit, engine (gasoline vehicles) kill wire, engine (gasoline vehicles) L low oil warning light lubrication M maintenance manifold (diesel vehicles) muffler muffler (diesel vehicles) muffler (gasoline vehicles) N neutral switch (diesel vehicles) neutral switch (gasoline vehicles) O oil filter oil warning light, low (diesel vehicles) oil warning light, low (gasoline vehicles) oil, engine 10-6 outlet hose, air (diesel vehicles) outlet hose, air (gasoline vehicles) output shaft P panel, instrument park brake pedal, accelerator pedal, brake periodic lubrication schedule 10-4 periodic service schedule 10-1 pinion gear pump, fuel (diesel vehicles) pump, fuel (gasoline vehicles) 13a-8 R rack and pinion radiator (diesel vehicles) rear axle rear differential rear driveshaft rear wheel bearing receiver hitch relay, accessory (diesel vehicles) relay, accessory (gasoline vehicles) relay, differential (diesel vehicles) relay, differential (gasoline vehicles) relay, start (diesel vehicles) relay, start (gasoline vehicles) reservoir, coolant reverse buzzer (diesel vehicles) reverse buzzer (gasoline vehicles) ring gear ROPS (roll-over protective structure) RPM adjustment (diesel vehicles) RPM adjustment (gasoline vehicles) S safety safety belt seat seat belt seat frame serial number, vehicle 3-1 service schedule service tools shaft seal shifter shaft shock absorber solenoid, fuel (diesel vehicles) spark plug (gasoline vehicles) specifications start relay (diesel vehicles) start relay (gasoline vehicles) starter control circuit (diesel vehicles) starter control circuit (gasoline vehicles) steering steering column steering upright steering wheel storage suspension, front suspension, rear switch, bed lift (gasoline vehicles) switch, neutral (diesel vehicles) switch, neutral (gasoline vehicles) T 12-volt power point (diesel vehicles) 12-volt power point (gasoline vehicles) test procedures (diesel vehicles) test procedures (gasoline vehicles) test procedures, index of (diesel vehicles) 11b-8 test procedures, index of (gasoline vehicles) 11a-8 thermostat switch (diesel vehicles) throttle tire tools torque converter (diesel vehicles) 13b-28 torque converter (gasoline vehicles) 13a-31 transmission transmission governor arm troubleshooting V v-belt (diesel vehicles) voltage regulator (gasoline vehicles) W WARNING wheel wheel bearing wheel, steering wire continuity (diesel vehicles) wire continuity (gasoline vehicles) wire harness diode (diesel vehicles) wire harness diode (gasoline vehicles) wiring diagram (diesel vehicles) 11b-6 wiring diagram (gasoline vehicles) 11a-6 . 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