BOBCAT 2200 2300 UTITLITY VEHICLE SERVICE REPAIR WORKSHOP MANUAL – PDF DOWNLOAD
DESCRIPTION:
Bobcat vehicles are designed and built to provide the ultimate in performance efficiency; however, proper maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation.
This manual provides detailed information for the maintenance and repair of the Bobcat 2200, 2200 Homologated, 2200S and Bobcat 2300 vehicles, and should be thoroughly reviewed prior to servicing the vehicles. The procedures provided must be properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded.
SCREENSHOT OF THE MANUAL:
TABLE OF CONTENTS:
SECTION 1 – SAFETY
General Warning 1-1
SECTION 2A – VEHICLE SPECIFICATIONS: HONDA GAS & KUBOTA DIESEL POWERED
2200 and 2200S Specifications 2a-1
2300 Specifications 2a-3
SECTION 2B – VEHICLE SPECIFICATIONS: KAWASAKI GAS & KUBOTA DIESEL
POWERED
2200 and 2200S Specifications 2b-1
2200 Homologated Specifications 2b-3
2300 Specifications 2b-5
SECTION 3 – GENERAL INFORMATION
General Information 3-1
Model Identification 3-1
Engine Serial Number Locations 3-2
Gasoline EngineS 3-2
Diesel Engine 3-2
Storage 3-2
Preparing the Vehicle for Extended Storage 3-3
Returning the Stored Vehicle to Service 3-4
Using A Booster Battery (Jump Starting) 3-5
SECTION 4 – BODY AND TRIM
Cleaning the Vehicle 4-1
Seat Cleaning 4-1
Front Body Repair 4-2
Light Scratches 4-2
Abrasions and Haze 4-2
Large Scratches and Abrasions 4-2
Page iv Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual
Front Body Components 4-3
Instrument Panel Removal 4-3
Instrument Panel Installation 4-3
Front Fascia Removal 4-4
Front Fascia Installation 4-4
Hood Removal 4-4
Hood Installation 4-4
Center Cowl Panel Removal 4-4
Center Cowl Panel Installation 4-5
Side Cowl Panel (Fender) Removal 4-5
Side Cowl Panel (Fender) Installation 4-5
Front Fender Flare Removal 4-6
Front Fender Flare Installation 4-6
Roll-Over Protective Structure (ROPS) 4-6
ROPS Removal 4-7
ROPS Installation 4-8
Seat 4-9
Seat Removal 4-9
Seat Adjustment 4-9
Seat Installation 4-9
Seat Support Removal 4-10
Seat Support Installation 4-10
Safety Belts 4-10
Safety Belt Removal 4-10
Safety Belt Installation 4-11
Cargo Bed – Electric Lift 4-11
Testing the Bed Lift Motor 4-11
Bed Lift Motor Removal 4-11
Bed Lift Motor Installation 4-12
Cargo Bed Removal 4-12
Cargo Bed Installation 4-12
Cargo Bed – Manual Lift 4-13
Cargo Bed Removal 4-13
Cargo Bed Installation 4-13
Rear Fender 4-15
Rear Fender Removal 4-15
Rear Fender Installation 4-15
Floor Mat 4-15
Floor Mat Removal 4-15
Floor Mat Installation 4-15
Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual Page v
SECTION 5 – ACCELERATOR AND BRAKE PEDAL ASSEMBLIES
Accelerator Pedal 5-1
Accelerator Pedal Removal 5-1
Accelerator Pedal Installation 5-2
Accelerator Pedal and RPM Adjustment 5-2
Brake Pedal 5-3
Brake Pedal Removal 5-3
Brake Pedal Installation 5-3
Brake Pedal Adjustment 5-4
Park Brake Pedal 5-4
Park Brake Pedal Assembly Removal 5-4
Park Brake Pedal Assembly Installation 5-4
SECTION 6 – HYDRAULIC AND PARK BRAKE SYSTEMS
Brake System Inspection 6-1
Brake System Troubleshooting 6-3
Brake Pads and Caliper 6-5
Front Brake Pad and Caliper Removal 6-5
Front Brake Pad and Caliper Installation 6-7
Rear Brake Pad and Caliper Removal 6-8
Rear Brake Pad and Caliper Installation 6-9
Brake Disc and Hub 6-10
Front Wheel Disc and Hub Removal 6-10
Front Wheel Disc and Hub Installation 6-14
Rear Wheel Disc Removal 6-15
Rear Wheel Disc Installation 6-16
Hydraulic Line Replacement 6-17
Front Brake Line Removal 6-17
Front Brake Line Installation 6-17
Rear Brake Line Removal 6-18
Rear Brake Line Installation 6-19
Master Cylinder and Reservoir 6-20
Filling the Hydraulic System 6-20
Reservoir Removal 6-20
Reservoir Installation 6-20
Master Cylinder Removal 6-21
Master Cylinder Installation 6-21
Bleeding the Hydraulic Brake System 6-22
Bleeding Brakes on a DOT 5 Fluid Filled System 6-22
Purging the Hydraulic System 6-24
Page vi Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual
Park Brake System 6-25
Park Brake Adjustment 6-25
Park Brake Cable Adjustment 6-25
Park Brake Wheel Cables 6-26
Front Park Brake Cable Removal 6-27
Front Park Brake Cable Installation 6-28
Park Brake Equalizer Removal 6-28
Park Brake Equalizer Installation 6-28
SECTION 7 – STEERING AND FRONT SUSPENSION
Steering Wheel 7-1
Steering Wheel Removal 7-1
Steering Wheel Installation 7-2
Steering Column 7-2
Steering Column Removal 7-2
Steering Column Installation 7-3
Rack and Pinion 7-3
Rack and Pinion Removal 7-3
Rack and Pinion Installation 7-4
Rack and Pinion Disassembly 7-5
Rack and Pinion Assembly 7-9
Front Suspension 7-11
Wheel Alignment 7-11
Front Suspension Components 7-13
Steering Upright Removal 7-13
Upper A-Arm Removal 7-14
Upper A-Arm Installation 7-16
Lower A-Arm Removal 7-16
Lower A-Arm Installation 7-17
Front Coil-Over Shock Absorber Removal 7-18
Front Coil-Over Shock Absorber Installation 7-19
Steering Upright Installation 7-19
SECTION 8 – WHEELS AND TIRES
General Information 8-1
Wheels 8-2
Wheel Removal 8-2
Wheel Installation 8-2
Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual Page vii
Tires 8-2
Tire Removal 8-2
Tire Installation 8-3
SECTION 9 – REAR SUSPENSION
Rear Coil-Over Shock Absorber 9-1
Swing Arms 9-2
Swing Arm Removal 9-2
Swing Arm Installation 9-3
SECTION 10A – PERIODIC MAINTENANCE: HONDA GASOLINE & KUBOTA DIESEL
VEHICLES
Periodic Service Schedule 10a-1
Periodic Lubrication Schedule – 2200 10a-4
Periodic Lubrication Schedule – 2300 10a-6
Lubricating The Attachment Arm And Interface 10a-7
Brake Fluid Reservoir 10a-8
Brake Fluid 10a-8
Engine Oil 10a-8
Oil Pressure – Gasoline Engine 10a-9
Engine Oil Level Check 10a-9
Engine Oil and Filter Change 10a-10
Oil Viscosity 10a-13
Gearcase Lubrication 10a-14
Lubrication Level Check for Front Differential, Transmission, and Rear Differential 10a-14
Lubrication Change for Front Differential, Transmission, and Rear Differential 10a-14
Hydraulic System – 2300 Vehicle 10a-16
Engine Coolant – Diesel Vehicles 10a-17
Engine Coolant Level Check 10a-17
Fueling Instructions 10a-17
Draining Water from Fuel Filter 10a-18
Battery 10a-19
SECTION 10B – PERIODIC MAINTENANCE: KAWASAKI GASOLINE & KUBOTA DIESEL
POWERED VEHICLES
Periodic Service Schedule 10b-1
Periodic Lubrication Schedule – 2200 10b-4
Lubricating The Attachment Arm And Interface 10b-6
Brake Fluid Reservoir 10b-7
Brake Fluid 10b-7
Page viii Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual
Engine Oil 10b-7
Oil Pressure – Gasoline Engine 10b-8
Engine Oil Level Check 10b-8
Engine Oil and Filter Change 10b-8
Oil Viscosity 10b-11
Spark Plugs 10b-12
Spark Plug Cleaning And Inspection 10b-12
Spark Plug Gap Inspection 10b-12
Gearcase Lubrication 10b-13
Lubrication Level Check for Front Differential, Transmission, and Rear Differential 10b-13
Lubrication Change for Front Differential, Transmission, and Rear Differential 10b-13
Hydraulic System – 2300 Vehicle 10b-15
Engine Coolant – Diesel Vehicles 10b-16
Engine Coolant Level Check 10b-16
Fueling Instructions 10b-16
Draining Water from Fuel Filter 10b-17
Battery 10b-18
SECTION 11A – TROUBLESHOOTING AND ELECTRICAL SYSTEM: KAWASAKI
POWERED GASOLINE VEHICLES
Troubleshooting Guide 11a-1
Wiring Diagram 11a-6
Test Procedures 11a-8
Index of Test Procedures 11a-8
SECTION 11B – TROUBLESHOOTING AND ELECTRICAL SYSTEM: HONDA POWERED
GASOLINE VEHICLES
Troubleshooting Guide 11b-1
Wiring Diagram 11b-6
Test Procedures 11b-8
Index of Test Procedures 11b-8
SECTION 11C – TROUBLESHOOTING AND ELECTRICAL SYSTEM: DIESEL VEHICLES
Troubleshooting Guide 11c-1
Wiring Diagram 11c-6
Test Procedures 11c-12
Index of Test Procedures 11c-12
Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual Page ix
SECTION 12A – ELECTRICAL COMPONENTS: KAWASAKI POWERED GASOLINE
VEHICLES
Starter and Starter Solenoid 12a-1
Relays 12a-1
Neutral Switch 12a-2
Carburetor Solenoid 12a-2
Carburetor Heater 12a-3
Voltage Regulator 12a-4
Warning Lights 12a-5
Fuel Gauge/Hour Meter 12a-6
Key Switch 12a-7
12-Volt Accessory Receptacle 12a-8
Bed Lift Switch 12a-9
Bed Lift Circuit Breaker 12a-9
Light Switch 12a-10
Fuse 12a-10
Reverse Warning Buzzer (If Equipped) 12a-11
Reverse Warning Buzzer Limit Switch (If Equipped) 12a-12
Front Differential Switch 12a-13
Fuel Level Sending Unit 12a-14
Ignition Coil and Charge Coil 12a-15
Oil Pressure Sensor 12a-15
Headlights 12a-15
Wire Harness Diodes 12a-16
Battery 12a-17
General Information 12a-17
SECTION 12B – ELECTRICAL COMPONENTS: HONDA POWERED GASOLINE VEHICLES
Starter and Starter Solenoid 12b-1
Relays 12b-1
Neutral Switch 12b-2
Carburetor Solenoid 12b-2
Voltage Regulator 12b-3
Warning Lights 12b-4
Fuel Gauge/Hour Meter 12b-5
Key Switch 12b-6
12-Volt Accessory Receptacle 12b-7
Bed Lift Switch 12b-8
Bed Lift Circuit Breaker 12b-8
Page x Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual
Light Switch 12b-9
Fuse 12b-9
Reverse Warning Buzzer 12b-10
Reverse Warning Buzzer Limit Switch 12b-11
Fuel Level Sending Unit 12b-12
Ignition Coil and Charge Coil 12b-12
Charge Coil 12b-13
Oil Pressure Sensor 12b-13
Headlights 12b-13
Wire Harness Diodes 12b-14
Battery 12b-15
General Information 12b-15
SECTION 12C – ELECTRICAL COMPONENTS: DIESEL VEHICLES
Starter and Starter Solenoid 12c-1
Relays 12c-1
Neutral Switch 12c-2
Fuel Solenoid 12c-2
60-Amp Fusible Link 12c-3
Warning Lights 12c-4
Fuel Gauge/Hour Meter 12c-6
Key Switch 12c-7
12-Volt Accessory Receptacle 12c-7
Bed Lift Switch 12c-8
Bed Lift Circuit Breaker 12c-8
Light Switch 12c-9
Fuse 12c-9
Reverse Warning Buzzer (If Equipped) 12c-10
Reverse Warning Buzzer Limit Switch (If Equipped) 12c-11
Electric Fuel Pump 12c-12
Fuel Level Sending Unit 12c-12
Alternator 12c-13
Oil Pressure Sensor 12c-15
Headlights 12c-15
Thermostat Switch 12c-16
Fan 12c-17
Wire Harness Diodes 12c-18
Battery 12c-19
General Information 12c-19
Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual Page xi
SECTION 13A – KAWASAKI GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND
CLUTCHES
Gasoline Engine 13a-1
Engine Removal 13a-1
Engine Installation 13a-3
Oil Filter Hoses 13a-5
Exhaust System 13a-6
Muffler Removal 13a-6
Intermediate Pipe Removal 13a-7
Intermediate Pipe Installation 13a-7
Muffler Installation 13a-8
Fuel System 13a-9
Fuel Lines 13a-10
Fuel Filter 13a-10
Fuel Pump 13a-10
Carburetor 13a-10
Fuel Level Sending Unit 13a-13
Fuel Tank 13a-16
Fuel Shut-Off Valve 13a-19
Engine Control Linkages 13a-20
Accelerator Cable 13a-20
Choke Cable 13a-22
Engine Governor Arm 13a-24
Engine RPM Adjustment 13a-24
Air Intake System 13a-25
Air Filter Replacement 13a-25
Air Canister Removal 13a-26
Air Canister Installation 13a-26
Air Filter Intake Hose Removal 13a-27
Air Filter Intake Hose Installation 13a-27
Air Filter Outlet Hose Removal 13a-28
Air Filter Outlet Hose Installation 13a-28
Clutches 13a-29
Clutch Troubleshooting 13a-29
Drive Belt 13a-30
Drive Clutch 13a-31
Driven Clutch 13a-36
Clutch Cover 13a-39
Page xii Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual
SECTION 13B – HONDA GASOLINE ENGINE, MUFFLER, FUEL SYSTEM, AND
CLUTCHES
Gasoline Engine 13b-1
Engine Removal 13b-1
Engine Installation 13b-3
Exhaust System 13b-5
Muffler Removal 13b-5
Intermediate Pipe Removal 13b-5
Intermediate Pipe Installation 13b-6
Muffler Installation 13b-6
Fuel System 13b-7
Fuel Lines 13b-8
Fuel Filter 13b-8
Fuel Pump 13b-8
Carburetor 13b-8
Fuel Level Sending Unit 13b-9
Fuel Tank 13b-12
Fuel Shut-Off Valve 13b-15
Oil Filter Hoses 13b-16
Engine Control Linkages 13b-16
Accelerator Cable 13b-16
Governor Guard 13b-19
Governor Cable 13b-19
Accelerator Cable Retention Clip Adjustment 13b-20
Ground Speed (Transmission) Governor Arm Adjustment 13b-21
Engine Governor Arm 13b-23
Engine RPM Adjustment 13b-23
Choke and Air Intake System 13b-24
Air Filter Replacement 13b-24
Choke Cable Removal 13b-25
Choke Cable Installation 13b-26
Air Canister Removal 13b-26
Air Canister Installation 13b-27
Air Filter Intake Hose Removal 13b-27
Air Filter Intake Hose Installation 13b-28
Air Filter Outlet Hose Removal 13b-28
Air Filter Outlet Hose Installation 13b-29
Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual Page xiii
Clutches 13b-29
Clutch Troubleshooting 13b-30
Drive Belt 13b-30
Drive Clutch 13b-31
Driven Clutch 13b-36
Clutch Cover 13b-39
SECTION 13C – DIESEL ENGINE, MUFFLER, FUEL SYSTEM, AND CLUTCHES
Diesel Engine 13c-1
Engine Removal 13c-1
Engine Installation 13c-3
Exhaust System 13c-5
Muffler Removal 13c-5
Intermediate Pipe Removal 13c-5
Manifold Pipe Removal 13c-6
Manifold Pipe Installation 13c-6
Intermediate Pipe Installation 13c-6
Muffler Installation 13c-7
Fuel System 13c-8
Fuel Lines 13c-9
Fuel Filter Replacement 13c-9
Draining Water from the Secondary Fuel Filter 13c-9
Electric Fuel Pump 13c-11
Fuel Level Sending Unit 13c-12
Fuel Tank 13c-16
Engine Control Linkages 13c-19
Accelerator Cable 13c-19
Engine RPM Adjustment 13c-20
Air Intake System 13c-23
Air Filter Replacement 13c-23
Air Canister Removal 13c-23
Air Canister Installation 13c-24
Air Filter Intake Hose Removal 13c-24
Air Filter Intake Hose Installation 13c-25
Air Filter Outlet Hose Removal 13c-26
Air Filter Outlet Hose Installation 13c-26
Page xiv Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual
Clutches 13c-27
Clutch Troubleshooting 13c-27
Drive Belt 13c-28
Drive Clutch 13c-29
Driven Clutch 13c-33
Clutch Cover 13c-35
SECTION 14 – DRIVETRAIN COMPONENTS
Half Shafts 14-1
Half Shaft Removal 14-1
Half Shaft Installation 14-3
Front Differential 14-4
Front Differential Removal 14-4
Front Differential Installation 14-6
Front Driveshaft 14-6
Front Driveshaft Removal 14-6
Front Driveshaft Installation 14-7
Rear Receiver Hitch 14-7
Rear Receiver Hitch Removal 14-7
Rear Receiver Hitch Installation 14-7
Rear Axle 14-8
Rear Axle Removal 14-8
Rear Axle Installation 14-10
Rear Driveshaft 14-11
Rear Driveshaft Removal 14-11
Rear Driveshaft Installation 14-12
Transmission 14-12
Transmission Removal 14-12
Transmission Installation 14-14
Forward/Reverse Shifter Cable 14-15
Forward/Reverse Shifter Handle 14-18
Rear Differential and Axle Shafts 14-18
Rear Differential and Axle Shaft Removal 14-18
Rear Differential and Axle Shaft Installation 14-20
Rear Wheel Bearings 14-20
SECTION 15 – RADIATOR AND COOLANT SYSTEM (DIESEL)
General Information 15-1
Engine Coolant Level Check 15-1
Engine Coolant Change 15-1
Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual Page xv
Coolant Reservoir 15-3
Coolant Reservoir Removal 15-3
Coolant Reservoir Installation 15-4
Radiator 15-4
Radiator Removal 15-4
Radiator Installation 15-5
Coolant Pipe Weldment 15-6
Coolant Pipe Weldment Removal 15-6
Coolant Pipe Weldment Installation 15-6
Fan 15-7
Fan Removal 15-7
Fan Installation 15-7
SECTION 16 – TRANSMISSION MODELS 421274 AND 421275
General Information 16-1
Model Identification 16-1
Service Fixture 16-2
Transmission Removal 16-2
Transmission Disassembly 16-3
Input Shaft Disassembly 16-8
Input Shaft Assembly 16-8
Intermediate Shaft Disassembly 16-8
Output Shaft Disassembly 16-12
Shifter Shaft Removal 16-13
Shifter Shaft Installation 16-14
Case Inspection 16-14
Shaft Seal Removal 16-15
Shaft Seal Installation 16-15
Output Shaft Assembly 16-15
Intermediate Shaft Assembly 16-18
Intermediate and Output Shaft Assembly 16-22
Transmission Assembly 16-23
Transmission Installation 16-27
SECTION 17 – FRONT DIFFERENTIAL MODELS 6203-01-139-S AND 6203-01-189-S
General Information 17-1
Axle Half Shaft Removal 17-1
Front Differential Removal 17-2
Tools Required For This Section 17-3
Page xvi Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual
Front Differential Coil And Output Cover 17-3
Coil and Output Cover Removal 17-3
Coil and Output Cover Installation 17-6
Front Differential 17-8
Front Differential Disassembly 17-8
Front Differential Assembly 17-14
Front Differential Installation 17-18
Axle Half Shaft Installation 17-18
SECTION 18 – REAR DIFFERENTIAL MODELS 420366 AND 420851
General Information 18-1
Axle Shafts and Differential Removal 18-2
Rear Differential Disassembly 18-2
Pinion Gear Removal 18-4
Ring Gear Removal 18-6
Clutch Carrier Assembly 18-7
Ring Gear Installation 18-8
Pinion Gear Installation 18-9
Rear Differential Assembly 18-9
Axle Shafts and Differential Installation 18-11
SECTION 19 – KUBOTA D722 DIESEL ENGINE MANUAL
SECTION 20A – KAWASAKI FH680D GASOLINE ENGINE MANUAL
SECTION 20B – HONDA GX 620 GASOLINE ENGINE MANUAL
SECTION 21 – HYDRAULIC ATTACHMENT SYSTEM
Model Identification 21-1
Relieving Hydraulic System Pressure 21-1
To Relieve Hydraulic Fluid Pressure 21-1
Attachment Interface 21-2
Inspection 21-2
Removing and Installing the Attachment Arm Mechanism 21-3
Bobcat 2200/2200S/2300 Gasoline and Diesel Vehicle Service Manual Page xvii
Electrical 21-8
Joystick 21-10
Joystick ON/OFF Switch 21-12
Attachment Arm Float Switch 21-14
Auxiliary Hydraulic Switch 21-15
Relays 21-17
Solenoid 21-19
Circuit Breaker 21-20
Control Valves 21-21
Hoses 21-23
Hose Routing 21-23
Hose Removal 21-24
Hose Installation 21-24
Quick Connect Fittings (Auxiliary Hydraulic Circuit only) 21-25
Quick Connect Removal 21-25
Quick Connect Installation 21-25
Cylinders 21-26
Vehicle Mounted Cylinders 21-26
Auxiliary Cylinder (Optional) 21-27
Cylinder Disassembly 21-29
Cylinder Assembly 21-32
Cylinder Bushings (If Equipped) 21-37
Angle Frame Bushings 21-39
Snow Blade Angle Frame 21-39
Whisk Broom Angle Frame 21-40
Front Mount 21-41
Front Mount Removal 21-41
Front Mount installation 21-42
Hydraulic Pump Assembly 21-43
Fluid Level Inspection 21-43
Fluid Change 21-43
Pump Assembly 21-44
Reservoir 21-47
Motor 21-48
Pump 21-49
Priming the Pump
VIDEO PREVIEW:
PLEASE NOTE:
This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
Contact us at heydownloadss @gmail.com should you have any queries before your purchase or that you need any other service / repair / parts operators manual.