BOBCAT B200 SN 570211001 Service Manual PDF DOWNLOAD
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TABLE OF CONTENTS:
BOBCAT B200 SN 570211001 Service Manual PDF DOWNLOAD
MAINTENANCE SAFETY……………………………………… 3
ALPHABETICAL INDEX……………………………………… 5
CONTENTS………………………………………………. 7
SAFETY INSTRUCTIONS…………………………………. 11
Fire Prevention…………………………………. 13
SERIAL NUMBER LOCATION………………………………. 15
Loader Backhoe Serial Number……………………… 15
Engine Serial Number…………………………….. 15
DELIVERY REPORT…………………………………….. 15
BOBCAT LOADER IDENTIFICATION…………………………. 16
SAFETY & MAINTENANCE……………………………………. 17
LIFTING AND BLOCKING THE LOADER BACKHOE……………….. 19
Procedure………………………………………. 19
LIFT ARM SUPPORT DEVICE……………………………… 21
Installing The Lift Arm Support Device…………….. 21
Removing The Lift Arm Support Device………………. 22
ENGINE COVER……………………………………….. 23
TRANSPORTING THE LOADER BACKHOE………………………. 25
Procedure………………………………………. 25
TOWING THE LOADER BACKHOE……………………………. 27
Procedure………………………………………. 27
AXLE TOE-IN………………………………………… 29
Adjustment……………………………………… 29
SERVICE SCHEDULE……………………………………. 31
Chart………………………………………….. 31
AIR CLEANER SERVICE…………………………………. 33
Replacing Filter Element…………………………. 33
ENGINE COOLING SYSTEM……………………………….. 35
Coolant Replacement……………………………… 35
FUEL SYSTEM………………………………………… 37
Fuel Specifications……………………………… 37
Filling The Fuel Tank……………………………. 37
Fuel Filter…………………………………….. 38
Removing Air From The Fuel System…………………. 38
ENGINE LUBRICATION SYSTEM……………………………. 39
Checking Engine Oil……………………………… 39
Oil Chart………………………………………. 39
Replacing Oil And Filter…………………………. 40
HYDRAULIC/HYDROSTATIC SYSTEM…………………………. 43
Checking And Adding Fluid………………………… 43
Cleaning The Cooler……………………………… 43
Replacing Hydraulic/Hydrostatic Filter…………….. 44
Replacing Hydraulic Fluid………………………… 45
REAR AXLE………………………………………….. 47
Checking Oil Level………………………………. 47
Draining Oil……………………………………. 47
FRONT AXLE…………………………………………. 48
Checking Oil Level………………………………. 48
Draining Oil……………………………………. 48
BACKHOE BOOM LOCK…………………………………… 49
Disengaging The Boom Lock………………………… 49
Engaging Boom Lock………………………………. 50
BOB-TACH HAND LEVER…………………………………. 51
Inspection And Maintenance……………………….. 51
ALTERNATOR BELT…………………………………….. 53
Adjusting The Alternator Belt…………………….. 53
LUBRICATING THE LOADER BACKHOE……………………….. 55
TIRE MAINTENANCE……………………………………. 61
Wheel Nuts……………………………………… 61
Mounting……………………………………….. 61
Tire Pressure…………………………………… 61
HYDRAULIC SYSTEM……………………………………….. 63
HYDRAULIC/HYDROSTATIC SCHEMATIC………………………. 67
HYDRAULIC SYSTEM INFORMATION…………………………. 69
Troubleshooting…………………………………. 73
Description…………………………………….. 74
ARM CYLINDER……………………………………….. 75
Checking……………………………………….. 75
Removal And Installation…………………………. 77
Parts Identification…………………………….. 79
Disassembly…………………………………….. 80
Assembly……………………………………….. 83
BOOM CYLINDER………………………………………. 87
Checking……………………………………….. 87
Removal And Installation…………………………. 88
Parts Identification…………………………….. 90
Disassembly…………………………………….. 91
Assembly……………………………………….. 94
SWING CYLINDER……………………………………… 97
Removal And Installation…………………………. 97
Bushing Removal And Installation………………….. 98
Parts Identification (Left Side)………………….. 99
Parts Identification (Right Side)………………….100
Disassembly……………………………………..101
Assembly………………………………………..104
BUCKET CYLINDER……………………………………..107
Checking………………………………………..107
Removal And Installation………………………….109
Parts Identification……………………………..111
Disassembly……………………………………..112
Assembly………………………………………..115
STABILIZER CYLINDER………………………………….119
Checking………………………………………..119
Removal And Installation………………………….121
Parts Identification……………………………..123
Disassembly……………………………………..124
Assembly………………………………………..127
TILT CYLINDER……………………………………….131
Checking………………………………………..131
Removal And Installation………………………….132
Parts Identification (Left Side)…………………..134
Parts Identification (Right Side)………………….135
Disassembly……………………………………..136
Assembly………………………………………..139
LIFT CYLINDER……………………………………….143
Checking………………………………………..143
Removal And Installation………………………….144
Parts Identification……………………………..145
Disassembly……………………………………..146
Assembly………………………………………..149
STEERING CYLINDER……………………………………153
Removal And Installation………………………….153
Parts Identification……………………………..157
Disassembly And Assembly………………………….158
Inspection………………………………………161
MAIN RELIEF VALVE……………………………………163
Testing The Main Relief Valve……………………..163
Adjustment………………………………………164
PORT RELIEF VALVE (BACKHOE CONTROL VALVE)………………165
Testing And Adjusting (Arm Control)………………..165
Testing And Adjusting (Boom Control)……………….167
Testing And Adjusting (Boom Swing Control)………….169
PORT RELIEF VALVE (LOADER CONTROL VALVE)……………….171
Testing And Adjusting (Bucket Tilt)………………..171
Testing And Adjusting (Front Auxiliary)…………….173
LOADER CONTROL VAVLE…………………………………175
Removal And Installation………………………….175
Parts Identification……………………………..177
Disassembly And Assembly………………………….178
Inlet/Outlet Valve Section………………………..179
Lift Arm Valve Section……………………………181
Tilt Valve Section……………………………….184
Auxiliary Valve Section…………………………..188
BACKHOE CONTROL VALVE………………………………..193
Removal And Installation………………………….193
Parts Identification……………………………..195
Disassembly And Assembly………………………….196
Inlet/Outlet Valve Section………………………..198
Arm Valve Section………………………………..200
Tilt Valve Section……………………………….203
Right Stabilizer Valve Section…………………….206
Left Stabilizer Valve Section……………………..209
Boom Valve Section……………………………….213
Boom Swing Valve Section………………………….216
Outlet Valve Section……………………………..219
HYDRAULIC FLUID RESERVOIR…………………………….221
Removal And Installation………………………….221
Filter Removal And Installation……………………223
HYDRAULIC FILTER HOUSING……………………………..225
Removal And Installation………………………….225
Disassembly……………………………………..226
Assembly………………………………………..227
GEAR PUMP…………………………………………..229
Removal And Installation………………………….229
Parts Identification……………………………..230
Disassembly And Assembly………………………….231
Inspection………………………………………233
STEERING PUMP……………………………………….235
Removal And Installation………………………….235
Parts Identification……………………………..238
Disassembly……………………………………..239
Inspection………………………………………248
Assembly………………………………………..248
TRAVEL PEDAL………………………………………..257
Removal And Installation………………………….257
Parts Identification……………………………..258
Disassembly And Assembly………………………….259
HYDROSTATIC SYSTEM………………………………………265
HYDROSTATIC SYSTEM INFORMATION………………………..267
Troubleshooting Chart…………………………….267
Replenishing Valve Function……………………….268
OIL COOLER………………………………………….269
Removal And Installation………………………….269
Parts Identification……………………………..272
Disassembly……………………………………..273
Assembly………………………………………..275
HYDROSTATIC DRIVE MOTOR………………………………279
Removal And Installation………………………….279
Parts Identification……………………………..281
Disassembly……………………………………..282
Inspection………………………………………286
Assembly………………………………………..288
HYDROSTATIC PUMP…………………………………….293
Removal And Installation………………………….293
Parts Identification……………………………..296
Disassembly……………………………………..298
Inspection………………………………………314
Assembly………………………………………..316
HYDROSTATIC TESTING………………………………….331
Pump Adjustment………………………………….331
DRIVE SYSTEM……………………………………………335
PARKING BRAKE……………………………………….337
Lever Removal And Installation…………………….337
Cable Removal And Installation…………………….338
Adjustment………………………………………341
BRAKE CALIPER……………………………………….343
Removal And Installation………………………….343
Parts Identification……………………………..346
Disassembly And Assembly………………………….347
BRAKE CALIPER……………………………………….353
Removal And Installation………………………….353
Parts Identification……………………………..356
Disassembly And Assembly………………………….357
REAR AXLE…………………………………………..363
Removal…………………………………………363
Installation…………………………………….365
AXLE AND DIFFERENTIAL (REAR)………………………….369
Troubleshooting Chart…………………………….369
General Information………………………………370
Wheel Hub/Axle Parts Identification………………..370
Wheel Hub/Axle Disassembly………………………..371
Differential Parts Identification………………….374
Differential Disassembly………………………….375
Differential Inspection…………………………..381
Pinion Group Parts identification………………….382
Pinion Group Disassembly………………………….383
Pinion Group Inspection…………………………..386
Pinion Group Assembly…………………………….387
Differential Assembly…………………………….394
Wheel Hub/Axle Assembly…………………………..403
FRONT AXLE………………………………………….407
Removal…………………………………………407
Installation…………………………………….409
DRIVESHAFT………………………………………….411
Removal And Installation………………………….411
DROP BOX……………………………………………413
Removal And Installation………………………….413
Parts Identification……………………………..416
Disassembly……………………………………..417
Inspection………………………………………424
Assembly………………………………………..424
MAIN FRAME……………………………………………..429
OPERATOR CAB………………………………………..431
Removal And Installation………………………….431
Cab Mount Removal And Installation…………………438
OPERATOR SEAT……………………………………….439
Removal And Installation………………………….439
FLOOR PANELS………………………………………..441
Left Front Panel Removal And Installation…………..441
Right Front Panel Removal And Installation………….441
Rear Panel Removal And Installation………………..442
GRILL………………………………………………443
Removal And Installation………………………….443
GRILL FRAME…………………………………………445
Removal And Installation………………………….445
ENGINE SIDE COVERS…………………………………..447
Removal And Installation………………………….447
FENDER……………………………………………..449
Removal And Installation………………………….449
ENGINE COVER………………………………………..451
Removal And Installation………………………….451
FUEL TANK…………………………………………..453
Removal And Installation………………………….453
Fuel Fill Screen Removal And Installation…………..454
LIFT ARMS…………………………………………..455
Removal And Installation………………………….455
BOB-TACH……………………………………………459
Removal And Installation………………………….459
Bob-Tach Lever And Wedge………………………….461
Pivot Pin Bushing Removal And Installation………….463
ARM………………………………………………..465
Removal And Installation………………………….465
Arm Pivot Bushing Removal And Installation………….466
BOOM……………………………………………….467
Removal And Installation………………………….467
Boom Pivot Bushing Removal And Installation…………469
SWING FRAME…………………………………………471
Removal And Installation………………………….471
Bushing Removal And Installation…………………..472
X-CHANGE™…………………………………………..473
Removal And Installation………………………….473
CAB DOOR……………………………………………475
Removal And Installation………………………….475
STABILIZER………………………………………….477
Removal And Installation………………………….477
FRONT AXLE PIVOT FRAME……………………………….481
Removal…………………………………………481
Installation…………………………………….482
Bushing Removal And Installation…………………..483
ELECTRICAL SYSTEM AND ANALYSIS……………………………485
ELECTRICAL SCHEMATIC…………………………………487
ELECTRICAL SYSTEM INFORMATION…………………………489
Troubleshooting Chart…………………………….489
Description……………………………………..490
Fuse Location……………………………………490
BATTERY…………………………………………….491
Removal And Installation………………………….491
Servicing The Electrical System……………………492
Using A Booster Battery (Jump Starting)…………….493
ALTERNATOR………………………………………….495
Adjusting The Alternator Belt……………………..495
Description……………………………………..495
Tests…………………………………………..496
Alternator Output Test……………………………496
Full Field Test………………………………….497
Alternator Regulator Test…………………………497
Alternator Regulator Test With Voltmeter……………498
Removal And Installation………………………….499
Parts Identification……………………………..500
Pulley Removal And Installation……………………501
Disassembly And Assembly………………………….502
Rotor Continuity Test…………………………….505
Stator Continuity Test……………………………505
Rectifier Continuity (Diode) Test………………….506
Brush Length…………………………………….506
STARTER…………………………………………….507
Removal And Installation………………………….507
Checking The Starter In The Loader…………………507
Parts Identification……………………………..509
Disassembly……………………………………..510
Inspection And Repair…………………………….515
No Load Test…………………………………….519
Assembly………………………………………..520
FRONT LIGHTS………………………………………..527
Bulb Removal And Installation……………………..527
Housing Removal And Installation…………………..529
TURN INDICATOR LIGHTS (FRONT)…………………………531
Bulb Removal And Installation……………………..531
TURN INDICATOR LIGHTS (REAR)………………………….533
Bulb Removal And Installation……………………..533
CAB LIGHTS………………………………………….535
Bulb Removal And Installation……………………..535
Housing Removal And Installation…………………..537
FUEL LEVEL SENDER……………………………………539
Removal And Installation………………………….539
INSTRUMENT PANEL…………………………………….541
Removal And Installation………………………….541
ENGINE SERVICE………………………………………….543
TROUBLESHOOTING……………………………………..547
Chart…………………………………………..547
ENGINE SPEED CONTROL…………………………………549
Removal And Installation………………………….549
Cable Removal And Installation…………………….550
MUFFLER…………………………………………….551
Removal And Installation………………………….551
AIR CLEANER…………………………………………553
Removal And Installation………………………….553
RADIATOR……………………………………………555
Removal And Installation………………………….555
ENGINE COMPONENTS AND TESTING…………………………557
Checking Engine Compression……………………….557
Checking Glow Plugs………………………………558
Glow Plug Removal And Installation…………………559
Fuel Shut-Off Solenoid Removal And Installation……..560
Checking Fuel Injection Pump………………………561
Fuel Injection Pump Removal And Installation………..562
Fuel Injection Pump Timing………………………..564
Fuel Injector Nozzles Removal And Installation………565
Checking Fuel Injector, Nozzles……………………567
Thermostat Removal And Installation………………..568
Water Pump Removal And Installation………………..569
ENGINE……………………………………………..571
Removal And Installation………………………….571
Mount Replacement………………………………..575
RECONDITIONING THE ENGINE…………………………….577
Timing Gear Case Cover Removal And Installation……..577
Oil Pump Removal And Installation………………….579
Crankshaft Front Seal Removal And Installation………581
Engine Speed Control Plate Removal And Installation….582
Idle Limit And Fuel Limit Adjustment……………….583
Exhaust Manifold Removal And Installation…………..583
Valve Cover Removal And Installation……………….584
Rocker Arm Removal And Installation………………..585
Push Rod Removal And Installation………………….586
Tappet Removal And Installation……………………587
Water Flange Removal And Installation………………587
Cylinder Head Removal And Installation……………..588
Checking Piston Top Clearance……………………..589
Cylinder Head Disassembly And Assembly……………..590
Servicing The Cylinder Head……………………….591
Combustion Chamber Removal And Installation…………594
Idler Gear Removal And Installation………………..595
Camshaft Removal And Installation………………….596
Fuel Camshaft Removal And Installation……………..598
Oil Pan Removal And Installation…………………..600
Governor Shaft Removal And Installation…………….601
Governor Fork Lever Removal And Installation………..604
Piston Removal And Installation……………………606
Checking The Piston And Connecting Rod……………..606
Connecting Rod Alignment………………………….607
Piston Ring Gap………………………………….607
Piston Ring Installation………………………….608
Connecting Rod Installation……………………….609
Checking Engine Cylinder Bore……………………..609
Crankshaft Removal And Installation………………..610
Checking Crankshaft Journal And Block Bearing……….612
Checking Crankshaft Journal And Main Bearing………..613
Connecting Rod Journal……………………………614
Checking The End Play Of The Crankshaft…………….615
Crankshaft Alignment……………………………..615
Engine Timing Installation………………………..616
Timing Gear Backlash, Idler Gear And Crankshaft……..616
Idler Gear And Camshaft Gear………………………617
Idler Gear And Fuel Camshaft Gear………………….617
Fuel Camshaft Gear And Governor Shaft Gear………….617
FLYWHEEL HOUSING…………………………………….619
Removal And Installation………………………….619
FLYWHEEL……………………………………………621
Removal And Installation………………………….621
Ring Gear Removal And Installation…………………621
RUBBER DRIVE COUPLER…………………………………623
Removal And Installation………………………….623
Disassembly……………………………………..623
TURBOCHARGER………………………………………..625
Removal And Installation………………………….625
SPECIFICATIONS………………………………………….629
LOADER SPECIFICATIONS………………………………..631
Loader Backhoe Dimensions…………………………631
Performance……………………………………..632
Controls………………………………………..632
Engine………………………………………….632
Electrical………………………………………633
Drive System…………………………………….633
Capacities………………………………………633
Tires…………………………………………..633
ENGINE SPECIFICATIONS………………………………..635
Engine Compression……………………………….635
Fuel Injection Nozzles……………………………635
Fuel Injection Pump………………………………635
Cylinder Head……………………………………635
Valves………………………………………….635
Valve Springs……………………………………636
Rocker Arms……………………………………..636
Camshaft………………………………………..636
Cylinders……………………………………….636
Piston Rings…………………………………….637
Pistons…………………………………………637
Crankshaft………………………………………637
Oil Pump………………………………………..638
Thermostat………………………………………638
Grinding Specifications for the Crankshaft………….639
LOADER BACKHOE TORQUE………………………………..641
Specifications…………………………………..641
TORQUE SPECIFICATIONS FOR BOLTS……………………….643
Torque For General Metric Bolts……………………643
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS……………..645
Specifications…………………………………..645
CONVERSIONS…………………………………………647
Decimal And Millimeter Equivalents…………………647
U.S. To Metric Conversion…………………………647
SMR……………………………………………………649
B200-1……………………………………………..649
B200-2……………………………………………..651
B200-3……………………………………………..653
B200-4……………………………………………..655
B200-5……………………………………………..657
B200-6……………………………………………..659
B200-7 …………………………………………….661
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DESCRIPTION:
BOBCAT B200 SN 570211001 Service Manual PDF DOWNLOAD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, Starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
- Check that ROPS mounting hardware is tightened and is Bobcat approved.
- The seat belt must be correctly installed, functional and in good condition.
- Check lift arm support device, replace if damaged.
- Machine signs must be legible and in the correct location.
- Foot pedal must return to neutral.
- Check for correct function of the work lights.
- The parking brake must function correctly.
- Enclosure door latches must open and close freely.
- Bob-Tach wedges and linkages must function correctly and be in good condition.
- Safety treads must be in good condition.
- Check for correct function of indicator lamps (Optional on some models).
- Check hydraulic fluid level, engine oil level and fuel supply.
- Inspect for fuel, oil or hydraulic fluid leaks.
- Lubricate the loader backhoe.
- Check the condition of the battery and cables.
- Inspect the air cleaner for damage or leaks. Check the condition of the element.
- Check the electrical charging system.
- Check tires for wear and pressure.
- Inspect for loosen or broken parts or connections.
- Operate the loader and check all functions.
- Check for any field modification not completed.
- Recommend to the owner that all necessary corrections be made before the machine is returned to service.
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
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