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Bobcat 2200 - Service Manual

Bobcat 2200
56 pages
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6903128 (3/04) Revised 07/07 (6) Printed in U.S.A. © Bobcat Company 2004
Operation
&
Maintenance
Manual
S/N 235311001 to 235312612 (Diesel)
S/N 235211001 to 235212052 (Gasoline)
Utility Vehicle
2200

Table of Contents

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Summary

NOTICE

FOREWORD

Safety Decal Identification - Gasoline Vehicles

UNDERAGE WARNING DECAL

Warning about underage drivers and supervision.

DRIVER;PASSENGER WARNING DECAL

Safety warnings for vehicle occupants regarding operation.

CERTIFICATION NOTICE AND WARNING DECAL

ROPS certification and critical warnings for safe operation.

BED LOAD WARNING DECAL

Warning against riding in the cargo bed due to severe injury risk.

ROTATING PARTS WARNING DECAL

Warning to keep clear of rotating parts to prevent injury.

TRAILER HITCH DECAL

Specifies maximum trailer hitch tongue weight.

CRUSH AREA DECAL

Warns of crush hazards when closing the bed.

VEHICLE LOADING DECAL

Details gross vehicle and cargo load weight limits.

BED LATCH WARNING DECAL

Warns of crush hazard when closing the bed latch.

PREVENT VEHICLE ROLL-OVER

Guidance on cargo placement to prevent rollovers.

GASOLINE WARNING DECAL

Warning regarding gasoline explosion and fire hazards.

OPERATING INSTRUCTIONS DECALS

Decals providing key operational instructions and warnings.

HOT SURFACE WARNING DECAL

Warns of hot surfaces that can cause severe burns.

WINCH CABLE WARNING DECAL

Safety warning for vehicles equipped with a winch accessory.

FRAME GROUND WARNING DECAL

Warning about electrical hazards related to frame grounding.

ROTATING PARTS AND HOT MANIFOLD WARNING DECAL

Warnings for rotating parts and hot manifold.

Safety Decal Identification - Diesel Vehicles

UNDERAGE WARNING DECAL

Warning about underage drivers and supervision.

DRIVER;PASSENGER WARNING DECAL

Safety warnings for vehicle occupants regarding operation.

CERTIFICATION NOTICE AND WARNING DECAL

ROPS certification and critical warnings for safe operation.

BED LOAD WARNING DECAL

Warning against riding in the cargo bed due to severe injury risk.

ROTATING PARTS DECAL

Warning to keep clear of rotating parts to prevent injury.

TRAILER HITCH DECAL

Specifies maximum trailer hitch tongue weight.

CRUSH AREA DECAL

Warns of crush hazards when closing the bed.

VEHICLE LOADING DECAL

Details gross vehicle and cargo load weight limits.

BED LATCH WARNING DECAL

Warns of crush hazard when closing the bed latch.

PREVENT VEHICLE ROLL-OVER

Guidance on cargo placement to prevent rollovers.

DIESEL WARNING DECAL

Warning regarding diesel fuel explosion and fire hazards.

ROTATING PARTS WARNING DECAL

Warning to keep clear of rotating parts to prevent injury.

HOT MANIFOLD WARNING DECAL

Warns of hot manifold and muffler surfaces.

OPERATING INSTRUCTIONS DECALS

Decals providing key operational instructions and warnings.

HOT SURFACE WARNING DECAL

Warns of hot surfaces that can cause severe burns.

WINCH CABLE WARNING DECAL

Safety warning for vehicles equipped with a winch accessory.

FRAME GROUND WARNING DECAL

Warning about electrical hazards related to frame grounding.

ROTATING PARTS AND HOT MANIFOLD DECAL

Warnings for rotating parts and hot manifold.

Practice Safety

PROPOSITION 65 - STATE OF CALIFORNIA

Warning about chemicals that may cause cancer or birth defects.

Safety Details

DANGER HAZARD DEFINITION

Defines DANGER as an immediate hazard leading to severe injury or death.

WARNING HAZARD DEFINITION

Defines WARNING as an immediate hazard leading to severe injury or death.

CAUTION WITH SYMBOL DEFINITION

Defines CAUTION with symbol as a hazard leading to minor personal injury.

CAUTION WITHOUT SYMBOL DEFINITION

Defines CAUTION without symbol as a situation leading to property damage.

General Warnings

BATTERY AND FUEL DANGER WARNINGS

Hazards related to battery, fuel, and enclosed spaces.

OPERATION AND MODIFICATION WARNINGS

Warnings on operation, passengers, seat belts, parking, and modifications.

TECHNICIAN AND STARTING WARNINGS

Warnings for technicians, preventing unintentional starts, and safety gear.

General Information

MODEL IDENTIFICATION

Explains how to find the vehicle's serial number.

CONTROLS AND INDICATORS OVERVIEW

Introduces the vehicle's controls and indicators.

Controls and Indicators

KEY SWITCH - GASOLINE VEHICLE OPERATION

Operation of the ignition key switch for gasoline models.

KEY SWITCH - DIESEL VEHICLE OPERATION

Operation of the ignition key switch for diesel models.

FORWARD;REVERSE SHIFT LEVER OPERATION

How to operate the forward and reverse shift lever.

ACCELERATOR PEDAL FUNCTION

Function and operation of the accelerator pedal.

BRAKE PEDAL FUNCTION

Function and operation of the brake pedal.

PARK BRAKE OPERATION

How to engage and disengage the park brake.

LOW OIL WARNING LIGHT INDICATOR

Indicates low engine oil level and necessary action.

FUEL GAUGE AND HOUR METER

Monitors fuel level and engine operating hours.

HEADLIGHT CONTROL OPERATION

How to operate the vehicle's headlights.

STEERING ADJUSTMENT LOCK MECHANISM

Mechanism for adjusting and locking the steering wheel.

ELECTRIC BED LIFT SYSTEM OPERATION

Operation of the electric bed lift system.

CHOKE OPERATION FOR GASOLINE ENGINES

Choke operation for starting gasoline engines in cold weather.

HIGH-TEMPERATURE WARNING LIGHT FOR DIESEL

Indicates overheating for diesel engines.

Roll-over Protective Structure (ROPS) and Safety Belts

ROPS AND SAFETY BELT WARNINGS

Warnings regarding ROPS installation, damage, and restraint use.

Seat Latch and Adjustment

SEAT OCCUPANCY AND CHILD SAFETY WARNINGS

Warnings about seat occupancy and child safety requirements.

SEAT LATCH AND ADJUSTMENT PROCEDURE

How to secure and adjust the vehicle seats.

Pre-Operation and Daily Safety Checklist

Driving Instructions

PERFORMANCE INSPECTION CHECKLIST

Checklist for testing vehicle performance before operation.

DRIVING SAFETY WARNINGS

Warnings for licensed drivers and operator familiarity.

PASSENGER AND NIGHT USE DRIVING WARNINGS

Continued driving warnings regarding passenger limits and night use.

VEHICLE STARTING PROCEDURE

Step-by-step procedure for starting the vehicle.

ALL-WHEEL DRIVE (AWD) OPERATION EXPLANATION

Explanation of how the AWD system functions.

CRITICAL DRIVING WARNINGS

Critical warnings about shifting, body positioning, and slopes.

VEHICLE STOPPING PROCEDURE

Procedure for safely stopping the vehicle.

PARKING AND LEAVING VEHICLE PROCEDURE

Steps for properly parking and securing the vehicle.

BED LATCH AND PROP ROD OPERATION

Operation of the bed latch and prop rod system.

Bed Latch and Prop Rod

BED AND PROP ROD SAFETY WARNINGS

Warnings about cargo bed safety and prop rod engagement.

FRONT SHOCK ABSORBER ADJUSTMENT

Information on front shock absorber adjustment.

LOADING AND UNLOADING GUIDELINES

Warnings and guidelines for loading and unloading the vehicle.

Loading and Unloading

LOAD AND HILL STOPPING WARNINGS

Warnings about top-heavy loads and stopping on hills.

TOWING VEHICLE AND TRAILER GUIDELINES

Safety warnings and guidelines for towing other vehicles or trailers.

Towing with the Vehicle

TOWING AND TRANSPORT WARNINGS

Continued warnings for towing, especially on hills and with sudden movements.

TRANSPORTING VEHICLE ON TRAILER PROCEDURE

Procedures and warnings for safely transporting the vehicle on a trailer.

Transporting on a Trailer

TRAILER TRANSPORT AND PUBLIC ROAD WARNINGS

Warnings for transporting on public roads and securing the vehicle.

VEHICLE STORAGE GENERAL WARNINGS

General warnings and considerations for vehicle storage.

STORAGE

FUEL STORAGE DANGERS AND PRECAUTIONS

Dangers associated with fuel handling and storage.

EXTENDED STORAGE PREPARATION STEPS

Steps to prepare the vehicle for long-term storage.

PREPARING THE VEHICLE FOR EXTENDED STORAGE

STORAGE PREPARATION WARNINGS

Storage warnings about key switch, fuel valve, and batteries.

BATTERY FREEZING CAUTION

Caution regarding battery freezing in low temperatures.

RETURNING STORED VEHICLE TO SERVICE PROCEDURE

Steps for bringing a stored vehicle back into service.

MAINTENANCE

GENERAL MAINTENANCE SAFETY WARNINGS

General warnings for maintenance procedures and safety.

Periodic Service Schedule

SERVICE AND REPAIR WARNINGS

Warnings related to performing service and repairs.

PERIODIC SERVICE SCHEDULE DETAILS

The schedule detailing regular service intervals.

DAILY SERVICE TASKS

Daily inspection and service tasks for engine, fuel filters, and brakes.

MONTHLY SERVICE TASKS

Monthly inspection and service tasks for engine and tires.

ADJUSTMENT INTERVALS

Initial and recurring adjustments for engine and transmission/differentials.

SEMIANNUAL SERVICE TASKS

Semi-annual service for general vehicle, engine, battery, and electrical systems.

ANNUAL SERVICE TASKS

Annual service for engine, radiator, and air intake systems.

1000-HOUR SERVICE TASKS

Specific service tasks for fuel filters and brake system at 1000 hours.

PERIODIC LUBRICATION SCHEDULE

ENGINE OIL AND FILTER CHANGE SCHEDULE

Engine oil and filter change schedule for gasoline and diesel vehicles.

DRIVESHAFT MONTHLY LUBRICATION

Monthly lubrication for the driveshaft.

BRAKE FLUID AND REAR SUSPENSION SEMIANNUAL LUBRICATION

Semi-annual lubrication for brake fluid and rear suspension.

FRONT DIFFERENTIAL LUBRICATION SCHEDULE

Lubrication schedule for the front differential.

REAR DIFFERENTIAL LUBRICATION SCHEDULE

Lubrication schedule for the rear differential.

TRANSMISSION LUBRICATION SCHEDULE

Schedule for changing transmission lubricant.

Brake Fluid Reservoir

BRAKE FLUID LEVEL AND TYPE CHECK

How to check and maintain brake fluid level and type.

ENGINE OIL LEVEL CHECK IMPORTANCE

Importance and procedure for checking engine oil level.

Engine Oil

GASOLINE ENGINE OIL PRESSURE SPECIFICATIONS

Information on oil pressure for gasoline engines.

ENGINE OIL LEVEL CHECK PROCEDURE

Step-by-step guide to checking the engine oil level.

ENGINE OIL AND FILTER CHANGE PROCEDURE

Procedure for changing engine oil and oil filter.

ENGINE OIL DRAINING STEPS

Steps for draining the engine oil.

ENGINE OIL FILTER CHANGE PROCEDURE

Detailed steps for replacing the engine oil filter.

ENGINE OIL FILLING PROCEDURE

Procedure for adding new engine oil, including capacity and viscosity.

ENGINE OIL VISCOSITY CHARTS

Charts showing recommended oil viscosity based on temperature.

Gearcase Lubrication

GEARCASE LUBRICANT LEVEL CHECK

How to check lubricant levels in gearcase components.

GEARCASE LUBRICANT CHANGE PROCEDURE

Procedures for changing lubricants in differentials and transmission.

Rear differential

DIESEL ENGINE COOLANT LEVEL CHECK

Procedure for checking engine coolant level in diesel vehicles.

Air Intake

AIR INTAKE SYSTEM FRAME DRILLING CAUTION

Caution against drilling into the frame near the air intake.

AIR FILTER REPLACEMENT PROCEDURE

Instructions for inspecting and replacing the air filter.

Fueling Instructions

FUELING DANGERS AND SAFETY PRECAUTIONS

Dangers and safety precautions to follow before and during fueling.

Draining Water From Fuel Filter

FUEL FILTER DRAINING WARNING

Warning about cleaning spilled fuel to prevent fire or explosion.

Battery

BATTERY EXPLOSION AND ACID DANGERS

Dangers associated with battery gases, sparks, and acid.

JUMP-STARTING BATTERY WARNING

Warning against jump-starting a dead battery.

Cleaning the Vehicle

BATTERY TERMINAL CORROSION CAUTION

Caution regarding battery wire terminal condition.

Accessories

ACCESSORY PROTECTION AND BED LIFT WARNINGS

Warnings about accessory protection and bed lift servicing.

ACCESSORY FRAME DRILLING CAUTION

Caution against drilling into frame for accessories.

ELECTRIC WINCH OPERATION INFORMATION

Information and warnings for electric winch operation.

Vehicle Specifications

MUD TIRE OPERATION WARNINGS

Warnings for operating vehicles with mud tires on paved surfaces.

VEHICLE SPECIFICATIONS SUMMARY

Summary table of vehicle specifications.

DIMENSIONS AND WEIGHT SPECIFICATIONS

Detailed table of vehicle dimensions and weights.

LIQUID CAPACITIES SPECIFICATIONS

Table listing all liquid capacities for the vehicle.

TIRE PRESSURE SPECIFICATIONS

Specifications for tire pressure for all-terrain and mud tires.

POWER SOURCE SPECIFICATIONS

Specifications for gasoline and diesel engines.

STEERING SUSPENSION BRAKES SPECIFICATIONS

Specifications for steering, suspension, and brake systems.

BODY AND CHASSIS SPECIFICATIONS

Specifications for the vehicle's body and chassis.

TIRE SPECIFICATIONS

Specifications for all-terrain and mud tires.

WARRANTY

Bobcat 2200 Specifications

General IconGeneral
BrandBobcat
Model2200
CategoryUtility Vehicle
LanguageEnglish