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Bobcat Utility Vehicle 2200 2200S 2300 Service Manual 6904893 (12-09) – PDF DOWNLOAD
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Bobcat Utility Vehicle 2200 2200S 2300 Service Manual 6904893 (12-09) – PDF DOWNLOAD
S/N A59Z11001 & ABOVE (2200 DIESEL)
S/N A5KR11001 & ABOVE (2200 DIESEL) HOM.
S/N A59Y11001 & ABOVE (2200 GASOLINE)
S/N A5A111001 & ABOVE (2200S DIESEL)
S/N A5A011001 & ABOVE (2200S GASOLINE)
S/N A59W11001 & ABOVE (2300 DIESEL)
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Description
Bobcat Utility Vehicle 2200 2200S 2300 Service Manual 6904893 (12-09) – PDF DOWNLOAD
FILE DETAILS:
Bobcat Utility Vehicle 2200 2200S 2300 Service Manual 6904893 (12-09) – PDF DOWNLOAD
Language : English
Pages : 892
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat Utility Vehicle 2200 2200S 2300 Service Manual 6904893 (12-09) – PDF DOWNLOAD
S/N A59Z11001 & ABOVE (2200 DIESEL)
S/N A5KR11001 & ABOVE (2200 DIESEL) HOM.
S/N A59Y11001 & ABOVE (2200 GASOLINE)
S/N A5A111001 & ABOVE (2200S DIESEL)
S/N A5A011001 & ABOVE (2200S GASOLINE)
S/N A59W11001 & ABOVE (2300 DIESEL)
FOREWORD
- 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. This manual was written for the trained technician who already possesses knowledge and skills in electrical and mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to the vehicle may render the vehicle unsafe.
- For this reason, Bobcat Company advises that all repairs and/or service be performed by an authorized Bobcat 2200 and 2200S distributor/dealer representative or by a Bobcat factory-trained technician. It is the policy of Bobcat Company to assist its distributors and dealers in continually updating their service knowledge and facilities so they can provide prompt and efficient service for vehicle owners.
- Regional technical representatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent Bobcat Company’s continuing commitment to customer support. This manual covers all aspects of typical vehicle service; however, unique situations sometimes occur when servicing a vehicle. If it appears that a service question is not answered in this manual, you may write to us at: P.O. Box 204658; Augusta, GA 30917; Attention: Technical Services, or contact a Technical Service Representative
at (706) 863-3000, ext. 3580.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat Utility Vehicle 2200 2200S 2300 Service Manual 6904893 (12-09) – PDF DOWNLOAD
Section 1 - Safety............................................................................. 21 General Warning............................................................................ 21 Section 2a - Vehicle Specifications: Honda Gas & Kubota Diesel Powered......................... 25 2200 and 2200S Specifications.............................................................. 25 2300 Specifications........................................................................ 27 Section 2b - Vehicle Specifications: Kawasaki Gas & Kubota Diesel Powered...................... 29 2200 and 2200S Specifications.............................................................. 29 2200 Homologated Specifications............................................................ 31 2300 Specifications........................................................................ 33 Section 3 - General Information................................................................ 35 General Information........................................................................ 35 Model Identification....................................................................... 35 Engine Serial Number Locations............................................................. 36 Gasoline EngineS....................................................................... 36 Diesel Engine.......................................................................... 36 Storage.................................................................................... 36 Preparing the Vehicle for Extended Storage............................................. 37 Returning the Stored Vehicle to Service................................................ 38 Using A Booster Battery (Jump Starting).................................................... 39 Section 4 - Body and Trim...................................................................... 41 Cleaning the Vehicle....................................................................... 41 Seat Cleaning.......................................................................... 41 Front Body Repair.......................................................................... 42 Light Scratches........................................................................ 42 Abrasions and Haze..................................................................... 42 Large Scratches and Abrasions.......................................................... 42 Front Body Components...................................................................... 43 Instrument Panel Removal............................................................... 43 Instrument Panel Installation.......................................................... 43 Front Fascia Removal................................................................... 44 Front Fascia Installation.............................................................. 44 Hood Removal........................................................................... 44 Hood Installation...................................................................... 44 Center Cowl Panel Removal.............................................................. 44 Center Cowl Panel Installation......................................................... 45 Side Cowl Panel (Fender) Removal....................................................... 45 Side Cowl Panel (Fender) Installation.................................................. 45 Front Fender Flare Removal............................................................. 46 Front Fender Flare Installation........................................................ 46 Roll-Over Protective Structure (ROPS)...................................................... 46 ROPS Removal........................................................................... 47 ROPS Installation...................................................................... 48 Seat....................................................................................... 49 Seat Removal........................................................................... 49 Seat Adjustment........................................................................ 49 Seat Installation...................................................................... 49 Seat Support Removal................................................................... 50 Seat Support Installation.............................................................. 50 Safety Belts............................................................................... 50 Safety Belt Removal.................................................................... 50 Safety Belt Installation............................................................... 51 Cargo Bed - Electric Lift.................................................................. 51 Testing the Bed Lift Motor............................................................. 51 Bed Lift Motor Removal................................................................. 51 Bed Lift Motor Installation............................................................ 52 Cargo Bed Removal...................................................................... 52 Cargo Bed Installation................................................................. 52 Cargo Bed - Manual Lift.................................................................... 53 Cargo Bed Removal...................................................................... 53 Cargo Bed Installation................................................................. 53 Rear Fender................................................................................ 55 Rear Fender Removal.................................................................... 55 Rear Fender Installation............................................................... 55 Floor Mat.................................................................................. 55 Floor Mat Removal...................................................................... 55 Floor Mat Installation................................................................. 55 Section 5 - Accelerator and Brake Pedal Assemblies............................................. 57 Accelerator Pedal.......................................................................... 57 Accelerator Pedal Removal.............................................................. 57 Accelerator Pedal Installation......................................................... 58 Accelerator Pedal and RPM Adjustment................................................... 58 Brake Pedal................................................................................ 59 Brake Pedal Removal.................................................................... 59 Brake Pedal Installation............................................................... 59 Brake Pedal Adjustment................................................................. 60 Park Brake Pedal........................................................................... 60 Park Brake Pedal Assembly Removal...................................................... 60 Park Brake Pedal Assembly Installation................................................. 60 Section 6 - Hydraulic and Park Brake Systems................................................... 63 Brake System Inspection.................................................................... 63 Brake System Troubleshooting............................................................... 65 Brake Pads and Caliper..................................................................... 67 Front Brake Pad and Caliper Removal.................................................... 67 Front Brake Pad and Caliper Installation............................................... 69 Rear Brake Pad and Caliper Removal..................................................... 70 Rear Brake Pad and Caliper Installation................................................ 71 Brake Disc and Hub......................................................................... 72 Front Wheel Disc and Hub Removal....................................................... 72 Front Wheel Disc and Hub Installation.................................................. 76 Rear Wheel Disc Removal................................................................ 77 Rear Wheel Disc Installation........................................................... 78 Hydraulic Line Replacement................................................................. 79 Front Brake Line Removal............................................................... 79 Front Brake Line Installation.......................................................... 79 Rear Brake Line Removal................................................................ 80 Rear Brake Line Installation........................................................... 81 Master Cylinder and Reservoir.............................................................. 82 Filling the Hydraulic System........................................................... 82 Reservoir Removal...................................................................... 82 Reservoir Installation................................................................. 82 Master Cylinder Removal................................................................ 83 Master Cylinder Installation........................................................... 83 Bleeding the Hydraulic Brake System........................................................ 84 Bleeding Brakes on a DOT 5 Fluid Filled System......................................... 84 Purging the Hydraulic System........................................................... 86 Park Brake System.......................................................................... 87 Park Brake Adjustment.................................................................. 87 Park Brake Cable Adjustment............................................................ 87 Park Brake Wheel Cables................................................................ 88 Front Park Brake Cable Removal......................................................... 89 Front Park Brake Cable Installation.................................................... 90 Park Brake Equalizer Removal........................................................... 90 Park Brake Equalizer Installation...................................................... 90 Section 7 - Steering and Front Suspension...................................................... 93 Steering Wheel............................................................................. 93 Steering Wheel Removal................................................................. 93 Steering Wheel Installation............................................................ 94 Steering Column............................................................................ 94 Steering Column Removal................................................................ 94 Steering Column Installation........................................................... 95 Rack and Pinion............................................................................ 95 Rack and Pinion Removal................................................................ 95 Rack and Pinion Installation........................................................... 96 Rack and Pinion Disassembly............................................................ 97 Rack and Pinion Assembly...............................................................101 Front Suspension...........................................................................103 Wheel Alignment........................................................................103 Front Suspension Components................................................................105 Steering Upright Removal...............................................................105 Upper A-Arm Removal....................................................................106 Upper A-Arm Installation...............................................................108 Lower A-Arm Removal....................................................................108 Lower A-Arm Installation...............................................................109 Front Coil-Over Shock Absorber Removal.................................................110 Front Coil-Over Shock Absorber Installation............................................111 Steering Upright Installation..........................................................111 Section 8 - Wheels and Tires...................................................................113 General Information........................................................................113 Wheels.....................................................................................114 Wheel Removal..........................................................................114 Wheel Installation.....................................................................114 Tires......................................................................................114 Tire Removal...........................................................................114 Tire Installation......................................................................115 Section 9 - Rear Suspension....................................................................117 Rear Coil-Over Shock Absorber..............................................................117 Swing Arms.................................................................................118 Swing Arm Removal......................................................................118 Swing Arm Installation.................................................................119 Section 10a - Periodic Maintenance: Honda Gasoline & Kubota Diesel Vehicles....................121 Periodic Service Schedule..................................................................121 Periodic Lubrication Schedule - 2200.......................................................124 Periodic Lubrication Schedule - 2300.......................................................126 Lubricating The Attachment Arm And Interface...............................................127 Brake Fluid Reservoir......................................................................128 Brake Fluid............................................................................128 Engine Oil.................................................................................128 Oil Pressure - Gasoline Engine.........................................................129 Engine Oil Level Check.................................................................129 Engine Oil and Filter Change...........................................................130 Oil Viscosity..........................................................................133 Gearcase Lubrication.......................................................................134 Lubrication Level Check for Front Differential, Transmission, and Rear Differential....134 Lubrication Change for Front Differential, Transmission, and Rear Differential.........134 Hydraulic System - 2300 Vehicle............................................................136 Engine Coolant - Diesel Vehicles...........................................................137 Engine Coolant Level Check.............................................................137 Fueling Instructions.......................................................................137 Draining Water from Fuel Filter........................................................138 Battery....................................................................................139 Section 10b - Periodic Maintenance: Kawasaki Gasoline & Kubota Diesel Powered Vehicles.........141 Periodic Service Schedule..................................................................141 Periodic Lubrication Schedule - 2200.......................................................144 Lubricating The Attachment Arm And Interface...............................................146 Brake Fluid Reservoir......................................................................147 Brake Fluid............................................................................147 Engine Oil.................................................................................147 Oil Pressure - Gasoline Engine.........................................................148 Engine Oil Level Check.................................................................148 Engine Oil and Filter Change...........................................................148 Oil Viscosity..........................................................................151 Spark Plugs................................................................................152 Spark Plug Cleaning And Inspection.....................................................152 Spark Plug Gap Inspection..............................................................152 Gearcase Lubrication.......................................................................153 Lubrication Level Check for Front Differential, Transmission, and Rear Differential....153 Lubrication Change for Front Differential, Transmission, and Rear Differential.........153 Hydraulic System - 2300 Vehicle............................................................155 Engine Coolant - Diesel Vehicles...........................................................156 Engine Coolant Level Check.............................................................156 Fueling Instructions.......................................................................156 Draining Water from Fuel Filter........................................................157 Battery....................................................................................158 Section 11a - Troubleshooting and Electrical System: Kawasaki Powered Gasoline Vehicles........159 Troubleshooting Guide......................................................................159 Wiring Diagram.............................................................................164 Test Procedures............................................................................166 Index of Test Procedures...............................................................166 Section 11b - Troubleshooting and Electrical System: Honda Powered Gasoline Vehicles...........201 Troubleshooting Guide......................................................................201 Wiring Diagram.............................................................................206 Test Procedures............................................................................208 Index of Test Procedures...............................................................208 Section 11c - Troubleshooting and Electrical System: Diesel Vehicles...........................241 Troubleshooting Guide......................................................................241 Wiring Diagram.............................................................................246 Test Procedures............................................................................252 Index of Test Procedures...............................................................252 Section 12a - Electrical Components: Kawasaki Powered Gasoline Vehicles........................295 Starter and Starter Solenoid...............................................................295 Relays.....................................................................................295 Neutral Switch.............................................................................296 Carburetor Solenoid........................................................................296 Carburetor Heater..........................................................................297 Voltage Regulator..........................................................................298 Warning Lights.............................................................................299 Fuel Gauge/Hour Meter......................................................................300 Key Switch.................................................................................301 12-Volt Accessory Receptacle...............................................................302 Bed Lift Switch............................................................................303 Bed Lift Circuit Breaker...................................................................303 Light Switch...............................................................................304 Fuse.......................................................................................304 Reverse Warning Buzzer (If Equipped).......................................................305 Reverse Warning Buzzer Limit Switch (If Equipped)..........................................306 Front Differential Switch..................................................................307 Fuel Level Sending Unit....................................................................308 Ignition Coil and Charge Coil..............................................................309 Oil Pressure Sensor........................................................................309 Headlights.................................................................................309 Wire Harness Diodes........................................................................310 Battery....................................................................................311 General Information....................................................................311 Section 12b - Electrical Components: Honda Powered Gasoline Vehicles...........................315 Starter and Starter Solenoid...............................................................315 Relays.....................................................................................315 Neutral Switch.............................................................................316 Carburetor Solenoid........................................................................316 Voltage Regulator..........................................................................317 Warning Lights.............................................................................318 Fuel Gauge/Hour Meter......................................................................319 Key Switch.................................................................................320 12-Volt Accessory Receptacle...............................................................321 Bed Lift Switch............................................................................322 Bed Lift Circuit Breaker...................................................................322 Light Switch...............................................................................323 Fuse.......................................................................................323 Reverse Warning Buzzer.....................................................................324 Reverse Warning Buzzer Limit Switch........................................................325 Fuel Level Sending Unit....................................................................326 Ignition Coil and Charge Coil..............................................................326 Charge Coil................................................................................327 Oil Pressure Sensor........................................................................327 Headlights.................................................................................327 Wire Harness Diodes........................................................................328 Battery....................................................................................329 General Information....................................................................329 Section 12c - Electrical Components: Diesel Vehicles...........................................333 Starter and Starter Solenoid...............................................................333 Relays.....................................................................................333 Neutral Switch.............................................................................334 Fuel Solenoid..............................................................................334 60-Amp Fusible Link........................................................................335 Warning Lights.............................................................................336 Fuel Gauge/Hour Meter......................................................................338 Key Switch.................................................................................339 12-Volt Accessory Receptacle...............................................................339 Bed Lift Switch............................................................................340 Bed Lift Circuit Breaker...................................................................340 Light Switch...............................................................................341 Fuse.......................................................................................341 Reverse Warning Buzzer (If Equipped).......................................................342 Reverse Warning Buzzer Limit Switch (If Equipped)..........................................343 Electric Fuel Pump.........................................................................344 Fuel Level Sending Unit....................................................................344 Alternator.................................................................................345 Oil Pressure Sensor........................................................................347 Headlights.................................................................................347 Thermostat Switch..........................................................................348 Fan........................................................................................349 Wire Harness Diodes........................................................................350 Battery....................................................................................351 General Information....................................................................351 Section 13a - Kawasaki Gasoline Engine, Muffler, Fuel System, and Clutches.....................355 Gasoline Engine............................................................................355 Engine Removal.........................................................................355 Engine Installation....................................................................357 Oil Filter Hoses.......................................................................359 Exhaust System.............................................................................360 Muffler Removal........................................................................360 Intermediate Pipe Removal..............................................................361 Intermediate Pipe Installation.........................................................361 Muffler Installation...................................................................362 Fuel System................................................................................363 Fuel Lines.............................................................................364 Fuel Filter............................................................................364 Fuel Pump..............................................................................364 Carburetor.............................................................................364 Fuel Level Sending Unit................................................................367 Fuel Tank..............................................................................370 Fuel Shut-Off Valve....................................................................373 Engine Control Linkages....................................................................374 Accelerator Cable......................................................................374 Choke Cable............................................................................376 Engine Governor Arm....................................................................378 Engine RPM Adjustment..................................................................378 Air Intake System..........................................................................379 Air Filter Replacement.................................................................379 Air Canister Removal...................................................................380 Air Canister Installation..............................................................380 Air Filter Intake Hose Removal.........................................................381 Air Filter Intake Hose Installation....................................................381 Air Filter Outlet Hose Removal.........................................................382 Air Filter Outlet Hose Installation....................................................382 Clutches...................................................................................383 Clutch Troubleshooting.................................................................383 Drive Belt.............................................................................384 Drive Clutch...........................................................................385 Driven Clutch..........................................................................390 Clutch Cover...........................................................................393 Section 13b - Honda Gasoline Engine, Muffler, Fuel System, and Clutches........................395 Gasoline Engine............................................................................395 Engine Removal.........................................................................395 Engine Installation....................................................................397 Exhaust System.............................................................................399 Muffler Removal........................................................................399 Intermediate Pipe Removal..............................................................399 Intermediate Pipe Installation.........................................................400 Muffler Installation...................................................................400 Fuel System................................................................................401 Fuel Lines.............................................................................402 Fuel Filter............................................................................402 Fuel Pump..............................................................................402 Carburetor.............................................................................402 Fuel Level Sending Unit................................................................403 Fuel Tank..............................................................................406 Fuel Shut-Off Valve....................................................................409 Oil Filter Hoses.......................................................................410 Engine Control Linkages....................................................................410 Accelerator Cable......................................................................410 Governor Guard.........................................................................413 Governor Cable.........................................................................413 Accelerator Cable Retention Clip Adjustment............................................414 Ground Speed (Transmission) Governor Arm Adjustment....................................415 Engine Governor Arm....................................................................417 Engine RPM Adjustment..................................................................417 Choke and Air Intake System................................................................418 Air Filter Replacement.................................................................418 Choke Cable Removal....................................................................419 Choke Cable Installation...............................................................420 Air Canister Removal...................................................................420 Air Canister Installation..............................................................421 Air Filter Intake Hose Removal.........................................................421 Air Filter Intake Hose Installation....................................................422 Air Filter Outlet Hose Removal.........................................................422 Air Filter Outlet Hose Installation....................................................423 Clutches...................................................................................423 Clutch Troubleshooting.................................................................424 Drive Belt.............................................................................424 Drive Clutch...........................................................................425 Driven Clutch..........................................................................430 Clutch Cover...........................................................................433 Section 13c - Diesel Engine, Muffler, Fuel System, and Clutches................................435 Diesel Engine..............................................................................435 Engine Removal.........................................................................435 Engine Installation....................................................................437 Exhaust System.............................................................................439 Muffler Removal........................................................................439 Intermediate Pipe Removal..............................................................439 Manifold Pipe Removal..................................................................440 Manifold Pipe Installation.............................................................440 Intermediate Pipe Installation.........................................................440 Muffler Installation...................................................................441 Fuel System................................................................................442 Fuel Lines.............................................................................443 Fuel Filter Replacement................................................................443 Draining Water from the Secondary Fuel Filter..........................................443 Electric Fuel Pump.....................................................................445 Fuel Level Sending Unit................................................................446 Fuel Tank..............................................................................450 Engine Control Linkages....................................................................453 Accelerator Cable......................................................................453 Engine RPM Adjustment..................................................................454 Air Intake System..........................................................................457 Air Filter Replacement.................................................................457 Air Canister Removal...................................................................457 Air Canister Installation..............................................................458 Air Filter Intake Hose Removal.........................................................458 Air Filter Intake Hose Installation....................................................459 Air Filter Outlet Hose Removal.........................................................460 Air Filter Outlet Hose Installation....................................................460 Clutches...................................................................................461 Clutch Troubleshooting.................................................................461 Drive Belt.............................................................................462 Drive Clutch...........................................................................463 Driven Clutch..........................................................................467 Clutch Cover...........................................................................469 Section 14 - Drivetrain Components.............................................................473 Half Shafts................................................................................473 Half Shaft Removal.....................................................................473 Half Shaft Installation................................................................475 Front Differential.........................................................................476 Front Differential Removal.............................................................476 Front Differential Installation........................................................478 Front Driveshaft...........................................................................478 Front Driveshaft Removal...............................................................478 Front Driveshaft Installation..........................................................479 Rear Receiver Hitch........................................................................479 Rear Receiver Hitch Removal............................................................479 Rear Receiver Hitch Installation.......................................................479 Rear Axle..................................................................................480 Rear Axle Removal......................................................................480 Rear Axle Installation.................................................................482 Rear Driveshaft............................................................................483 Rear Driveshaft Removal................................................................483 Rear Driveshaft Installation...........................................................484 Transmission...............................................................................484 Transmission Removal...................................................................484 Transmission Installation..............................................................486 Forward/Reverse Shifter Cable..........................................................487 Forward/Reverse Shifter Handle.........................................................490 Rear Differential and Axle Shafts..........................................................490 Rear Differential and Axle Shaft Removal...............................................490 Rear Differential and Axle Shaft Installation..........................................492 Rear Wheel Bearings....................................................................492 Section 15 - Radiator and Coolant System (Diesel)..............................................495 General Information........................................................................495 Engine Coolant Level Check.............................................................495 Engine Coolant Change..................................................................495 Coolant Reservoir..........................................................................497 Coolant Reservoir Removal..............................................................497 Coolant Reservoir Installation.........................................................498 Radiator...................................................................................498 Radiator Removal.......................................................................498 Radiator Installation..................................................................499 Coolant Pipe Weldment......................................................................500 Coolant Pipe Weldment Removal..........................................................500 Coolant Pipe Weldment Installation.....................................................500 Fan........................................................................................501 Fan Removal............................................................................501 Fan Installation.......................................................................501 Section 16 - Transmission Models 421274 and 421275.............................................503 General Information........................................................................503 Model Identification.......................................................................503 Service Fixture............................................................................504 Transmission Removal.......................................................................504 Transmission Disassembly...................................................................505 Input Shaft Disassembly................................................................510 Input Shaft Assembly...................................................................510 Intermediate Shaft Disassembly.........................................................510 Output Shaft Disassembly...............................................................514 Shifter Shaft Removal..................................................................515 Shifter Shaft Installation.............................................................516 Case Inspection........................................................................516 Shaft Seal Removal.....................................................................517 Shaft Seal Installation................................................................517 Output Shaft Assembly..................................................................517 Intermediate Shaft Assembly............................................................520 Intermediate and Output Shaft Assembly.................................................524 Transmission Assembly......................................................................525 Transmission Installation..................................................................529 Section 17 - Front Differential Models 6203-01-139-S and 6203-01-189-S.........................531 General Information........................................................................531 Axle Half Shaft Removal....................................................................531 Front Differential Removal.................................................................532 Tools Required For This Section........................................................533 Front Differential Coil And Output Cover...................................................533 Coil and Output Cover Removal..........................................................533 Coil and Output Cover Installation.....................................................536 Front Differential.........................................................................538 Front Differential Disassembly.........................................................538 Front Differential Assembly............................................................544 Front Differential Installation............................................................548 Axle Half Shaft Installation...............................................................548 Section 18 - Rear Differential Models 420366 and 420851........................................549 General Information........................................................................549 Axle Shafts and Differential Removal.......................................................550 Rear Differential Disassembly..............................................................550 Pinion Gear Removal....................................................................552 Ring Gear Removal......................................................................554 Clutch Carrier Assembly................................................................555 Ring Gear Installation.................................................................556 Pinion Gear Installation...............................................................557 Rear Differential Assembly.............................................................557 Axle Shafts and Differential Installation..................................................559 Section 19 - Kubota D722 Diesel Engine Manual..................................................561 Section 20a - Kawasaki FH680D Gasoline Engine Manual...........................................615 Section 20b - Honda GX 620 Gasoline Engine Manual..............................................729 Section 21 - Hydraulic Attachment System.......................................................829 Model Identification.......................................................................829 Relieving Hydraulic System Pressure........................................................829 To Relieve Hydraulic Fluid Pressure....................................................829 Attachment Interface.......................................................................830 Inspection.............................................................................830 Removing and Installing the Attachment Arm Mechanism...................................831 Electrical.................................................................................836 Joystick...............................................................................838 Joystick ON/OFF Switch.................................................................840 Attachment Arm Float Switch............................................................842 Auxiliary Hydraulic Switch.............................................................843 Relays.................................................................................845 Solenoid...............................................................................847 Circuit Breaker........................................................................848 Control Valves.........................................................................849 Hoses......................................................................................851 Hose Routing...........................................................................851 Hose Removal...........................................................................852 Hose Installation......................................................................852 Quick Connect Fittings (Auxiliary Hydraulic Circuit only)..................................853 Quick Connect Removal..................................................................853 Quick Connect Installation.............................................................853 Cylinders..................................................................................854 Vehicle Mounted Cylinders..............................................................854 Auxiliary Cylinder (Optional)..........................................................855 Cylinder Disassembly...................................................................857 Cylinder Assembly......................................................................860 Cylinder Bushings (If Equipped)........................................................865 Angle Frame Bushings.......................................................................867 Snow Blade Angle Frame.................................................................867 Whisk Broom Angle Frame................................................................868 Front Mount................................................................................869 Front Mount Removal....................................................................869 Front Mount installation...............................................................870 Hydraulic Pump Assembly....................................................................871 Fluid Level Inspection.................................................................871 Fluid Change...........................................................................871 Pump Assembly..........................................................................872 Reservoir..............................................................................875 Motor..................................................................................876 Pump...................................................................................877 Priming the Pump.......................................................................877 A..........................................................................................879 a-arm, lower...........................................................................879 a-arm, upper...........................................................................879 accelerator............................................................................879 air canister (diesel vehicles).........................................................879 air canister (gasoline vehicles).......................................................879 air filter (diesel vehicles)...........................................................879 air filter (gasoline vehicles).........................................................879 alternator (diesel vehicles)...........................................................879 antifreeze.............................................................................879 attachment arm.........................................................................879 attachment interface (hydraulic attachment vehicles)...................................879 axle half shaft........................................................................879 axle shaft and differential............................................................879 axle, rear.............................................................................879 B..........................................................................................879 ball joint, lower......................................................................879 ball joint, upper......................................................................879 battery (diesel vehicles) 12c-19.......................................................879 battery (gasoline vehicles) 12a-17, 12b-15.............................................879 bed lift circuit breaker (diesel vehicles).............................................879 bed lift circuit breaker (gasoline vehicles)...........................................879 bed lift motor.........................................................................879 bed lift motor (diesel vehicles).......................................................879 bed lift motor (gasoline vehicles).....................................................879 bed lift switch (diesel vehicles)......................................................880 bed lift switch (gasoline vehicles)....................................................880 bed, cargo.............................................................................880 belt, drive............................................................................880 belt, seat.............................................................................880 body, front............................................................................880 box bed................................................................................880 brakes.................................................................................880 bushings...............................................................................880 C..........................................................................................880 cable, accelerator.....................................................................880 cable, forward/reverse.................................................................880 cable, governor........................................................................880 camber.................................................................................880 carburetor (diesel vehicles)...........................................................880 carburetor (gasoline vehicles).........................................................880 carburetor heater (gasoline vehicles)..................................................880 carburetor heater relay (gasoline vehicles)............................................880 carburetor solenoid (gasoline vehicles)................................................880 cargo bed..............................................................................881 CAUTION................................................................................881 charge coil (gasoline vehicles) 12a-15, 12b-12.........................................881 choke cable (gasoline vehicles)........................................................881 circuit breaker, bed lift (diesel vehicles)............................................881 circuit breaker, bed lift (gasoline vehicles)..........................................881 circuit breaker, hydraulic attachment..................................................881 cleaning...............................................................................881 clutch and ring gear...................................................................881 clutch carrier.........................................................................881 clutch inner cover (diesel vehicles)...................................................881 clutch inner cover (gasoline vehicles).................................................881 clutch outer cover (diesel vehicles)...................................................881 clutch outer cover (gasoline vehicles).................................................881 clutch, drive..........................................................................881 clutch, driven.........................................................................881 coil and output cover..................................................................881 coil, charge (gasoline vehicles) 12a-15, 12b-12........................................881 coil, ignition (gasoline vehicles) 12a-15, 12b-12......................................881 column, steering.......................................................................881 coolant reservoir (diesel vehicles)....................................................881 coolant temperature warning light circuit (diesel vehicles)............................881 coolant, engine (diesel vehicles)......................................................881 cylinder, auxiliary....................................................................881 cylinder, hydraulic....................................................................881 cylinder, vehicle mounted..............................................................881 D..........................................................................................881 DANGER.................................................................................881 differential relay (diesel vehicles)...................................................881 differential relay (gasoline vehicles).................................................881 differential, front....................................................................881 differential, rear.....................................................................881 diode, wire harness (diesel vehicles)..................................................881 diode, wire harness (gasoline vehicles)................................................882 drive belt (diesel vehicles)...........................................................882 drive belt (gasoline vehicles).........................................................882 drive clutch (diesel vehicles) 13c-27..................................................882 drive clutch (gasoline vehicles) 13a-29, 13b-29........................................882 driven clutch (diesel vehicles) 13c-27.................................................882 driven clutch (gasoline vehicles) 13a-29, 13b-29.......................................882 driveshaft, front......................................................................882 driveshaft, rear.......................................................................882 E..........................................................................................882 engine (diesel vehicles)...............................................................882 engine (gasoline vehicles).............................................................882 engine governor arm....................................................................882 engine oil.............................................................................882 exhaust system (diesel vehicles).......................................................882 exhaust system (gasoline vehicles).....................................................882 F..........................................................................................882 fan motor (diesel vehicles)............................................................882 fan relay (diesel vehicles)............................................................882 fender, front..........................................................................882 fender, rear...........................................................................882 floor mat..............................................................................882 fluid..................................................................................882 fluid, brake 10a-8, 10b-7..............................................................882 forward/reverse cable..................................................................882 forward/reverse shifter handle.........................................................882 front differential.....................................................................882 front drive gearcase coil (diesel vehicles)............................................883 front drive gearcase coil (gasoline vehicles)..........................................883 front driveshaft.......................................................................883 front mount............................................................................883 fuel filter (gasoline vehicles) 13a-10, 13b-8..........................................883 fuel filter, primary (diesel vehicles).................................................883 fuel filter, secondary (diesel vehicles)...............................................883 fuel gauge/hour meter (diesel vehicles)................................................883 fuel gauge/hour meter (gasoline vehicles)..............................................883 fuel level sending unit (diesel vehicles)..............................................883 fuel level sending unit (gasoline vehicles)............................................883 fuel pump (diesel vehicles)............................................................883 fuel pump (gasoline vehicles) 13a-10, 13b-8............................................883 fuel shut-off valve (gasoline vehicles) 13a-19, 13b-15.................................883 fuel solenoid (diesel vehicles)........................................................883 fuel system (diesel vehicles) 13c-8....................................................883 fuel system (gasoline vehicles) 13a-9, 13b-7...........................................883 fuel tank (diesel vehicles)............................................................883 fuel tank (gasoline vehicles)..........................................................883 fueling instructions 10a-17, 10b-16....................................................883 fuse (diesel vehicles).................................................................883 fuse (gasoline vehicles)...............................................................883 fusible link (diesel vehicles).........................................................883 G..........................................................................................883 gearcase...............................................................................883 gearcase coil..........................................................................883 glow plug circuit (diesel vehicles)....................................................883 governor arm, engine (gasoline vehicles)...............................................883 governor arm, transmission (gasoline vehicles).........................................883 governor cable (gasoline vehicles).....................................................883 governor guard (gasoline vehicles).....................................................883 ground cables (diesel vehicles)........................................................883 ground cables (gasoline vehicles)......................................................883 H..........................................................................................883 half shaft.............................................................................883 handle, forward/reverse shifter........................................................884 headlight (diesel vehicles)............................................................884 headlight (gasoline vehicles)..........................................................884 hitch, receiver........................................................................884 hoses, hydraulic.......................................................................884 hydrometer test (diesel vehicles) 11c-13...............................................884 hydrometer test (gasoline vehicles) 11a-9, 11b-9.......................................884 I..........................................................................................884 ignition (gasoline vehicles)...........................................................884 ignition coil (gasoline vehicles) 12a-15, 12b-12.......................................884 input shaft............................................................................884 input shaft seal.......................................................................884 inspection.............................................................................884 instrument panel.......................................................................884 intake hose, air (diesel vehicles).....................................................884 intake hose, air (gasoline vehicles)...................................................884 intermediate and output shaft..........................................................884 intermediate shaft.....................................................................884 J..........................................................................................884 jetting, carburetor (gasoline vehicles) 13a-12, 13b-8..................................884 joystick (hydraulic attachment vehicles)...............................................884 K..........................................................................................884 key switch (diesel vehicles)...........................................................884 key switch (gasoline vehicles).........................................................884 kill circuit, engine (gasoline vehicles)...............................................884 kill wire, engine (gasoline vehicles)..................................................884 L..........................................................................................884 lubrication............................................................................884 M..........................................................................................885 maintenance............................................................................885 manifold (diesel vehicles).............................................................885 motor, hydraulic pump..................................................................885 muffler................................................................................885 muffler (diesel vehicles)..............................................................885 muffler (gasoline vehicles)............................................................885 N..........................................................................................885 neutral switch (diesel vehicles).......................................................885 neutral switch (gasoline vehicles).....................................................885 O..........................................................................................885 oil filter.............................................................................885 oil warning light, low (diesel vehicles)...............................................885 oil warning light, low (gasoline vehicles).............................................885 oil, engine 10a-8, 10b-7...............................................................885 outlet hose, air (diesel vehicles).....................................................885 outlet hose, air (gasoline vehicles)...................................................885 output shaft...........................................................................885 P..........................................................................................885 panel, instrument......................................................................885 park brake.............................................................................885 pedal, accelerator.....................................................................885 pedal, brake...........................................................................885 periodic lubrication schedule 10b-4....................................................885 periodic lubrication schedule - 2200 10a-4.............................................885 periodic lubrication schedule - 2300 10a-6.............................................885 periodic service schedule 10a-1, 10b-1.................................................885 pinion gear............................................................................885 pump assembly, hydraulic...............................................................885 pump, fuel (diesel vehicles)...........................................................885 pump, fuel (gasoline vehicles) 13a-10, 13b-8...........................................886 pump, hydraulic........................................................................886 Q..........................................................................................886 quick connect fitting..................................................................886 R..........................................................................................886 rack and pinion........................................................................886 radiator (diesel vehicles).............................................................886 rear axle..............................................................................886 rear differential......................................................................886 rear driveshaft........................................................................886 rear wheel bearing.....................................................................886 receiver hitch.........................................................................886 relay, accessory (diesel vehicles).....................................................886 relay, accessory (gasoline vehicles)...................................................886 relay, differential (diesel vehicles)..................................................886 relay, differential (gasoline vehicles)................................................886 relay, float...........................................................................886 relay, start (diesel vehicles).........................................................886 relay, start (gasoline vehicles).......................................................886 reservoir, coolant.....................................................................886 reservoir, hydraulic fluid.............................................................886 reverse buzzer (diesel vehicles).......................................................886 reverse buzzer (gasoline vehicles).....................................................886 ring gear..............................................................................886 ROPS (roll-over protective structure)..................................................886 RPM adjustment (diesel vehicles).......................................................886 RPM adjustment (gasoline vehicles).....................................................886 S..........................................................................................886 safety.................................................................................886 safety belt............................................................................887 seat...................................................................................887 seat belt..............................................................................887 seat frame.............................................................................887 serial number, vehicle 3-1.............................................................887 service schedule.......................................................................887 service tools..........................................................................887 shaft seal.............................................................................887 shifter shaft..........................................................................887 shock absorber.........................................................................887 solenoid, fuel (diesel vehicles).......................................................887 solenoid, hydraulic attachment.........................................................887 spark plug (gasoline vehicles).........................................................887 specifications.........................................................................887 start relay (diesel vehicles)..........................................................887 start relay (gasoline vehicles)........................................................887 starter control circuit (diesel vehicles)..............................................887 starter control circuit (gasoline vehicles)............................................887 steering...............................................................................887 steering column........................................................................887 steering upright.......................................................................887 steering wheel.........................................................................887 storage................................................................................887 suspension, front......................................................................887 suspension, rear.......................................................................887 switch, auxiliary......................................................................887 switch, bed lift (diesel vehicles).....................................................887 switch, bed lift (gasoline vehicles)...................................................888 switch, float..........................................................................888 switch, joystick ON/OFF................................................................888 switch, neutral (diesel vehicles)......................................................888 switch, neutral (gasoline vehicles)....................................................888 T..........................................................................................888 12-volt accessory receptacle (diesel vehicles).........................................888 12-volt accessory receptacle (gasoline vehicles).......................................888 test procedures (diesel vehicles)......................................................888 test procedures (hydraulic attachment vehicles)........................................888 test procedures (gasoline vehicles)....................................................888 test procedures, index of (diesel vehicles) 11c-12.....................................888 test procedures, index of (gasoline vehicles) 11a-8, 11b-8.............................888 thermostat switch (diesel vehicles)....................................................889 throttle...............................................................................889 tire...................................................................................889 tools..................................................................................889 torque converter (diesel vehicles) 13c-27..............................................889 torque converter (gasoline vehicles) 13a-29, 13b-29....................................889 transmission...........................................................................889 transmission governor arm..............................................................889 troubleshooting........................................................................889 V..........................................................................................889 v-belt (diesel vehicles)...............................................................889 voltage regulator (gasoline vehicles)..................................................889 W..........................................................................................889 WARNING................................................................................889 wheel..................................................................................889 wheel bearing..........................................................................889 wheel, steering........................................................................889 wire continuity (diesel vehicles)......................................................889 wire continuity (gasoline vehicles)....................................................889 wire harness diode (diesel vehicles)...................................................889 wire harness diode (gasoline vehicles).................................................889 wiring diagram (diesel vehicles) 11c-6.................................................889 wiring diagram (gasoline vehicles) 11a-6, 11b-6........................................889 wiring diagram (hydraulic attachment) 21-8.............................................889
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