EN Utility Vehicle 2200D Operation & Maintenance Manual S/N 235211001 & Above EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 6903128-EN (09-05) Printed in Europe © Bobcat Europe 2005
U.S.
CONTENTS FOREWORD ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III OPERATING INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SAFETY PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bobcat 2200 Diesel Vehicle Operation & Maintenance Manual II
FOREWORD Thank you for choosing Bobcat. You have chosen the finest utility vehicle on the market; the vehicle most widely recognized as the industry leader in vehicle efficiency and longlasting value. Please protect your investment and ensure that your Bobcat vehicle provides years of reliable, superior performance by reading and following the maintenance instructions in this manual.
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SAFETY GENERAL WARNINGS........................................................................... VIII PRACTICE SAFETY ................................................................................ VII MACHINE SIGNS.......................................................................................
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PRACTICE SAFETY DANGER ! WARNING • Rotating Parts A DANGER indicates an immediate hazard that will result in severe personal injury or death. Safety signs like you see above may at first seem shocking, but their impact is mild compared with the reality of severe personal injury. WARNING Your safety and satisfaction are of the utmost importance to Bobcat. That is why before operating the vehicle, we urge you to review the information in this manual.
• GENERAL WARNINGS DANGER • • • • • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries. Diesel – Flammable! Explosive! Do not smoke. Keep sparks and flames away from the vehicle and service area. Service only in a well-ventilated area. Do not operate engine in an enclosed area without proper ventilation.
GENERAL WARNINGS (CONT’D) Figure 2 All-wheel Drive Warning WARNING WHEN OPERATING VEHICLE ON PUBLIC ROADS THIS VEHICLE OFFERS MUCH LESS CRASH PROTECTION THAN A REGULAR CAR, VAN, OR TRUCK. THIS MEANS A HIGHER RISK OF INJURY OR DEATH IN COLLISIONS, EVEN AT LOW SPEEDS. The higher the speed of the traffic around you, the higher the risk of injury. To reduce these risks: • Avoid roads with regular traffic, even if the speed limit is low.
MACHINE SIGNS CCI 102459401 UNDERAGE WARNING DECAL ! Club Car, Inc Augusta, Georgia. USA Roll-over Protective Structure (ROPS) ROPS per ISO 3471, SAE J1040, AS 2294.1, and CSA B352.2 Certified for vehicle models: Carryall 294, XRT 1500, and Bobcat 2200 Max. unladen vehicle mass: 2094 lb (950 kg) WARNING ! • Do not modify or remove Roll-over Protective Structure (ROPS). • Replace ROPS if damaged. Do not attempt repair. • Use seat belts during operation. Do not jump from vehicle.
MACHINE SIGNS (CONT’D) DIESEL WARNING DECAL OPERATING INSTRUCTIONS WARNING ! • Read owner's manual and vehicle safety warnings. Study and understand controls. TOSTAR T ENGINE • Place shift lever in Neutral ( N ) position and press brake pedal. • To preheat glow plugs, turn key to "PREHEAT" position and hold for 10-15 seconds. • Turn key to “START” position and hold until engine starts. DIESEL FUEL EXPLOSION / FIRE. • Can cause severe injury or death. • No smoking, sparks, or open flame.
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OPERATING INSTRUCTIONS BED LATCH AND PROP ROD ..................................................................14 CONTROLS AND INDICATORS .................................................................3 Accelerator Pedal ...................................................................................6 Brake Pedal............................................................................................6 Electric Bed Lift ................................................................................
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GENERAL INFORMATION CONTROLS AND INDICATORS This manual is designed to include information on both the diesel Bobcat 2200 vehicles. Both are key-start vehicles. The vehicles start and operate similar to an automobile. Each has a feature that allows the engine to run at idle or advanced RPM using the accelerator pedal when the Forward/Reverse handle is in the NEUTRAL position. See GENERAL WARNINGS on page 7.
CAUTION • Do not shift the Forward/Reverse handle while the accelerator pedal is pressed. Shift the handle only when the vehicle is at a complete stop and the engine is at idle. Failure to heed this caution could result in damage to the transmission. NOTE: The key can be removed only when the key switch is in the OFF position. Forward/Reverse Control The Forward/Reverse handle (1) is located on right-hand side of the instrument panel.
CONTROLS AND INDICATORS (CONT’D) Forward/Reverse Control (Cont’d) Figure 2 Instrument Panel 7 A 8 9 1 ! WARNING F 0 1/2 1 1 10 N OFF ON PREHEAT START R (P) 2 6 5 10 C B 4 5 Bobcat 2200 Diesel Vehicle Operation & Maintenance Manual
CONTROLS AND INDICATORS (CONT’D) Park Brake Accelerator Pedal The park brake pedal (3) is located to the left of the brake pedal [Figure 3]. To engage the park brake, first apply pressure to the brake pedal, then firmly press the park brake pedal until it latches into place. To disengage, pull the park brake release handle [Figure 4]. See following WARNING. The accelerator pedal (1) is the pedal on the right [Figure 3].
CONTROLS AND INDICATORS (CONT’D) High-Temperature Warning LIght Fuel Gauge/Hour Meter The high-temperature warning light is located on the instrument panel below the low oil warning light. The diesel engine is liquid-cooled; if the engine coolant has exceeded its normal safe operating temperature, the warning lamp will illuminate. If the warning light comes on, stop the vehicle and allow it to idle for approximately five minutes before stopping the engine. Contact a Bobcat dealer or a trained technician.
CONTROLS AND DIESEL VEHICLE) INDICATORS Hazard Lamps (HOMOLOGATED The hazard lamp switch (2) is located behind the turn signal handle [Figure 5]. To activate the hazard lamps, make sure that the turn signal handle is in the center (off) position, then pull the switch marked "HAZARD" until it is locked in place. To deactivate the hazard lamps, move the turn signal handle in either direction and return it to the center position.
ROLL-OVER PROTECTIVE STRUCTURE (ROPS) AND SAFETY BELTS WARNING The Bobcat 2200 is equipped with a certified Roll-over Protective Structure (ROPS) and safety belts for each occupant. See following WARNING. • WARNING • • The ROPS must be properly installed before operating the vehicle. • Bobcat strongly urges that the vehicle’s occupants be properly restrained at all times with the safety belts provided. • Pregnant woman: Consult your doctor for specific recommendations.
ROLL-OVER PROTECTIVE STRUCTURE (ROPS) AND SAFETY BELTS (CONT’D) SEAT LATCH AND ADJUSTMENT The seats are hinged to allow easy access to the engine compartment. A latch at the rear of each seat bottom keeps the seat from moving on its hinges while the vehicle is in operation. To disengage the latch, grasp the seat back and pull firmly in a forward/upward direction until the latch releases. To engage the seat latch, push down firmly on the seat back until the seat locks into place. See following WARNING.
PRE-OPERATION AND DAILY SAFETY CHECKLIST Performance Inspection Each Bobcat vehicle has been thoroughly inspected and adjusted at the factory; however, upon receiving your new vehicle(s), you should become familiar with its controls, indicators, and operation. Carefully inspect each vehicle to ensure that it is in proper working condition before accepting delivery.
• DRIVING INSTRUCTIONS WARNING • • • • • • • • • • • • • • • • • • • Only licensed drivers should be allowed to drive the vehicle. Before allowing anyone to drive the vehicle, make sure the driver is familiar with all controls and operating procedures. No one under the age of 16 years should be allowed to drive the vehicle. No more than one person per bucket seat at one time, or two persons per bench seat. Do not allow riders in the cargo bed.
DRIVING INSTRUCTIONS (CONT’D) WARNING Starting The Vehicle 1. Read safety warnings on the instrument panel and vehicle loading information located above pedals. • 2. Be sure load, if any, is secure. • 3. Study and understand controls. 4. Be sure all passengers are seated with safety belt fastened and holding on to hand holds. Driver should have both hands on the steering wheel. • 5. Make sure wheels are turned in desired direction and nothing is in your path.
DRIVING INSTRUCTIONS (CONT’D) BED LATCH AND PROP ROD Stopping The Vehicle See GENERAL WARNINGS on page 7. The bed latch [Figure 8] has an automatically engaging prop rod and prop rod track [Figure 9] as standard features. To lift the bed, pull the bed latch handle toward the rear of the vehicle and lift the bed. The prop rod will come to rest in one of the notches in the prop rod track. To close the bed, lift the bed so that the prop rod is no longer supported in one of the track notches.
BED LATCH AND PROP ROD (CONT’D) FRONT SHOCK ABSORBERS The vehicle arrives from the factory with the front coil-over shock absorbers pre-adjusted for optimum vehicle performance. We do not recommend adjusting the shock absorbers unless the vehicle will be equipped with a cab enclosure or snow plow. In that event, please refer to the cab installation instructions for the shock absorber adjustment procedure.
LOADING AND UNLOADING (CONT’D) TOWING WITH THE VEHICLE Center and secure cargo as far forward as possible in the cargo bed. Do not overload the vehicle. See the following chart for vehicle capacities.
TRANSPORTING ON A TRAILER STORAGE See GENERAL WARNINGS on page 7. WARNING • • • • • • • • • • DANGER Do not allow riders in the trailer being towed. Avoid sudden starts, sudden stops, and tight turns when towing. Avoid stopping on a hill when towing. If you must stop on a hill, avoid sudden starts, or rolling backwards and stopping suddenly. Failure to heed this warning could cause the vehicle to overturn, possibly resulting in severe personal injury.
STORAGE (CONT’D) Figure 10 Preparing the Vehicle for Extended Storage Fuel Shut-off Valve – Closed Position 1. Unload the vehicle so that the tires are supporting only the weight of the vehicle. CLOSED (OFF) POSITION 2. Store the vehicle in a cool, dry place. This will minimize battery self-discharge. If the battery appears to be weak, have it charged by a trained technician. Use an automotive-type 12-volt battery charger rated at 10 amps or less.
STORAGE (CONT’D) Returning the Stored Vehicle to Service 1. Make sure the key switch is in the OFF position and the Forward/Reverse handle is in the NEUTRAL position. Chock the wheels. 2. Restore the fuel system to operation. See Figure 26 on page 34. 2.1. Remove the plug from the fuel tank vent. 2.2. Connect the vent tube to the fuel tank vent. 3. Connect the battery cables, positive (+) cable first, and tighten the terminals to 27,1 Nm. Coat terminals with Battery Terminal Protector Spray (1014305 CC). 4.
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PREVENTIVE MAINTENANCE AIR INTAKE ...............................................................................................33 Air Filter Replacement .........................................................................33 BATTERY ..................................................................................................35 BRAKE FLUID RESERVOIR .....................................................................28 Brake Fluid ..................................................................
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• MAINTENANCE See GENERAL WARNINGS on page 7. To ensure trouble-free vehicle performance, follow an established preventive maintenance program. Regular and consistent maintenance can prevent vehicle downtime and expensive repairs. Use the on page 11 and the following Periodic Service Schedule and Periodic Lubrication Schedule to keep the vehicle in proper working condition. • Any vehicle not functioning correctly should not be used until it is properly repaired.
PERIODIC SERVICE SCHEDULE See GENERAL WARNINGS on page 7. WARNING • Service, repairs, and adjustments must be made per instructions in the appropriate maintenance and service manual. NOTE: If the vehicle is constantly subjected to heavy use or severe operating conditions, the preventive maintenance procedures should be performed more often than recommended in the Periodic Service and Lubrication Schedule.
PERIODIC SERVICE SCHEDULE (CONT’D) REGULAR INTERVAL SERVICE Daily service by owner or trained technician Check engine oil level; add if necessary. See Engine Oil Level Check on page 28. Engine Check engine coolant; add if necessary. See Engine Coolant Level Check on page 33. Monthly service by owner or trained technician Semiannual service by trained technician only (or every 50 hours of operation, whichever comes first) Fuel filters Drain water from fuel filter.
PERIODIC SERVICE SCHEDULE (CONT’D) WARNING • If any problems are found during scheduled inspection or service, do not operate the vehicle until repairs are made. Failure to make necessary repairs could result in fire, property damage, severe personal injury, or death.
PERIODIC LUBRICATION SCHEDULE LUBRICATION POINTS REGULAR INTERVAL SERVICE First change 50 hours – additional change for both every 100 hours of operation or annually, whichever comes first.
BRAKE FLUID RESERVOIR ENGINE OIL Figure 14 Brake Fluid and Coolant Access Door Even though the low oil warning light on the instrument panel should illuminate if the oil level becomes low, the engine oil level should be checked daily. The vehicle should be on a level surface when the oil is checked. Do not overfill with oil. Engine Oil Level Check 1 1. Remove the oil level dipstick from the oil filler tube and wipe oil from the dipstick [Figure 16]. See following CAUTION.
ENGINE OIL (CONT’D) Figure 17 Engine Oil Drain Plug and Oil Filter Engine Oil and Filter Change 2 Engine oil and oil filter should be changed after the first 50 hours of operation. After that, they should be changed every 100 hours of operation or annually, whichever comes first. Engine Oil Draining 1. Turn the key switch to the OFF position and remove the key. Place the Forward/Reverse handle in the NEUTRAL position. Chock the front wheels. 2. Disconnect the battery cables, negative (–) cable first.
ENGINE OIL (CONT’D) 4. Use a clean, lint-free rag to wipe the oil filter port flange surface clean where the oil filter gasket seats. Engine Oil and Filter Change (Cont’d) 5. To help seal the new oil filter to the oil port flange, apply a light coat of white lithium NLGI Number 2 grease (Dow Corning® BR2-Plus or equivalent) or new engine oil to the rubber seal around the outside surface of the filter before attaching it to the oil filter port [Figure 19].
ENGINE OIL (CONT’D) Oil Viscosity Choose the viscosity according to the temperature as shown in the appropriate oil viscosity chart [Figure 21]. See following NOTE. NOTE: Use engine oil with API classification CF Figure 21 Oil Viscosity Chart SAE 30 SAE 20 SAE 10W SAE 10W-30/SAE 10W-40 Using multi-grade oils (5W-20, 10W-30, and 10W-40) will increase oil consumption. If multi-grade oil is used, check the oil level more frequently.
Figure 22 Front Differential Lubrication Level GEARCASE LUBRICATION NOTE: Dispose of used oil according to the environmental laws and regulations for your area. Lubrication Level Check for Front Differential, Transmission, and Rear Differential 1 Each gearcase component is equipped with two oil port plugs (1 and 2) [Figure 22, Figure 23, or Figure 24]. When the vehicle is on a level surface, use the level indicator hole (upper plug) (1) as a lubricant level indicator.
ENGINE COOLANT AIR INTAKE Engine Coolant Level Check CAUTION The coolant reserve tank is located under the dashboard next to the brake fluid reservoir [Figure 14]. Raise the access panel located on top of the dashboard to check the coolant level before every operation. • 1. Check the coolant level of the reserve tank (2). If the coolant is at or below the LOW mark, add water until level reaches the FULL mark. If a leak is detected, have it checked by a trained technician. See following WARNING.
FUELING INSTRUCTIONS Draining Water from Fuel Filter See GENERAL WARNINGS on page 7. Water should be drained from the fuel filter daily. The fuel filter is mounted on a plate by the lower seat support panel [Figure 27]. DANGER 1. Position a pan under the fuel filter. 2. Lift the passenger-side seat. • • • • Turn key switch to the OFF position before fueling. Never pour fuel into the fuel tank when the engine is hot or while it is running.
Figure 28 Battery BATTERY See GENERAL WARNINGS on page 7. FRONT OF VEHICLE DANGER POS NEG • • • • • Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries. Tools, wires, and metal objects can cause sparks when shorted across a battery. Follow all instructions carefully when working with batteries.
CLEANING THE VEHICLE BATTERY (CONT’D) Each vehicle is equipped with an ABS/DR acrylic front body and an all-aluminum rear body. The vehicle has a powder-coated steel cargo bed. Use a commercial automotive cleaning solutions with a sponge or soft cloth for normal cleaning. A garden hose at normal residential water pressure is adequate. To remove oxidation or discoloration from aluminum, use a commercially available aluminum cleaner paste and fine grade (No. 00) steel wool.
ACCESSORIES ACCESSORIES.........................................................................................39 Electric Winch Accessory.....................................................................39 Mud Tire Option ...................................................................................
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ACCESSORIES Electric Winch Accessory There is a complete line of accessory equipment available from Bobcat and our dealers. You can obtain the name and phone number of your closest Bobcat contact by visiting our web site at www.bobcat.com and clicking the “Dealer Locator” link. If your vehicle is equipped with an electric winch, read and follow all manufacturer safety warnings and instructions in the winch operator manual, as well as the following WARNING and CAUTION statements.
ACCESSORIES (CONT’D) Mud Tire Option All-wheel drive (AWD) vehicles equipped with optional mud tires are intended only for off-road operation; they are not designed for use on paved surfaces such as asphalt and concrete. Frequent driving on paved surfaces will significantly decrease the life of the mud tires. Vehicle performance will also be reduced when driving on paved surfaces. See following WARNING.
SPECIFICATIONS DIESEL VEHICLE SPECIFICATIONS.......................................................43 Controls................................................................................................44 Drive System........................................................................................45 Electrical ..............................................................................................45 Engine......................................................................................
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DIESEL VEHICLE SPECIFICATIONS • • Dimensions are given for loader equipped with standard dirt bucket and may vary with other bucket types. All dimensions are shown in millimeters. Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice. Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.
DIESEL VEHICLE SPECIFICATIONS (CONT’D) Machine Rating Ground pressure with all terrain tyres 1,38–1,52 bar Maximum bed load 476 kg Weights Operating weight 835 kg Shipping weight 745 kg Controls Engine speed Foot pedal Starting Key-type starter switch and shutdown. Glow plugs, automatically activated. Cargo box Electrical switch on dashboard Service brake Four-wheel hydraulic disc brake system controlled by foot pedal.
DIESEL VEHICLE SPECIFICATIONS (CONT’D) Electrical Alternator 12 V, belt driven with internal regulator Battery 12 V, 105 minutes reserve capacity, 35 A charging capacity Starter 12 V Drive System Transmission Torque converter with 6:1 ratio Differentials Front and rear differential with IntelliTrak® automatic lock system Wheel bolts Four 1/2–20 UNF 2A bolts on 4-inch circle Traction Standard tyres, front All-terrain 23 x 8-12, tubeless, 4-ply rating Standard tyres, rear All-terrain 23 x 10.
DIESEL VEHICLE SPECIFICATIONS (CONT’D) Fluid Capacities Cooling system capacity 7,8 l Engine oil with filter capacity 2,8 l Fuel tank capacity 24,6 l Brake system capacity 0,25 l Front differential capacity 0,15 l Rear differential capacity 0,6 l Transmission capacity 0,6 l Fluid Specifications Engine coolant Polypropylene glycol/water mix (55% – 45%) with freeze protection to -37°C Engine oil Oil must meet API Service Classification of CF or better.
WARRANTY UTILITY VEHICLE INGERSOLL RAND INTERNATIONAL (IRI) WARRANTS TO ITS AUTHORISED DEALERS, WHO IN TURN WARRANT TO THE END-USER / OWNER, THAT EACH NEW BOBCAT UTILITY VEHICLE WILL BE FREE FROM PROVEN DEFECTS IN MATERIAL AND WORKMANSHIP FOR TWELVE (12) MONTHS FROM THE DATE OF DELIVERY TO THE END-USER / OWNER OR 1000 HOURS OF MACHINE USAGE, WHICHEVER OCCURS FIRST.
