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This service manual PDF download for the 2400 Series Bobcat Wheel Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
Bobcat Loader 2400 Series
TABLE OF CONTENTS :
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT ARTICULATED LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
SPECIFICATIONS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6720455 (5–90)
Total Pages : 390
This Bobcat Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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MAINTENANCE SAFETY
FOREWORD
CONTENTS
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
LOADER SERIAL NUMBER
ENGINE SERIAL NUMBER
DELIVERY REPORT
BOBCAT ARTICULATED LOADER IDENTIFICATION
PREVENTIVE MAINTENANCE
SERVICE SCHEDULE
LIFTING AND BLOCKING THE LOADER
Procedure
TRANSPORTING THE LOADER
Procedure
LIFT ARM STOP
Procedure
STEERING FRAME LOCK
Procedure
AIR CLEANER
Replacement Of Filter Element
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Replacement Of Oil And Filter
ENGINE COOLANT SYSTEM
Checking Coolant Level
Removing Coolant From The Cooling System
Radiator Side Screen
Cooling System Maintenance
USING A BOOSTER BATTERY (JUMP STARTING)
Procedure
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic/Hydrostatic Filter Replacement
Hydraulic Fluid Replacement
SPARK ARRESTOR MUFFLER
Cleaning Procedure
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Tire Inflation
FRONT AND REAR DIFFERENTIAL
Checking Differential Oil Level
Checking Gear–Drop Box Oil Level
Checking Wheel End Oil Level
LUBRICATION OF THE LOADER
Procedure
BLOWER FILTER (OPERATOR CAB)
Cleaning The Filter
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
TROUBLESHOOTING
HYDRAULIC SYSTEM INFORMATION
Flare Connections
O–Ring Face Seal Connection
Straight Thread O–Ring Fitting
Tubelines And Hoses
TILT CYLINDER
Checking The Tilt Cylinder
Removal And Installation
Pivot Pin Seals
Bucket Anti–Roll Back Linkage Adjustment (11000 Series)
Bucket Indicator Linkage Adjustment (12000 Series)
LIFT CYLINDER
Checking The Lift Cylinder
Removal And Installation
STEERING CYLINDER
Checking The Steering Cylinder
Removal And Installation
Rod End Bearing
HYDRAULIC CONTROL VALVE (11000 Series)
Checking The Main Relief Valve
Main Relief Valve
Removal And Installation
HYDRAULIC CONTROL VALVE (12000 Series)
Checking The Main Relief Valve
Main Relief Valve
Removal And Installation
BUCKET POSITION VALVE
Removal And Installation
HYDRAULIC PUMP (11000 Series)
Checking Hydraulic Pump Output (Small Section)
Checking Hydraulic Pump Output (Large Section)
Removal And Installation
HYDRAULIC PUMP (12000 Series)
Checking Hydraulic Pump Output (Small Section)
Checking Hydraulic Pump Output (Large Section)
Removal And Installation
PORT BLOCK (11000 Series)
Removal And Installation
Normally–Open Switch
Charge Pressure Switch
Temperature Sender
Oil Cooler By–Pass Valve
Two–Speed Solenoid
PORT BLOCK (12000 Series)
Removal And Installation
Two–Speed Solenoid
Normally–Open Switch
Temperature Sender
Oil Cooler By–Pass Valve
HYDRAULIC VALVE CONTROL HANDLE (11000 Series)
Removal And Installation
Disassembly And Assembly
Control Handle Electrical Harness
HYDRAULIC VALVE CONTROL HANDLE (12000Series)
Removal And Installation
Disassembly And Assembly
STEERING CONTROL VALVE
Removal And Installation
Disassembly
Inspection
Assembly
Checking Steering Relief Valve
HYDRAULIC RESERVOIR
Removal And Installation
PRIORITY VALVE
Removal And Installation
Disassembly And Assembly
Adjustment Of Steering Relief Valve
HYDROSTATIC SYSTEM
TROUBLESHOOTING
HYDROSTATIC SYSTEM INFORMATION
High Pressure Relief/Replenishing Valve Function
HYDROSTATIC MOTOR
Removal And Installation
MULTI–DISC BRAKE
Removal And Installation
Disassembly And Assembly
HYDROSTATIC PUMP (11000 Series)
Checking Charge Pressure
Checking The High Pressure Relief/Replenishing Valve
Removal And Installation
HYDROSTATIC PUMP (12000 Series)
Checking Charge Pressure
Checking The High Pressure Relief/Replenishing Valve
Removal And Installation
DRIVE BELT
Adjustment
Removal And Installation
DRIVE BELT TENSION PULLEY
Removal And Installation
FOOT PEDAL CONTROL (11000 Series)
Removal And Installation
FOOT PEDAL CONTROL (12000 Series)
Removal And Installation
TOWING THE LOADER
Procedure
DRIVE SYSTEM
TROUBLESHOOTING
DRIVE SHAFT
Removal And Installation
AXLE AND DIFFERENTIAL
Front Axle Removal And Installation
Rear Axle Removal And Installation
Oscillation Blocks And Bushings
Oscillation Frame Removal And Installation
Axle Hub Housing Removal And Installation
Axle Hub Housing Disassembly
Axle Hub Housing Assembly
Axle Hub Removal And Installation
Axle Seal Removal And Installation
Axle End Housing Removal And Installation
Axle End Housing Disassembly And Assembly
Axle Housing End Clearance
Axle End Cover Removal And Installation
Differential Axle And Seal
Brake And Drum
Disassembly Of Differential
Assembly Of The Differential
DROP–BOX GEARCASE
Removal And Installation
Disassembly And Assembly
BRAKE PEDAL MECHANISM
Removal And Installation
Disassembly And Assembly
Brake Pedal Adjustment
MAIN FRAME
FLOOR PANEL
Removal And Installation
THROTTLE COVER
Removal And Installation
SEAT AND SEAT MOUNTING FRAME
Removal And Installation
REAR FLOOR PANEL
Removal And Installation
ENGINE HOOD
Removal And Installation
Hood Adjustment (12000 Series)
BOB–TACH TILT ROD (11000 Series)
Removal And Installation
BOB–TACH TILT ROD (12000 Series)
Removal And Installation
TILT TRANSFER ARM (11000 Series)
Removal And Installation
TILT TRANSFER ARM (12000 Series)
Removal And Installation
BOB–TACH
Removal And Installation
Bob–Tach Wedges
STEERING WHEEL (11000 Series)
Removal And Installation
STEERING WHEEL (12000 Series)
Removal And Installation
STEERING COLUMN
Removal And Installation
Tilt Lock Mechanism
FUEL TANK
Removal And Installation
Fuel Sender
REAR DOOR (12000 Series)
Removal And Installation
Adjustment
LOADER MAIN FRAME
Separating The Front And Rear Main Frame
Bottom Pivot Pin Bearing
Top Pivot Pin Bearing
ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
TROUBLESHOOTING
ELECTRICAL SYSTEM
Description
Electrical Breaker (11000 Series)
Fuses (11000 Series)
Fuses (12000 Series)
80 Amp. Fuse (12000 Series)
Electrical System Service
SEALED ELECTRICAL TERMINAL
Removal And Installation
DIODES
Checking The Diodes
BATTERY
Checking The Battery
Removal And Installation (11000 Series)
Removal And Installation (12000 Series)
ALTERNATOR
Belt Tension
Troubleshooting The Alternator
Checking The Alternator Output
Removal And Installation
Disassembly And Assembly
Brush Inspection
Testing Diode–Trio & Rectifier Assembly
Checking The Stator
Rotor Testing And Inspection
Replacing The Rear Rotor Bearing
Inspection Of Rear Housing
STARTER (11000 Series)
Checking The Starter
Removal And Installation
Disassembly And Assembly
Cleaning And Inspection
Replacing The Brushes
STARTER (12000 Series)
Checking The Starter
Removal And Installation
Disassembly And Assembly
Cleaning And Inspection
INSTRUMENT PANEL (11000 Series)
Removal And Installation
INSTRUMENT PANEL (12000 Series)
Removal And Installation
SIGNAL LIGHT CONTROL
Removal And Installation
ENGINE SERVICE
TROUBLESHOOTING
VALVE CLEARANCE
Adjustment
AIR CLEANER HOUSING
Removal And Installation
FUEL FILTERS
Water Trap
Removal And Installation
Removing Air From The Fuel System
FUEL LIFT PUMP
Checking
Removal And Installation
FUEL INJECTION PUMP
Removal And Installation
TIMING
Engine Timing To Injection Pump
Checking Timing Mark On Injection Pump Flange
FUEL INJECTOR NOZZLES
Removal And Installation
Checking
ENGINE COMPRESSION
Checking
COOLANT RECOVERY TANK
Removal And Installation
RADIATOR AND OIL COOLER
Removal And Installation
RADIATOR FAN
Removal And Installation
ENGINE
Removal And Installation
ENGINE FLYWHEEL
Removal And Installation
Flywheel Ring Gear
ENGINE MUFFLER
Removal And Installation
CYLINDER HEAD
Removing The Cylinder Head
Cylinder Head Surface Alignment
Installing The Cylinder Head
VALVES
Removal Of The Valves
Installing The Valves
Reconditioning The Valve And Valve Seats
Installing Valve Guides
Installing The Valve Seats
Checking The Valve Springs
ROCKER ARMS
Disassembly
Assembly
PISTON AND CONNECTING RODS
Removal
Disassembly
Inspection
Installation
CYLINDER LINERS
Inspection
Removal
Installation
MAIN BEARINGS
Removal
Installation
Crankshaft End Play
CRANKSHAFT
Removal
Checking
Installation
REAR MAIN OIL SEAL
Removal And Installation
TIMING CASE COVER
Removal And Installation
IDLER GEAR AND HUB
Removal And Installation
CAMSHAFT GEAR
Removal And Installation
FUEL INJECTION PUMP GEAR
Removal
Installation
CRANKSHAFT GEAR
Removal
TIMING CASE
Removal And Installation
CAMSHAFT
Removal And Installation
BALANCER UNIT AND OIL PUMP
Balancer Removal And Installation
Engine Timing To Balancer Unit
Oil Pump Removal And Installation
Oil Pump Inspection
Oil Pump Relief Valve
Balancer Disassembly And Assembly
Inspection
SPECIFICATIONS
LOADER SPECIFICATIONS – 2400
LOADER DIMENSIONS
OPERATION & PERFORMANCE
ENGINE
HYDRAULIC SYSTEM
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
LOADER SPECIFICATIONS – 2410
LOADER DIMENSIONS
OPERATION & PERFORMANCE
ENGINE
HYDRAULIC SYSTEM
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
ENGINE SPECIFICATIONS
Cylinder Head
Valve Guides
Exhaust Valve
Intake Valve
Valve Springs
Rocker Arms & Tappets
Piston & Piston Rings
Piston Pin & Bushing
Cylinder Block & Liners
Crankshaft, Main Bearings & Thrust Washer
Connecting Rod and Bearings
Camshaft & Thrust Washer
Timing Case & Timing Gears
Oil Pump, Gear & Relief Valve
Cooling System & Water Pump
Fuel Lift Pump
Fuel Injection Pump & Injectors
De–Rating for Altitude
Balancer Unit
Engine Bolt Torques
Service Wear Limits
Crankshaft Re–Grind Data
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
SERVICE MANUAL REVISIONS
2400-1
2400-2
2400-3
2400-4
2400-5
2400-6
Bobcat 2400 Series Wheel Loader Service Manual - 6720455.pdf