Bobcat 2400 Loader Service Manual 6720455 (6-12) – PDF DOWNLOAD
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Bobcat 2400 Loader Service Manual 6720455 (6-12) – PDF DOWNLOAD
Language : English
Pages : 392
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
Bobcat 2400 Loader Service Manual 6720455 (6-12) – PDF DOWNLOAD
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the loader and attachments:
1. The Delivery Report is used to assure that complete instructions have been given to the new owner and
that the machine is in safe operating condition.
2. The Operation & Maintenance Manual delivered with the loader gives operating information as well as
routine maintenance and service procedures. It is a part of the loader and must stay with the machine when
it is sold. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
3. The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their
locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your
Bobcat loader dealer.
4. The FIEI Safety Manual delivered with the loader gives general safety information.
5. The Service Manual and Parts Manual are available from your dealer for use by mechanics to do
shop–type service and repair work.
Wear tight fitting clothing and any other required safety apparel when operating or servicing the loader.
• Wear safety glasses when maintaining or servicing the loader.
• Exhaust gases can kill, vent engine exhaust outdoors.
• Know where fire extinguishers and first aid kits are located and how to use them.
• Do not run the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.
• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel
for cleaning parts. Use commercial nonflammable solvents.
• Clean the loader before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher
near the loader when welding
• Have good ventilation when welding or grinding painted parts. Wear a dust mask when grinding painted parts. Toxic dust
and gas can be produced.
• Stop the engine and let it cool before adding fuel. No smoking.
• Use the procedure in this manual for connecting and charging batteries.J
• Use the procedure in the Operator’s Manual for cleaning the spark arrestor muffler after each 100 hours of operation.
TABLE OF CONTENTS:
Bobcat 2400 Loader Service Manual 6720455 (6-12) – PDF DOWNLOAD
MAINTENANCE SAFETY 3
FOREWORD 5
CONTENTS 7
SAFETY INSTRUCTIONS 9
SERIAL NUMBER LOCATIONS 10
LOADER SERIAL NUMBER 10
ENGINE SERIAL NUMBER 10
DELIVERY REPORT 10
BOBCAT ARTICULATED LOADER IDENTIFICATION 11
PREVENTIVE MAINTENANCE 13
SERVICE SCHEDULE 15
LIFTING AND BLOCKING THE LOADER 16
Procedure 16
TRANSPORTING THE LOADER 17
Procedure 17
LIFT ARM STOP 18
Procedure 18
STEERING FRAME LOCK 18
Procedure 18
AIR CLEANER 19
Replacement Of Filter Element 19
FUEL SYSTEM 21
Fuel Specifications 21
Filling The Fuel Tank 21
ENGINE LUBRICATION SYSTEM 22
Checking Engine Oil 22
Replacement Of Oil And Filter 22
ENGINE COOLANT SYSTEM 23
Checking Coolant Level 23
Removing Coolant From The Cooling System 23
Radiator Side Screen 24
Cooling System Maintenance 24
USING A BOOSTER BATTERY (JUMP STARTING) 25
Procedure 25
HYDRAULIC/HYDROSTATIC SYSTEM 26
Checking And Adding Fluid 26
Hydraulic/Hydrostatic Filter Replacement 26
Hydraulic Fluid Replacement 27
SPARK ARRESTOR MUFFLER 28
Cleaning Procedure 28
TIRE MAINTENANCE 29
Wheel Nuts 29
Tire Rotation 29
Tire Inflation 29
FRONT AND REAR DIFFERENTIAL 30
Checking Differential Oil Level 30
Checking Gear–Drop Box Oil Level 30
Checking Wheel End Oil Level 30
LUBRICATION OF THE LOADER 31
Procedure 31
BLOWER FILTER (OPERATOR CAB) 34
Cleaning The Filter 34
HYDRAULIC SYSTEM 35
HYDRAULIC / HYDROSTATIC SCHEMATICS 37
TROUBLESHOOTING 67
HYDRAULIC SYSTEM INFORMATION 68
Flare Connections 68
O–Ring Face Seal Connection 68
Straight Thread O–Ring Fitting 68
Tubelines And Hoses 68
TILT CYLINDER 69
Checking The Tilt Cylinder 69
Removal And Installation 69
Pivot Pin Seals 71
Bucket Anti–Roll Back Linkage Adjustment (11000 Series) 72
Bucket Indicator Linkage Adjustment (12000 Series) 73
LIFT CYLINDER 74
Checking The Lift Cylinder 74
Removal And Installation 75
STEERING CYLINDER 77
Checking The Steering Cylinder 77
Removal And Installation 77
Rod End Bearing 78
HYDRAULIC CONTROL VALVE (11000 Series) 79
Checking The Main Relief Valve 79
Main Relief Valve 79
Removal And Installation 80
HYDRAULIC CONTROL VALVE (12000 Series) 84
Checking The Main Relief Valve 84
Main Relief Valve 84
Removal And Installation 85
BUCKET POSITION VALVE 88
Removal And Installation 88
HYDRAULIC PUMP (11000 Series) 90
Checking Hydraulic Pump Output (Small Section) 90
Checking Hydraulic Pump Output (Large Section) 91
Removal And Installation 93
HYDRAULIC PUMP (12000 Series) 95
Checking Hydraulic Pump Output (Small Section) 95
Checking Hydraulic Pump Output (Large Section) 96
Removal And Installation 97
PORT BLOCK (11000 Series) 99
Removal And Installation 99
Normally–Open Switch 102
Charge Pressure Switch 103
Temperature Sender 103
Oil Cooler By–Pass Valve 104
Two–Speed Solenoid 104
PORT BLOCK (12000 Series) 106
Removal And Installation 106
Two–Speed Solenoid 108
Normally–Open Switch 109
Temperature Sender 110
Oil Cooler By–Pass Valve 111
HYDRAULIC VALVE CONTROL HANDLE (11000 Series) 112
Removal And Installation 112
Disassembly And Assembly 113
Control Handle Electrical Harness 115
HYDRAULIC VALVE CONTROL HANDLE (12000Series) 117
Removal And Installation 117
Disassembly And Assembly 118
STEERING CONTROL VALVE 120
Removal And Installation 120
Disassembly 122
Inspection 125
Assembly 125
Checking Steering Relief Valve 129
HYDRAULIC RESERVOIR 130
Removal And Installation 130
PRIORITY VALVE 132
Removal And Installation 132
Disassembly And Assembly 132
Adjustment Of Steering Relief Valve 132
HYDROSTATIC SYSTEM 133
TROUBLESHOOTING 135
HYDROSTATIC SYSTEM INFORMATION 136
High Pressure Relief/Replenishing Valve Function 136
HYDROSTATIC MOTOR 137
Removal And Installation 137
MULTI–DISC BRAKE 140
Removal And Installation 140
Disassembly And Assembly 140
HYDROSTATIC PUMP (11000 Series) 144
Checking Charge Pressure 144
Checking The High Pressure Relief/Replenishing Valve 144
Removal And Installation 145
HYDROSTATIC PUMP (12000 Series) 150
Checking Charge Pressure 150
Checking The High Pressure Relief/Replenishing Valve 150
Removal And Installation 151
DRIVE BELT 155
Adjustment 155
Removal And Installation 155
DRIVE BELT TENSION PULLEY 157
Removal And Installation 157
FOOT PEDAL CONTROL (11000 Series) 159
Removal And Installation 159
FOOT PEDAL CONTROL (12000 Series) 161
Removal And Installation 161
TOWING THE LOADER 163
Procedure 163
DRIVE SYSTEM 165
TROUBLESHOOTING 167
DRIVE SHAFT 168
Removal And Installation 168
AXLE AND DIFFERENTIAL 169
Front Axle Removal And Installation 169
Rear Axle Removal And Installation 170
Oscillation Blocks And Bushings 171
Oscillation Frame Removal And Installation 173
Axle Hub Housing Removal And Installation 174
Axle Hub Housing Disassembly 174
Axle Hub Housing Assembly 178
Axle Hub Removal And Installation 181
Axle Seal Removal And Installation 182
Axle End Housing Removal And Installation 182
Axle End Housing Disassembly And Assembly 183
Axle Housing End Clearance 187
Axle End Cover Removal And Installation 189
Differential Axle And Seal 190
Brake And Drum 193
Disassembly Of Differential 195
Assembly Of The Differential 204
DROP–BOX GEARCASE 213
Removal And Installation 213
Disassembly And Assembly 213
BRAKE PEDAL MECHANISM 218
Removal And Installation 218
Disassembly And Assembly 219
Brake Pedal Adjustment 221
MAIN FRAME 223
FLOOR PANEL 225
Removal And Installation 225
THROTTLE COVER 227
Removal And Installation 227
SEAT AND SEAT MOUNTING FRAME 228
Removal And Installation 228
REAR FLOOR PANEL 229
Removal And Installation 229
ENGINE HOOD 230
Removal And Installation 230
Hood Adjustment (12000 Series) 231
BOB–TACH TILT ROD (11000 Series) 232
Removal And Installation 232
BOB–TACH TILT ROD (12000 Series) 234
Removal And Installation 234
TILT TRANSFER ARM (11000 Series) 236
Removal And Installation 236
TILT TRANSFER ARM (12000 Series) 237
Removal And Installation 237
BOB–TACH 238
Removal And Installation 238
Bob–Tach Wedges 239
STEERING WHEEL (11000 Series) 240
Removal And Installation 240
STEERING WHEEL (12000 Series) 243
Removal And Installation 243
STEERING COLUMN 246
Removal And Installation 246
Tilt Lock Mechanism 246
FUEL TANK 248
Removal And Installation 248
Fuel Sender 249
REAR DOOR (12000 Series) 250
Removal And Installation 250
Adjustment 250
LOADER MAIN FRAME 251
Separating The Front And Rear Main Frame 251
Bottom Pivot Pin Bearing 254
Top Pivot Pin Bearing 256
ELECTRICAL SYSTEM 257
ELECTRICAL SCHEMATICS 260
TROUBLESHOOTING 285
ELECTRICAL SYSTEM 285
Description 285
Electrical Breaker (11000 Series) 286
Fuses (11000 Series) 286
Fuses (12000 Series) 287
80 Amp Fuse (12000 Series) 287
Electrical System Service 289
SEALED ELECTRICAL TERMINAL 289
Removal And Installation 289
DIODES 289
Checking The Diodes 289
BATTERY 290
Checking The Battery 290
Removal And Installation (11000 Series) 290
Removal And Installation (12000 Series) 291
ALTERNATOR 292
Belt Tension 292
Troubleshooting The Alternator 292
Checking The Alternator Output 293
Removal And Installation 294
Disassembly And Assembly 294
Brush Inspection 298
Testing Diode–Trio & Rectifier Assembly 298
Checking The Stator 298
Rotor Testing And Inspection 299
Replacing The Rear Rotor Bearing 299
Inspection Of Rear Housing 300
STARTER (11000 Series) 301
Checking The Starter 301
Removal And Installation 301
Disassembly And Assembly 302
Cleaning And Inspection 302
Replacing The Brushes 303
STARTER (12000 Series) 304
Checking The Starter 304
Removal And Installation 304
Disassembly And Assembly 305
Cleaning And Inspection 307
INSTRUMENT PANEL (11000 Series) 308
Removal And Installation 308
INSTRUMENT PANEL (12000 Series) 309
Removal And Installation 309
SIGNAL LIGHT CONTROL 311
Removal And Installation 311
ENGINE SERVICE 313
TROUBLESHOOTING 315
VALVE CLEARANCE 316
Adjustment 316
AIR CLEANER HOUSING 316
Removal And Installation 316
FUEL FILTERS 317
Water Trap 317
Removal And Installation 317
Removing Air From The Fuel System 318
FUEL LIFT PUMP 319
Checking 319
Removal And Installation 319
FUEL INJECTION PUMP 320
Removal And Installation 320
TIMING 323
Engine Timing To Injection Pump 323
Checking Timing Mark On Injection Pump Flange 324
FUEL INJECTOR NOZZLES 325
Removal And Installation 325
Checking 326
ENGINE COMPRESSION 327
Checking 327
COOLANT RECOVERY TANK 328
Removal And Installation 328
RADIATOR AND OIL COOLER 329
Removal And Installation 329
RADIATOR FAN 333
Removal And Installation 333
ENGINE 334
Removal And Installation 334
ENGINE FLYWHEEL 335
Removal And Installation 335
Flywheel Ring Gear 335
ENGINE MUFFLER 336
Removal And Installation 336
CYLINDER HEAD 337
Removing The Cylinder Head 337
Cylinder Head Surface Alignment 337
Installing The Cylinder Head 337
VALVES 339
Removal Of The Valves 339
Installing The Valves 339
Reconditioning The Valve And Valve Seats 339
Installing Valve Guides 340
Installing The Valve Seats 341
Checking The Valve Springs 341
ROCKER ARMS 342
Disassembly 342
Assembly 342
PISTON AND CONNECTING RODS 343
Removal 343
Disassembly 344
Inspection 344
Installation 345
CYLINDER LINERS 346
Inspection 346
Removal 346
Installation 346
MAIN BEARINGS 347
Removal 347
Installation 348
Crankshaft End Play 348
CRANKSHAFT 349
Removal 349
Checking 349
Installation 350
REAR MAIN OIL SEAL 350
Removal And Installation 350
TIMING CASE COVER 351
Removal And Installation 351
IDLER GEAR AND HUB 352
Removal And Installation 352
CAMSHAFT GEAR 353
Removal And Installation 353
FUEL INJECTION PUMP GEAR 353
Removal 353
Installation 353
CRANKSHAFT GEAR 353
Removal 353
TIMING CASE 354
Removal And Installation 354
CAMSHAFT 354
Removal And Installation 354
BALANCER UNIT AND OIL PUMP 356
Balancer Removal And Installation 356
Engine Timing To Balancer Unit 356
Oil Pump Removal And Installation 356
Oil Pump Inspection 357
Oil Pump Relief Valve 357
Balancer Disassembly And Assembly 358
Inspection 359
SPECIFICATIONS 361
LOADER SPECIFICATIONS – 2400 363
LOADER DIMENSIONS 363
OPERATION & PERFORMANCE 363
ENGINE 363
HYDRAULIC SYSTEM 364
ELECTRICAL 364
DRIVE SYSTEM 364
CAPACITIES 364
TIRES 364
LOADER SPECIFICATIONS – 2410 365
LOADER DIMENSIONS 365
OPERATION & PERFORMANCE 365
ENGINE 365
HYDRAULIC SYSTEM 366
ELECTRICAL 366
DRIVE SYSTEM 366
CAPACITIES 366
TIRES 366
ENGINE SPECIFICATIONS 367
Cylinder Head 367
Valve Guides 367
Exhaust Valve 367
Intake Valve 367
Valve Springs 367
Rocker Arms & Tappets 367
Piston & Piston Rings 368
Piston Pin & Bushing 368
Cylinder Block & Liners 368
Crankshaft, Main Bearings & Thrust Washer 369
Connecting Rod and Bearings 369
Camshaft & Thrust Washer 370
Timing Case & Timing Gears 370
Oil Pump, Gear & Relief Valve 370
Cooling System & Water Pump 371
Fuel Lift Pump 371
Fuel Injection Pump & Injectors 371
De–Rating for Altitude 372
Balancer Unit 372
Engine Bolt Torques 373
Service Wear Limits 373
Crankshaft Re–Grind Data 374
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 375
Specifications 375
DECIMAL AND MILLIMETER EQUIVALENTS 376
U S TO METRIC CONVERSION 376
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 377
SERVICE MANUAL REVISIONS 379
2400-1 379
2400-2 381
2400-3 383
2400-4 385
2400-5 387
2400-6 389
2400-7 391
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