Bobcat 2410 Loader Service Manual SN 13001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat 2410 Loader Service Manual SN 13001 & Above – PDF DOWNLOAD
Language : English
Pages : 296
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat 2410 Loader Service Manual SN 13001 & Above – 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 2410 Loader Service Manual SN 13001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
SAFETY INSTRUCTIONS 9
SERIAL NUMBER LOCATIONS 10
LOADER SERIAL NUMBER 10
ENGINE SERIAL NUMBER 10
DELIVERY REPORT 10
BOBCAT ARTICLATED 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 SUPPORT DEVICE 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 49
HYDRAULIC SYSTEM INFORMATION 50
Flare Connections 50
O-Ring Face Seal Connectin 50
Straight Thread O-Ring Fitting 50
Tubelines And Hoses 50
TILT CYLINDER 51
Checking The Tilt Cylinder 51
Removal And Installation 51
Tilt Cylinder Base End Pivot Pin 52
Pivot Pin Seals 53
Bucket Indicator Linkage Adjustment 53
LIFT CYLINDER 54
Checking The Lift Cylinder 54
Removal And Installation 55
STEERING CYLINDER 57
Checking The Steering Cylinder 57
Removal And Installation 57
Rod End Bearing 58
HYDRAULIC CONTROL VALVE 59
Checking The Main Relief Valve 59
Main Relief Valve 59
Removal And Installation 60
BUCKET POSITION VALVE 64
Removal And Installation 64
HYDRAULIC PUMP 66
Checking Hydraulic Pump Output (Small Section) 66
Checking Hydraulic Pump Output (Large Section) 67
Removal And Installation 68
HYDRAULIC CONTROL LEVER 70
Removal And Installation 70
Disassembly And Assembly 71
STEERING CONTROL VALVE 73
Removal And Installation 73
Disassembly 75
Checking Steering Relief Valve 82
Assembly 77
PRIORITY VALVE 83
Removal And Installation 83
Disassembly And Assembly 84
Adjustment Of Steering Relief Valve 84
HYDRAULIC RESERVOIR 85
Removal And Installation 85
HYDRAULIC FILTER HOUSING 87
Oil Cooler By-Pass 87
Removal And Installation 87
HYDROSTATIC SYSTEM 89
TROUBLESHOOTING 91
HYDROSTATIC SYSTEM INFORMATION 92
High Pressure Relief/Replenishing Valve Function 92
HYDROSTATIC MOTOR 93
Removal And Installation 93
MULTI-DISC BRAKE 96
Removal And Installation 96
Disassembly And Assembly 96
HYDROSTATIC PUMP 100
Checking Charge Pressure 100
Removal And Installation 101
DRIVE BELT 105
Removal And Installation 105
TENSION ARM & PULLEY 108
Disassembly And Assembly 108
FOOT PEDAL CONTROL 111
Removal And Installation 111
DRIVE SYSTEM 113
TROUBLESHOOTING 115
DRIVE SHAFT 116
Removal And Installation 116
AXLE AND DIFFERENTIAL 117
Front Axle Removal And Installation 117
Rear Axle Removal And Installation 118
Oscillation Blocks And Bushings 119
Oscillation Frame Removal And Installation 120
Axle Hub Removal And Installation 121
Axle Seal Removal And Installation 122
Axle End Housing Removal And Installation 123
Axle End Housing Disassembly And Assembly 123
Axle Housing End Clearance 127
Axle Hub Shaft End Play 129
Differential Axle Removal And Installation 129
Differential Axle And Seal 130
Brake And Drum 133
Disassembly Of Differential 134
Assembly Of Differential 143
DROP-BOX GEARCASE 151
Removal And Installation 151
Disassembly And Assembly 152
BRAKE PEDAL MECHANISM 156
Removal And Installation 156
Disassembly And Assenbly 157
Brake Pedal Adjustment 159
MAIN FRAME 161
FLOOR PANEL 163
Removal And Installation 163
THROTTLE COVER 165
Removal And Installation 165
SEAT AND SEAT MOUNTING FRAME 166
Removal And Installation 166
REAR FLOOR PANEL 167
Removal And Installation 167
ENGINE HOOD 168
Removal And Installation 168
Hood Adjustment 169
FRONT BUMPER 169
Removal And Installation 169
BOB-TACH TILT ROD 170
Removal And Installation 170
TILT TRANSFER ARM 172
Removal And Installation 172
BOB-TACH 173
Removal And Installation 173
Bob-Tach Lever And Wedge 174
STEERING WHEEL 176
Removal And Installation 176
STEERING COLUMN 179
Removal And Installation 179
Tilt Lock Mechanism 179
FUEL TANK 181
Removal And Installation 181
Fuel Sender 182
REAR DOOR 183
Removal And Installation 183
Adjustment 183
LOADER MAIN FRAME 184
Seperating The Front And Rear Main Frame 184
Bottom Pivot Pin Bearing 187
Top Pivot Pin Bearing 188
ELECTRICAL SYSTEM 189
ELECTRICAL SCHEMATICS 192
TROUBLESHOOTING 201
ELECTRICAL SYSTEM 201
Description 201
Fuses 202
In-Line Master Fuse 202
Electrical System Service 204
SEALED ELECTRICAL TERMINAL 204
Removal And Installation 204
DIODES 204
Checking The Diodes 204
BATTERY 205
Checking The Battery 205
Removal And Installation 205
ALTERNATOR 206
Belt Tension 206
Troubleshooting The Alternator 207
Checking The Alternator Output 208
Removal And Installation 209
Disassembly And Assembly 209
Brush Inspection 213
Testing Diode-Trio & Rectifier Assemble 213
Checking The Stator 213
Rotor Testing And Inspection 214
Replacing The Rear Rotor Bearing 214
Inspection Of Rear Housing 215
STARTER 216
Checking The Starter 216
Removal And Installation 216
Disassembly And Assembly 217
Cleaning And Inspection 219
INSRTUMENT PANEL 220
Removal And Installation 220
SIGNAL LIGHT CONTROL 222
Removal And Installation 222
ENGINE SERVICE 223
TROUBLESHOOTING 225
VALVE CLEARANCE 226
Adjustment 226
AIR CLEANER HOUSING 226
Removal And Installation 226
FUEL FILTER 227
Water Trap 227
Removal And Installation 227
Removing Air From The Fuel System 228
FUEL LIFT PUMP 229
Checking 229
Removal And Installation 229
FUEL INJECTION PUMP 230
Removal And Installation 230
TIMING 233
Engine Timing To Injection Pump 233
Checking Timing Mark On Injection Pump Flange 234
FUEL INJECTOR NOZZLES 235
Removal And Installation 235
Checking 236
ENGINE COMPRESSION 237
Checking 237
COOLANT RECOVERY TANK 238
Removal And Installation 238
RADIATOR AND OIL COOLER 239
Removal And Installation 239
RADIATOR FAN 243
Removal And Installation 243
ENGINE 244
Removal And Installation 244
ENGINE FLYWHEEL 246
Removal And Installation 246
Flywheel Ring Gear 246
ENGINE MUFFLER 247
Removal And Installation 247
CYLINDER HEAD 249
Removing The Cylinder Head 249
Cylinder Head Surface Alignment 249
Installing The Cylinder Head 249
VALVES 251
Removal Of The Valves 251
Installing The Valves 251
Reconditioning The Valve And Valve Seats 251
Installing Valve Guides 252
Installing The Valve Seats 253
Checking The Valve Springs 253
ROCKER ARMS 254
Disassembly 254
Assembly 254
PISTON AND CONNECTING RODS 255
Removal 255
Disassembly 256
Inspection 256
Installation 257
CYLINDER LINERS 258
Inspection 258
Removal 258
Installation 258
MAIN BEARINGS 259
Removal 259
Installation 260
Crankshaft End Play 260
CRANKSHAFT 261
Removal 261
Checking 261
Installation 262
REAR MAIN OIL SEAL 262
Removal And Installation 262
TIMING CASE COVER 263
Removal And Installation 263
IDLER GEAR AND HUB 264
Removal And Installation 264
CAMSHAFT GEAR 265
Removal And Installation 265
FUEL INJECTION PUMP GEAR 265
Removal 265
Installation 265
CRANKSHAFT GEAR 265
Removal 265
TIMING CASE 266
Removal And Installation 266
CAMSHAFT 266
Removal And Installation 266
WATER PUMP 267
Disassembly Of The Water Pump 267
Inspection Of The Water Pump 267
Assembly Of The Water Pump 268
BALANCER UNIT AND OIL PUMP 270
Balancer Removal And Installation 270
Engine Timing To Balancer Unit 270
Oil Pump Removal And Installation 270
Oil Pump Inspection 271
Oil Pump Relief Valve 271
Balancer Disassembly And Assembly 272
Inspection 273
Installing Balancer Bushings 273
SPECIFICATIONS 275
LOADER SPECIFICATIONS 277
Loader Dimensions 277
Operation & Performance 277
Engine 277
Hydraulic System 278
Electrical 278
Drive System 278
Capacities 278
Tires 278
ENGINE SPECIFICATIONS 279
Cylinder Head 279
Valve Guides 279
Exhaust Valve 279
Intake Valve 279
Valve Springs 279
Rocker Arms & Tappets 279
Piston & Piston Rings 280
Piston Pin & Bushing 280
Cylinder Block & Liners 280
Crankshaft, Main Bearings & Thrust Washer 281
Connecting Rod And Bearings 281
Camshaft & Thrust Washer 282
Timing Case & Timing Gears 282
Oil Pump, Gear & Relief Valve 282
Cooling System & Water Pump 283
Fuel Lift Pump 283
Fuel Injection Pump & Injectors 283
De-Rating For Altitude 284
Balancer Unit 284
Engine Bolt Torques 285
Service Wear Limits 285
Crankshaft Re-Grind Data 286
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 287
DECIMAL AND MILLIMETER EQUIVALENTS 288
U S TO METRIC CONVERSION 288
STANDARD TORQUE SPECIFICATION FOR BOLTS 289
SERVICE MANUAL REVISIONS 291
2410-1 291
2410-2 293
2410-3 295
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