Bobcat 2400 Series Wheel Loader Repair Service Manual - 6720455

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This workshop repair 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 
SERVICE MANUAL REVISIONS


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 !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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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
    
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