Bobcat 2400 Service Manual 6720455 (5–90) - PDF DOWNLOAD

2 4 0 0

Service Manual

6720455 (5–90)

Printed in U.S.A.

© Melroe Company 1990

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

B-10731a

CORRECT

CORRECT

B-6700

B-6699

Never service the Bobcat Loader without instructions. See Service Manual.

Check engine and hydraulic fluids daily.

Use recommended fluids.

Cleaning and required daily.

maintenance

are

WRONG

B-15547

Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged.

WRONG

WRONG

WRONG

B-6688

B-6672

B-6673

Always connect steering frame lock before working on the loader.

WRONG

B-6697

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust loader with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Do not fill the fuel tank with engine running, while smoking or when near an open flame.

Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device.

Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

WRONG

B-6698 B-16102

B-6589 B-16102

Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding.

Keep rear door closed except for service. Close and latch door before operating the loader.

Lead-acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer.

MSW04-0805

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.

A general inspection of the following items must be made after the loader has had service or repair: 1. Check that the ROPS/FOPS is in good condition and is not modified.

9. Enclosure door latches must open and close freely.

2. Check that ROPS mounting hardware is tightened and is Melroe approved.

10. Bob–Tach wedges and linkages must function correctly and be in good condition.

3. The seat belt must be correctly installed, functional and in good condition.

11. Safety treads must be in good condition.

4. The restraint arm must function correctly.

12. Check for correct function of indicator lamps.

5. Machine signs must be legible and in the correct location.

13. Check hydraulic fluid level, engine oil level and fuel supply.

6. Foot pedal must return to neutral.

14. Inspect for fuel, oil or hydraulic fluid leaks.

7. Check for correct function of the work lights.

15. Lubricate the loader.

8. The parking brake must . function correctly.

16. Check the condition of the battery and cables.

–3

2400 Series Loader Service Manual

17. Inspect the air cleaner for damage or leaks. Check the condition of the element.

18. Check the electrical charging system.

19. Check tires for wear and pressure.

20. Inspect for loose or broken parts or connections.

Recommend to the owner that all necessary corrections be made before the machine is returned to service.

–2

2400 Series Loader Service Manual

CONTENTS SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii BOBCAT ARTICULATED LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . iii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

HYDROSTATIC DRIVE SYSTEM

DRIVE SYSTEM

MAIN FRAME

ELECTRICAL SYSTEM

ENGINE SERVICE

SPECIFICATIONS

–1

2400 Series Loader Service Manual

0

2400 Series Loader Service Manual

SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–1289

The following publications provide information on the safe use and maintenance of the loader and attachments: * 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. * 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 Excavator dealer. * 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. * The FIEI Safety Manual delivered with the loader gives general safety information. * The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and repair work.

This notice identifies procedures which must be followed to avoid damage to the machine.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

W–2044–1285

I–2019–0284

This safety message symbol is used for important safety messages. When you see this symbol, follow the safety message to avoid personal injury or death. * 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 extinguisher 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. Remove both battery cables (negative (–) cable first). Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the excavator when welding. * Have good ventilation when welding or grinding painted parts. Wear a dust mask when grinding painted parts. Toxic dust or gas can be produced. * Stop the engine and let it cool before adding fuel. NO SMOKING! * Use the procedures in this manual for connecting batteries. * Use the procedures in this manual for cleaning the spark arrestor muffler after each 100 hours of operation. i

2400 Series Loader Service Manual

SERIAL NUMBER LOCATIONS

A

Always use the serial number of the machine when requesting service information or when ordering parts.

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

LOADER SERIAL NUMBER The Bobcat loader serial number is located on the left upright frame, above the left engine door [A].

PI–09377

ENGINE SERIAL NUMBER

B

The engine serial number is located on the engine block, near the fuel injection pump [B].

PI–09378

DELIVERY REPORT

C

The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [C].

ii

2400 Series Loader Service Manual

BOBCAT ARTICULATED LOADER IDENTIFICATION FRONT LIGHTS

FLASHERS

OPERATOR CAB (***ROPS, FOPS) LIFT CYLINDER TILT CYLINDER GRAB HANDLES ENGINE HOOD

STEP

STEERING FRAME LOCK *BUCKET

LIFT ARMS RESTRAINT ARM

REAR LIGHTS

BACK–UP ALARM RADIATOR SIDE SCREEN REAR DOOR

COUNTERWEIGHT

**TIRES B–13224 B–13225

* ** *** ***

BUCKET – Several different buckets and other attachments are available for the loader.

TIRES – Tires shown are optional flotation tires.

ROPS – Roll–Over Protective Structure Per SAE 1040.

FOPS – Falling Object Protective Structure Per SAE J1043. iii

2400 Series Loader Service Manual

iv

2400 Series Loader Service Manual

PREVENTIVE MAINTENANCE

Page Number

PREVENTIVE MAINTENANCE

AIR CLEANER Replacement Of The Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 BLOWER FILTER (OPERATOR CAB) Cleaning The Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20 ENGINE COOLANT SYSTEM Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator Side Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Coolant From The Cooling System . . . . . . . . . . . . . . . . . . . . .

1–9 1–10 1–10 1–9

ENGINE LUBRICATION SYSTEM Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 Replacement Of Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 FRONT AND REAR DIFFERENTIAL Checking Differential Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 Checking Gear–Drop Box Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 Checking Wheel End Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 FUEL SYSTEM Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 HYDRAULIC/HYDROSTATIC SYSTEM Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 Hydraulic Fluid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 LIFT ARM STOP Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 LIFTING AND BLOCKING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 LUBRICATION OF THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 SPARK ARRESTOR MUFFLER Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 STEERING FRAME LOCK Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 TIRE MAINTENANCE Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15 TRANSPORTING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 USING A BOOSTER BATTERY (JUMP STARTING) Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 –1––1–

2400 Series Loader Service Manual

–1–0–

2400 Series Loader Service Manual

SERVICE SCHEDULE You must do maintenance work at regular intervals. Failure to do so may result in damage to the loader or the engine. The SERVICE SCHEDULE is a guide for correct maintenance of the Bobcat loader. Follow this SERVICE SCHEDULE as explained below unless it is to increase the frequency of intervals when the loader is used in very hot, cold, dusty or corrosion conditions.

Instructions are necessary before operating or servicing machine.

Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–1089

ITEM

SERVICE REQUIRED

8–10

50

100

250

500 1000

Engine Oil Engine Air Cleaner

Check the oil level and add as needed.

Check restriction indicator. See Page 1–5 for correct procedure to service filter elements.

Engine Coolant System Check coolant recovery tank level and add coolant as needed. Remove debris from the grill area.

Seat Belt Check the condition of seat belt and restraint arm.

Loader Pivot Points Add lubricant to all fittings. (See Page 1–17.)

Fuel Filter Remove any trapped water.

Hyd.Tubelines and Hoses Check for damage and leaks and replace as needed.

Tires Check tires for damage and correct pressure.

Hyd. Fluid Reservoir Check the fluid level & add as needed.

Safety Signs (Decals) & Check for damaged decals and safety treads. Replace Safety Tread any decals or safety treads that are damaged or missing.

Wheel Nuts K Tighten wheel nuts to 140 ft.–lbs. (190 Nm) torque.

Battery and Cables Check the battery condition. Clean cable ends and cover with grease.

Hydraulic Control Lever Check the lever for correct operation. Make repair and adjust as needed.

Bob–Tach Check the locking levers and wedges for condition and correct operation.

Brakes and Controls Check the brake for correct operation.

Alternator Belt Check condition and tension of belt.

Drive Belt ∗ Check condition and tension. Adjust as needed. (See Page 3–21.)

Deluxe Cab Blower Filter Remove and clean with reduced air pressure.

Engine Oil and Filter Replace oil and filter.

Spark Arrestor Muffler Empty spark chamber.

U–Joints (Drive Shaft) Lubricate with the correct grease. (See Page 1–17.)

Pivot Points Lubricate axle oscillation and Bob–Tach wedge fittings.

Fuel Filter Replace the filter element.

Front and Rear Axle Check oil level and add as needed (See Page 1–16).

Hydraulic Filter D Replace filter element.

Hydraulic/Hydrostatic Replace the fluid and filter. Replace the vent filter.

System K Check wheel nut torque every 8 hours for the first 24 hours of operation.

D Replace the element sooner if the warning light comes ON. ∗ Check every 8 hours for the first 40 hours of operation.

–1–1–

2400 Series Loader Service Manual

PREVENTIVE MAINTENANCE

A

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death [A].

W–2003–0797

LIFTING AND BLOCKING THE LOADER

B–07023

Procedure Always park the loader on a level surface.

Install the steering frame lock. (See Page 1–4.)

Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.

B

W–2017–0286

Put the floor jack under the rear of the loader [B].

Lift the rear of the loader and install the heavy duty jackstands [B].

PI–05901

C

Put the floor jack under the front axle differential housing [C].

Lift the front of the loader and put heavy duty jackstands under the axle tube housing [C].

NOTE: Make sure the jackstands do not touch the tires.

PI–05900

–1–2–

2400 Series Loader Service Manual

TRANSPORTING THE LOADER

A

Procedure

Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

W–2058–0494

PI–05342

A loader with an empty bucket or no attachment should be loaded backward onto the transport vehicle [A].

B

Install chains to hold the loader in position during sudden stops or when going up or down slopes. Use the following procedure to fasten the Bobcat loader to the transport vehicle: 1. Lower the bucket or attachment to the floor. Stop the engine.

2. Engage the parking brake.

3. Install the steering frame lock. (See Page 1–4.)

PI–05343

4. Fasten a chain under the rear of the loader frame and transport vehicle [B].

C

5. Put a chain through the tube at the lift arms [C].

Fasten the chain to both sides of the transport vehicle. Use chain binders to tighten all the chains.

PI–05344

–1–3–

2400 Series Loader Service Manual

LIFT ARM STOP

A

Procedure

Never work on a machine with the lift arms up unless the lift arms are secured by a lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.

W–2059–0991

PI–05405

B

Remove the knob fastening the lift arm stop. Remove the lift arm stop from the operator cab [A].

One person must stay in the operator seat, with the seat belt fastened and restraint arm lowered, while the other person installs the lift arm stop.

Start the engine and raise the lift arms. Have the second person install the lift arm stop over the rod of one of the lift cylinders [B].

Lower the lift arms slowly until the stop is held between the lift arm and lift cylinder.

NOTE: Always store the lift arm stop in the correct location in the operator cab.

B–12128

C

STEERING FRAME LOCK Procedure Before any service work is done on the Bobcat loader, always install the steering frame lock, use the following procedure: 1. Remove the cotter pin at the pin [C].

2. Remove the pin from the mounting bracket and steering frame lock [C].

3. Rotate the steering frame lock into the brackets at the front loader frame.

PI–05406

D

4. Install the pin and cotter pin [D].

NOTE: The steering frame lock is shown on the left side of the loader. There are brackets installed on the right side of the loader frame so the steering frame lock can be used on the right side also.

PI–05407

–1–4–

2400 Series Loader Service Manual

AIR CLEANER

A

Replacement Of Filter Element It is important to service the air cleaner at regular intervals, see the SERVICE SCHEDULE Page 1–1.

1

The large filter element (outer) must be replaced when the restriction indicator (Item 1) [A] reads more than 22 in.

H20.

PI–09397

B

Before replacing the outer filter element, push the button on the restriction indicator and start the engine. Run the engine at full RPM. If the reading is less than 22 in. H20, do not replace the filter element. Service the air cleaner as follows: 1. Stop the engine. Open the engine hood.

2. Loosen the wing nut and remove the air cleaner cap from the housing [B].

PI–09398

C

3. Remove the wing nut from the filter element [C].

PI–09399

4. Remove the outer filter element [D]. DO NOT remove the inner filter element.

D

5. Install the new filter element and tighten the wing nut.

6. Install the end cap and tighten the wing nut.

7. Push the button at the restriction indicator (Item 1) [A].

PI–09400

–1–5–

2400 Series Loader Service Manual

AIR CLEANER (Cont’d)

A

Replacement Of Filter Element (Cont’d) NOTE: Replace the inner filter element every third time the outer filter element is replaced or when the restriction indicator reads 15 in.

H20 at full engine RPM after the outer filter element has been replaced [A].

8. Check to make sure the air cleaner hose clamps are tight.

PI–09401

–1–6–

2400 Series Loader Service Manual

FUEL SYSTEM

A

Fuel Specifications Use only clean, high–quality fuel.

Use Grade No. 2 fuel above 40°F (4°C). Use Grade No. 1 fuel at temperatures below 40°F (4°C).

Filling The Fuel Tank Clean the area around the fuel fill cap.

Remove the fuel fill cap [A].

PI–05354

B

WRONG

Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can cause an explosion or fire.

W–2063–0887

B–12115

C

Use a clean, approved safety container to add fuel of the correct specifications [C].

Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING! Install and tighten the fuel fill cap.

PI–05355

–1–7–

2400 Series Loader Service Manual

ENGINE LUBRICATION SYSTEM

A

Checking Engine Oil To check the oil level, open the engine hood and remove the dipstick [A].

Keep the oil level between the marks on the dipstick [A].

Do not fill above the top mark. Use a good quality engine oil that meets API Service Classification of CC or CD. (See Chart.)

Replacement Of Oil And Filter

A–01528

See the SERVICE SCHEDULE Page 1–1, for the correct interval when to replace the engine oil and filter.

B

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE) C°–34 –29

–23 –18

–13

–7

–1

+4

+10 +15

+21

+27 +32 +38

+43

+49

PI–05364

+54 +60

SAE 40 or 20W–50

SAE 10W–30/30

SAE 15W–40

SAE 5W–30

SAE 30

SAE 20W–20

PI–05365 SAE 10W

F°–30 –20

–10

0

+10

+20 +30

+40 +50 +60

+70

C

+80 +90 +100 +110 +120 +130 +140

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL: USE API CLASSIFICATION CC OR CD) 1. Let the engine warm to operating temperature. Stop the engine.

2. Open the engine hood and right access door.

3. Remove the plug from the oil drain hose and drain the oil into a container [B].

4. Clean the area around the oil filter housing. Remove the oil filter [C].

PI–09402

5. Put clean oil on the filter gasket. Install the oil filter and hand tighten. Install and tighten the plug in the oil drain hose.

D

6. Remove the oil fill cap. Fill the engine with oil of the correct grade and viscosity [D]. (See SPECIFICATIONS, Section 8 for correct capacity.)

7. Operate the engine and check for leaks at the oil filter. Stop the engine. Check the oil level and add oil as needed to bring the oil level to the top mark on the dipstick.

PI–05367

–1–8–

2400 Series Loader Service Manual

ENGINE COOLANT SYSTEM

A

Checking Coolant Level The coolant recovery tank (Item 1) [A] is located in the engine compartment at the right side.

When the engine is cool, the coolant recovery tank must be 1/3 full. Add coolant to the recovery tank when the coolant level is low.

1 Removing Coolant From The Cooling System

PI–09405

B Do not remove radiator cap when the engine is hot. You can be seriously burned.

W–2070–1285

1. Remove the radiator cap [B].

PI–09406

C

2. Remove the drain plug at the bottom of the radiator and drain the coolant into a container [C].

3. Remove the plug (Item 1) [D] to drain all the coolant from the engine block.

4. After all the coolant is removed, close and tighten the engine block drain. Install and tighten the radiator plug drain.

PI–05370

5. Mix the coolant in a separate container. (See SPECIFICATIONS Section for the correct capacity.)

D

NOTE: Protect the cooling system by adding pre–mixed 50% ethylene glycol and 50% water to the system. This mixture will protect the cooling systems to –34°F (–36°C).

6. Fill the radiator with the pre–mixed coolant. Install the radiator cap.

1

7. Add coolant to the recovery tank until it is 1/3 full.

8. Run the engine until it is at operating temperature.

Stop the engine. Check the coolant level in the recovery tank and add coolant as needed.

PI–09548

–1–9–

2400 Series Loader Service Manual

ENGINE COOLING SYSTEM (Cont’d)

A

Radiator Side Screen To remove the radiator side screen, use the following procedure: 1. Remove both fastening knobs [A].

PI–09403

B

2. Remove the side screen from the loader frame [B].

PI–09404

Cooling System Maintenance Check the cooling system every day to prevent over–heating, loss of performance or engine damage.

C

Check for leaks in the cooling system. Check for worn or damaged hoses, clamps or radiator. Check for loose or worn water pump belt.

1. Open the right access door.

2. Remove the radiator side screen.

PI–05371

D

Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

W–2019–1285

3. Use air pressure to clean the radiator and oil cooler fins [C].

4. Clean the radiator side screen using air pressure [D].

PI–05372

–1–10–

2400 Series Loader Service Manual

USING A BOOSTER BATTERY (JUMP STARTING)

A

Procedure If it is necessary to use a booster battery to start the engine, use the following procedure:

2

This is a two person operation. There must be one person in the operator seat and one person to connect and disconnect the jumper cables from the battery.

1. The key switch must be in the OFF position.

2. The booster battery must be 12 volts.

3

3. Connect the end of the first cable (Item 1) [A] to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the positive (+) terminal (Item 2) [A] of the loader battery.

1 PI–05378

4. Connect the end of the second cable (Item 3) [A] to the negative (–) terminal of the booster battery.

Connect the other end of the same cable to a good clean ground (–) on the loader frame.

Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.

5. Keep the cables away from moving parts.

6. Start the engine. (See the Operation and Maintenance Manual, Cold Starting Procedure.)

Do not jump start or charge a frozen or damaged battery. Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

Never lean over battery while boosting, testing or charging.

7. After the engine is running. Remove the ground (–) cable first.

8. Remove the cable connected to the positive (+) terminal of the loader battery.

Battery gas can explode and cause serious injury.

W–2066–1296

Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a •

fast charger or when welding on the loader.

(Remove both cables from the battery.)

Extra battery cables (booster cables) are connected wrong.

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

I–2023–1285

In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W–2065–1296

–1–11–

2400 Series Loader Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM

A

Checking And Adding Fluid 1. Put the loader on a level surface. Lower the lift arms and tilt the Bob–Tach fully back. Stop the engine.

2. Remove the dipstick from the fluid reservoir. The fluid level must be between the top and bottom mark on the dipstick [A].

Keep Oil Level Between These Marks

B–06756

3. If the fluid level is not correct, add fluid as needed to bring it to the top mark on the dipstick [B]. (See SPECIFICATIONS Section for the correct fluid.)

PI–09411

B

Hydraulic/Hydrostatic Filter Replacement See the SERVICE SCHEDULE Page 1–1 for the correct service interval.

PI–09412

1. Clean the area around the filter housing.

C

2. Remove the filter element [C].

3. Clean the surface of the filter housing head where the element seal makes contact.

4. Lubricate the seal of the new filter element with clean fluid.

5. Install the filter element and hand tighten.

6. Start the engine, operate the loader hydraulic functions. Stop the engine. Check the fluid level in the reservoir and add as needed.

PI–09413

–1–12–

2400 Series Loader Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Hydraulic Fluid Replacement See the SERVICE SCHEDULE Page 1–1 for the correct service interval.

1. Lower the lift arms and tilt the Bob–Tach fully back.

Stop the engine.

2. Remove the plug at the bottom of the reservoir and drain the fluid into a container [A].

3. Remove the hydraulic/hydrostatic filter. (See Page 1–12.)

PI–05383

4. Install a new filter element. Install and tighten the drain plug. Do Not over–tighten the plug.

B

5. Fill the fluid reservoir to the top mark on the dipstick.

(See SPECIFICATIONS, Section 8 for capacity and fluid type.)

1

6. Check the hydraulic reservoir breather cap (Item 1) [B]. Replace the breather if plugged.

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

PI–09414

W–2103–1285

–1–13–

2400 Series Loader Service Manual

SPARK ARRESTOR MUFFLER

A

Cleaning Procedure Do not use the loader with a defective exhaust system.

Stop the engine. Install the steering frame lock. (See Page 1–4.)

Open the engine hood.

Wear safety glasses. Remove the plug from the muffler [A].

Engage the parking brake. Start the engine. Hold a piece of wood over the outlet of the muffler for about 10 seconds.

PI–09415

Stop the engine. Install and tighten the plug.

Disengage the steering frame lock.

When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside.

Exhaust fumes contain odorless, invisible gases which can kill without warning.

This loader is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation.

W–2050–1285

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles. Failure to obey can cause serious injury.

If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC.

W–2011–1285

Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.

W–2068–1285

Make reference to local laws and regulations for spark arrestor requirements.

I–2022–0595

–1–14–

2400 Series Loader Service Manual

TIRE MAINTENANCE

A

Wheel Nuts See the SERVICE SCHEDULE Page 1–1 for the service interval to check the wheel nuts.

The correct torque for the wheel nuts is 140 ft.–lbs. (190 Nm). [A].

Tire Rotation Check the tires regularly for wear, damage and pressure.

(See SPECIFICATIONS, Section 8 for the correct tire pressure.)

PI–05389

Always keep the same size tires on each axle to avoid damage to the differentials.

It is important to keep the same size tires on each axle/differential of this loader to avoid excessive wear. If different sizes are used on the same differential, each tire will be turning at a different speed and cause excessive wear on the gears in the differentials. When a tire wears, always install two new tires on the same axle/differential.

The tread bars of all the tires must face the same direction.

Do not inflate tires above specified pressure.

Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.

W–2078–1285

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for correct tire pressure before operating the loader.

Tire Inflation Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. Tires and rims must always be checked for proper size before operating the loader.

The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire to avoid damage to the rim or tire. When inflating a tire avoid excess pressure which can rupture the tire and cause serious injury. During inflation of the tire, check the tire pressure frequently to avoid over–inflation. (See SPECIFICATIONS, Section 8 for the correct tire pressure.)

–1–15–

2400 Series Loader Service Manual

FRONT AND REAR DIFFERENTIAL

A

Checking Differential Oil Level NOTE: The gear–drop box, differentials and wheel ends use SAE 90W weight gear lube. Each has a separate reservoir and must be checked separately.

1

See the SERVICE SCHEDULE Page 1–1 for the correct service interval.

1. Put the loader on a level surface. Lower the lift arms.

Stop the engine.

2. Remove the check/fill plug at the differentials; Front (Item 1) [A]: Rear (Item 1) [B].

PI–05385

B

3. The gear lube level must be at the check plug hole.

If not, add the gear lube through the hole until it flows from the plug hole.

1

4. Install and tighten the plug.

PI–05386

Checking Gear–Drop Box Oil Level

C

1. Put the loader on a level surface. Lower the lift arms.

Stop the engine.

2. Remove the check/fill plug (Item 1) [C] at the gear–drop box.

3. The gear lube level must be at the check plug hole.

If not, add gear lube through the hole until it flows from the plug hole.

1

4. Install and tighten the plug.

PI–05387

Checking Wheel End Oil Level The gear lube level at the four wheel ends is separate from the differential gear lube.

REAR

D

FRONT

1. Put the loader on a level surface. Lower the lift arms.

Stop the engine.

2. Remove the check/fill plug (Item 1) [D] at the wheel end.

3. The gear lube level must be at the check plug hole.

If not, add gear lube through the hole until it flows from the plug hole.

1 1

4. Install and tighten the plug.

PI–06999

–1–16–

PI–05388

2400 Series Loader Service Manual

LUBRICATION OF THE LOADER

A

Procedure See the SERVICE SCHEDULE Page 1–1 for the correct service interval.

1

AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual.

PI–05391

W–2012–0497

B The drive shaft connects the front and rear differential together and there is a U–joint at each end. Lubricate the U–joints with high impact type grease (P/N 6599719).

1. Front U–joint Grease Fitting [A].

2

3

2. Rear U–joint Grease Fitting [B].

3. Drive Shaft Splines [B].

PI–05392

Always use a good quality lithium–based multi–purpose grease when lubricating the loader.

C

1. Steering Cylinder Rod End Pivot [C].

2 2. Steering Cylinder Base End Pivot [C].

1

PI–05393

D 3. Loader Center Top Pivot Bushing [D].

4. Loader Center Lower Pivot Bushing [D].

3

4 PI–05394

–1–17–

2400 Series Loader Service Manual

LUBRICATION OF THE LOADER (Cont’d)

A

Procedure (Cont’d)

Never lubricate the machine or attachment when the lift arms are raised unless the lift arms are held with a lift arm support device and the attachment is supported. Failure to provide support can cause injury or death.

5

6

PI–05395

W–2032–1192

B 5. Bob–Tach Wedge (both sides) [A].

9

6. Bob–Tach Linkage (both sides) [A].

8 7. Bob–Tach Pivot Pin (both sides) [B].

8. Bob–Tach Tilt Linkage (both sides ) [B].

7

9. Bob–Tach Tilt Cylinder Rod End (both sides) [B].

PI–05396

C

10. Tilt Cylinder Base End (both sides) [C].

10

PI–05398

D

11. Lift Cylinder Rod End (both sides) [D].

12. Lift Cylinder Base End (both sides) [D].

12

11

PI–05399

–1–18–

2400 Series Loader Service Manual

LUBRICATION OF THE LOADER (Cont’d)

A

Procedure (Cont’d)

13

13. Oscillation Pivot Block (front and rear) [A].

PI–06998

Lubricate the seat rails for easy movement when the seat is adjusted [B].

B

PI–05397

–1–19–

2400 Series Loader Service Manual

BLOWER FILTER (OPERATOR CAB)

A

Cleaning The Filter The blower filter is located behind the door on the outside of the enclosed operator cab (Optional) [A].

Clean the blower filter with reduced compressed air pressure every 50 hours of loader operation. In extreme dusty conditions it will be necessary to clean the filter every 8 hours.

To remove the blower filter, use the following procedure: 1. Open the side door on the operator cab [A].

PI–08068

2. Remove the fastening knob (Item 1) [B] and filter holddown bracket (Item 2) [B].

B

1

3. Remove and clean the filter.

2

PI–08069

–1–20–

2400 Series Loader Service Manual

HYDRAULIC SECTION Page Number BUCKET POSITION VALVE Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22 HYDRAULIC CONTROL VALVE (11000 SERIES) Checking The Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13 Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14

HYDRAULIC SYSTEM

HYDRAULIC CONTROL VALVE (12000 SERIES) Checking The Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18 Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19 HYDRAULIC PUMP (11000 SERIES) Checking Hydraulic Pump Output (Large Section) . . . . . . . . . . . . . . . . . 2–25 Checking Hydraulic Pump Output (Small Section) . . . . . . . . . . . . . . . . . 2–24 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27 HYDRAULIC PUMP (12000 SERIES) Checking Hydraulic Pump Output (Large Section) . . . . . . . . . . . . . . . . . 2–30 Checking Hydraulic Pump Output (Small Section) . . . . . . . . . . . . . . . . . 2–29 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–31 HYDRAULIC RESERVOIR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–64 HYDRAULIC SYSTEM INFORMATION Flare Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O–Ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Straight Thread O–Ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–2 2–2 2–2 2–2

HYDRAULIC VALVE CONTROL HANDLE (11000 SERIES) Control Handle Electrical Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–49 Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–47 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46 HYDRAULIC VALVE CONTROL HANDLE (12000 SERIES) Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–52 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–51 LIFT CYLINDER Checking The Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 PORT BLOCK (11000 SERIES) Charge Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Normally–Open Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Cooler By–Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two–Speed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–37 2–36 2–38 2–33 2–37 2–38

TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8) UNLESS OTHERWISE SPECIFIED. Continued On Next Page –2––1–

2400 Series Loader Service Manual

HYDRAULIC SECTION (Cont’d) Page Number PORT BLOCK (12000 SERIES) Normally–Open switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Cooler By–Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two–Speed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–43 2–45 2–40 2–44 2–42

PRIORITY VALVE Adjustment Of Steering Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–66 Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–66 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–66 STEERING CONTROL VALVE Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Steering Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–59 2–63 2–56 2–59 2–54

STEERING CYLINDER Checking The Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 Rod End Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 TILT CYLINDER Bucket Anti–Roll Back Linkage Adjustment (11000 Series) . . . . . . . . . .

Bucket Indicator Linkage Adjustment (12000 Series) . . . . . . . . . . . . . . .

Checking The Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pivot Pin Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–6 2–7 2–3 2–3 2–5

TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

–2–0–

2400 Series Loader Service Manual

HYDRAULIC SYSTEM TROUBLESHOOTING The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Loader Service personnel only.

PROBLEM

CAUSE

The hydraulic system will not operate.

1, 2, 3, 4, 5

Slow hydraulic system action.

1, 3, 5, 6, 7, 8, 9, 10, 12

Hydraulic action is not smooth.

1, 3, 5, 7, 8, 10, 11

Slow or no hydraulic action on one side of the control valve.

2, 6, 13, 14

Lift arms go up slowly at full engine RPM.

5, 6, 7, 8, 9, 11, 13, 15, 16

Lift arms or Bob–Tach move with linkage in neutral position.

6, 15

Lift arms come down with linkage in neutral.

6, 16, 17, 18, 19

KEY TO CORRECT THE CAUSE 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

The hydraulic reservoir fluid is not at the correct level.

The linkage is disconnected.

The hydraulic pump has a defect.

The relief valve is not at the correct pressure.

Slow engine RPM. The linkage is not adjusted correctly.

Auxiliary hydraulics (optional) are in detent position.

Suction leak in the hydraulic system.

Fluid is cold.

Flow divider valve is not working correctly.

Internal restriction.

Steering relief valve is not at the correct pressure setting.

Cylinder seals are leaking.

Port relief valve is not set at the correct pressure.

Spool in the valve section is not returning to neutral or spring is broken.

Internal leak at the lift cylinder.

External leak at the lift cylinder.

Port relief valve seal is leaking.

Load check in valve section has a defect.

–2–1–

2400 Series Loader Service Manual

HYDRAULIC SYSTEM INFORMATION

A

Mark a Line on Nut Flats of Both Nuts

Tighten to Correct Amount from Chart

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

I–2003–0888

A–01897

Flare Connections

B

Use the following procedure to tighten the flare fittings: Tighten the nut until it makes contact with the seat.

Put a mark across the flats of both the male and female parts of the connection [A].

Use the chart to find the correct number of turns for your size fitting [B].

If the fitting leaks after tightening, disconnect it and inspect the seat area for damage.

Wrench Size 5/8” 11/16” 7/8” 1”

Tube Size Outside Dia. 5/16” 3/8” 1/2” 5/8”

Thread Size 1/2”–20 9/16”–18 3/4”–16 7/8”–14

Rotate No. of Hex Flats 2–1/2 2 2 1–1/2–2

1–1/4” 1–3/8” 2” 2–1/4”

3/4” 1” 1–1/4” 1–1/2”

1–1/16”–12 1–5/16”–12 1–5/8”–12 1–7/8”–12

1 3/4–1 3/4–1 1/2–3/4

C

O–Ring Face Seal Connection Tube assemblies slide together, there is no need to push or pry them into position. When the fitting is tightened, you can feel when the fitting is tight to eliminate leakage caused by under or over torqued fittings [C].

Use Vaseline petroleum jelly to hold the O–ring in position until the fitting is assembled.

Straight Thread O–Ring Fitting When installing this fitting, the O–ring must first be lubricated. Loosen the jam nut, install the fitting into place, then tighten the jam nut.

B–07575

Tighten the jam nut until it and the washer are tight against the surface [D].

D NUT

Tubelines And Hoses

NUT

WASHER

Replace tubelines which are bent or have become flat.

They restrict fluid flow, which slows hydraulic action and causes heat.

O–RING

WASHER O–RING

Replace hoses which show signs of wear, damage or weather cracked rubber. When installing hoses or tubelines, make sure to use two wrenches.

A–01852

–2–2–

2400 Series Loader Service Manual

TILT CYLINDER

A

Checking The Tilt Cylinder Lower the lift arms. Roll the Bob–Tach fully back. Stop the engine.

Operate the hydraulic control lever to release the hydraulic pressure.

Install the steering frame lock. (See Page 1–4.)

Lift and block the loader. (See Page 1–2.)

Disconnect the hose that goes to the base end of the tilt cylinder [A].

PI–05461

B

Put a plug in the hose [B].

Start the engine. Operate the hydraulic control lever to roll the Bob–Tach backward.

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately.

PI–05462

W–2145–0290

C

If there is leakage at the open port, remove the cylinder for repair.

Repeat the procedure to check the other tilt cylinder.

Removal And Installation Lower the lift arms and tilt the Bob–Tach forward until it is on the floor. Stop the engine.

Operate the hydraulic control lever to release the hydraulic pressure. Install the steering frame lock. (See Page 1–4.)

PI–05463

Disconnect the base end hose [A].

D

Disconnect the rod end hose [C].

Remove the bolt at the rod end pivot pin [D].

Installation: Put LOCTITE on the threads and tighten the bolt to 25 ft.–lbs. (34 Nm) torque.

PI–09767

–2–3–

2400 Series Loader Service Manual

TILT CYLINDER (Cont’d)

A

Removal And Installation (Cont’d) Use a drift punch and hammer to remove the pivot pin [A].

PI–09768

B

Remove the rod end pivot pin [B].

PI–09769

C

Loosen the bolt at the base end pivot pin [C].

Installation: Tighten the bolt to 220–245 ft.–lbs.

(298–332 Nm) torque.

PI–09770

Do not remove the bolt. Hit the bolt to remove the base end pivot pin from its tapered seat [D].

D

PI–09771

–2–4–

2400 Series Loader Service Manual

TILT CYLINDER (Cont’d)

A

Removal And Installation (Cont’d) Remove the bolt. Remove the tilt cylinder and base end pivot pin [A].

PI–05468

B

Pivot Pin Seals Remove the base end pivot pin [B].

PI–05469

C

Check the condition of the pivot pin seals (base and rod end seals).

If the seals need replacement, use a screwdriver and remove the seals from the cylinder [C].

PI–05470

Use the correct size driver tool to install the new seal [D].

D

NOTE: SEE THE COMPONENT REPAIR MANUAL FOR HYDRAULIC CYLINDERS FOR DISASSEMBLY AND ASSEMBLY OF THE TILT CYLINDER.

PI–05471

–2–5–

2400 Series Loader Service Manual

TILT CYLINDER (Cont’d)

A

Bucket Anti–Roll Back Linkage Adjustment (11000 Series) Put the bucket on a flat surface [A].

Stop the engine.

PI–05330

B

Loosen the two nuts [B].

PI–05336

C

Turn the nuts until the rod (Item 1) [C] is even with the upper end of the tube.

Tighten the two nuts.

NOTE: The rod (Item 1) [C] can also be used as a bucket position indicator when digging into the ground with the bucket.

1

PI–05337

D

Adjust the stop collar from the tube about 1.90–2.0 inch (48–51 mm) [D].

1.90–2.0” (48–51 mm)

This adjustment will prevent the bucket from being tilted backward when the lift arms are being raised.

PI–05338

–2–6–

2400 Series Loader Service Manual

TILT CYLINDER (Cont’d)

A

Bucket Indicator Linkage Adjustment (12000 Series) Put the bucket on a flat surface [A].

PI–09390

B

The end of the rod (Item 1) [B] inside the tube should be flush with the end of the outside tube.

If not, loosen the two nuts (Item 2) [B].

1

Move the outside tube until it is even with the inside rod.

Tighten the nuts.

NOTE: The inside rod (Item 1) [B] can be used as a bucket position level indicator when digging into the ground.

2 PI–09391

–2–7–

2400 Series Loader Service Manual

LIFT CYLINDER

A

Checking The Lift Cylinder Lower the lift arms. Stop the engine.

Operate the hydraulic control lever to release the hydraulic pressure.

Install the steering frame lock. (See Page 1–4.)

Lift and block the loader. (See Page 1–2.)

NOTE: Check only one lift cylinder at a time.

Remove the side screen at the right side of the loader.

PI–05472

Disconnect the hose or tubeline which goes to the base end of the lift cylinder; Right [A]: Left [B].

B

PI–05473

Put a plug in the hose or tubeline; Right [C]: Left [D].

C

Start the engine. Operate the hydraulic control lever to lower the lift arms.

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately.

PI–05474

W–2145–0290

D If there is any leakage at the open port, remove the lift cylinder for repair.

PI–05475

–2–8–

2400 Series Loader Service Manual

LIFT CYLINDER (Cont’d)

A

Removal And Installation Raise the lift arms. Have a second person install jackstands under the Bob–Tach frame [A].

Stop the engine. Operate the hydraulic control lever to release the hydraulic pressure.

PI–09772

B

Disconnect the hose at the rod end of the lift cylinder [B].

PI–05477

C

Remove the bolt at the rod end pivot pin [C].

Installation: Tighten the bolt to 25 ft.–lbs. (34 Nm) torque.

PI–05478

D

Remove the rod end pivot pin [D].

PI–05479

–2–9–

2400 Series Loader Service Manual

LIFT CYLINDER (Cont’d)

A

Removal And Installation (Cont’d) Remove the retainer bolt and lock nut (Item 1) [A] at the base end pivot pin.

1

Installation: Tighten the bolt and nut to 25 ft.–lbs. (34 Nm) torque.

PI–05480

B

Use a brass punch and hammer, remove the base end pivot pin [B].

Slide the lift cylinder forward.

Disconnect the base end hose.

Remove the lift cylinder from the loader.

NOTE: SEE THE COMPONENT REPAIR MANUAL FOR HYDRAULIC CYLINDERS FOR DISASSEMBLY AND ASSEMBLY OF THE LIFT CYLINDER.

PI–05481

–2–10–

2400 Series Loader Service Manual

STEERING CYLINDER

A

Checking The Steering Cylinder Lower the lift arms. Stop the engine.

Turn the steering wheel to release the hydraulic pressure.

Install the steering frame lock. (See Page 1–4.)

Remove the floor panel. (See Page 5–1.)

Disconnect the hose at the base end of the steering cylinder [A].

PI–05554

B

Put a plug into the hose [B].

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately.

W–2145–0290

PI–05555

Start the engine. Operate the steering wheel.

C

If there is leakage at the open port, remove the steering cylinder for repair.

Removal And Installation Install the steering frame lock. (See Page 1–4.)

Remove the floor panel. (See Page 5–1.)

Remove the brake pedal mechanism. (See Page 4–44.)

Disconnect the hydraulic hoses [A].

PI–05482

Remove the bolt at the rod end of the pivot pin [C].

D

Installation: Tighten the bolt to 25 ft.–lbs. (34 Nm) torque.

Remove the rod end pivot pin [D].

PI–05483

–2–11–

2400 Series Loader Service Manual

STEERING CYLINDER (Cont’d)

A

Removal And Installation (Cont’d) Disconnect the grease fitting hose at the base end pivot pin [A].

PI–05556

B

Remove the retainer bolt at the base end pivot pin [B].

Remove the base end pivot pin.

Remove the steering cylinder from the loader.

NOTE: SEE COMPONENT REPAIR MANUAL FOR HYDRAULIC CYLINDERS FOR DISASSEMBLY AND ASSEMBLY OF THE STEERING CYLINDER.

PI–05557

C

Rod End Bearing If the rod end bearing for the pivot pin needs replacement, use the following procedure: 1. Install a gear puller and spacer at the bearing and loader frame [C].

2. Remove the bearing from the loader frame.

PI–05484

D

3. Install the new bearing, make sure the alignment is correct so it will press in straight [D].

4. Install the gear puller and spacer and press the bearing into the loader frame [C].

PI–05485

–2–12–

2400 Series Loader Service Manual

HYDRAULIC CONTROL VALVE (11000 Series)

A

Checking The Main Relief Valve The tool listed will be needed to do the following procedure: MEL10006 – Hydraulic Test Kit

1

Lower the lift arms. Stop the engine.

Install the steering frame lock. (See Page 1–4.)

Lift and block the loader. (See Page 1–2.)

Connect the gauge to the diagnostic quick coupler on the control valve [A].

PI–05890

Have a second person start the engine. Run the engine at full RPM.

B

Operate the hydraulic control lever to tilt the Bob–Tach backward and hold this position. The pressure must increase to 2450–2550 PSI (16893–17582 kPa).

O–Ring

If the pressure is not correct, adjust or replace the main relief valve.

Main Relief Valve

1

To remove and install the main relief valve, use the following procedure: Back–Up Stop the engine. Operate the hydraulic control lever to release the hydraulic pressure.

B–06764

Remove the main relief valve (Item 1) [A] from the control valve.

Remove the O–rings and back–up washers [B].

Clean the main relief valve. Blow dry with compressed air.

Install new O–rings and back–up washers. Install the main relief valve and tighten to 35–40 ft.–lbs. (47–54 Nm) torque.

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

Check the operation of the main relief valve. If the pressure is not correct, adjust the main relief valve.

Remove the cap (Item 1) [B].

I–2003–0888

Turn the adjustment screw in to increase pressure or out to decrease pressure until the main relief setting is correct. If the pressure can not be adjusted, replace the main relief valve.

–2–13–

2400 Series Loader Service Manual

HYDRAULIC (Cont’d)

CONTROL

VALVE

(11000

Series)

A

Removal And Installation Lower the lift arms. Stop the engine.

Operate the hydraulic control lever to release the hydraulic pressure.

Install the steering frame lock. (See Page 1–4.)

Mark the tubelines for correct installation.

Disconnect all the tubelines from the control valve [A].

PI–05486

B

Disconnect all the tubelines from the tee fittings [B].

Remove the tubelines.

PI–05490

C

Disconnect the inlet hose [C].

PI–05488

Disconnect the top return hose [D].

D

PI–05489

–2–14–

2400 Series Loader Service Manual

HYDRAULIC (Cont’d)

CONTROL

VALVE

(11000

Series)

A

Removal And Installation (Cont’d) Disconnect the power–beyond hose [A].

PI–05487

B

Remove the bottom bolt from the tilt control and lock–out bracket [B].

PI–05491

C

Remove the top bolt from the tilt control and lock–out bracket [C].

Installation: Tighten the bolts to 100 in.–lbs. (11,3 Nm) torque.

Adjust the cables so the spool movement from natural is 0.300 inch (7,6 mm) in both directions.

PI–05492

Remove the cotter pin and pivot pin from the tilt spool and lockout linkage clevis [D].

D

Pull the assembly away from the control valve.

PI–05493

–2–15–

2400 Series Loader Service Manual

HYDRAULIC (Cont’d)

CONTROL

VALVE

(11000

Series)

A

Removal And Installation (Cont’d) Loosen the nut from the mounting tube for the lift control cable [A].

PI–05494

B

Measure the cable threads [B]. Record this dimension so the sleeve can be positioned correctly when re–installed.

PI–05558

Remove the bolts from the lift control cable sleeve [C].

C

Installation: Tighten the bolts to 100 in.–lbs. (11,3 Nm) torque.

PI–05495

Remove the cotter pin and pivot pin from the lift spool [D].

D

PI–05496

–2–16–

2400 Series Loader Service Manual

HYDRAULIC (Cont’d)

CONTROL

VALVE

(11000

Series)

A

Removal And Installation (Cont’d) Disconnect the connectors at the auxiliary electrical harness [A].

PI–05559

B

Remove the inlet hose from the hydraulic fluid filter [B].

PI–05560

C

Remove the mounting bolts for the control valve [C].

Installation: Tighten the bolts to 15–17 ft.–lbs. (20–23 Nm) torque.

PI–05497

Remove the control valve from the mounting bracket [D].

D

NOTE: SEE COMPONENT REPAIR MANUAL FOR HYDRAULIC CONTROL VALVE FOR DISASSEMBLY AND ASSEMBLY OF THE CONTROL VALVE.

PI–05498

–2–17–

2400 Series Loader Service Manual

HYDRAULIC CONTROL VALVE (12000 Series)

A

Checking The Main Relief Valve The tool listed will be needed to do the following procedure: MEL10006 – Hydraulic Test Kit Lower the lift arms. Stop the engine.

Install the steering frame lock. (See Page 1–4.)

Lift and block the loader. (See Page 1–2.)

Connect the gauge to the diagnostic quick coupler on the control valve [A].

PI–09773

Have a second person start the engine. Run the engine at full RPM.

B

Operate the hydraulic control lever to tilt the Bob–Tach backward and hold this position. The pressure must increase to 2450–2550 PSI (16893–17582 kPa).

If the pressure is not correct, adjust or replace the main relief valve.

Main Relief Valve To remove and install the main relief valve, use the following procedure:

O–Ring

Stop the engine. Operate the hydraulic control lever to release the hydraulic pressure.

Back–Up

Remove the main relief valve from the control valve [B].

Remove the O–rings and back–up washers [B].

B–06764

PI–09774

C

Clean the main relief valve. Blow dry with compressed air.

Install new O–rings and back–up washers. Install the main relief valve and tighten to 35–40 ft.–lbs. (47–54 Nm) torque.

Check the operation of the main relief valve.

If the pressure is not correct, adjust the main relief valve.

Remove the cap [C].

Turn the adjustment screw in to increase the pressure or out to decrease the pressure until the main relief setting is correct [D].

PI–09775

If the pressure can not be adjusted, replace the main relief valve.

D

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

I–2003–0888 PI–09776

–2–18–

2400 Series Loader Service Manual

HYDRAULIC (Cont’d)

CONTROL

VALVE

(12000

Series)

A

Removal And Installation Lower the lift arms. Stop the engine.

Operate the hydraulic control lever to release the hydraulic pressure.

Install the steering frame lock. (See Page 1–4.)

Mark the tubelines and hoses for correct installation.

Disconnect all the tubelines from the control valve [A].

PI–09777

B

Disconnect the tubelines from the tee fittings [B].

PI–09778

C

Disconnect the tubelines from the bucket position valve [C].

Remove all the tubelines.

PI–09779

Disconnect the top return hose [D].

D

PI–09780

–2–19–

2400 Series Loader Service Manual

HYDRAULIC (Cont’d)

CONTROL

VALVE

(12000

Series)

A

Removal And Installation (Cont’d) Disconnect the power–beyond hose [A].

PI–09781

B

Disconnect the hose from the front hydraulic auxiliary section of the control valve [B].

PI–09782

C

Disconnect the electrical harness from the control valve solenoids [C].

PI–09783

Disconnect the in–let hose [D].

D

PI–09784

–2–20–

2400 Series Loader Service Manual

HYDRAULIC (Cont’d)

CONTROL

VALVE

(12000

Series)

A

Removal And Installation (Cont’d) Remove the control valve mounting bolts [A].

Installation: Tighten the mounting bolts to 15–17 ft.lbs.

(20–23 Nm) torque.

Slide the control valve forward, off the mounting bracket.

Count or measure the cable threads. Record this dimension so the sleeve can be positioned correctly when re–installed.

PI–09785

B

Loosen the nut at the mounting sleeve for the control cable [B].

PI–09786

C

Remove the bolts from the control cable retainer plate [C].

Installation: Tighten the bolts to 100 in.–lbs. (11,3 Nm) torque.

PI–09787

Remove the cotter pin and pivot pin from the valve spool [D].

D

Repeat the procedure to disconnect the other control cable from the control valve.

Remove the control valve from the loader.

NOTE: SEE COMPONENT REPAIR MANUAL FOR HYDRAULIC CONTROL VALVE FOR DISASSEMBLY AND ASSEMBLY OF THE CONTROL VALVE.

PI–09788

–2–21–

2400 Series Loader Service Manual

BUCKET POSITION VALVE

A

Removal And Installation Lower the lift arms. Stop the engine.

Operate the hydraulic control lever to release the hydraulic pressure.

Install the steering frame lock. (See Page 1–4.)

Mark the tubelines for correct installation.

Disconnect the tubelines from the front fittings of the bucket position valve [A].

PI–09789

B

Some of the tubelines will have to be disconnected from the control valve so there will be clearance at the bucket position valve [B].

PI–09790

C

Disconnect the tubeline from the top fitting on the valve [C].

PI–09791

Disconnect the tubeline from the rear fitting on the valve [D].

D

PI–09792

–2–22–

2400 Series Loader Service Manual

BUCKET POSITION VALVE (Cont’d)

A

Removal And Installation (Cont’d) Remove the two mounting bolts and nuts from the bucket position valve [A] & [B].

Installation: Tighten the mounting bolts and nuts to 15–17 ft.–lbs. (20–23 Nm) torque.

Remove the bucket position valve from the loader.

PI–09793

B

PI–09794

–2–23–

2400 Series Loader Service Manual

HYDRAULIC PUMP (11000 Series)

A

Checking Hydraulic Pump Output (Small Section) The hydraulic pump is a two section (double gear) pump.

Each section of the pump must be checked separately.

The tools listed will be needed to do the following procedure:

1

MEL1238 – Hydraulic Tester MEL10006 – Hydraulic Test Kit Install the steering frame lock. (See Page 1–4.)

Lift and block the loader. (See Page 1–2.)

PI–05891

NOTE: Make sure that all the air is removed from the system before beginning the test. Air in the system can give an inaccurate test.

B

Connect the hydraulic tester and check output as follows: Disconnect the outlet hose (Item 1) [A] from the frame port block.

Connect the inlet hose from the tester to the hose just removed from the frame port block [B].

Connect the outlet of the tester to the fitting on the frame port block [B].

PI–05892

NOTE: Make sure the restrictor valve on the tester is fully open.

C

Start the engine and run at low RPM. Make sure the tester is connected correctly. If no flow is indicated at the tester, the hoses are connected wrong [C].

Increase the engine speed to full RPM*. Warm the hydraulic fluid to 140°F (60°C) by turning the restrictor valve until the gauge reads about 1000 PSI (6895 kPa) pressure. Do not exceed system pressure.

Open the restrictor and record the free flow (GPM) at full RPM. Turn the restrictor valve so there is about 2000 PSI (13790 kPa) pressure.

Record the pressure (PSI) and flow (GPM). The highest pressure flow must be at least 80% of free flow.

%= %=

HIGH FREE PRESSURE FLOWFLOW (GPM)(GPM) FREE FLOW (GPM)

PI–05893

X 100 x 100

A low percentage may indicate a failed pump.

Be careful when turning the flow control restrictor at the hydraulic tester. When the tester is connected this way there is not relief valve in the system. DO NOT close the flow restrictor, on the tester, all the way.

*Refer to the SPECIFICATIONS, Section 8 for system relief pressure and full RPM.

–2–24–

2400 Series Loader Service Manual

HYDRAULIC PUMP (11000 Series) (Cont’d)

A

Checking Hydraulic Pump Output (Large Section) The hydraulic pump is a two section (double gear) pump.

Each section of the pump must be checked separately.

The tools listed will be needed to do the following procedures: MEL1238 – Hydraulic Tester MEL10006 – Hydraulic Test Kit Install the steering frame lock. (See Page 1–4.)

Lift and block the loader. (See Page 1–2.)

PI–05894

NOTE: Make sure that all the air is removed from the system before beginning the test. Air in the system can give an inaccurate test.

B

Disconnect the negative (–) cable from the battery.

Remove the battery holddown clamp [A].

Turn the battery (positive side of the battery) toward the front of the loader. Connect the negative (–) cable to the battery.

Disconnect the hose from the large section of the hydraulic pump [B].

Install and tighten a plug in the hose.

PI–05895

Connect the inlet hose from the hydraulic tester to the large section of the hydraulic pump.

C

Disconnect the hose from the port block [C].

Install and tighten a plug in the hose.

PI–05896

Connect the outlet hose from the hydraulic tester to the port block [D].

D

PI–05897

–2–25–

2400 Series Loader Service Manual

HYDRAULIC PUMP (11000 Series) (Cont’d)

A

Checking Hydraulic Pump Output (Large Section) (Cont’d) NOTE: Make sure that the restrictor valve on the tester is fully open.

Start the engine and run at low RPM. Make sure the tester is connected correctly. If no flow is indicated at the tester, the hoses are connected wrong [A].

Increase the engine speed to full RPM*. Warm the hydraulic fluid to 140°F (60°C) by turning restrictor valve until the gauge reads about 1000 PSI (6895 kPa). Do not exceed system pressure.

PI–05898

Open the restrictor and record the free flow (GPM) at full RPM. Turn the restrictor valve so there is about 2200 PSI (15169 kPa) pressure.

Record the pressure (PSI) and flow (GPM). The highest pressure flow must be at least 80% of free flow.

%=

HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)

x 100

A low percentage may indicate a failed pump. *Refer to the SPECIFICATIONS, Section 8 for system relief pressure and full RPM.

Be careful when turning the flow control restrictor at the hydraulic tester. When the tester is connected this way there is not relief valve in the system. DO NOT close the flow restrictor, on the tester, all the way.

–2–26–

2400 Series Loader Service Manual

HYDRAULIC PUMP (11000 Series) (Cont’d)

A

Removal And Installation

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

PI–05499

I–2003–0888

B

Remove the port block. (See Page 2–33.)

Disconnect the hoses from the small section of the hydraulic pump [A].

Disconnect the hoses from the large section of the pump [B].

PI–05500

C

Remove the top and bottom mounting bolts for the pump [C].

Installation: Tighten the bolts to 25 ft.–lbs. (34 Nm) torque.

Using a long extension, socket and rachet, remove the bolts at the bottom of the support bracket.

PI–05501

D

Remove the hydraulic pump from the hydrostatic pump [D].

PI–05503

–2–27–

2400 Series Loader Service Manual

HYDRAULIC PUMP (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the hydraulic pump bracket from the hydrostatic pump [A].

Installation: Always use new O–ring on the mounting flange of the hydraulic pump.

NOTE: SEE COMPONENT REPAIR MANUAL FOR HYDRAULIC PUMPS FOR DISASSEMBLY AND ASSEMBLY OF THE HYDRAULIC PUMP.

PI–05502

–2–28–

2400 Series Loader Service Manual

HYDRAULIC PUMP (12000 Series)

A

Checking Hydraulic Pump Output (Small Section) The hydraulic pump is a two section (double gear) pump.

Each section of the pump must be checked separately.

2

The tools listed will be needed to do the following procedure:

1

MEL1238 – Hydraulic Tester MEL10006 – Hydraulic Test Kit Install the steering frame lock. (See Page 1–4.)

Lift and block the loader. (See Page 1–2.)

PI–09835

NOTE: Make sure that all the air is removed from the system before beginning the test. Air in the system can give an inaccurate test.

B

Connect the hydraulic tester and check output as follows: Disconnect the outlet hose from the small section of the hydraulic pump.

Connect the outlet hose (Item 1) [A] from the tester to the hose just removed from the hydraulic pump.

Connect the inlet hose (Item 2) [A] of the tester to the fitting on the hydraulic pump.

NOTE: Make sure the restrictor valve on the tester is fully open.

PI–09836

Start the engine and run at low RPM. Make sure the tester is connected correctly. If no flow is indicated at the tester, the hoses are connected wrong [B].

Increase the engine speed to full RPM*. Warm the hydraulic fluid to 140°F (60°C) by turning the restrictor valve until the gauge reads about 1000 PSI (6895 kPa) pressure. Do not exceed system pressure.

Be careful when turning the flow control restrictor at the hydraulic tester. When the tester is connected this way there is not relief valve in the system. DO NOT close the flow restrictor, on the tester, all the way.

Open the restrictor and record the free flow (GPM) at full RPM. Turn the restrictor valve so there is about 2000 PSI (13790 kPa) pressure.

Record the pressure (PSI) and flow (GPM). The highest pressure flow must be at least 80% of free flow.

%=

HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)

x 100

A low percentage may indicate a failed pump. *Refer to the SPECIFICATIONS, Section 8 for system relief pressure and full RPM.

Revised May 91

–2–29–

2400 Series Loader Service Manual

HYDRAULIC PUMP (12000 Series) (Cont’d)

A

Checking Hydraulic Pump Output (Large Section) The hydraulic pump is a two section (double gear) pump.

Each section of the pump must be checked separately.

The tools listed will be needed to do the following procedure:

2

MEL1238 – Hydraulic Tester MEL10006 – Hydraulic Test Kit Install the steering frame lock. (See Page 1–4.)

1

Lift and block the loader. (See Page 1–2.)

PI–09837

NOTE: Make sure that all the air is removed from the system before beginning the test. Air in the system can give an inaccurate test.

B

Connect the hydraulic tester and check output as follows: Disconnect the outlet hose from the large section of the hydraulic pump.

Connect the outlet hose (Item 1) [A] from the tester to the hose just removed from the hydraulic pump.

Connect the inlet hose (Item 2) [A] of the tester to the fitting on the hydraulic pump.

NOTE: Make sure the restrictor valve on the tester is fully open.

PI–09836

Start the engine and run at low RPM. Make sure the tester is connected correctly. If no flow is indicated at the tester, the hoses are connected wrong [B].

Increase the engine speed to full RPM*. Warm the hydraulic fluid to 140°F (60°C) by turning the restrictor valve until the gauge reads about 1000 PSI (6895 kPa) pressure. Do not exceed system pressure.

Be careful when turning the flow control restrictor at the hydraulic tester. When the tester is connected this way there is not relief valve in the system. DO NOT close the flow restrictor, on the tester, all the way.

Open the restrictor and record the free flow (GPM) at full RPM. Turn the restrictor valve so there is about 2000 PSI (13790 kPa) pressure.

Record the pressure (PSI) and flow (GPM). The highest pressure flow must be at least 80% of free flow.

%=

HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)

x 100

A low percentage may indicate a failed pump. *Refer to the SPECIFICATIONS, Section 8 for system relief pressure and full RPM.

Revised May 91

–2–30–

2400 Series Loader Service Manual

HYDRAULIC PUMP (12000 Series) (Cont’d)

A

Removal And Installation

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

PI–09795

I–2003–0888

B Remove the port block. (See Page 2–40.)

Disconnect the hose from the large section of the hydraulic pump [A].

Disconnect the hose from the small section of the hydraulic pump [B].

PI–09796

Use a long extension, socket and rachet, remove the bolts at the bottom of the pump support bracket [C].

C

PI–09797

Remove the top and bottom mounting bolts from the pump [D].

D

Installation: Tighten the bolts to 25 ft.–lbs. (34 Nm) torque.

PI–09798

–2–31–

2400 Series Loader Service Manual

HYDRAULIC PUMP (12000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the pump support bracket [A].

PI–09799

B

Remove the hydraulic pump from the hydrostatic pump [B].

PI–09800

C

Installation: Always use a new O–ring on the mounting flange of the pump [C].

NOTE: SEE COMPONENT REPAIR MANUAL FOR HYDRAULIC PUMPS FOR DISASSEMBLY AND ASSEMBLY OF THE HYDRAULIC PUMP.

PI–09801

–2–32–

2400 Series Loader Service Manual

PORT BLOCK (11000 Series)

A

Removal And Installation

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

PI–05504

I–2003–0888

B Remove the air cleaner housing. (See Page 7–2.)

Mark all hoses and tubelines for correct installation.

Disconnect the case drain hose from the port block for the hydrostatic motor [A].

Disconnect the return hose from the control valve [B].

PI–05505

Disconnect the charge pressure hose from the tee fitting [C].

C

PI–05506

D

Disconnect the oil cooler by–pass hose [D].

PI–05507

–2–33–

2400 Series Loader Service Manual

PORT BLOCK (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the bolt from the wire harness clamp [A].

PI–05508

B

Disconnect the electrical harness from the temperature sender [B].

PI–05509

C

Disconnect the wires from the normally–open switch [C].

PI–05510

Disconnect the connector from the two–speed solenoid [D].

D

Disconnect the connector from the charge pressure switch.

PI–05511

–2–34–

2400 Series Loader Service Manual

PORT BLOCK (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Disconnect both two–speed hoses [A].

PI–05512

B

Disconnect the tubeline which goes to the hydraulic reservoir [B].

PI–05513

C

Disconnect and remove the charge pressure tubeline [C].

PI–05514

Loosen the port block from the hydraulic pump [D].

D

PI–05515

–2–35–

2400 Series Loader Service Manual

PORT BLOCK (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Turn the port block out of the hydraulic pump and remove it [A].

PI–05516

Normally–Open Switch

B

To remove the normally–open switch, use the following procedure: 1. Remove the diagnostic coupler [B].

2. Remove the elbow fitting (Item 1) [B].

1

PI–05517

C

3. Loosen the switch [C].

PI–05518

4. Remove the switch from the port block [D].

D

PI–5519

–2–36–

2400 Series Loader Service Manual

PORT BLOCK (11000 Series) (Cont’d)

A

Charge Pressure Switch To remove the charge pressure switch, use the following procedure: 1. Loosen the charge pressure switch [A].

PI–05520

B

2. Remove the switch from the port block [B]. Always install a new O–ring before installing the switch.

PI–05521

C

Temperature Sender To remove the temperature sender, use the following procedure: 1. Loosen the temperature sender [C].

PI–05522

D

2. Remove the temperature sender from the port block [D].

PI–05523

–2–37–

2400 Series Loader Service Manual

PORT BLOCK (11000 Series) (Cont’d)

A

Oil Cooler By–Pass Valve To remove the oil cooler by–pass valve, use the following procedure: 1. Remove the plug [A].

PI–05524

B

2. Remove the spring and poppet [B].

3. Check the poppet and spring for wear and replace as needed.

PI–05525

C

Two–Speed Solenoid To remove the two–speed solenoid, use the following procedure: 1. Remove the nut from the solenoid housing [C].

Installation: Tighten the nut to 100 in.–lbs. (11 Nm) torque.

PI–05526

D

2. Remove the solenoid housing [D].

PI–05527

–2–38–

2400 Series Loader Service Manual

PORT BLOCK (11000 Series) (Cont’d)

A

Two–Speed Solenoid (Cont’d) 3. Loosen the solenoid valve [A].

Installation: Tighten the solenoid valve to 100 in.–lbs.

(11 Nm) torque.

PI–05528

B

4. Remove the solenoid valve from the port block [B].

Installation: Always use new O–rings and back–up washers when installing the solenoid valve.

PI–05529

–2–39–

2400 Series Loader Service Manual

PORT BLOCK (12000 Series)

A

Removal And Installation

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

PI–09802

I–2003–0888

B

Remove the air cleaner housing. (See Page 7–2.)

Mark all the hoses and tubelines for correct installation.

Disconnect the case drain hose from the port block for the hydrostatic motor [A].

Disconnect the return hose from the control valve [B].

PI–09803

C

Disconnect the charge pressure hose [C].

PI–09804

D

Disconnect the two–speed hoses [D].

PI–09805

–2–40–

2400 Series Loader Service Manual

PORT BLOCK (12000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the two mounting bolts and nuts from the port block [A].

PI–09806

B

Disconnect the electrical wiring harness from the temperature switch [B].

PI–09807

C

Disconnect the wires from the normally–open switch [C].

PI–09808

Disconnect the tubeline which goes to the hydraulic reservoir [D].

D

PI–09809

–2–41–

2400 Series Loader Service Manual

PORT BLOCK (12000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Disconnect the charge pressure tubeline [A].

PI–09810

B

Loosen the port block from the hydraulic pump [B].

PI–09811

C

Turn the port block out of the hydraulic pump and remove the port block [C].

PI–09812

Two–Speed Solenoid

D

To remove the two–speed solenoid, use the following procedure: 1. Remove the nut from the solenoid housing [D].

Installation: Tighten the nut to 100 in.–lbs. (11,3 Nm) torque.

PI–09813

–2–42–

2400 Series Loader Service Manual

PORT BLOCK (12000 Series) (Cont’d)

A

Two–Speed Solenoid (Cont’d) 2. Remove the solenoid housing [A].

PI–09814

3. Loosen the solenoid valve [B].

B

Installation: Tighten the solenoid valve to 100 in.–lbs.

(11,3 Nm) torque.

PI–09815

C

4. Remove the solenoid valve [C].

Installation: Always use new O–rings and back–up washers when installing the solenoid valve.

PI–09816

Normally–Open Switch

D

To remove the normally–open switch, use the following procedure: 1. Remove the plug next to the switch for clearance [D].

PI–09817

–2–43–

2400 Series Loader Service Manual

PORT BLOCK (12000 Series) (Cont’d)

A

Normally–Open Switch (Cont’d) 2. Loosen the switch [A].

PI–09818

B

3. Remove the switch from the port block [B].

PI–09819

Temperature Sender

C

To remove the temperature sender, use the following procedure: 1. Loosen the temperature sender [C].

PI–09820

D

2. Remove the temperature sender from the port block [D].

PI–09821

–2–44–

2400 Series Loader Service Manual

PORT BLOCK (12000 Series) (Cont’d)

A

Oil Cooler By–Pass Valve To remove the oil cooler by–pass valve, use the following procedure: 1. Remove the plug [A].

PI–09822

B

2. Remove the spring and poppet [B].

Installation: Check the poppet for wear and replace as needed.

PI–09823

–2–45–

2400 Series Loader Service Manual

HYDRAULIC VALVE CONTROL HANDLE (11000 Series)

A

Removal And Installation Remove the four mounting bolts from the hydraulic control lever mounting bracket [A].

PI–05530

B

Lift the control lever assembly from the instrument panel mounting frame [B].

PI–05531

C

Disconnect the electrical wiring harness from the control handle [C].

Pull out enough control cables so the control lever assembly can be disconnected from the cables.

PI–05561

Remove the bolts and nuts from the cover [D].

D

Remove the cover from the control handle assembly.

PI–05562

–2–46–

2400 Series Loader Service Manual

HYDRAULIC VALVE CONTROL HANDLE (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Use two wrenches, loosen the nut which fastens the control cables to the control unit [A].

PI–05532

B

Pull the control cables out of the control unit assembly [B].

Installation: The lock nuts must be flush with the end of the control cables [B].

PI–05533

Disassembly And Assembly

C

Remove the four screws which fastens the rubber boot to the mounting bracket [C].

PI–05534

D

Loosen the lock nut on the control lever [D].

Remove the control lever.

PI–05535

–2–47–

2400 Series Loader Service Manual

HYDRAULIC VALVE CONTROL HANDLE (11000 Series) (Cont’d)

A

Disassembly And Assembly (Cont’d) Remove the four bolts and nuts which fasten the control unit to the mounting bracket [A].

PI–05536

B

Put a mark across the control unit parts for correct assembly.

Remove the two screws from the retainer plate [B].

PI–05537

C

Remove the plungers and cross shaft assembly from the housing [C].

PI–05538

Remove the plungers from the cross shaft [D].

D

PI–05539

–2–48–

2400 Series Loader Service Manual

HYDRAULIC VALVE CONTROL HANDLE (11000 Series) (Cont’d)

A

Disassembly And Assembly (Cont’d) Remove the retainer snap rings from both housing barrels [A].

PI–05540

B

Remove the plungers and springs [B].

Check all parts for wear and damage. Replace the parts as needed.

Assembly: Put grease on all moving parts when assembling the hydraulic valve control unit.

PI–05541

Control Handle Electrical Harness

C

Remove the screws and nuts from the control handle [C].

PI–05563

Remove one side of the control handle [D].

D

PI–05564

–2–49–

2400 Series Loader Service Manual

HYDRAULIC VALVE CONTROL HANDLE (11000 Series) (Cont’d)

A

Control Handle Electrical Harness (Cont’d) Disconnect the wires and remove the other half of the handle with the switch plate [A].

PI–05565

B

When connecting the electrical wires to the switches, see figure [B] for the correct installation.

50C 50B

50 50AA

–2–50–

Wire #

Color

50 50AA 50B 50C

Black Black/Red Black/White Black/Yellow

B–12139

2400 Series Loader Service Manual

HYDRAULIC VALVE CONTROL HANDLE (12000 Series)

A

Removal And Installation Remove the four mounting bolts from the hydraulic control lever mounting bracket [A].

Lift the control assembly from the instrument panel.

PI–09824

B

Disconnect the wiring harness from the control handle [B].

PI–09825

C

Pull out enough control cables so the control lever assembly can be disconnected from the control cables.

Use two wrenches, disconnect the control cable from the cable control block [C].

PI–09826

Remove the U–bolt from the control cable [D].

D

Repeat the procedure to disconnect the other control cable.

PI–09827

–2–51–

2400 Series Loader Service Manual

HYDRAULIC VALVE CONTROL HANDLE (12000 Series) (Cont’d)

A

Disassembly And Assembly Loosen the nut at the bottom of the control handle [A].

PI–09828

B

Turn the control handle out and remove it [B].

NOTE: See Page 2–49 for disassembly of the control handle and electrical wiring.

PI–09829

C

Remove the four mounting screws for the rubber boot [C].

Remove the rubber boot.

PI–09830

D

Remove the nut from the pivot shaft for the control cable block [D].

PI–09831

–2–52–

2400 Series Loader Service Manual

HYDRAULIC VALVE CONTROL HANDLE (12000 Series) (Cont’d)

A

Disassembly And Assembly (Cont’d) Remove the cable control block from the pivot shaft [A].

PI–09832

B

Assembly: Check the bushings for wear and replace as needed [B]. Use new O–rings when installing the cable control block.

PI–09833

–2–53–

2400 Series Loader Service Manual

STEERING CONTROL VALVE

A

Removal And Installation

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

PI–05566

I–2003–0888

B

Remove the steering wheel. (See Page 5–16 or 5–19.)

NOTE: For the 12000 Series loader, remove the signal lights and lever assembly. (See Page 6–27.)

Remove the top cover bolts. Remove the top cover [A].

Remove the two–speed lever and switch assembly from the steering column [B].

PI–05567

C

Remove the small and large rubber boots [C].

PI–05545

Mark the hoses at the steering control valve for correct installation [D].

D

PI–05568

–2–54–

2400 Series Loader Service Manual

STEERING CONTROL VALVE (Cont’d)

A

Removal And Installation (Cont’d) Disconnect the horn wire [A].

PI–05569

B

Disconnect the case drain hose [B].

PI–05570

C

Disconnect the hoses from the steering control valve [C].

PI–05542

Remove the bolts from the steering column [D].

D

Installation: Tighten the bolts to 25 ft.–lbs. (34 Nm) torque.

PI–05543

–2–55–

2400 Series Loader Service Manual

STEERING CONTROL VALVE (Cont’d)

A

Removal And Installation (Cont’d) Remove the two spacers [A].

Remove the steering control valve and steering column assembly.

PI–05544

B

Remove the four bolts from the steering column [B].

Installation: Tighten the bolts to 25 ft.–lbs. (34 Nm) torque.

PI–05573

Disassembly

C

Install an elbow fitting (Item 1) [C] in a lower port of the steering control valve. Install the fitting in the vise to hold the steering control valve [C].

1

B–05551

Remove the bolts (Item 1) [D] from the steering control valve.

D

3

Remove the end cap (Item 2) [D].

1

Remove the O–ring (Item 3) [D].

2

B–05564

–2–56–

2400 Series Loader Service Manual

STEERING CONTROL VALVE (Cont’d)

A

Disassembly (Cont’d)

2

Remove the meter (Item 1) [A] from the housing.

3

Be careful not to drop the star out of the meter.

Remove the O–ring (Item 2) [A].

Remove the driver spacer (Item 3) [A].

1 B–05563

B

Remove the drive (Item 1) [B] from the housing.

1

3

Remove the spacer plate (Item 2) [B].

Remove the O–ring (Item 3) [B].

Remove the steering control valve housing from the vise and put it on a clean cloth to protect the surface finish.

2

B–05565

C

Use a small screwdriver and pry the retaining ring from the housing [C].

B–05552

Turn the spool and sleeve until the pin is in the horizontal position. Push the spool and sleeve assembly forward with your thumbs, just far enough to free the gland bushing from the housing [D].

D 1

Remove the gland bushing from the spool and sleeve [D].

Remove the quad ring (Item 1) [D] from the gland bushing.

2

Use a small screwdriver to remove the dust seal (Item 2) [D].

Do not damage the bushing.

A–02800 B–05568

–2–57–

2400 Series Loader Service Manual

STEERING CONTROL VALVE (Cont’d)

A

Disassembly (Cont’d) Remove the two bearing races and thrust bearing [A].

B–05567

B

Remove the spool and sleeve assembly from the housing in the direction shown in figure [B].

NOTE: Keep the spool centered to avoid binding in the housing. Turn the spool and sleeve assembly slowly and remove them from the housing at the same time.

B–05566

C

Remove the pin (Item 1) [C] from the spool.

Push the spool part of the way out of the control end of the sleeve [C].

1

A–02793 B–05553

D

Remove the six centering springs (Item 1) [D] from the spool.

1

Push the spool back through and out of the sleeve [D].

NOTE: Turn the spool slowly when removing it from the sleeve.

B–05553

–2–58–

2400 Series Loader Service Manual

STEERING CONTROL VALVE (Cont’d)

A

Disassembly (Cont’d)

1

Remove the O–ring (Item 1) [A].

Remove the set screw (Item 2) [A].

Turn a machine bolt (1/8 inch – 24) into the end of the check ball seat. Then pull the machine bolt out to remove the seat (Item 3) [A] from the housing.

2 5

Turn the housing over to remove the check ball (Item 4) [A] and retainer (Item 5) [A].

4 3 B–05554

Inspection Check all the matching surfaces for burrs or scratches.

Replace any parts that can cause leakage.

B

Clean all the parts in clean solvent. Use air pressure to dry the parts. DO NOT use cloth or paper towels. DO NOT grind or file any parts.

2

Assembly

4 5

NOTE: Lubricate all the O–rings (Item 3) [B] (except the new quad ring seal) with clean petroleum jelly. Always use new O–rings and seals when assembling the steering control valve.

1 3

Use a needle nose pliers and install the check ball retainer (Item 1) [B]. Make sure it is straight in the housing.

A–02803

Install the check ball (Item 2) [B].

C

NOTE: Lubricate the check ball seat (Item 4) [B] thoroughly before installation. DO NOT turn or damage O–rings when installing them.

Install the check ball seat, open end first and push the seat to the bottom of the hole.

Control Sleeve

Spring Slot

Spring Slot

Install the set screw (Item 5) [B] and tighten to 100 in.–lbs.

(11,3 Nm) torque.

Control Spool

Assemble the spool and sleeve carefully so the spring holes make alignment [C]. Rotate the spool while sliding the two parts together. The spool must rotate smoothly in the sleeve.

Identification Marks A–02794

D

A special installation tool will be needed to install the centering springs in the spool and sleeve assembly. Make a tool as shown in figure [D]. Use 0.250 inch key stock.

3.0” (76 mm) 6.0” (152 mm) 0.175” (4,4 mm)

0.110” (2,8 mm)

0.240” (6 mm)

A–02802

–2–59–

2400 Series Loader Service Manual

STEERING CONTROL VALVE (Cont’d)

A

Assembly (Cont’d) Install the tool through the spring hole. Position the three pairs of springs at each side as shown in the end of the tool [A].

Compress the ends of the centering spring sets and push into the spool and pull the installation tool out [A].

Center the centering spring sets in the spool and sleeve assembly so that they push down evenly and are even with the upper surface of the spool and sleeve.

B–05555

B

Install the pin through the spool and sleeve until the pin is even at both sides of the sleeve [B].

A–02793

C

Position the spool and sleeve so that the splined end of the spool enters the 14 hole side of the housing [C].

Be careful that the parts do not tilt out of this position while installing them. Push the parts gently into position with a small rotating action. Keep the pin horizontal position. Install the spool assembly until it is even at the meter end of the housing. DO NOT pull the spool assembly beyond this position to prevent the cross pin from dropping into the discharge port. With the spool assembly in this position, it must rotate freely.

B–05566

D 1

Install the 2.125 inch (54 mm) diameter O–ring (Item 1) [D].

2 3

Install the bearing races (Item 2) [D] and bearing (Item 3) [D].

2

A–02797

–2–60–

2400 Series Loader Service Manual

STEERING CONTROL VALVE (Cont’d)

A

Assembly (Cont’d) Install the 1.250 inch (31,6 mm) diameter dust seal in the gland bushing [A].

The flat or smooth side of the dust seal must face down or toward the bushing.

A–02798

B

Install the dry quad ring seal in the seal gland bushing.

Push the seal into position with your fingers. Do not use any seal that falls freely into the pocket of the bushing [B].

Screwdriver Dust Seal Retaining Ring

Install the seal gland bushing over the spool end with a rotating motion [B].

Seal Gland Bushing Seal

Tap the bushing into position. Make sure the bushing is against the bearing race.

Quad Ring Seal

A–02799

C

Install the retainer ring (Item 1) [C]. Tap the retainer ring around the circumference to make sure it is in position.

Install the housing in the vise. Make sure the spool and sleeve are even with the 14 hole surface of the housing.

1

NOTE: Clean the upper surface of the housing with the palm of a clean hand. Clean each of the flat surfaces of the meter section when assembling. DO NOT use paper or cloth.

B–11693

D

Install the 3.0 inch (76,2 mm) diameter O–ring (Item 1) [D].

1

Install the spacer plate (Item 2) [D].

2 Align the bolt holes in the spacer plate with the tapered holes in the housing.

A–02796

–2–61–

2400 Series Loader Service Manual

STEERING CONTROL VALVE (Cont’d)

A

Assembly (Cont’d)

2

Rotate the spool and sleeve assembly until the pin (Item 1) [A] is parallel with the port face.

Install the drive (Item 2) [A], make sure it engages the pin.

1 B–05569

B

Install the 3.0 inch (76,2 mm) diameter O–ring (Item 1) [B] on the meter.

1 A–02795

C

With the seal side of the meter toward the spacer plate, align the star valleys [C].

Make sure there is a parallel relationship between the meter, drive pin and port face [C].

Make alignment of the bolt holes in the meter with out disengaging the meter from the drive.

B–06930

Install the drive spacer.

D

Install the 3.0 inch (76,2 mm) diameter O–ring.

Install the end cap on the housing. Align the bolt holes.

Install the 7 bolts dry in the end cap.

Pre–tighten the bolts to 150 in.–lbs. (17 Nm) torque in the sequence shown in figure [D].

Then tighten the bolts to 23 ft.–lbs. (31 Nm) torque in the same sequence shown in figure [D].

A–02801

–2–62–

2400 Series Loader Service Manual

STEERING CONTROL VALVE (Cont’d)

A

Checking Steering Relief Valve The tools listed will be needed to do the following procedure: MEL10003 – Hydraulic Tester MEL10006 – Hydraulic Test Kit Lower the lift arms. Stop the engine.

Operate the hydraulic controls to release the hydraulic pressure.

Install the steering frame lock. (See Page 1–4.)

PI–05899

Lift and block the loader. (See Page 1–2.)

B

Open the engine hood.

Connect the gauge to the diagnostic coupler at the hydraulic pump (small section) (11,000 Series) [A]: (12,000 Series) [B].

Start the engine and increase speed to full RPM. Turn the steering wheel in one direction and hold it in this direction.

The pressure must increase to 2500 PSI (17238 kPa) and not higher. If the pressure goes higher than 2500 PSI (17238 kPa) the steering relief valve is not working.

If the pressure does not reach 2500 PSI (17238 kPa):

PI–09834

1. The priority valve may have damage.

2. The steering valve may have damage.

3. The steering relief valve (located in the priority valve) may not be adjusted correctly.

–2–63–

2400 Series Loader Service Manual

HYDRAULIC RESERVOIR

A

Removal And Installation

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

PI–05546

I–2003–0888

B

Remove the bolts from the fender for the reservoir cover [A].

Remove the bolts from the bottom of the reservoir cover [B].

PI–05547

C

Remove the reservoir cover [C].

PI–05548

D

Remove the plug from the bottom of the hydraulic reservoir and drain the fluid into a container [D].

PI–05549

–2–64–

2400 Series Loader Service Manual

HYDRAULIC RESERVOIR (Cont’d)

A

Removal And Installation (Cont’d) Remove the bolt from the vent hose clamp [A].

PI–05550

B

Disconnect the tubeline from the bottom of the reservoir [B].

PI–05551

C

Pull the reservoir away from the loader frame [C].

PI–05552

D

Disconnect the hose from the hydraulic reservoir [D].

Remove the hydraulic reservoir from the loader.

PI–05553

–2–65–

2400 Series Loader Service Manual

PRIORITY VALVE

A

Removal And Installation Install the steering frame lock. (See Page 1–4.)

Remove the floor panel. (See Page 5–1.)

Mark the hoses for correct installation at the priority valve.

Disconnect the inlet hose from the main frame center port block [A].

PI–05571

B

Disconnect all the hoses from the priority valve [B].

Remove the mounting bolts and nuts.

Remove the priority valve from the loader.

1 PI–05572

Disassembly And Assembly

C

Remove the spool, spring and poppet (Item 1) [C] from the valve body.

1

Remove the spring and poppet (Item 2) [C] from the valve body.

NOTE: When the valve is being disassembled or assembled, do not damage the spool.

Inspect the spool, spring and poppet for wear and damage. Replace the parts as needed.

2

Assembly: Always use new O–rings when assembling the priority valve.

B–11522

Adjustment Of Steering Relief Valve If the pressure is not correct (See Page 2–63), use the following procedure: 1. Disconnect the fitting (Item 1) [B].

2. Use an Allen wrench to adjust the steering relief valve. Turn the Allen wrench clockwise to increase the pressure.

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

3. If the correct pressure can not be reached, replace the relief valve. When the pressure is correct, connect the fitting.

W–2103–1285

–2–66–

2400 Series Loader Service Manual

HYDROSTATIC SYSTEM Page Number DRIVE BELT Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21 DRIVE BELT TENSION PULLEY Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23 FOOT PEDAL CONTROL (11000 SERIES) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25

HYDROSTATIC SYSTEM

FOOT PEDAL CONTROL (12000 SERIES) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27 HYDROSTATIC MOTOR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 HYDROSTATIC PUMP (11000 SERIES) Checking Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10 Checking The High Pressure Relief/Replenishing Valve . . . . . . . . . . . . 3–10 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11 HYDROSTATIC PUMP (12000 SERIES) Checking Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16 Checking The High Pressure Relief/Replenishing Valve . . . . . . . . . . . . 3–16 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17 HYDROSTATIC SYSTEM INFORMATION High Pressure Relief/Replenishing Valve Function . . . . . . . . . . . . . . . . . 3–2 MULTI–DISC BRAKE Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6 TOWING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8) UNLESS OTHERWISE SPECIFIED.

–3––1–

2400 Series Loader Service Manual

–3–0–

2400 Series Loader Service Manual

HYDROSTATIC SYSTEM TROUBLESHOOTING The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Loader Service personnel only.

PROBLEM

CAUSE

Excessive noise in the hydrostatic pump.

1, 2, 3, 4, 5

Hydrostatic pump overheating.

1, 4, 6, 7

System not developing pressure.

1, 8, 9, 10

Loss of fluid.

11, 12

Drive with light on.

1, 13, 14, 15

No drive in one direction.

5, 8, 9

Loader moves with foot pedal in neutral.

16

Slow or no drive.

5, 8, 9, 10, 17, 18, 19, 20, 21

No forward high speed.

5, 16

Loss of hydrostatic power under load.

5, 8, 10, 20, 21

Loss of charge pressure or partial loss

17, 18, 19, 21, 22

KEY TO CORRECT THE CAUSE 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

Low fluid in the reservoir.

Air in the system.

Incorrect hydraulic fluid.

Excessive internal wear.

Lack of charge pressure.

Oil cooler not working or dirty.

Engine not being operated at correct RPM. High pressure relief valve not working correctly.

Replenishing valve not working correctly.

Tow valve in open position.

Leaking tubelines.

Hydrostatic motor seal leaking.

Fluid temperature/pressure switch not working correctly.

The #3 element filter is plugged.

Short in the electrical system.

Foot pedal linkage not adjusted correctly.

Charge relief valve is not working correctly.

Oil cooler by–pass is not working correctly.

Hydraulic pump is not working correctly.

Hydrostatic motor is damaged.

Hydrostatic pump is damaged.

Charge pump is damaged.

–3–1–

2400 Series Loader Service Manual

HYDROSTATIC SYSTEM INFORMATION

A

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

Charge Fluid

FUNCTION 1 Valve Moves For Charge Fluid Replacement

I–2003–0888

High Pressure Relief/Replenishing Valve Function The high pressure relief/replenishing valve is used in forward travel.

FUNCTION 2

The function of the high pressure relief/replenishing valve is as follows:

Valve Stays On Seat To Hold High Pressure For Drive

1. Give replacement fluid to the low pressure side of the closed hydrostatic circuit (Function 1).

2. To keep the high pressure flow of fluid out of the low pressure side of the closed hydrostatic circuit (Function 2).

FUNCTION 3 Valve Release Very High Pressure To Protect System

3. It will also release very high pressure caused by an overload when traveling in a forward direction (Function 3).

C–02526

–3–2–

2400 Series Loader Service Manual

HYDROSTATIC MOTOR

A

Removal And Installation

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

PI–05574

I–2003–0888

B

Remove the hydraulic control valve. (See Page 2–14; 11000 Series: Page 2–19; 12000 Series.)

Remove the bolts from the mounting plate for the control valve [A].

Installation: Tighten the bolts to 25 ft.–lbs. (34 Nm) torque.

NOTE: Make sure to mark all the hoses for correct installation.

Disconnect the case drain hose [B].

PI–05575

Disconnect the two–speed hose from the front of the hydrostatic motor [C].

C

PI–05576

D

Disconnect the other two–speed hose at the side of the motor [D].

PI–05577

–3–3–

2400 Series Loader Service Manual

HYDROSTATIC MOTOR (Cont’d)

A

Removal And Installation (Cont’d) Disconnect the charge pressure hose [A].

PI–05578

B

Loosen the four bolts at the collars for the high pressure hose [B].

Installation: Tighten the bolts to 40–45 ft.–lbs. (54–61 Nm) torque.

PI–05579

C

Remove the front half of the collar and disconnect the high pressure hose [C].

PI–05580

Disconnect the small hose (Item 1) [D] from the spacer.

D

Loosen the four bolts (Item 2) [D] securing the collar.

Installation: Tighten the bolts to 40–45 ft.–lbs. (54–61 Nm) torque.

Remove the front half of the collar and disconnect the high pressure hose [D].

1 2

PI–05581

–3–4–

2400 Series Loader Service Manual

HYDROSTATIC MOTOR (Cont’d)

A

Removal And Installation (Cont’d) Loosen the four mounting bolts [A].

Installation: Tighten the bolts to 65–70 ft.–lbs. (88–95 Nm) torque.

PI–05582

B

Remove the hydrostatic motor from the multi–disc brake housing [B].

Installation: Put lubricant (P/N 6519251) on the splines before installing the motor into the brake.

NOTE: SEE COMPONENT REPAIR MANUAL FOR THE HYDROSTATIC MOTOR TO DISASSEMBLE AND ASSEMBLE THE MOTOR.

PI–05583

–3–5–

2400 Series Loader Service Manual

MULTI–DISC BRAKE

A

Removal And Installation Remove the hydrostatic motor. (See Page 3–3.)

Disconnect the hose from the fitting at the brake.

Remove the brake assembly from the reduction gearcase housing [A].

NOTE: DO NOT put silicone sealant on the brake housing surface when installing it into the gearcase housing.

PI–05619

B

Remove the splined coupler [B].

PI–05614

C

Disassembly And Assembly Remove the bolt from the housing [C].

Remove the spring plate housing.

B–12261

D

Remove the old shaft seal using a punch and hammer [D].

B–11689

–3–6–

2400 Series Loader Service Manual

MULTI–DISC BRAKE (Cont’d)

A

Disassembly And Assembly (Cont’d) Remove the four bolts [A].

B–12262

B

Remove the primary plate [B].

B–12255

C

Remove the stator plate [C].

B–12254

Remove the spring plate [D].

D

B–12253

–3–7–

2400 Series Loader Service Manual

MULTI–DISC BRAKE (Cont’d)

A

Disassembly And Assembly (Cont’d) Remove the O–ring from the spring plate [A].

B–11673

B

Remove the outer retainer ring [B].

B–12259

C

Remove the splined gear [C].

B–12260

Remove the inner retainer ring [D].

D

B–12258

–3–8–

2400 Series Loader Service Manual

MULTI–DISC BRAKE (Cont’d)

A

Disassembly And Assembly (Cont’d) Remove the Belleville spring [A].

B–12252

B

Use low air pressure at the hydraulic inlet to remove the piston [B].

B–12257

C

Remove the O–ring on the inside diameter of the piston [C].

B–11712

Remove the O–ring on the outside diameter of the piston [D].

D

Clean and inspect all the parts. Replace the parts that are worn or damaged as needed.

Always use new O–rings and seals when assembling the brake.

B–11713

–3–9–

2400 Series Loader Service Manual

HYDROSTATIC PUMP (11000 Series)

A

Checking Charge Pressure The tool listed will be needed to do the following procedure: MEL10006 – Hydraulic Test Kit Install the steering frame lock. (See Page 1–4.)

Lift and block the loader. (See Page 1–2.)

Connect a gauge to the diagnostic coupler on the port block [A].

PI–05928

Start the engine.

The gauge must read as follows:

B

370–400 PSI (2551–2758 kPa) with approximately 70° F. (20° C) fluid.

2

340–370 PSI (2344–2551 kPa) with 150°F (66°C) fluid.

1

If the pressure is not correct, remove the charge relief valve (Item 1) [B] at the pump.

Check the poppet and spring for wear or damage. Add or remove shim(s) until the pressure is correct.

NOTE: DO NOT add more than 0.250 inch (6,35 mm) thickness of shims.

PI–05929

Checking The High Pressure Relief/Replenishing Valve If there is a loss of drive in one direction, use the following procedure to check the high pressure relief valve: Open the engine hood. Remove the high pressure relief (Item 2) [B] from the top side of the pump.

Remove the high pressure relief from the bottom side of the pump and switch them around. If the loss of the drive goes to the other direction, the valve which controls that direction must be cleaned or replaced.

Check the poppet, spring and seat for wear or damage.

Replace the parts as needed.

–3–10–

2400 Series Loader Service Manual

HYDROSTATIC PUMP (11000 Series) (Cont’d)

A

Removal And Installation

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

PI–05584

I–2003–0888

B

Remove the battery. (See Page 6–6.)

Disconnect the control cable at the pump lever [A].

Remove the control cable from the mounting bracket.

Remove the port block. (See Page 2–33.)

Remove the hydraulic pump. (See Page 2–27.)

Remove the drive belt. (See Page 3–21.)

Disconnect the electrical harness from the neutral and back–up alarm switches [B].

PI–05585

NOTE: Make sure to mark all hoses for correct installation.

C

Disconnect the hose/tubeline which comes from the filter [C].

PI–05586

Disconnect both hoses from the tee fitting at the front of the pump [D].

D

PI–05615

–3–11–

2400 Series Loader Service Manual

HYDROSTATIC PUMP (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Disconnect both high pressure hoses from the hydrostatic motor.

Disconnect the hose from the top tee fitting (comes from the hydrostatic motor) [A].

PI–05616

B

Disconnect the hose at the top tee fitting that goes to the reservoir [B].

PI–05617

C

Installation: Before connecting the hose from the hydraulic reservoir to the top tee fitting of the pump, make sure the 0.183–0.191 inch (4,65–4,85 mm) diameter orifice is in position [C].

PI–05618

Before loosening any of the hydrostatic pump mounting bolts, measure from the pump bracket to the loader frame [D].

D

Record this measurement for correct alignment of the pump and drive belt. See Page 3–15 for drive belt alignment if this procedure is not followed.

PI–05587

–3–12–

2400 Series Loader Service Manual

HYDROSTATIC PUMP (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Make a mark across the pump mounting bracket and engine bracket [A].

Connect a chain hoist to the pump and mounting bracket assembly.

PI–05588

B

Remove the mounting bolts for the pump [B].

PI–05589

C

Remove the hydrostatic pump from the loader [C].

PI–05590

Remove the drive belt tension pulley and bracket [D].

D

If the drive belt tension pulley needs repair. (See Page 3–23.)

PI–05591

–3–13–

2400 Series Loader Service Manual

HYDROSTATIC PUMP (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the nut and washer from the pulley [A].

Installation: Tighten the bolt to 175–200 ft.–lbs.

(237–271 Nm) torque.

PI–05592

B

Install a puller on the pump pulley [B].

Remove the pump pulley from the shaft.

PI–05593

C

Remove the bolts and nuts from the pump mounting bracket [C].

Installation: Tighten the bolts and nuts to 65–70 ft.–lbs.

(88–95 Nm) torque.

PI–05594

Remove the high pressure hoses (Item 1) [D] from the pump.

D

Remove the neutral and back–up alarm switch (Item 2) [D] from the pump.

NOTE: SEE THE COMPONENT REPAIR MANUAL FOR THE HYDROSTATIC PUMP FOR DISASSEMBLY AND ASSEMBLY OF THE PUMP.

1 2 PI–05595

–3–14–

2400 Series Loader Service Manual

HYDROSTATIC PUMP (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Installation: If the mounting brackets for the hydrostatic pump were not marked for correct alignment of the drive belt, the engine and hydrostatic must be removed from the loader frame.

Loosen all the hydrostatic pump and hydraulic pump mounting bolts. Use a straight edge to get the correct alignment of the pump pulley and engine flywheel [A].

Tighten all the mounting bolts and nuts.

PI–05608

–3–15–

2400 Series Loader Service Manual

HYDROSTATIC PUMP (12000 Series)

A

Checking Charge Pressure The tool listed will be needed to do the following procedure: MEL10006 – Hydraulic Test Kit Install the steering frame lock. (See Page 1–4.)

Lift and block the loader. (See Page 1–2.)

Connect a gauge to the diagnostic coupler on the port block [A].

PI–09839

Start the engine.

The gauge must read as follows:

B

370–400 PSI (2551–2758 kPa) with approximately 70°F (20°C) fluid.

2

340–370 PSI (2344–2551 kPa) with 150°F (66°C) fluid.

1 If the pressure is not correct, remove the charge relief valve (Item 1) [B] at the pump.

Check the poppet and spring for wear or damage. Add or remove shim(s) until the pressure is correct.

NOTE: DO NOT add more than 0.250 inch (6,35 mm) thickness of shims.

PI–05929

Checking The High Pressure Relief/Replenishing Valve If there is a loss of drive in one direction, use the following procedure to check the high pressure relief valve: Open the engine hood. Remove the high pressure relief (Item 2) [B] from the top side of the pump.

Remove the high pressure relief from the bottom side of the pump and switch them around. If the loss of the drive goes to the other direction, the valve which controls that direction must be cleaned or replaced.

Check the poppet, spring and seat for wear or damage.

Replace the parts as needed.

–3–16–

2400 Series Loader Service Manual

HYDROSTATIC PUMP (12000 Series) (Cont’d)

A

Removal And Installation

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

PI–09840

I–2003–0888

B

Remove the battery. (See Page 6–6.)

Disconnect the control cable from the pump lever [A].

Remove the control cable from the mounting bracket.

Remove the port block. (See Page 2–40.)

Remove the hydraulic pump. (See Page 2–31.)

Remove the drive belt. (See Page 3–21.)

Disconnect the electrical harness from the neutral and back–up alarm switches [B].

PI–05585

NOTE: Make sure to mark all hoses for correct installation.

C

Disconnect the hose from the top tee fitting (comes from the hydrostatic motor) [C].

PI–09841

Disconnect the hose from the top tee fitting that goes to the reservoir [D].

D

Installation: Before connecting the hose from the hydraulic reservoir to the top tee fitting, make sure the 0.183–0.191 (4,65–4,85 mm) diameter orifice is in position.

PI–09842

–3–17–

2400 Series Loader Service Manual

HYDROSTATIC PUMP (12000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Disconnect both high pressure hoses from the hydrostatic motor.

Disconnect the charge pressure hose [A].

PI–09843

B

Disconnect both hoses from the tee fitting on the hydrostatic pump [B].

PI–09844

C

Disconnect the hose/tubeline which comes from the hydraulic filter [C].

PI–09845

Before loosening any of the hydrostatic pump mounting bolts, measure from the pump bracket to the loader frame [D].

D

Record this measurement for correct alignment of the pump and drive belt. See Page 3–15 for drive belt alignment if this procedure is not followed.

Installation: If the mounting brackets for the hydrostatic pump where not marked for correct alignment of the drive belt, the engine and hydrostatic pump must be removed from the loader frame.

PI–05587

–3–18–

2400 Series Loader Service Manual

HYDROSTATIC PUMP (12000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Make a mark across the pump mounting and engine bracket [A].

Connect a chain hoist to the pump and mounting bracket assembly.

PI–05588

B

Remove the mounting bolts for the pump [B].

PI–05589

C

Remove the hydrostatic pump from the loader [C].

PI–05590

Remove the drive belt tension pulley and bracket [D].

D

If the drive belt tension pulley needs repair. (See Page 3–23.)

PI–05591

–3–19–

2400 Series Loader Service Manual

HYDROSTATIC PUMP (12000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the nut and washer from the pulley [A].

Installation: Tighten the bolt to 175–200 ft.–lbs.

(237–271 Nm) torque.

PI–05592

B

Install a puller on the pump pulley [B].

Remove the pump pulley from the shaft.

PI–05593

C

Remove the bolts and nuts from the pump mounting bracket [C].

Installation: Tighten the bolts and nuts to 65–70 ft.–lbs.

(88–95 Nm) torque.

PI–05594

Remove the high pressure hoses (Item 1) [D] from the pump.

D

Remove the neutral and back–up switches (Item 2) [D] from the pump.

NOTE: SEE THE COMPONENT REPAIR MANUAL FOR THE HYDROSTATIC PUMP FOR DISASSEMBLY AND ASSEMBLY OF THE PUMP.

1 2 PI–05595

–3–20–

2400 Series Loader Service Manual

DRIVE BELT

A

Adjustment

0.060–0.120” (1,5–3,0 mm)

The correct gap between the spring bolt and lock nut should be 0.060–0.120 inch (1,5–3,0 mm) [A].

PI–05596

B

If the adjustment is not correct, turn the lock nut until the gap is correct [B].

Removal And Installation To remove the drive belt with the engine and hydrostatic pump installed in the loader, use the following procedure: Remove the adjustment nut [B].

PI–05597

C

Turn the spring bolt out until all the spring tension is removed [C].

PI–05598

Remove the snap ring at the spring anchor pivot [D].

D

PI–05599

–3–21–

2400 Series Loader Service Manual

DRIVE BELT (Cont’d)

A

Removal And Installation (Cont’d) Remove the spring anchor pivot from the mounting bracket [A].

Lift the drive belt tension pulley so there is clearance for removal of the drive belt.

PI–05600

B

Remove the drive belt from the hydrostatic pump pulley and slip it between the pulley and the loader frame [B].

PI–05601

C

Remove the drive belt from the engine flywheel pulley and slip it between the pulley and the loader frame [C].

PI–05602

D

Remove the drive belt from the loader [D].

Reverse the procedure to install the drive belt, and also make the correct adjustment to the tension pulley.

PI–05603

–3–22–

2400 Series Loader Service Manual

DRIVE BELT TENSION PULLEY

A

Removal And Installation Remove the adjustment nut [A].

PI–05597

B

Turn the spring bolt out to release the spring tension [B].

PI–05598

C

Remove the snap ring from the spring anchor pivot [C].

PI–05599

Remove the spring anchor pivot from the mounting bracket [D].

D

PI–05600

–3–23–

2400 Series Loader Service Manual

DRIVE BELT TENSION PULLEY (Cont’d)

A

Removal And Installation (Cont’d) Remove the pivot bolt from the pulley bracket [A].

Installation: Tighten the bolt to 65–70 ft.–lbs. (88–95 Nm) torque.

Remove the pivot bracket and pulley assembly from the loader.

PI–05604

B

Remove the pivot bolt for the pulley [B].

Installation: Tighten the bolt to 25–28 ft.–lbs. (34–38 Nm) torque.

PI–05605

C

To replace the bearing in the pulley, remove the snap ring [C].

Use a hammer to tap the bearings from the pulley.

NOTE: On later model loaders there will be a spacer installed between the bearings.

PI–05606

Remove the pivot bushing. Check the seal at both sides [D].

D

Replace the parts as needed.

PI–05607

Revised July 92

–3–24–

2400 Series Loader Service Manual

FOOT PEDAL CONTROL (11000 Series)

A

Removal And Installation Remove the front floor panel. (See Page 5–1.)

Remove the mounting bolts for the foot pedal control.

Remove the foot pedal control assembly.

Remove the bolts from the side cover [A].

PI–05609

B

Remove the side cover [B].

PI–05610

C

Disconnect the cable end from the foot pedal [C].

PI–05611

Remove the inside nut from the control cable [D].

D

Remove the control cable from the control box.

PI–05612

–3–25–

2400 Series Loader Service Manual

FOOT PEDAL CONTROL (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the foot pedal control assembly from the loader [A].

Check the foot pedal pivot bearings (Item 1) [A] (both sides).

If they need replacement, remove the mounting bolts and brackets to replace the bearings.

1 PI–05613

–3–26–

2400 Series Loader Service Manual

FOOT PEDAL CONTROL (12000 Series)

A

Removal And Installation Remove the floor panel. (See Page 5–1.)

Remove the mounting bolts for the foot pedal control [A].

PI–09846

B

Remove the foot pedal control assembly [B].

Pull out enough control cable so the cable can be disconnected.

PI–09847

C

Disconnect the cable end from the foot pedal [C].

PI–09848

Loosen the inside nut on the control cable [D].

D

PI–09849

–3–27–

2400 Series Loader Service Manual

FOOT PEDAL CONTROL (12000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the end from the control cable [A].

Remove the control cable from the control box.

Remove the foot pedal control assembly from the loader.

PI–09850

B

Remove the cotter pin (Item 1) [B] from the pivot shaft.

Remove the pivot shaft to remove the control pedal.

1

PI–09851

C

The stops (Item 1) [C] should be adjusted so pedal stroke is less than the stroke for the hydrostatic pump.

1

1

PI–09852

–3–28–

2400 Series Loader Service Manual

TOWING THE LOADER

A

Procedure If the machine can not be moved of its own power (Example: Engine will not start), use the following procedure to tow the loader: The Brake Release Kit (P/N 6533227) must be installed on the loader (Instructions included in the Kit).

1. Engage the parking brake and block the wheels to prevent the loader from rolling.

2. Disconnect the brake hose coupler from the port block. Connect the pump to the brake [A].

PI–07916

3. Operate the pump until the gauge indicates 250–300 PSI (1723–2068 kPa).

B

4. Open the tow valve (Item 1) [B] on the hydrostatic pump.

1

5. Remove the wheel blocks. Release the parking brake.

DO NOT move the loader more than 50 feet (15 meters).

NOTE: Before operating the loader, close the tow valve. Disconnect the pump from the brake hose. Reconnect the brake hose to the port block.

PI–09392

–3–29–

2400 Series Loader Service Manual

–3–30–

2400 Series Loader Service Manual

DRIVE SYSTEM Page Number AXLE AND DIFFERENTIAL Assembly Of The Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle End Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . .

Axle End Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . .

Axle End Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . .

Axle Housing End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Hub Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Hub Housing Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Hub Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . .

Axle Hub Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake And Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential Axle And Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly of Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Axle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oscillation Blocks And Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oscillation Frame Removal And Installation . . . . . . . . . . . . . . . . . . . . . .

Rear Axle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–30 4–15 4–14c 4–14b 4–14g 4–12 4–8 4–8 4–14a 4–14b 4–19 4–16 4–21 4–3 4–5 4–7 4–4

DRIVE SYSTEM

BRAKE PEDAL MECHANISM Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–45 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–44 DRIVE SHAFT Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 DROP–BOX GEARCASE Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–39 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–39 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE UNLESS OTHERWISE SPECIFIED (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8).

Revised Feb. 94

–4––1–

2400 Series Loader Service Manual

–4–0–

2400 Series Loader Service Manual

DRIVE SYSTEM TROUBLESHOOTING The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM

CAUSE

Noise

1, 2, 3

Vibration

2, 4, 5, 6, 7

Chatter

8

KEY TO CORRECT THE CAUSE 1.

2.

3.

4.

5.

6.

7.

8.

System needs lubrication.

Drive line out of balance.

Backlash due to worn universal cross trunnion or bearing.

Yokes are out–of–alignment.

Drive line bent due to contact with obstruction.

Excessive run–out or distorted yokes.

Loose bolts or differential flange.

Incorrect or contaminated lubrication in the differential.

–4–1–

2400 Series Loader Service Manual

DRIVE SHAFT

A

Removal And Installation Lower the lift arms. Stop the engine.

Install the steering frame lock. (See Page 1–4.)

Lift and block the loader. (See Page 1–2.)

Remove the four bolts and nuts from the front U–joint mounting flange [A].

PI–05620

B

Remove the four bolts and nuts from the rear U–joint [B].

Installation: Tighten the bolts and nuts to 40–45 ft.–lbs.

(54–61 Nm) torque.

PI–05621

C

Remove the drive shaft from the loader.

Installation: Make sure the bearing cups and yokes are aligned with each other from one end to the other. The drive shaft is balanced at the factory. To assure this balance is maintained, both halves of the drive shaft must be kept together and reassembled correctly [C].

B–05735

–4–2–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL

A

Front Axle Removal And Installation Raise the lift arms and install a lift arm stop. (See Page 1–4.)

Stop the engine.

Install the steering frame lock. (See Page 1–4.)

Lift and block the loader. (See Page 1–2.)

NOTE: Make sure to position the front jackstands under the loader frame so the front axle assembly can be removed.

PI–05622

Remove the tire and wheel assembly (both sides).

B

Remove the drive shaft. (See Page 4–2.)

Remove the hydraulic control valve. (See Page 2–14; 11000 Series); (Page 2–19; 12000 Series.)

Remove the hydrostatic motor. (See Page 3–2.)

Put a floor jack under the front differential housing.

Remove the rear mounting bolts and nuts (both sides) [A].

Installation: Tighten the bolts and nuts to 150 ft.–lbs.

(203 Nm) torque.

PI–05624

Remove the six mounting bolts at the front of the axle: Left [B]; Right [C].

C

Installation: Tighten the bolts to 150 ft.–lbs. (203 Nm) torque.

PI–05623

D

Lower the axle and differential assembly from the loader frame [D].

See Page 4–39 to remove the drop–box gearcase from the differential.

PI–05625

–4–3–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Rear Axle Removal And Installation Lower the lift arms. Stop the engine.

Install the steering frame lock. (See Page 1–4.)

Remove the drive shaft. (See Page 4–2.)

Remove the floor panel in the operator cab. (See Page 5–1.)

1

Remove the seat and seat mounting frame. (See Page 5–4.)

PI–05626

Remove the fuel tank. (See Page 5–24.)

Disconnect the brake cable from the brake lever (Item 1) [A] (both sides).

B

Loosen the locking nuts from the brake cable (both sides) [B].

Remove the brake cables from the axle/differential.

Put a floor jack under the rear of the loader. Lift the loader until the wheels are just off the floor. Remove the tire and wheel assembly.

PI–05627

C

Remove the bolts from the oscillation stop block (both sides) [C].

PI–05628

Use the same bolts and fasten the caster wheel axle supports on the bottom of the axle housing (both sides) [D].

D

Lower the rear of the loader until the caster wheels touch the floor [D].

PI–05629

–4–4–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Rear Axle Removal And Installation (Cont’d) Remove the four bolts from the rear oscillation pivot block [A].

PI–05630

B

Remove the four bolts at the front oscillation pivot block in the operator cab [B].

Installation: Tighten the mounting bolts for the oscillation blocks to 220–245 ft.–lbs. (298–332 Nm) torque.

PI–05631

C

Raise the rear of the loader until it is high enough so the rear axle assembly can be rolled out the side of the loader.

Install jackstands at both rear corners of the loader frame [C].

Installation: Remove the jackstands. Lower the loader over the rear axle assembly until the holes in the oscillation blocks make alignment.

Roll the axle assembly out from under the loader frame [C].

PI–05632

Oscillation Blocks And Bushings

D

Remove the rear oscillation block [D].

Check the pivot bushing. Replace the bushing if worn.

PI–05633

–4–5–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Oscillation Blocks And Bushings (Cont’d) Loosen the mounting bolts for the front oscillation block [A].

Installation: Put LOCTITE 242 on the threads of the bolt.

Tighten the bolt to 280–320 ft.–lbs. (380–434 Nm) torque.

PI–05634

Remove the bolt and washer [B].

B

PI–05635

Remove the oscillation block assembly [C].

C

PI–05636

Remove the two bolts which fasten the front oscillation block together [D].

D

Assembly: Tighten the bolts to 25 ft.–lbs. (34 Nm) torque.

Separate the blocks and inspect the bushings for wear and damage [D]. Replace the parts as needed.

PI–05637

–4–6–

PI–05638

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Oscillation Frame Removal And Installation Remove the top cover from the oscillation frame (both sides) [A].

PI–05639

B

Remove the top six mounting bolts from the oscillation frame (both sides) [B].

Installation: Tighten the bolts to 150 ft.–lbs. (203 Nm) torque.

PI–05640

C

Remove the front mounting bolts (both sides) [C].

Installation: Tighten the bolts to 150 ft.–lbs. (203 Nm) torque.

Attach a chain hoist to the oscillation frame.

PI–05641

Remove the mounting bolts from the frame and axle end housing (both sides) [D].

D

Installation: Tighten the bolts to 100 ft.–lbs. (136 Nm) torque.

Lift the oscillation frame from the axle assembly.

PI–05642

–4–7–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Oscillation Frame Removal And Installation (Cont’d) NOTE: The service procedure for disassembly and assembly require the use of special Tool Set (MEL2400). The front and rear axle disassembly and assembly are the same except where noted in the service procedure in the copy.

Axle Hub Housing Removal And Installation Drain all the gear lube from the axle housing.

PI–05643

Loosen and remove the two Allen head bolts [A].

B

Loosen and remove the bolts [B].

Installation: Put LOCTITE 515 on the housing surface before assembly. Put LOCTITE 242 on the bolts and tighten to 60–65 ft.–lbs. (81–88 Nm) torque.

PI–05644

Use a hammer and tap the axle hub housing from the end cover mounting surface [C].

C

PI–05645

Axle Hub Housing Disassembly

D

Remove the large gear bolt [D].

NOTE: Heat may have to be put on the bolt head to brake it loose because permanent thread locker was used during assembly.

PI–05646

–4–8–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle Hub Housing Disassembly (Cont’d) Remove the bolt and washer [A].

PI–05647

B

Use a press to push the hub axle out [B].

Be sure to block the housing high enough so that the axle hub shaft has clearance.

PI–05648

C

Remove the bearing and spacer washer [C].

PI–05649

Remove the large gear [D].

D

PI–05650

–4–9–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle Hub Housing Disassembly (Cont’d) Remove the spacer [A].

PI–05651

B

Remove the bearing [B].

PI–05652

C

Remove the axle hub housing [C].

PI–05653

Remove the bearing spacer from the axle hub shaft [D].

D

PI–05654

–4–10–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle Hub Housing Disassembly (Cont’d) Remove the shield from the axle seal [A].

Remove the seal with a bearing driver tool of the correct size.

If the bearing race has wear or damage, remove the snap ring. With the correct size bearing driver, remove the race by driving it to the inside. To install the race, replace the snap ring first, then drive the race from the inside until it is seated.

PI–05655

B

Use the correct size bearing driver tool, install the new axle seal [B].

Install the shield over the seal with the outer lip of the seal to the inside.

PI–05656

C

If the differential axle roller bearing is damaged, use a slide hammer puller and remove the roller bearing [C].

PI–05657

Use the correct size bearing driver tool and install the new bearing [D].

D

PI–05658

–4–11–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle Hub Housing Disassembly (Cont’d) If the race at the differential axle is damaged, use a puller clamp and install it behind the race [A].

Install a puller on the puller clamp and remove the bearing race.

PI–05659

B

Use the driver tool (MEL1348) to install the new race on the differential axle [B].

PI–05660

Axle Hub Housing Assembly

C

Install the bearing spacer on the axle hub shaft [C].

PI–05654

Install the axle hub housing over the axle hub shaft [D].

D

PI–05653

–4–12–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle Hub Housing Assembly (Cont’d) Install the bearing on the axle hub shaft and into the bearing race [A].

PI–05652

B

Install the bearing spacer, with the large inside diameter down [B].

PI–05651

C

Install the large gear with the raised collar down [C].

PI–05650

Put the axle hub and housing assembly in a press [D].

D

Support the axle hub shaft so the lug bolts do not touch the press table.

PI–05661

–4–13–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle Hub Housing Assembly (Cont’d) Use the driver tool (MEL1348) and press the large gear onto the axle hub shaft [A].

PI–05662

B

Install the bearing using the correct size bearing driver tool [B].

PI–05663

C

Thoroughly clean the bolt and bore threads with thread cleaner (LOCTITE Primer T or N).

Use air pressure to blow–dry the threads.

1.700” (43 mm)

For axle with 0.625 inch UNF threads, use thread locker LOCTITE 680) and fill the bore threads to 1.700 inch (43 mm) from the top of the washer (Inset) [C].

0.625” UNF Thread

For axle with metric threads, fill the bore threads to 1.200 inch (40 mm) from the top of the washer (Inset) [C].

1.200” (40 mm) Metric Thread

B–13266

Install the bolt and washer [C].

PI–05647

Tighten the bolt to the correct torque [D].

D

Allen Head Bolt – 200 ft.–lbs. (271 Nm) Hex Head Bolt – 240 ft.–lbs. (325 Nm)

PI–05664

Revised Aug. 90

–4–14–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

NOTE: See BTI bulletin 256 before doing the following procedure.

Axle Hub Removal And Installation The tool listed will be needed to do the following procedure: MEL1242 – Port–A–Power Lift and block the loader. (See Page 1–2.)

Remove the tire/wheel assembly.

P–01322

Installation: Tighten the wheel nuts to 140 ft.–lbs. (190 Nm) torque.

B

Loosen the bolts at the end of the hub [A].

Installation: Tighten the mounting bolts to 185–200 ft.–lbs. (251–271 Nm) torque.

Remove the bolts and washer [B].

P–01312

C

Install the wheel nuts on two wheel studs straight across from each other. Use a hammer to remove the wheel studs [C].

Installation: After the hub is removed, install the wheel studs into the hub using a hammer [C].

P–01329

Install a puller on the wheel hub [D].

Install a spacer on the end of the axle against the Port–A–Power ram [D].

P–01328

D

NEVER STAND IN LINE WITH AXLE WHEN REMOVING THE HUB FROM THE AXLE. The hub has a tapered fit and can come off the axle with great force and cause serious injury.

Remove the hub from the axle.

P–01314

Added Feb. 94

–4–14a–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle Seal Removal And Installation The tool listed will be needed to do the following procedure: MEL1407 – Seal Tool Remove the key from the axle.

Using a small punch and hammer, punch a hole in the axle seal [A].

P–01313

B

Install a puller and remove the axle seal [B].

P–01327

C

Installation: Use a hammer and seal tool, install the new axle seal until the tool is flush with the edge of the axle housing [C].

NOTE: See BTI Bulletin 256 before doing the following procedure.

P–01331

Axle End Housing Removal And Installation

D

NOTE: If the axle is going to be removed from the housing, it will be easier to remove the axle hub (See Page 4–14a) before removing the axle housing from the differential end cover.

Drain all the gear lube from the axle end housing.

Loosen and remove the Allen head bolts [D].

P–01335

Added Feb. 94

–4–14b–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle End Housing Removal And Installation (Cont’d) Loosen and remove the bolts [A].

Installation: Put LOCTITE 515 on the axle housing surface before assembly. Put LOCTITE 242 on the bolts and tighten to 60–65 ft.–lbs. (81–88 Nm) torque.

P–01344

B

Use a hammer and tap the axle housing from the differential end cover mounting surface [B].

P–01339

C

Axle End Housing Disassembly And Assembly Remove the key from the axle [C].

P–01361

Remove the large gear/axle assembly from the housing [D].

D

P–01357

Added Feb. 94

–4–14c–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle End Housing Disassembly And Assembly (Cont’d) Loosen the bearing retainer bolts [A].

P–01351

B

Assembly: See Page 4–14g for checking the axle end washer clearance. Put LOCTITE 680 on the bolt threads.

Tighten the bolts to 95 ft.–lbs. (134 Nm) torque [B].

P–01355

Remove the washer and bolts [C].

C

P–01352

Remove the bearing [D].

D

P–01350

Added Feb. 94

–4–14d–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle End Housing Disassembly And Assembly (Cont’d) Remove the large gear [A].

P–01353

B

Remove the spacer [B].

P–01343

C

Use a press to remove the axle bearing from the axle [C].

P–01349

Use a press to install the new axle bearing [D].

D

P–01347

Added Feb. 94

–4–14e–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle End Housing Disassembly And Assembly (Cont’d) Use the correct size driver tool, remove the axle seal and bearing cup [A].

P–01348

B

Use the correct size driver tool, install the new bearing cup and axle seal [B].

P–01341

C

Assembly: After the axle end housing is reassembled, install the hub on the axle shaft. Tighten the bolts to 185–200 ft.–lbs. (251–271 Nm) torque [C].

P–01371

Added Feb. 94

–4–14f–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle Housing End Clearance

Clearance 0.002–0.012” (0,05–0,30 mm)

End Washer

The correct axle shaft to end washer clearance is 0.002–0.012 inch (0,05–0,30 mm) [A].

To check and/or set the clearance, use the following procedure: With the end washer removed, use a 0.500–13 UNC bottoming tap and clean the threaded hole in the axle.

Thoroughly clean the original bolts. Clean the end surface of the shaft.

Axle Shaft MC–01948

Place three 0.125 inch (3,2 mm) pieces of thin soldering wire on the end of the axle [B].

B

Place the solder equal distance apart. Temporarily install the washer using the original bolts. Tighten the bolts to 95 ft.–lbs. (134 Nm).

Place Solder Here

Remove the bolts and end washer. Using a micrometer, measure and record the thickness of each solder piece.

The average thickness of the three pieces is the clearance between the end washer and the axle.

If the thickness is greater than 0.012 inch (0,30 mm), use the end washer (P/N 6589043). This washer will reduce the measured clearance by 0.006 inch (0,15 mm). It can also be identified by a 6 mark.

P–01352

NOTE: Use new bolts when assembling the end washer on the axle. Install the bolts with LOCTITE 680 on the threads. Use primer T or M. Tighten each bolt to 95 ft.–lbs. (134 Nm) torque.

Added Feb. 94

–4–14g–

2400 Series Loader Service Manual

–4–14h–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle Housing End Clearance (Cont’d) Install the axle hub housing assembly on the axle end cover. Install two bolts and tighten them. Install a dial indicator [A].

The correct end play for the axle hub shaft is 0.002 inch (0,051 mm) maximum to 0.0005 inch (0,013 mm) minimum.

P–05665

B

If the end play is not correct, remove the axle hub housing assembly. Remove the bearing race and add or remove shims until the end play is correct [B].

See Page 4–8 for the correct procedure to install the axle hub housing and correct bolt torque.

P–05666

Axle End Cover Removal And Installation

C

Remove the axle hub housing assembly. (See Page 4–8.)

Remove the nuts and bolts at the axle end cover [C].

Installation: Put LOCTITE 515 on the end cover surface before assembling. Put LOCTITE 262 on the threads and tighten the nuts and bolts to 99–102 ft.–lbs. (134–138 Nm) torque.

P–05667

Check the differential on production machines to see if they are equipped with a differential lock lever (non–functional from factory). Before removing the axle and end cover assembly, put a block of wood at the lock lever to hold it in the engaged position. This will prevent the differential lock sleeve from falling into the axle tube housing and make it easier for axle installation [D].

D

P–05668

–4–15–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Axle End Cover Removal And Installation (Cont’d) Remove the end cover and axle assembly from the axle tube housing [A].

P–05669

Differential Axle And Seal

B

REAR AXLE: Remove the snap ring from the brake drum [B].

FRONT AXLE: The front axle does not have brakes or snap ring to remove.

PI–05670

C

Remove the differential axle from the end cover [C].

Be sure to block the housing high enough so that the axle shaft can move 3.0 inches (76 mm).

PI–05671

REAR AXLE: Remove the brake drum [D].

D

PI–05672

–4–16–

2400 Series Loader Service Manual

AXLE DIFFERENTIAL (Cont’d)

A

Differential Axle And Seal (Cont’d) Remove the axle seal from the end cover [A].

PI–05673

B

Using the correct size bearing driver tool, install the new axle seal [B].

PI–05674

C

If the bearing on the axle is damaged, use the following procedure to replace the bearing: 1. Remove both Woodruff keys from the axle [C].

PI–05675

D

2. Remove the snap ring from the bearing [D].

PI–05676

–4–17–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Differential Axle And Seal (Cont’d) 3. Use a press, remove the bearing from the axle [A].

PI–05677

B

4. Install the new bearing, using the press [B].

5. Install the snap ring and Woodruff keys.

NOTE: The following procedure for replacing the inner differential axle seal is shown on the rear axle with brakes, the same procedure can be used on the front axle to remove and replace the inner differential axle seal.

PI–05678

C

Drill two holes in the seal [C].

PI–05679

D

Install a slide hammer seal puller and remove the seal [D].

PI–05680

–4–18–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Differential Axle And Seal (Cont’d) Use the correct size bearing driver tool and install the new seal [A].

PI–05681

Brake And Drum

B

NOTE: The brake shoes and drum assembly are located only on the rear differential.

To remove the drum and brake shoes, use the following procedure: 1. Remove the end cover from the differential tube housing. (See Page 4–8.)

2. Remove the snap ring from the brake drum [B].

PI–05670

3. Remove the axle from the drum [C]. Be sure to block the housing high enough so that the axle shaft can move 3.0 inches (76 mm).

C

PI–05671

4. Remove the brake drum. Inspect the brake drum for wear or damage. Replace the parts as needed.

D

5. Use a pry bar, remove the lower brake shoe from the brake shoe anchor pivot [D].

PI–05682

–4–19–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Brake And Drum (Cont’d) 6. Remove the brake shoes and springs [A].

7. Inspect the brake shoes. If damaged or worn, replace as needed.

PI–05683

8. Inspect the brake shoe anchor pivot for wear and replace as needed [B].

B

PI–05684

If the brake shoe actuator cam, shaft or splines are damaged, use the following procedure to replace them:

C

1. Remove the snap ring from the brake shoe lever [C].

PI–05685

D

2. Mark the brake lever and the shaft for correct installation of the brake lever [D].

3. Remove the brake lever.

4. Remove the brake shaft.

PI–05686

–4–20–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Disassembly Of Differential FRONT AXLE: Remove the drop–box gearcase from the pinion housing. (See Page 4–39.)

REAR AXLE: Loosen the nut from the pinion hub [A].

PI–05707

B

REAR AXLE: Remove the O–ring and nut [B].

PI–05687

C

REAR AXLE: Remove the pinion hub [C].

PI–05688

D

REAR AXLE: Remove the Allen head bolts from the pinion seal housing [D].

PI–05689

–4–21–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Disassembly Of Differential (Cont’d) REAR AXLE: Remove the pinion seal housing [A].

PI–05690

B

REAR AXLE: Remove the seal. Use the correct size bearing driver tool and install the new seal [B].

NOTE: The following service procedure is for both the front and rear axle, unless otherwise noted in the copy.

PI–05691

Before removing the pinion shaft and housing assembly from the differential housing, do the following procedure:

C

1. Install the tool (MEL1347) on the pinion nut [C].

PI–05692

D

2. Install the socket (MEL1350) on the pinion shaft spline [D].

3. Loosen the nut.

PI–05693

–4–22–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Disassembly Of Differential (Cont’d) 4. Remove the pinion nut from the pinion shaft [A].

PI–05694

B

Remove the pinion housing bolts [B].

PI–05695

C

Take two bolts, turn them into the threaded holes at the pinion housing [C]. Turn the bolts into the pinion housing until it is removed from the differential housing.

PI–05696

D

REAR AXLE: Remove the pinion shaft and housing assembly [D].

PI–05697

–4–23–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Disassembly Of Differential (Cont’d) FRONT AXLE: Remove the pinion shaft and housing assembly [A].

PI–05698

B

Remove the shim from the pinion housing [B].

PI–05699

C

Put the pinion shaft and housing assembly into a press.

Press the pinion shaft out of the bearings and the housing [C].

PI–05700

Remove the bearing, spacer and shims from the pinion shaft [D].

D

PI–05701

–4–24–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Disassembly Of Differential (Cont’d) Remove the bearing from the pinion shaft using the press [A].

Inspect all the bearings, races and pinion gear teeth for wear or damage, replace the parts as needed.

PI–05702

B

Remove the bolts from the differential cover [B].

PI–05703

C

Remove the cover from the differential housing [C].

PI–05704

REAR AXLE: Remove the snap ring from the brake lever [D]. Mark the lever and shaft for correct installation.

Remove the brake lever (both sides).

D

PI–05685

–4–25–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Disassembly Of Differential (Cont’d) Remove the bolts and nuts from the differential and axle housing tube [A].

Use the tool (MEL1349) which consists of support plates, end tubes and threaded rods to remove the axle tube.

PI–05705

B

Install the support plate at both sides of the differential housing [B] & [C].

Install the end tubes at each end of the threaded rod.

Install a bolt into the end cover mounting hole (the bolt will be used as a guide for the end tube and threaded rod).

Install the end tube and threaded rod assembly [B] & [C].

Turn the nuts evenly at the threaded rods (both sides) until the axle housing tube is removed from the differential housing.

Remove the end tubes and threaded rods assembly and repeat the procedure for the other side axle housing tube.

PI–05706

C

PI–05708

D

NOTE: When the axle housing tube is removed, hold the large carrier bearing at the ring gear carrier so it pulls out of the axle housing mounting flange [D].

PI–05709

–4–26–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Disassembly Of Differential (Cont’d) If the differential is equipped with a differential lock (non–functional), remove the locking sleeve and discard [A].

PI–05710

B

Remove the large carrier bearing from the ring gear housing [B].

PI–05711

C

Remove the bearing shim [C].

PI–05712

Remove the bolts from the ring gear [D].

D

PI–05713

–4–27–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Disassembly Of Differential (Cont’d) Install a slide hammer puller into the hub of the differential ring gear carrier [A].

PI–05714

B

Remove the hub, spider gear and thrust washer from the ring gear carrier [B].

PI–05715

C

Put wood blocks under the carrier housing. Use a punch and hammer, evenly remove the ring gear from the carrier housing [C].

PI–05716

Remove the ring gear from the differential housing [D].

D

PI–05717

–4–28–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Disassembly Of Differential (Cont’d)

1 2

Remove the carrier housing and spider gear assembly from the differential housing [A].

NOTE: If the carrier housing (Item 1) [A] or the dowel pins (Item 2) [A] are replaced with new parts, do the following procedure. Install the ring gear on the carrier housing. Align the locating dowel pin holes in the ring gear with the carrier housing. Install three ring gear bolts and tighten. Enlarge the dowel pin holes using a 12 mm drill bit. Install the dowel pins into the carrier housing using a press.

PI–05718

Remove the roll pin from the spider gear shaft [B].

B

PI–05719

Remove the shaft from the spider gears [C].

C

PI–05720

Remove the spacer, spider gears and thrust washers [D].

D

PI–05721

Revised Feb. 94 –4–29–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Disassembly Of Differential (Cont’d) Remove the spider gear and thrust washer [A].

Assembly Of The Differential Clean and inspect all the parts for wear or damage.

Replace the parts as needed.

Install the spider gear and thrust washer into the carrier housing [A].

PI–05722

NOTE: Put grease between the washers and gears before installation.

B

Install the spider gears and thrust washers [B].

Install the spacer [B].

PI–05721

C

Install the shaft into the spider gears and make alignment of the hole in the shaft and spacer [C].

PI–05720

D

Start the roll pin into the hole [D].

Use a punch and hammer to install the roll pin and peen the ends of the roll pin.

PI–05723

–4–30–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Assembly Of The Differential (Cont’d)

F

If any of the bearings, races, spacers or pinion shaft is replaced the pre–load must be set as follows: 1. Install the bearings into the races in the pinion housing. Put the assembly on a level surface [A].

B–11804

2. Use a depth micrometer and measure the dimension F and make a record of the measurement [A].

PI–05724

B

3. Put the bearings on each side of the spacer and put the assembly on a level surface [B].

G

4. Use the depth micrometer and measure the dimension G and make a record of the measurement [B].

B–11804

5. The shim thickness is as follows: F minus G plus 0.002–0.003 inch (0,05–0,07 mm) = shim thickness.

EXAMPLE: 4.023 inch (102,2 mm) Dim. F – 3.965 inch (100,7 mm) Dim. G 0.058 inch (1,47 mm + 0.002 inch (0,05 mm) 0.060 inch (1,52 mm) shim thickness

PI–05725

C

Use the bearing tool (MEL1348) and press the bearing on the pinion shaft [C].

PI–05726

D

Install the correct amount of shim(s) (Item 1) [D] as determined from dimension F and G. Install the spacer (Item 2) [D] and pinion housing (Item 3) [D].

2

1 3

PI–05701

–4–31–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Assembly Of The Differential (Cont’d) Put the assembly in a press. Use the bearing tool (MEL1348) to install the bearing [A].

NOTE: DO NOT OVER–PRESS on the bearing when installing it on the pinion shaft, use the correct torque at the pinion nut to set the bearing pre–load.

PI–05727

B

Put LOCTITE on the pinion nut and install it on the pinion shaft. Tighten the pinion nut to 435–509 ft.–lbs. (590–690 Nm) torque [B].

Use an inch pound torque wrench and special pinion shaft socket (MEL1350) and check the pinion bearing pre–load, which should be 13–17 in.–lbs. (1,5–2,0 Nm) torque.

PI–05728

C

To set the correct ring gear height to the pinion gear, do the following procedure: 1. Install the pinion housing assembly (without the shim) into the differential housing [C]. Fasten with two bolts.

PI–05697

D

2. Install the tool (MEL1367), gauge spacer into each side of the differential housing [D].

PI–05729

–4–32–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Assembly Of The Differential (Cont’d) 3. Install the gauge tube into the spacers [A].

PI–05730

B

4. Install the calipers into the hole in the gauge tube [B].

5. Measure the distance from the gauge tube to the pinion bearing surface Dim. H [C]. Record the measurement.

PI–05731

C

6. Measure the gauge tube diameter and divide by 2.

Subtract this number from Dim. H. 7. Subtract Dim. H from the number stamped on the surface of the pinion gear. Subtract 0.020 inch (0,51 mm) from this and it will be the correct thickness shim needed at the pinion housing.

Dim. H

NOTE: For replacement of new spiral bevel gear set, do not subtract the nominal depth, 0.020 inch (0,51 mm). Nominal depth is for worn–in spiral bevel gear set ONLY.

Dim. I

EXAMPLE: B–11803

4.750 inch (120,7 mm) Dim. H [C] 1.250 inch (31,8 mm) Shaft Diameter B 2 half of shaft diameter 0.625 inch (15,9 mm) 4.750 inch (120,7 mm) Dim. H – 0.625 inch (31,8 mm) 4.125 inch (104,8 mm) Dim. I * 4.091 inch (103,9 mm) Number Stamped on Pinion Gear 0.034 inch (0,86 mm) – 0.020 inch (0,051 mm) Nominal Depth 0.014 inch (0,36 mm) Shim Thickness Needed * Number stamped on pinion gear 103,9 millimeters converted to inches 4.091.

–4–33–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Assembly Of The Differential (Cont’d)

1 2

Remove the pinion housing assembly and special tool.

Install the carrier housing assembly into the differential housing [A].

NOTE: If the carrier housing (Item 1) [A] or the dowel pins (Item 2) [A] are replaced with new parts, do the following procedure [A]. Install the ring gear on the carrier housing. Align the locating dowel pin holes in the ring gear with the carrier housing. Install three ring gear bolts and tighten. Enlarge the dowel pin holes using a 12 mm drill bit. Install the dowel pins into the carrier housing using a press.

PI–05718

B Install the ring gear on the dowel pin at the carrier housing [B].

PI–05717

Install the spider gear and carrier hub assembly into the ring gear [C].

C

Make sure the dowel pin make alignment.

PI–05715

Put LOCTITE 262 on the ring gear bolts. Install the bolts and tighten them to 65 ft.–lbs. (88 Nm) torque [D].

D

PI–05713

Revised Feb. 94 –4–34–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Assembly Of The Differential (Cont’d) Put LOCTITE 515 on the mounting flange of the axle tube.

Install the axle housing tube into the differential housing [A].

Put LOCTITE 262 on the threads of the studs and bolts.

Tighten the bolts and nuts to 95–102 ft.–lbs. (129–138 Nm) torque [A].

PI–05732

B

Use a soft hammer, seat the carrier bearing into the axle housing mounting flange [B].

PI–05733

C

Install the correct thickness shim(s) (as determined on Page 4–31) on the pinion housing [C].

PI–05699

Put LOCTITE 515 on the mounting surface of the pinion housing. Install the pinion housing assembly on the differential housing. Put LOCTITE 262 on the bolts.

Tighten the bolts to 36 ft.–lbs. (49 Nm) torque [D].

D

PI–05734

–4–35–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Assembly Of The Differential (Cont’d) Install a dial indicator at a tangent to the ring gear and against one tooth of the ring gear [A].

Force the ring gear against the pinion to a zero backlash position.

Calculate and install shims behind the bearing at the right hand axle tube to achieve 0.006–0.009 inch (0,15–0,23 mm) backlash required.

The ring gear floats toward the pinion and is contained by the bearing position on the right hand side.

PI–05735

B

Put coloring (Prussian blue) on the teeth of the ring gear.

Turn the ring gear and pinion gear and make a tooth pattern.

See figure [B] for different tooth patterns, adjust the pinion ring gear as needed.

Put LOCTITE 515 on the mounting flange of the other axle housing tube. Install the axle housing tube. Put LOCTITE 262 on the threads of the studs and bolts.

Tighten the bolts and nuts to 95–102 ft.–lbs. (129–138 Nm) torque.

MC–01035 B–11815 B–11814 B–11813

REAR AXLE: Install the brake lever and snap ring (both sides) [C].

C

PI–05685

–4–36–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Assembly Of The Differential (Cont’d) Put LOCTITE 515 on the rear cover of the differential housing. Install the cover [A].

PI–05704

B

Install the bolts and tighten to 36 ft.–lbs. (49 Nm) torque [B].

PI–05703

C

REAR AXLE: Install the new seal and put LOCTITE 515 on the pinion seal housing. Install the housing [C].

PI–05690

REAR AXLE: Install the bolts and tighten to 18 ft.–lbs (24 Nm) torque [D].

D

PI–05689

–4–37–

2400 Series Loader Service Manual

AXLE AND DIFFERENTIAL (Cont’d)

A

Assembly Of The Differential (Cont’d) REAR AXLE: Install the pinion hub [A].

PI–05688

B

REAR AXLE: Install the O–ring. Put LOCTITE 262 on the threads and install the nut [B].

PI–05687

C

REAR AXLE: Tighten the nut to 200 ft.–lbs. (271 Nm) torque [C].

FRONT AXLE: Install the drop–box gear case. (See Page 4–39.)

To finish assembling the differential, install the axles, end covers and axle hubs. (See Page 4–8.)

Add the correct amount of 90W gear lube to the differential and axle assembly as follows: Differential Housing (Front & Rear) 2.75 qts. (2,6 L) Wheel End Housing (Each Side) 1.75 qts. (1,7 L)

PI–05707

Drop–Box Gearcase 0.75 qts. (0,71 L)

–4–38–

2400 Series Loader Service Manual

DROP–BOX GEARCASE

A

Removal And Installation Remove the front axle and differential assembly from the loader. (See Page 4–3.)

Connect a chain hoist to the drop–box case.

Remove the bolts which fasten the drop–box case to the pinion housing [A].

Installation: Put LOCTITE 515 on the mounting flange.

Put LOCTITE 262 on the bolts and tighten to 37 ft.–lbs.

(50 Nm) torque.

PI–05739

B

Lift and remove the drop–box gearcase from the pinion housing [B].

PI–05740

C

Disassembly And Assembly Loosen the nut at the hub of the output shaft [C].

Assembly: Put LOCTITE 262 on the threads and tighten the nut to 200 ft.–lbs. (271 Nm) torque.

PI–05741

Remove the nut and O–ring from the output shaft [D].

D

PI–05742

–4–39–

2400 Series Loader Service Manual

DROP–BOX GEARCASE (Cont’d)

A

Disassembly And Assembly (Cont’d) Remove the hub from the output shaft [A].

PI–05743

B

Remove the bolts from the bearing cover for the input shaft [B].

Assembly: Tighten the bolts to 37 ft.–lbs (50 Nm) torque.

PI–05744

C

Make sure to mark the bolts for correct installation, because the bolts at the cover are different lengths [C].

PI–05745

Remove the cover from the case and bearing [D].

D

Assembly: Put LOCTITE 515 on the cover surface.

PI–05746

–4–40–

2400 Series Loader Service Manual

DROP–BOX GEARCASE (Cont’d)

A

Disassembly And Assembly (Cont’d) Remove the bolts from the intermediate gear cover [A].

Assembly: Tighten the bolts to 37 ft.–lbs. (50 Nm) torque.

PI–05747

B

Remove the cover and shims [B].

PI–05748

C

Assembly: To set the intermediate gear bearing end play, measure the depth of the cover [C].

PI–05749

Assembly: Measure the bearing height above the case [D].

D

Assembly: Add or remove shim(s) so the intermediate gear bearings have 0.008 inch (0,12 mm) end play.

PI–05750

–4–41–

2400 Series Loader Service Manual

DROP–BOX GEARCASE (Cont’d)

A

Disassembly And Assembly (Cont’d) Remove the bolts from the output shaft seal housing [A].

Assembly: Tighten the bolts to 38 ft.–lbs. (50 Nm) torque.

PI–05751

B

Remove the output shaft seal housing [B].

Assembly: Install a new hub seal into the housing.

PI–05752

C

Remove the input shaft bearing retainer bolt (Item 1) [C] and washer.

1

Assembly: Tighten the retainer bolt (Item 1) [C] to 65 ft.–lbs. (88 Nm) torque.

Remove the bolts and nuts which fasten the drop–box gearcase halves together [C].

Assembly: Tighten the bolts and nuts to 100 ft.–lbs. (136 Nm) torque.

PI–05753

Remove the case halves [D].

D

Assembly: Put LOCTITE 515 on the case halves.

PI–05754

–4–42–

2400 Series Loader Service Manual

DROP–BOX GEARCASE (Cont’d)

A

Disassembly And Assembly (Cont’d) Remove the output shaft, spacer and gear [A].

PI–05755

B

Use the correct size driver tool and remove the input shaft from the bearing [B].

PI–05756

C

Use the correct size driver tool to remove the intermediate gears from the bearing [C].

PI–05757

Remove the intermediate gears from the bearing [D].

D

Check all bearings, gears and splines for wear and damage. Replace the parts as needed.

Add the correct amount of 90W gear lube to the drop–box gearcase: 0.75 qts. (0,71 L)

PI–05758

–4–43–

2400 Series Loader Service Manual

BRAKE PEDAL MECHANISM

A

Removal And Installation Remove the floor panel in the operator cab. (See Page 5–1.)

1

Remove the nut (Item 1) [A] from the brake cable and lever (both sides).

PI–05626

B

Loosen the lock nut at the brake cable (both sides) [B].

Remove the brake cable from the mounting bracket (both sides).

PI–05627

C

Disconnect the electrical wiring harness from the brake pedal switch [C].

PI–05659

Remove the mounting bolts and nuts from the brake pedal mechanism [D].

D

PI–05760

–4–44–

2400 Series Loader Service Manual

BRAKE PEDAL MECHANISM (Cont’d)

A

Removal And Installation (Cont’d) Remove the brake pedal mechanism and cables as an assembly from the loader [A].

PI–05761

Disassembly And Assembly

B

Remove the screws from the electrical switch and remove the switch [B].

Assembly: Adjust the switch so the roller just touches the lock release cam.

PI–05762

C

Disconnect the spring (Item 1) [C] from the brake pedal.

1 PI–05763

Loosen the lock nuts at the brake cables [D].

D

Remove the cotter pin and pivot pin (Item 1) [D] from the brake cable linkage.

Remove the brake cables and linkage assembly.

1

PI–05764

–4–45–

2400 Series Loader Service Manual

BRAKE PEDAL MECHANISM (Cont’d)

A

Disassembly And Assembly (Cont’d) Remove the nut and bolt from the brake release pivot [A].

Remove the brake release pedal.

PI–05765

B

Check and replace the bushings as needed [B].

PI–05766

C

Remove the snap ring from the brake pedal pivot [C].

Remove the washer and brake pedal.

PI–05767

Check and replace the bushings as needed [D].

D

PI–05768

–4–46–

2400 Series Loader Service Manual

BRAKE PEDAL MECHANISM (Cont’d)

A

Brake Pedal Adjustment

2

Turn the nut (Item 1) [A] to be two threads maximum from the end of the cable shaft.

Turn the nuts (Item 2) [A] until there is 1.0 inch (25 mm) maximum brake pedal movement (Item 3) [A] before brake resistance is felt.

2 PI–05763

1.0” (25 mm)

3

2 1 2

1

PI–05626

Added July 92

–4–47–

MC–01666

2400 Series Loader Service Manual

–4–48–

2400 Series Loader Service Manual

MAIN FRAME Page Number BOB–TACH Bob–Tach Wedges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–15 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14 BOB–TACH TILT ROD (11000 SERIES) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8 BOB–TACH TILT ROD (12000 SERIES) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10 ENGINE HOOD Hood Adjustment (12000 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6 FLOOR PANEL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 FUEL TANK Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–25 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–24

MAIN FRAME

LOADER MAIN FRAME Bottom Pivot Pin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–30 Top Pivot Pin Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–32 Separating The Front And Rear Main Frame . . . . . . . . . . . . . . . . . . . . . . 5–27 REAR DOOR (12000 SERIES) Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–26 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–26 REAR FLOOR PANEL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5 SEAT AND SEAT MOUNTING FRAME Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 STEERING COLUMN Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–22 Tilt Lock Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–22 STEERING WHEEL (11000 SERIES) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16 STEERING WHEEL (12000 SERIES) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–19 THROTTLE COVER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 TILT TRANSFER ARM (11000 SERIES) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12 TILT TRANSFER ARM (12000 SERIES) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8) UNLESS OTHERWISE SPECIFIED. –5––1–

2400 Series Loader Service Manual

–5–0–

2400 Series Loader Service Manual

MAIN FRAME

A

FLOOR PANEL Removal And Installation Remove the rubber floor mat.

Remove the four bolts from the rubber boot for the brake pedal [A].

PI–05769

B

Loosen the nut [B].

PI–05770

C

Remove the brake pedal [C].

PI–05771

Remove the pedal for the brake lock release mechanism [D].

D

PI–05772

–5–1–

2400 Series Loader Service Manual

FLOOR PANEL (Cont’d)

A

Removal And Installation (Cont’d) Remove all the floor panel fastening bolts [A].

PI–09838

B

Lift the floor panel and remove it from the operator cab [B].

PI–09853

–5–2–

2400 Series Loader Service Manual

THROTTLE COVER

A

Removal And Installation Remove the grip from the throttle lever [A].

PI–05773

B

Remove the fastening bolt from the front of the cover [B].

PI–05774

C

Remove the fastening bolts from the throttle cover and seat mounting frame [C].

PI–05775

Lift the cover up and over the throttle lever.

D

PI–05776

–5–3–

2400 Series Loader Service Manual

SEAT AND SEAT MOUNTING FRAME

A

Removal And Installation Remove the floor panel. (See Page 5–1.)

Remove the cover from the throttle lever. (See Page 5–3.)

Remove the four bolts from the rear auxiliary cover [A].

PI–05777

B

Remove the cover [B].

PI–05778

C

Remove the bolts from the side of the seat mounting frame [C].

PI–05779

Remove the two bolts from the front of the seat mounting frame [D].

D

PI–05780

–5–4–

2400 Series Loader Service Manual

SEAT AND SEAT MOUNTING FRAME (Cont’d)

A

Removal And Installation (Cont’d) Remove the two bolts from the rear of the seat mounting frame [A].

Remove the seat and mounting frame assembly from the operator cab.

PI–05781

REAR FLOOR PANEL

B

Removal And Installation Remove the seat and mounting frame. (See Page 5–4.)

Remove the bolts from the rear floor panel [B] & [C].

PI–05782

C

PI–05783

D

Remove the rear floor panel from the operator cab [D].

PI–05784

–5–5–

2400 Series Loader Service Manual

ENGINE HOOD

A

Removal And Installation Open the engine hood.

Do the following procedure to one side at a time: 1. Remove the nut from the gas cylinder mounting bolt [A].

PI–05785

B

2. Remove the gas cylinder mounting bolt. Connect a chain hoist to the hood [B].

3. Lift the chain hoist a small amount to hold the engine hood.

4. Disconnect the gas cylinder at the other side of the engine hood. Connect the chain hoist.

PI–05786

C

Remove the retaining pin from the rod end of the gas cylinder [C].

Remove the gas cylinder (both sides).

AVOID INJURY Gas cylinder holds the rod under high pressure. NEVER OPEN THE GAS CYLINDER. PI–05787

D

Remove the bolts from the engine hood hinge [D].

Lift the engine hood with the chain hoist a small amount and remove it from the loader.

PI–05788

–5–6–

2400 Series Loader Service Manual

ENGINE HOOD (Cont’d)

A

Hood Adjustment (12000 Series) Loosen the nut at the rubber stops (Item 1) [A].

1

PI–09858

B

Turn the rubber stops in or out so they make contact with the stops (Item 1) [B] on the loader frame when the engine hood is closed.

Tighten the nut at the rubber stops.

1

PI–09859

–5–7–

2400 Series Loader Service Manual

BOB–TACH TILT ROD (11000 Series)

A

Removal And Installation Lower the lift arms. Stop the engine.

Operate the hydraulic control lever to release the hydraulic pressure.

Remove the retainer bolt from the rod end pivot pin [A].

Installation: Put LOCTITE 262 on the threads and tighten the retainer bolt to 25 ft.–lbs. (34 Nm) torque.

PI–05464

B

Remove the pivot pin from the rod end [B].

Repeat the procedure for the other side.

Put the Bob–Tach on the floor.

PI–05465

C

Remove the retainer bolt and nut from the linkage rod end pivot pin [C].

Installation: Tighten the retainer bolt to 25 ft.–lbs. (34 Nm) torque.

PI–05789

Remove the pivot pin from the Bob–Tach tilt rod [D].

D

PI–05790

–5–8–

2400 Series Loader Service Manual

BOB–TACH TILT ROD (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the Bob–Tach tilt rod [A].

PI–05791

B

Check the seals. If they need replacement, use a screwdriver to remove them [B].

PI–05792

C

Use a bearing driver tool of the correct size to install the new seals [C].

PI–05793

–5–9–

2400 Series Loader Service Manual

BOB–TACH TILT ROD (12000 Series)

A

Removal And Installation Lower the lift arms. Stop the engine.

Operate the hydraulic control lever to release the hydraulic pressure.

Remove the retainer bolt from the rod end pivot pin [A].

Installation: Put LOCTITE 262 on the threads and tighten the retainer bolt to 25 ft.–lbs. (34 Nm) torque.

PI–09767

B

Use a punch and hammer to remove the pivot pin [B].

PI–09768

C

Remove the pivot pin from the rod end [C].

Repeat the procedure for the other side.

Put the Bob–Tach on the floor.

PI–09769

Remove the retainer bolt and nut from the linkage rod end pivot pin [D].

D

Installation: Tighten the retainer bolt to 25 ft.–lbs. (34 Nm) torque.

PI–05789

–5–10–

2400 Series Loader Service Manual

BOB–TACH TILT ROD (12000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the pivot from the Bob–Tach tilt rod [A].

PI–05790

B

Remove the Bob–Tach tilt rod [B].

PI–05791

C

Check the seals. If they need replacement, use a screwdriver to remove them [C].

PI–05792

Use a bearing driver tool of the correct size and install the new seals [D].

D

PI–05793

–5–11–

2400 Series Loader Service Manual

TILT TRANSFER ARM (11000 Series)

A

Removal And Installation Remove the Bob–Tach tilt rod. (See Page 5–7.)

Remove the retainer bolt from the pivot pin for the tilt transfer arm [A].

Installation: Put LOCTITE 262 on the threads and tighten the retainer bolt to 25 ft.–lbs. (34 Nm) torque.

PI–05794

B

Remove the pivot pin from the tilt transfer arm [B].

Remove the tilt transfer arm.

PI–05795

C

Check the seals. If they need replacement, use a screwdriver to remove them [C].

PI–05796

Use a bearing tool of the correct size and install the new seals [D].

D

PI–05797

–5–12–

2400 Series Loader Service Manual

TILT TRANSFER ARM (12000 Series)

A

Removal And Installation Remove the Bob–Tach tilt rod. (See Page 5–9.)

Remove the retainer bolt from the pivot pin for the tilt transfer arm [A].

Installation: Put LOCTITE 262 on the threads and tighten the retainer bolt to 25 ft.–lbs. (34 Nm) torque.

PI–09854

B

Remove the pivot pin from the tilt transfer arm [B].

Remove the tilt transfer arm.

PI–09855

C

Check the seals. If they need replacement, use a screwdriver to remove them [C].

PI–09856

Use a bearing tool of the correct size and install the new seals [D].

D

PI–09857

–5–13–

2400 Series Loader Service Manual

BOB–TACH

A

Removal And Installation Lower the Bob–Tach to the floor. Stop the engine.

Operate the hydraulic control lever to release the hydraulic pressure.

Disconnect the Bob–Tach tilt rod. (See Page 5–7 or 5–9.)

Remove the grease fitting from the pivot pin for the Bob–Tach (both sides) [A].

PI–05798

B

Loosen the retainer bolt at the Bob–Tach pivot pin, do not remove the bolt (both sides) [B].

Installation: Tighten the bolt to 220–245 ft.–lbs.

(298–332 Nm) torque.

PI–05799

C

Put a rag over the grease fitting hole. Hit the bolt to remove the taper pivot pin from its seat (both sides) [C].

PI–05800

Installation: Use a punch through the grease fitting hole to push the pivot pin into the tapered seat and then install the retainer bolt [D].

D

Remove the retainer bolt. Push the pivot pin into the Bob–Tach frame.

Remove the Bob–Tach from the lift arms.

PI–05801

–5–14–

2400 Series Loader Service Manual

BOB–TACH (Cont’d)

A

Bob–Tach Wedges Use the following procedure to remove and install the Bob–Tach lever and wedge: 1. Remove the pivot bolt from the lever [A].

Installation: Tighten the pivot bolt to 25 ft.–lbs. (34 Nm) torque.

PI–05802

B

2. Remove the lever and wedge assembly from the Bob–Tach frame [B].

PI–05803

C

3. Inspect the wedge for being worn or damaged [C].

Check the spring tension and pivot bolts for wear.

Replace the parts as needed.

PI–05804

–5–15–

2400 Series Loader Service Manual

STEERING WHEEL (11000 Series)

A

Removal And Installation Remove the horn cover [A].

PI–05805

B

Remove the horn button by pushing down and turning counterclockwise [B].

PI–05806

C

Remove the spring from the horn button [C].

PI–05807

Remove the screws from the plate [D].

D

PI–05808

–5–16–

2400 Series Loader Service Manual

STEERING WHEEL (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the horn plate [A].

PI–05809

B

Remove the screws from the insulation ring [B].

PI–05810

C

Remove the insulation ring [C].

PI–05811

Remove the nut from the steering wheel [D].

D

Installation: Tighten the nut to 80–100 ft.–lbs. (108–136 Nm) torque.

PI–05812

–5–17–

2400 Series Loader Service Manual

STEERING WHEEL (11000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the steering wheel [A].

PI–05813

–5–18–

2400 Series Loader Service Manual

STEERING WHEEL (12000 Series)

A

Removal And Installation Remove the horn cover [A].

PI–09860

B

Remove the horn button by pushing down and turning counterclockwise [B].

PI–09861

C

Remove the spring from the horn button [C].

PI–09862

Remove the screws from the plate [D].

D

PI–09863

–5–19–

2400 Series Loader Service Manual

STEERING WHEEL (12000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the horn plate [A].

PI–09864

B

Remove the screws from the insulation ring [B].

PI–09865

C

Remove the insulation ring [C].

PI–09866

Remove the nut from the steering wheel [D].

D

Installation: Tighten the nut to 80–100 ft.–lbs. (108–136 Nm) torque.

PI–09867

–5–20–

2400 Series Loader Service Manual

STEERING WHEEL (12000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Install a puller to remove the steering wheel [A].

PI–09868

B

Remove the steering wheel [B].

PI–09869

–5–21–

2400 Series Loader Service Manual

STEERING COLUMN

A

Removal And Installation Remove the steering wheel. (See Page 5–16 or 5–19.)

Remove the restraint arm (11000 Series) [A].

PI–05814

B

Remove the restraint arm (12000 Series) [B].

Remove the signal lever and signal lights. (See Page 6–27.)

Remove the steering control valve. (See Page 2–54.)

PI–09870

C

Remove the mounting bolts and nuts from the steering column [C].

Remove the steering column assembly from the operator cab.

PI–05815

Tilt Lock Mechanism

D

Use the following procedure to disassemble and assemble the tilt lock mechanism for the steering wheel and restraint arm.

Remove the bolt from the pivot shaft for the steering column mounting bracket (both sides) [D].

Assembly: Put LOCTITE 262 on the threads and tighten the bolts to 45–55 ft.–lbs. (61–75 Nm) torque.

PI–05816

–5–22–

2400 Series Loader Service Manual

STEERING COLUMN (Cont’d)

A

Tilt Lock Mechanism (Cont’d) Remove the spring and mounting bracket assembly [A].

PI–05817

B

Remove the pivot shaft [B].

Remove the spring.

PI–05818

C

Remove the bolts from the tilt lock gear [C].

Assembly: Tighten the bolts to 15 ft.–lbs. (20 Nm) torque.

PI–05819

Remove the tilt lock gear [D].

D

Check all parts for wear or damage. Replace the parts as needed.

PI–05820

–5–23–

2400 Series Loader Service Manual

FUEL TANK

A

Removal And Installation Remove the counterweight, backhoe or three–point hitch from the rear of the loader.

NOTE: The hydraulic lock cylinder must be removed (if so equipped) before the fuel tank can be removed.

Remove the seat and seat mounting frame. (See Page 5–4.)

Remove the rear floor panel. (See Page 5–5.)

CD–05821

Drain the fuel from the fuel tank.

Disconnect the electrical wiring harness from the fuel sender [A].

B

Disconnect fuel pick–up hose and fuel return hose [B].

CD–05822

C

Disconnect the fuel fill hose [C].

Disconnect the vent hose (Item 1) [C].

CD–05823

Remove all the bolts from the fuel tank rear cover [D].

D

CD–05824

–5–24–

2400 Series Loader Service Manual

FUEL TANK (Cont’d)

A

Removal And Installation (Cont’d) Remove the fuel tank cover [A].

CD–05825

B

Remove the fuel tank [B].

CD–05826

Fuel Sender

C

To remove and install the fuel sender, use the following procedure: Remove the seat and seat mounting frame. (See Page 5–4.)

Remove the rear floor panel. (See Page 5–5.)

Disconnect the electrical wiring harness from the fuel sender.

Loosen the fuel sender from the fuel tank [C].

CD–05827

Remove the fuel sender assembly from the fuel tank [D].

D

CD–05828

–5–25–

2400 Series Loader Service Manual

REAR DOOR (12000 Series)

A

Removal And Installation Disconnect the electrical wiring harness connector from the rear light (both sides) [A].

Remove the wiring harness from the wiring harness clip (Item 1) [A] (both sides).

1

PI–09871

B

Remove the nuts from the rear door pivot bolts [B].

Remove the pivot bolts and rear door.

PI–09872

Adjustment

C

Loosen the bolts at the rear door latch mechanism and adjust as needed [C].

PI–09873

Loosen the bolts at the rear door catch and adjust as needed [D].

D

PI–09874

–5–26–

2400 Series Loader Service Manual

LOADER MAIN FRAME

A

Separating The Front And Rear Main Frame Remove the counterweight, backhoe or three–point hitch from the rear of the loader.

Remove the rubber bumpers at the front of the rear section. Install the front mobile support frame at this location [A].

CD–05829

B

Install the rear mobile support frame at the holes on the rear of the main frame [B].

Install jackstands under each rear corner of the front main frame section of the loader. Do not lift the loader front section to install the jackstands. Be sure the jackstands just touch the bottom of the front main frame.

Remove the seat and seat mounting frame. (See Page 5–4.)

Disconnect the control cables from the hydraulic control valve. (See Page 2–14 or 2–19.)

Disconnect the drive shaft. (See Page 4–2.)

CD–05830

C

Disconnect all the loader electrical wiring harness in the operator cab [C].

PI–05831

Mark the hoses for correct installation at the manifold block.

D

Disconnect the hydraulic hoses from the front section manifold block [D].

PI–05571

–5–27–

2400 Series Loader Service Manual

LOADER MAIN FRAME (Cont’d)

A

Separating The Front And Rear Main Frame (Cont’d) Remove the retainer bolt from the rod end pivot pin for the steering cylinder [A].

Installation: Tighten the bolt to 25 ft.–lbs. (34 Nm) torque.

PI–05482

B

Remove the pivot pin from the steering cylinder [B].

PI–05483

C

Loosen the retainer bolt and nut at the bottom center pivot pin [C].

Installation: Tighten the bolt to 250 ft.–lbs. (339 Nm) torque.

PI–05832

Remove the nut and spacer [D].

D

PI–05823

–5–28–

2400 Series Loader Service Manual

LOADER MAIN FRAME (Cont’d)

A

Separating The Front And Rear Main Frame (Cont’d) Remove the retainer bolt [A].

PI–05834

B

Remove the retainer bolt from the bottom center pivot pin [B].

Installation: Tighten the retainer bolt to 25 ft.–lbs. (34 Nm) torque.

NOTE: Install a floor jack under the center of the front section. The floor jack will be used to lift or lower the front section main frame to make alignment of the top and/or bottom center pivot pins when they are removed or installed.

PI–05835

C

Remove the bottom center pivot pin [C].

PI–05836

D

Remove the retainer bolt and nut from the top center pivot pin [D].

Installation: Tighten the retainer bolt and nut to 25 ft.–lbs. (34 Nm) torque.

PI–05837

–5–29–

2400 Series Loader Service Manual

LOADER MAIN FRAME (Cont’d)

A

Separating The Front And Rear Main Frame (Cont’d) Use a small hydraulic jack. Push the top center pivot pin out of the frame [A].

PI–05838

B

Roll the rear main frame away from the front main frame section [B].

PI–05839

C

Remove and check the bottom spacer for wear or damage [C]. Replace the spacer as needed.

PI–05840

Bottom Pivot Pin Bearing

D

Use the following procedure to remove and replace the bottom pivot pin bearing: Remove the four bolts from the retainer plate [D].

Installation: Tighten the bolts to 25 ft.–lbs. (34 Nm) torque.

PI–05841

–5–30–

2400 Series Loader Service Manual

LOADER MAIN FRAME (Cont’d)

A

Bottom Pivot Pin Bearing (Cont’d) Remove the bearing retainer plate [A].

PI–05842

B

Use a bearing puller. Push the bearing out of the frame [B].

PI–05843

C

Install a new bearing. Make sure it is straight in the hole in the frame [C].

PI–05844

Install the bearing puller, push the bearing into the frame until it seats on the flange in the bottom of the hole [D].

D

PI–05845

–5–31–

2400 Series Loader Service Manual

LOADER MAIN FRAME (Cont’d)

A

Top Pivot Pin Bearing To remove and replace the top pivot pin bearing, use the following procedure: Use a bearing puller and spacer. Push the bearing out of the frame [A].

PI–05846

B

Install the new bearing, make sure it is straight with the hole in the frame [B].

PI–05847

C

Install the bearing puller. Push the bearing into the frame until the top of the bearing is even with the frame [C].

PI–05848

–5–32–

2400 Series Loader Service Manual

ELECTRICAL SYSTEM

Page Number

ALTERNATOR Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brush Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking The Alternator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking The Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection Of Rear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing The Rear Rotor Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotor Testing And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Diode–Trio & Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting The Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6–8 6–14 6–9 6–14 6–10 6–16 6–10 6–15 6–15 6–14 6–8

BATTERY Checking The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 Removal And Installation (11000 Series) . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 Removal And Installation (12000 Series) . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 DIODES Checking The Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 ELECTRICAL SYSTEM Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Breaker (11000 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses (11000 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses (12000 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 Amp. Fuse (12000 Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6–1 6–2 6–5 6–2 6–3 6–3

ELECTRICAL SYSTEM

INSTRUMENT PANEL (11000 SERIES) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24 INSTRUMENT PANEL (12000 SERIES) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25 SEALED ELECTRICAL TERMINAL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 SIGNAL LIGHT CONTROL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–27 STARTER (11000 SERIES) Checking The Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing The Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6–17 6–18 6–18 6–17 6–19

STARTER (12000 SERIES) Checking The Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6–20 6–23 6–21 6–20

TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS FOR BOLTS, SECTION 8) UNLESS OTHERWISE SPECIFIED. –6––1–

2400 Series Loader Service Manual

–6–0–

2400 Series Loader Service Manual

ELECTRICAL SYSTEM TROUBLESHOOTING The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM

CAUSE

Battery will not take a charge.

1, 2, 3, 4, 5

Alternator will not charge.

1, 2, 5

Starter will not turn the engine.

2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE 1.

2.

3.

4.

5.

6.

7.

8.

9.

Alternator belt is loose or damaged.

Battery connections are dirty or loose.

Battery is damaged.

The ground connection is not making a good contact.

The alternator is damaged.

The engine is locked.

The starter is damaged.

The wiring or the solenoid is damaged.

Check the fuses.

ELECTRICAL SYSTEM Description The loader has a 12 volt, negative ground electrical system.

There are two main circuits.

1. The charging circuit has an alternator (with built–in regulator), and a battery.

2. The starting circuit has a starter motor and solenoid for starting the engine.

The electrical system is protected by fuses installed in the fuse panel. Fuses protect the electrical system from an overload. The reason for the overload must be found before starting the engine.

–6–1–

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–0797

2400 Series Loader Service Manual

ELECTRICAL SYSTEM (Cont’d)

A

Electrical Breaker (11000 Series) The electrical breaker (Item 1) [A] is located under the engine hood in front of the battery.

1

The breaker protects the electrical system from an electrical over–load. This breaker disconnects the battery from the electrical circuit when turned OFF. The breaker must be in the ON position before the loader engine can be started.

PI–05375

B

Fuses (11000 Series) The fuses protect electrical circuits from damage. The fuses are located under the seat mounting frame.

To replace the fuse(s), remove the bolts from the cover [B].

Replace the fuse(s) with the same type and capacity.

NOTE: Before replacing any fuse, make sure the electrical breaker is in the OFF position.

PI–05376

The fuse capacity and circuit are as listed in the chart below and figure [C].

No. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Fuse Capacity 25 Amp. 15 Amp. 20 Amp. 10. Amp. 5 Amp. 7.5 Amp. 7.5 Amp. 5 Amp. 10 Amp. 30 Amp. 7.5 Amp. 7.5 Amp.

C

Circuit Wiper, Horn, Dome Light Beacon (Opt.) Lights Flashers Accessory Turn Signals Hyd. Solenoid Fuel Solenoid Ign. Switch Blower–Heater/A.C. (Opt.) Future Use Instrument Panel

1

5

2

6

3

7

4

8

9 10 11 12

PI–05377

–6–2–

2400 Series Loader Service Manual

ELECTRICAL SYSTEM (Cont’d)

A

Fuses (12000 Series) The fuses protect the electrical system from damage. The fuses are located under the seat mounting frame.

Pull the door latch to open the compartment below the seat mounting frame [A].

PI–06997

B

The fuse capacity and circuit are as listed in the chart below and figure [B].

Fuse Capacity 25 Amp. 15 Amp. 20 amp.

10 Amp. 5 Amp. 7.5 Amp. 7.5 Amp. 10 Amp. 10 Amp. 30 Amp. 7.5 Amp. 7.5 Amp.

Circuit Wiper, Horn, Dome Light Beacon (Opt.) Lights Flashers Accessory Turn Signal Hyd. Solenoid Fuel Solenoid Ign. Switch Blower–Heater/ (A.C. (Opt.) Accessory Instrument Panel

PI–05377

C

80 Amp. Fuse (12000 Series) The electrical harness is protected by a 80 amp. in–line fuse (Item 1) [C] located in the engine harness.

1

PI–09875

D

To replace the 80 amp. fuse, use the following procedure: 1. Disconnect the negative (–) cable from the battery.

Remove the old fuse from the wiring harness.

2. Install the shrink–wrap on the wire [D].

PI–09877

–6–3–

2400 Series Loader Service Manual

ELECTRICAL SYSTEM (Cont’d)

A

80 Amp. Fuse (12000 Series) (Cont’d) 3. Install the new fuse using the screws and nuts.

Tighten the screws and nuts [A].

PI–09877

B

4. Put a piece of conduit over the fuse and fuse terminals [B].

PI–09894

C

5. Put the shrink–wrap over the fuse [C]. Use a heat gun to shrink the wrap.

6. Connect the negative (–) cable at the battery.

PI–09878

–6–4–

2400 Series Loader Service Manual

ELECTRICAL SYSTEM (Cont’d)

A

Electrical System Service

Water and Baking Soda Solution

Use the following procedure to service the electrical system: 1. Check that the battery cable ends are clean and tight. Remove any acid or corrosion from the battery cable ends with a baking soda and water solution [A]. Cover the battery terminals with grease to prevent corrosion.

2. Check the alternator belt for wear and correct tension.

A–02741

3. Check all wire connections for loose connections.

B

SEALED ELECTRICAL TERMINAL Removal And Installation The tool listed will be needed to do the following procedure: MEL1248 – Terminal Extractor Tool Un–latch the cover over the rubber seat.

Push the terminal extractor tool into the plastic housing to release the locking tabs [B].

B–08039

C

Pull the terminal from the housing [C].

B–08057

DIODES

D

Checking The Diodes

2

Find the diode in the wiring harness (Item 1) [D].

Disconnect the diode.

1

Connect an ohmmeter (Item 2) [D] between the diode lead (Item 3) [D] and the wire that was disconnected.

Measure the resistance. Reverse the ohmmeter leads.

Measure the resistance again. If the resistance in one direction is not at least 10 times greater than in the other direction, the diode is damaged. Replace the diode as needed.

1.

2.

3.

4.

Wiring Harness Ohmmeter Diode Electrical Symbol

3 A–02847

–6–5–

2400 Series Loader Service Manual

BATTERY

A

Checking The Battery The tool listed will be needed to do the following procedure: MEL10004 – Battery Tester To make a safe and complete check of the battery, see the Melroe Battery Manual (P/N 6566047). The battery manual has all the information needed for checking and servicing the battery.

PI–05379

Removal And Installation (11000 Series) Open the engine hood. Turn the electrical breaker to the OFF position.

B

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

PI–05380

C

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W–2065–1296

Disconnect the negative (–) cable first [A].

Disconnect the positive (+) cable [B].

Remove the battery holddown clamp [C].

PI–05381

Remove the battery from the loader.

D

Always clean the terminals and cable ends even when installing a new battery [D].

B–03707

–6–6–

2400 Series Loader Service Manual

BATTERY (Cont’d)

A

Removal And Installation (12000 Series) Open the engine hood.

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

PI–09408

In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

B

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W–2065–1296

Disconnect the negative (–) cable first [A].

Disconnect the positive (+) cable [B].

PI–09409

Remove the battery holddown clamp [C].

C

Installation: Make sure the insulator (Item 1) [C] is installed. Do not over–tighten the bolts.

Remove the battery from the loader.

1

PI–09410

Always clean the terminals and cable ends even when installing a new battery [D].

D

B–03707

–6–7–

2400 Series Loader Service Manual

ALTERNATOR

A

Belt Tension To adjust the belt tension, use the following procedure: 1. Stop the engine. Open the right rear access door.

2. Loosen the alternator mounting bolt [A].

3. Loosen the alternator adjusting bolt [A].

PI–09407

PI–05373

B

4. Move the alternator to give the belt about 3/8 inch (9,5 mm) deflection with about 20 lbs. (89 N) force between the pulleys [B].

5. Tighten the adjusting bolt and mounting bolt. Close the rear access door.

PI–05374

Troubleshooting The Alternator

PROBLEM

CAUSE

CORRECTION

Battery undercharged 1. Defective cables, corroded –Voltmeter indicates discharge. battery terminals, etc.

2. Loose or broken belt.

3. Worn or broken brushes.

4. Defective alternator system.

5. Defective wire harness.

1.

2.

3.

4.

5.

Battery overcharges –Excessive use of water –Voltmeter indicates more than 14.5 volts (engine @ idle RPM)

1.

2.

3.

4.

1. Refer to Checking The Alternator.

2. Check ground.

3. Check, clean or repair as needed.

Battery charges at idle, but discharges under load conditions

1. Slipping belts.

2. Alternator defective

Defective wire harness.

Defective alternator system.

Bad ground.

Broken sense lead.

–6–8–

Check, clean or replace as needed.

Check belt.

Replace brush assembly.

Refer to Checking the Alternator.

Check wiring harness.

1. Check belt and adjust tension or replace as needed.

2. Disassemble, check diodes.

2400 Series Loader Service Manual

ALTERNATOR (Cont’d)

A

Checking The Alternator Output

3 1

2

AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual.

W–2012–0497

Install the steering frame lock. (See Page 1–4.)

Lift and block the loader. (See Page 1–2.)

Open Diode–Trio Test

PI–05902

Open the right rear access door.

Engine is running at idle RPM, unless otherwise specified.

BATTERY UNDERCHARGED 1. Remove battery sense only. a. Perform Harness Voltage Test (Test No. 3) 2. Test Lamp On. a. Perform Open Diode–Trio Test (Test No. 1) 3. Test Lamp Off (Ignition On & Engine Stopped). a. Perform Regulator Test (Test No. 2) b. If regulator O.K., the cause is probably an open filed circuit and alternator must be repaired.

BATTERY OVERCHARGED 1. Regulator Shorted, Replace Regulator.

TEST NO. 1 – OPEN DIODE–TRIO TEST [A].

With the ignition on and engine not running (no electrical load), check for battery voltage at terminal (Item 1) [A] and 1.5–3.0 volts at terminal (Item 2) [A]. Connect a jumper wire (Item 3) [A] between the terminals (Item 1 & 2) [A]. Start the engine. If charging voltage is present at terminal (Item 1) [A], the diode–trio is defective and alternator needs repair.

B 1

2

3

TEST NO. 2 – OPEN REGULATOR TEST [B].

Remove the back cover from the alternator. With ignition ON and engine not running. Check for battery voltage at terminals (Item 1 & 2) [B]. Connect jumper wire (Item 3) [B] between field and ground. If 1.5–3.0 volts is present at terminal (Item 2) [B] and light is ON, a defective regulator is indicated. If light is not ON, it is an open field circuit (brushes, slip–rings, etc.), repair the alternator.

Regulator Test (Back Cover Removed)

–6–9–

PI–05903

2400 Series Loader Service Manual

ALTERNATOR (Cont’d)

A

Checking The Alternator Output (Cont’d) TEST NO. 3 – HARNESS VOLTAGE TEST [A].

Integral Regulator

Disconnect the harness from sense terminal and connect voltmeter leads. Voltmeter should indicate battery voltage (approximately 12.6 volts). If voltage is zero, the harness sense wire is defective and must be repaired or replaced.

*Sense To BATT (+) Harness Sense Lead

Excite (To IGN. SW.) BLK RED *Remote Battery Sense Only

PI–05904

B

AC Tap (TACH)

TEST NO. 4 – ALTERNATOR OUTPUT TEST [B].

After voltmeter is connected, start the engine and run at approximately 1500 RPM. Turn on the work lights. Check for output voltage of between 13.8–14.8 for proper operating charging system (voltage may vary due to ambient temperature variations).

Ground Integral Regulator Excite (To IGN. SW. or Oil Press. SW.) RED

POS + Output (B+) *Sense To BATT (+)

BLK

POS. + Output 13.8 to 14.8V

*Remote Battery Sense Only

Removal And Installation

PI–05905

Stop the engine.

C

Disconnect the negative (–) cable from the battery.

1

Disconnect the alternator connector from the wiring harness.

Disconnect the wire from the alternator battery terminal.

Remove the adjusting bolt (Item 1) [C].

Remove the belt from the alternator pulley.

Remove the mounting bolt (Item 2) [C].

2

Remove the alternator from the mounting bracket.

PI–05373

Installation: Make sure to adjust the alternator belt to the correct tension. (See Page 6–8.)

D Disassembly And Assembly Remove the nuts from the terminals. Remove the two screws securing the back cover to the rear housing [D].

(2) Back Cover Mounting Screws CD–05930

–6–10–

2400 Series Loader Service Manual

ALTERNATOR (Cont’d)

A

Disassembly And Assembly (Cont’d) Assembly: Make sure the felt gasket is in place [A].

Felt Gasket

CD–05906

B

Remove the two lock nuts from the brush holder [B]. Pull out the brush holder.

Assembly: Install the brush holder into grooves in the rear housing. Put D+ strap (or male terminal where applicable) on stud and fasten brush holder with the lock nuts. Fasten the other end of D + strap.

(2) Brusholder Mounting Locknut

CD–05907

C

Remove the two screws fastening the integral regulator to the rear housing [C]. Remove the regulator.

(2) Regulator Mounting Screw The diode–trio and rectifier diode bridge are removed as an assembly. Remove the cone lock nut from the positive output (B+) terminal [D]. Straight B+ strap. Remove the three terminal screws and four mounting screws for the diode–trio. Remove the assembly from rear housing and separate diode–trio assembly from rectifier bridge.

D

CD–05908

(3) Terminal Screw (4) Mounting Screw

Assembly: Install B+ strap through slot in diode–trio body. Bend strap over B+ terminal and secure with cone lock nut. Apply thin film of heat sink compound to back of diode–rectifier bridge and to mating area on rear housing.

Install assembly to rear housing (four screws). Put the strap (AC tap) in position and connect the stator leads (three screws).

Cone Locknut And B+ Strap

CD–05909

–6–11–

2400 Series Loader Service Manual

ALTERNATOR (Cont’d)

A

Disassembly And Assembly (Cont’d)

(4) Thru–Bolts

Remove the four thru–bolts [A].

Assembly: Install thru–bolts and tighten to 50–60 in.–lbs.

(5,7–6,8 Nm) torque. When installing a new front housing, the thru–bolt holes are not tapped. Therefore more torque will be required to drive the thread forming thru–bolts.

CD–05910

Blade Screwdrivers At Opposite Openings

B

Carefully install two screwdrivers in opposite openings between stator and front housing [B]. Pry units apart.

NOTE: Do not insert screwdriver blades deeper than 0.0625 inch (1,6 mm) to avoid damaging stator windings.

CAUTION: Do Not Insert Blade Of Screwdriver More Than 0.0625”

CD–05911

C

The pulley is a slip–fit on the rotor shaft, positioned with a key. Remove the nut and lock washer from the shaft using an impact wrench [C].

Remove the pulley and fan from the shaft. Remove the key.

Inspect the fan for cracked or broken fins. Check mounting hole, if worn from running loose, replace the fan.

Inspect the pulley for any defects.

Assembly: Tighten the nut at the pulley to 35–50 ft.–lbs.

(47–68 Nm) torque. Spin rotor by hand to check the bearing for free movement.

CD–05912

D

Position the front housing on support blocks on a press [D].

Rotor Shaft

Press Front Housing

Push the rotor assembly from the housing [D].

Block

CD–05913

–6–12–

2400 Series Loader Service Manual

ALTERNATOR (Cont’d)

A

Disassembly And Assembly (Cont’d)

Press Driver Sleeve

Assembly: Support the rotor with two blocks as shown in figure [A]. Put the front housing over the shaft. Using a drive sleeve that contacts the inner bearing race, press the front housing down until the inner bearing race contacts the shoulder on the shaft. Make sure the rotor leads are clear of the blocks.

Front Housing

Block

Rotor Assembly

(3) Bearing Retainer Screw

B

Remove the three bearing screws [B].

CD–05914

Assembly: Tighten the screws to 25–35 in.–lbs. (2,8–4,0 Nm) torque.

Front Housing

CD–05915

C

Position the housing on blocks. Using a tool that contacts the inner race of the bearing, press the front bearing out [C].

Front Housing Hub

Bearing

Tool

Inner Race PI–05916

Assembly: Place the front bearing and housing in a press. Select a driver tool that contacts the outer race of the bearing [D]. Press the bearing into position.

D Press Drive Tool Contacts Outer Bearing Race Only Front Bearing

Front Housing PI–05917

–6–13–

2400 Series Loader Service Manual

ALTERNATOR (Cont’d)

A

Brush Inspection

D

B

Figure [A] shows the terminal brush arrangement and testing procedure.

The original brush set may be reused if the brushes are 0.1875 inch (4,76 mm) or longer, and if brushes are not oil soaked, cracked or show evidence of grooves on the sides caused by vibration.

Test

A

Continuity From A To B From C To D

C

No Circuit: From A Or B Test With 12 Volt DC Test To C Or D Lamp Or Ohmmeter Testing Diode–Trio & Rectifier Assembly

B

Using a diode tester or 12 volt DC test lamp, check the continuity from each terminal separately to the D+ stud.

Continuity should be observed in one direction (polarity) only, and all diodes must check the same [B]. If any diode is defective, replace the complete diode–trio assembly.

Commercial Diode Tester

Terminal (3)

D+ Stud (Ind. Light Terminal)

C

Check between point A and each of the three terminals C for negative diodes [C]. Continuity must be shown in one direction (polarity) only, and all diodes must check the same. Then check between point B (B+ strap) and each of the three terminals C for positive diodes. Continuity must be shown in one direction only, and all diodes must check the same.

C

PI–05918

CD–05919

Commercial Diode Tester

A

If any is defective, replace the complete diode–rectifier assembly.

B CD–05920

Checking The Stator

D

The stator assembly consists of three separate windings.

Using an ohmmeter or test lamp, check for winding continuity between terminals A, B and C [D]. There should be no continuity from any terminal to point D (frame). Also, stator showing any signs of discoloration must be replaced.

C D

B A CD–05921

–6–14–

2400 Series Loader Service Manual

ALTERNATOR (Cont’d)

A

Rotor Testing And Inspection

Rear Bearing

Pole Fingers

Slip Rings

Make the following electrical checks on the rotor [A]:

Bearing Area Key Slot

NOTE: Turn off DC power source before removing test leads to avoid arc damage to slip ring surfaces.

1. Current Draw or Resistance of Winding Current Draw in Amperes, 3.2–3.7 amps.

Test Current Draw Or Resistance Between Rings

Resistance of Winding in OHMS, 4.0–4.7 OHMS

Shaft Threads CD–05922

2. Grounded Slip Ring or Winding Use a 12 volt DC test lamp or ohmmeter. Connect one test lead to the rotor body and the other to either slip ring. Open circuit from either slip ring to rotor body is a correct condition.

3.

Condition of Slip Rings 1. Clean brush contacting surface with fine crocus cloth, wipe dust and residue away. If surfaces are worn beyond this restoration, replace the complete rotor assembly.

4.

Rotor Shaft And Pole Pieces 1.

2.

3.

4.

5.

Stripped threads on shaft.

Worn key slot.

Worn bearing surfaces.

Scuffed pole fingers.

Worn or dry rear bearing.

Replace rotor assembly if any of the above are found defective except for Item 5. See replacement of the rear bearing for correct procedure.

Replacing The Rear Rotor Bearing

B

Un–solder the rotor leads from the slip ring terminals.

Carefully unwind the ends of the rotor coil leads from the slip ring terminals [B].

Remove All Residue From Between Slip Rings

Unsolder

CAUTION: Do Not Overheat CD–05923

–6–15–

2400 Series Loader Service Manual

ALTERNATOR (Cont’d)

Straighten Rotor Leads

A

Replacing The Rear Rotor Bearing (Cont’d)

No. 10 x 1.0” Cap Screws

Straighten rotor leads. Install a No. 10 x 1.0 inch screw into the opening at the center of the slip ring assembly.

Position the bearing puller and pull the slip ring off the rotor shaft [A].

CD–05924

B

Move the rotor leads away from the bearing puller contact area. Adjust puller to contact the inner bearing race, remove the bearing from the shaft [B].

Dress Rotor Leads Away From Puller

CD–05925

C

Place the rotor on blocks in a press [C]. Install the new rear bearing. Install the correct size driver tool that if only contacts the inner bearing race. Press the bearing down until it contacts the shoulder [C].

Rear Bearing Rotor

Block

Guide the rotor leads through one of the passages in the slip ring assembly. Make sure the passage is in line with the groove in the rotor shaft. Put the rotor on blocks in a press [D]. Install the correct size drive tool that clears the rotor leads. Press the slip ring assembly on the shaft.

Press Driver Sleeve Rotor Leads

CD–05926

D Slip Ring Assembly

Solder the rotor leads to the leads on the slip ring. Trim excess slip ring leads extending above the solder connections.

Press Driver Sleeve

Inspection Of Rear Housing Block

Inspect the rear housing for a cracked or broken casting, stripped threads or wear in the bearing bore due to a worn rear bearing.

If casting is to be used again, clean in solvent, dry with compressed air and install a new rear bearing retainer.

CD–05927

–6–16–

2400 Series Loader Service Manual

STARTER (11000 Series)

Jumper Wire

A

Checking The Starter

Bat S M

The key switch must be in the OFF position.

The battery must be at full charge.

The cable connections on the battery must be clean and tight.

Cranking Motor

Connect a jumper wire between S terminal and BAT terminal [A].

If the starter turns but does not turn the engine, the starter drive has a defect.

A–01992

B

Connect a jumper wire between the M terminal and BAT terminal [B].

If the starter turns, the defect is in the solenoid.

Jumper Wire Bat S M

If the starter does not turn, the starter is defective.

Cranking Motor

A–01991

C

Removal And Installation Remove the air cleaner. (See Page 7–2.)

Turn the electrical breaker to the OFF position.

Disconnect the negative (–) cable from the battery.

Remove the bolts from the starter support bracket [C].

PI–05849

Remove the support bracket.

D

Disconnect the positive (+) cable from the starter solenoid.

Disconnect all the wires from the starter solenoid.

Remove the starter mounting bolts [D].

Remove the starter from the engine.

PI–05850

–6–17–

2400 Series Loader Service Manual

A

4

2

9

8

3

5

1 10 6

7 15

12 11 1.

2.

3.

4.

5.

6.

7.

8.

Bolt, Solenoid Solenoid Spring, Plunger Pin, Plunger/Shift Fork Plunger Shift Fork Bolt, Shift Fork Pivot Bolt, End Cap

16 9.

10.

11.

12.

13.

14.

15.

16.

End Cap Shim Washer Armature Thrust Washer Drive Assembly Drive Stop Ring Thrust Collar Bushing

13 14

B–01192

STARTER (11000 Series) (Cont’d)

B

Disassembly And Assembly Disassemble the starter as shown in figure [A].

Cleaning And Inspection Use a brush and air pressure to clean the drive, field coils, armature and starter housing.

NOTE: Do not use solvent to clean the drive assembly. The solvent will remove the lubricant and the drive will slip.

Check the following items:

A–01995

Armature Broken or burned insulation Loose connections at commutator Open or grounded circuits [B] & [C].

Worn shaft or bearings Rough commutator

C

Brush Holders Broken springs Broken insulation Spring tension

A–01994

–6–18–

2400 Series Loader Service Manual

STARTER (11000 Series) (Cont’d)

A

Cleaning And Inspection (Cont’d) Field Coils Broken or burned insulation Electrical continuity [A].

Brush connections

PI–02122

B

Drive Gear Worn teeth Tooth engagement (drive gear must engage ring gear by 1/2 the depth of the ring gear tooth) To test for ground, use a test light and touch one probe to the body and the other probe to the field winding end of the brush. The lamp should not light [B].

PI–09576

Replacing The Brushes

C

Remove the screws from the brushes [C].

Remove the screws from the brush leads.

Remove the old brushes.

Install the new brushes and make sure to tighten the screws.

Assembly: Reverse the order of disassembly. Put a small amount of grease on the splines of the armature and the bushings. Add or remove shims at the drive end of the armature to adjust the end play.

PI–09940

–6–19–

2400 Series Loader Service Manual

STARTER (12000 Series)

Jumper Wire

A

Checking The Starter

Bat S M

The key switch must be in the OFF position.

The battery must be at full charge.

The cable connections on the battery must be clean and tight.

Cranking Motor

Connect a jumper wire between S terminal and BAT terminal [A].

If the starter turns but does not turn the engine, the starter drive has a defect.

A–01992

B

Connect a jumper wire between the M terminal and BAT terminal [B].

If the starter turns, the defect is in the solenoid.

Jumper Wire Bat S M

If the starter does not turn, the starter is defective.

Cranking Motor

A–01991

C

Removal And Installation Remove the air cleaner. (See Page 7–2.)

Disconnect the negative (–) cable from the battery.

Disconnect the positive (+) cable from the starter solenoid [C].

Disconnect all the wires form the starter solenoid.

PI–09879

Remove the mounting bolts from the starter flange [D].

D

PI–09880

–6–20–

2400 Series Loader Service Manual

STARTER (12000 Series) (Cont’d)

A

Removal And Installation (Cont’d) Remove the starter from the engine [A].

PI–09881

Disassembly And Assembly

B

Remove the starter thru–bolts [B].

PI–08924

C

Remove the screws for the brush holders [C].

PI–08925

Remove the starter end cap [D].

D

PI–08926

–6–21–

2400 Series Loader Service Manual

STARTER (12000 Series) (Cont’d)

A

Disassembly And Assembly (Cont’d) Remove the starter housing/armature assembly from the reduction gear drive [A].

PI–08927

B

Remove the armature and brushes from the starter housing [B].

PI–08928

C

Remove the bolts from the reduction gear housing [C].

PI–08929

Remove the reduction gear housing [D].

D

PI–08930

–6–22–

2400 Series Loader Service Manual

STARTER (12000 Series) (Cont’d)

A

Cleaning And Inspection Use a brush and air pressure to clean the drive, field coils, armature and starter housing.

NOTE: Do not use solvent to clean the drive assembly. The solvent will remove the lubricant and the drive will slip.

Check the following items: Armature Broken or burned insulation Loose connections at commutator Open or grounded circuits [A] & [B].

Worn shaft or bearings Rough commutator

A–01995

B

Brush Holders Broken springs Broken insulation Spring tension Field Coils Broken or burned insulation Electrical continuity Brush connections Drive Gears Worn teeth Tooth engagement A–01994

–6–23–

2400 Series Loader Service Manual

INSTRUMENT PANEL (11000 Series)

A

Removal And Installation Turn the electrical breaker to the OFF position [A].

PI–05851

B

Remove the cover from the wiring harness [B].

PI–05852

C

Remove all the bolts from the instrument panel [C].

PI–05853

Lift the instrument panel assembly up and out of the mounting frame [D].

D

If any of the light and/or gauges are replaced, use the Electrical Wiring Diagram for correct installation of the wires.

PI–05854

–6–24–

2400 Series Loader Service Manual

INSTRUMENT PANEL (12000 Series)

A

Removal And Installation NOTE: Rear auxiliary control shown in figure’s, is optional.

Disconnect the negative (–) cable from the battery.

Remove the bolts from the wiring harness cover [A].

PI–09882

B

Remove the cover from the wiring harness [B].

PI–09883

Remove the rear auxiliary control handle knob (if so equipped) [C].

C

PI–09884

D

Remove the bolts from the top edge of the instrument panel [D].

PI–09885

–6–25–

2400 Series Loader Service Manual

INSTRUMENT PANEL (12000 Series) (Cont’d)

A

Remove the bolts along the bottom edge of the instrument panel [A].

PI–09886

B

Lift the instrument panel assembly up and out of the mounting frame [B].

If any of the lights and/or gauges are replaced, use the Electrical Wiring Diagram for correct installation of wires.

PI–09887

–6–26–

2400 Series Loader Service Manual

SIGNAL LIGHT CONTROL

A

Removal And Installation Disconnect the negative (–) cable from the battery.

Remove the mounting bolts from the signal light control box [A].

PI–09888

B

Remove this signal light control box from the steering column [B].

Disconnect the wiring harness from the signal lights and control lever [B].

PI–09889

–6–27–

2400 Series Loader Service Manual

–6–28–

2400 Series Loader Service Manual

ENGINE SERVICE Page Number AIR CLEANER HOUSING Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 BALANCER UNIT AND OIL PUMP Balancer Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Balancer Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Timing To Balancer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–44 7–42 7–42 7–45 7–43 7–43 7–42

CAMSHAFT Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40 CAMSHAFT GEAR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39 COOLANT RECOVERY TANK Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–14 CRANKSHAFT Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–35 CRANKSHAFT GEAR Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39 CYLINDER HEAD Cylinder Head Surface Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23 Installing The Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23 Removing The Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–23 CYLINDER LINERS Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–32

ENGINE SERVICE

ENGINE Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–20 ENGINE COMPRESSION Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–13 ENGINE FLYWHEEL Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21 ENGINE MUFFLER Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–22 FUEL FILTERS Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 Water Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3 TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE SPECIFICATIONS, SECTION 8) UNLESS OTHERWISE SPECIFIED. Continued On Next Page

–7––1–

2400 Series Loader Service Manual

ENGINE SERVICE (Cont’d)

Page Number

FUEL INJECTOR NOZZLES Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11 FUEL INJECTION PUMP Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–6 FUEL INJECTION PUMP GEAR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39 FUEL LIFT PUMP Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5 IDLER GEAR AND HUB Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–38 MAIN BEARINGS Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–34 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–33 PISTONS AND CONNECTING RODS Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–30 7–30 7–31 7–29

REAR MAIN OIL SEAL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36 RADIATOR AND OIL COOLER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–15 RADIATOR FAN Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–19 ROCKER ARMS Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–28 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–28 TIMING Checking Timing Mark On Injection Pump Flange . . . . . . . . . . . . . . . . . 7–10 Engine Timing To Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9 TIMING CASE Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–40 TIMING CASE COVER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–37 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 VALVES Checking Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing The Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing The Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reconditioning The Valves & Valve Seats . . . . . . . . . . . . . . . . . . . . . . . .

Removal Of The Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–27 7–26 7–25 7–27 7–25 7–25

VALVE CLEARANCE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2

–7–0–

2400 Series Loader Service Manual

ENGINE SERVICE TROUBLESHOOTING The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.

PROBLEM Slow cranking speed.

Engine will not start.

Difficult to start.

No power from engine.

Engine mis–firing.

Too much fuel consumption.

Black exhaust.

Blue/white exhaust.

Low oil pressure.

Engine knocking.

Engine running rough.

Vibration.

High oil pressure.

Overheating.

Too much crankcase pressure.

Poor compression.

Start and stop.

CAUSE 1, 2, 3, 4 2, 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 16, 17, 18, 19 , 20, 22, 30, 31, 32 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 23, 28, 30, 31, 32 8. 9. 10, 11, 12, 13, 14, 18, 19, 20, 21, 23, 24, 25, 26, 30, 31, 32 8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 24, 25, 27, 28, 29, 31 11, 13, 14, 18, 19, 20, 22, 23, 24, 26, 27, 28, 29, 31 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32 4, 11, 18, 19, 20, 24, 26, 30, 32, 33, 53 4, 34, 35, 36, 37, 38, 40, 41, 42, 55 9, 14, 16, 18, 19, 22, 25, 27, 28, 30, 32, 34, 43, 44, 56 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 25, 27, 28, 29, 32, 43, 56 13, 14, 20, 24, 25, 28, 29, 32, 43, 45, 46 4, 36, 39 11, 13, 14, 16, 18, 19, 23, 24, 43, 47, 48, 49, 50, 51, 54 25, 30, 32, 33, 43, 52 11, 19, 24, 27, 28, 30, 31, 32, 33, 44, 56 10, 11, 12

KEY TO CORRECT THE CAUSE 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

Battery capacity low.

Bad electrical connections.

Faulty starter motor.

Incorrect grade of oil.

Low cranking speed.

Fuel tank empty.

Faulty stop control operation.

Plugged fuel line.

Faulty fuel lift pump.

Plugged fuel filter.

Restriction in air cleaner.

Air in fuel system.

Faulty fuel injection pump.

Faulty fuel injectors.

Incorrect use of ether start unit.

Faulty ether start unit.

Broken fuel injection pump drive.

Incorrect injection pump timing.

Incorrect valve timing.

Poor compression.

Plugged fuel tank vent.

Incorrect type or grade of fuel.

Exhaust pipe restriction.

Cylinder head gasket leaking.

Overheating.

Cold running.

Incorrect tappet adjustment.

Sticking valves.

29. Incorrect high pressure fuel pipes.

30. Worn cylinder bores.

31. Worn valves and seats.

32. Broken or worn piston rings.

33. Worn valve stems or guides.

34. Worn or damaged bearings.

35. Not enough oil in the oil pan.

36. Switch is defective.

37. Oil pump worn.

38. Relief valve is sticking open.

39. Relief valve is sticking closed.

40. Broken relief valve spring.

41. Faulty suction pipe.

42. Plugged oil filter.

43. Piston seizure.

44. Incorrect piston height.

45. Faulty engine mounting.

46. Incorrect alignment of flywheel.

47. Faulty thermostat.

48. Restriction in the water jacket.

49. Loose alternator belt.

50. Plugged radiator.

51. Faulty water pump.

52. Plugged breather pipe.

53. Damaged valve stem oil deflectors.

54. Coolant level too low.

55. Plugged oil pump pipe strainer.

56. Broken valve spring.

–7–1–

2400 Series Loader Service Manual

VALVE CLEARANCE

A

Adjustment Make the valve clearance adjustment with engine stopped and cold.

Put the correct size feeler gauge between the rocker arm and the valve stem. Turn the adjustment bolt until the clearance is correct [A].

B–03302

B

The correct clearance is 0.012 inch (0,30 mm) with the engine cold [B].

0.012 in. (0,30 mm) Cold

Use the following sequence to set the valve clearance: 1. With the rocker arms rocking on No. 4, set clearance at No. 1 valves.

2. With the rocker arms rocking on No. 2, set clearance at No. 3 valves.

3. With the rocker arms rocking on No. 1, set clearance at No. 4 valves.

4. With the rocker arms rocking on No. 3, set clearance at No. 2 valves.

PI–02596

C

AIR CLEANER HOUSING Removal And Installation Clean the area around the air cleaner housing and hoses.

Loosen both hose clamps [C].

Disconnect the hoses from the air cleaner housing.

PI–05886

Remove the air cleaner assembly from the brackets [D].

D

PI–05887

–7–2–

2400 Series Loader Service Manual

FUEL FILTERS

A

Water Trap See the SERVICE SCHEDULE Page 1–1 for the correct service interval.

Loosen the thumb screw at the bottom of the filter bowl and drain the water from the filter [A].

Tighten the thumb screw when all the water is removed.

Removal And Installation See the SERVICE SCHEDULE Page 1–1 for the correct service interval.

PI–05356

Clean the area around the filter.

B

Loosen the thumb screw to drain the fuel from the filter bowl [A].

Remove the bolt from the top of the filter housing [B].

PI–05357

C

Remove the filter bowl [C].

Remove the filter element [D].

Installation: installation.

Lubricate

the

new

O–ring

PI–05358

before

D

Remove the air from the fuel system. (See Page 7–4.)

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285 PI–05359

–7–3–

2400 Series Loader Service Manual

FUEL FILTERS (Cont’d)

A

Removing Air From The Fuel System

1

2

After replacing the final fuel filter or when the fuel tank has run out of fuel, the air must be removed from the fuel system.

1. Loosen the inlet fuel line (Item 1) [A] from the fuel injection pump.

3

PI–05360

2. Open the left rear access door. Operate the fuel lift pump lever [B]. Operate the lift pump until the fuel coming out of the inlet fuel line (at the injection pump) does not have any air bubbles. Tighten the inlet fuel line.

B

3. Open the top plug (Item 2) [A] and side plug (Item 3) [A] at the injection pump.

4. Operate the fuel lift pump lever [B]. When fuel flows with no air bubbles showing, tighten the vent plugs in the following order: a. Injection pump side plug (Item 3) [A]. b. Injection pump top plug (Item 2) [A].

PI–05361

5. Loosen the four fittings (Item 1) [C] at the fuel injectors.

C

6. Move the throttle to 1/2 open position. Turn the engine with the starter until no air bubbles show at the fittings.

7. Tighten all the high pressure fittings at the fuel injectors.

1

PI–05363

–7–4–

2400 Series Loader Service Manual

FUEL LIFT PUMP

A

Checking Disconnect the fuel shut–off wire from the fuel injection pump.

Install a gauge on the outlet side of the lift pump. Turn the engine, with the starter for 10 seconds.

STANDARD PRESSURE – 6 PSI (41 kPa) MINIMUM PRESSURE ACCEPTED – 3.75 PSI (26 kPa) Connect the shut–off wire.

B–12250

Removal And Installation

B

Disconnect the fuel in–let hose from the lift pump [A].

Disconnect the fuel line going to the fuel filter [B].

B–12249

C

Remove the four nuts which fasten the fuel lift pump to the engine block [C].

Remove the lift pump.

B–12251

–7–5–

2400 Series Loader Service Manual

FUEL INJECTION PUMP

A

The injection pump contains parts which have a very close tolerance and its operation has a direct effect on the performance of the engine.

Do not attempt to maintain or adjust unless you are trained and have the correct equipment.

I–2028–0289

B–07658

Removal And Installation

B

Disconnect the throttle linkage.

Disconnect the wires from the fuel shut–off solenoid [A].

Disconnect the high pressure line from injection pump [B].

B–07698

Do not bend the high pressure fuel injection tubes when removing or installing them.

I–2029–0289

C

Disconnect the high pressure tubelines from the fuel injectors [C].

Remove all the high pressure tubelines.

Installation: Tighten the high pressure fittings to 15 ft.–lbs. (20 Nm) torque.

B–12241

Disconnect the low pressure tubelines from the fuel filter and injection pump [D].

D

B–07699

–7–6–

2400 Series Loader Service Manual

FUEL INJECTION PUMP (Cont’d)

A

Removal And Installation (Cont’d) Disconnect the return tubeline from the injector pump [A].

B–07700

B

Remove the bolts from the timing case cover [B].

B–07701

C

Remove the cover [C].

B–07702

Remove the three bolts from the gear from the injection pump [D].

D

Installation: Make sure the injection pump shaft is in correct alignment with the dowel pin.

B–07703

–7–7–

2400 Series Loader Service Manual

FUEL INJECTION PUMP (Cont’d)

A

Removal And Installation (Cont’d) Remove the mounting nuts and washers [A].

Installation: Before tightening the nuts, make sure the timing marks are in correct alignment.

B–07704

B

Remove the injection pump [B].

Installation: After the injection pump is installed, the air must be removed from the fuel system. (See Page 7–4.)

B–07830

–7–8–

2400 Series Loader Service Manual

TIMING

A

Engine Timing To Injection Pump The tool listed will be needed to do the following procedure: MEL1056 – Timing Tool Remove the valve cover. Turn the engine crankshaft until No. 1 cylinder is at TDC, compression stroke (both rocker arms are moving at No. 4 cylinder).

1

Align the TDC bolt (Item 1) [A] with the notch in the pulley.

Remove the fuel injection pump. (See Page 7–6.)

B–07628

ENGINE AND INJECTION PUMP TIMING MARKS Injection Pump Code

Engine Checking

Injection Pump Marking Angle

Static Timing (BTDC– Degrees)

RT

282

292

22

B

1

Loosen the screw (Item 1) [B] on the timing tool.

Set the correct angle at the gauge according to the chart.

B–08069

Install the adapter into the gear [C].

C

Make sure the dowel pin is in correct alignment. Install the three bolts and tighten.

Move the plate (with V–notch) over engine mounting flange [D].

Turn the timing tool in opposite direction of engine rotation to remove any gear play.

B–07838

The engine flange timing mark must be in alignment in the notch on the timing tool plate.

D

NOTE: If the marks are 180° apart, the No. 1 cylinder is not at TDC.

Make sure to turn the TDC bolt out of the front pulley after timing procedure is done.

B–07839

I–2079–0995

–7–9–

2400 Series Loader Service Manual

TIMING (Cont’d)

A

Checking Timing Mark On Injection Pump Flange Loosen the screw (Item 1) [A] and install the shaft (Item 2) [A] into the timing tool.

3

4 1

Loosen the screw (Item 3) [A] and turn the plate in the opposite direction.

2

Loosen the screw (Item 4) [A] and set the gauge to the correct angle according to Injection Pump Chart. (See Page 7–9.)

Install the timing tool on the injection pump.

B–08070

B

Locate and mark No. 1 port at the injection pump.

Connect a test pump to the No. 1 port [B].

Operate the test pump until the pressure is about 440 PSI (3033 kPa) maximum.

Turn the tool in the normal rotation of the pump. When the pump reaches No. 1 port there will be resistance or it will not turn.

B–07842

C

Move the plate over the mounting flange [C].

NOTE: The mark on the mounting flange is put on at the factory. The mark should be correct. If it is not, you must grind the old mark off and make a new mark for correct injection pump timing.

B–07847

–7–10–

2400 Series Loader Service Manual

FUEL INJECTOR NOZZLES

A

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

B–12241

W–2072–0496

B

Some problems caused by faulty injector nozzles: D D D D

The engine is hard to start or will not start.

Rough engine operation and idle.

The engine will not have full power.

The engine exhaust smoke is black, white or blue.

Removal And Installation Remove the high pressure tubelines [A].

B–12242

C Do not bend the high pressure fuel injection tubes when removing or installing them.

I–2029–0289

Remove the fuel return tubelines [B].

Remove the nuts from the mounting flange [C].

Installation: Tighten the nuts to 12 ft.–lbs. (16 Nm) torque.

B–12240

D

Remove the fuel injector nozzle from the cylinder head [D].

B–12243

–7–11–

2400 Series Loader Service Manual

FUEL INJECTOR NOZZLES (Cont’d)

A

Removal And Installation (Cont’d)

1

When installing the fuel injector nozzles always replace the copper washer (Item 1) [A] with a new copper washer.

B–07915

Checking

B Do not disassemble or test the fuel injector nozzles unless you have the correct service and testing tools.

I–2027–0284

The tools listed will be needed to do the following procedure: MEL10018 – Injection Nozzle Tester MEL10019 – Accessory Set

A–02513

Connect the nozzle to a test pump, in a down position [B].

C

Operate the test pump until the nozzle valve opens:

WRONG

CORRECT

SETTING PRESSURE – 2572 PSI (17734 kPa) WORKING PRESSURE – 2498 PSI (17223 kPa) If the pressure is not correct, replace or clean the nozzle.

Check for inside leakage as follows: Operate the test pump to almost opening pressure.

Record the pressure, and check pressure decrease for six seconds. The nozzle has a defect if the pressure decreases more than 740 PSI (5162 kPa).

B–13330

Checking nozzle spray pattern [C].

D Does not come out the side of nozzle.

D Does not have drops coming from nozzle.

D Does not have a solid stream coming from the nozzle.

Any of the above conditions show a defect or dirty injector nozzle. Clean or replace any injector nozzle that does not operate correctly.

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

W–2072–0496

Revised Aug. 90

–7–12–

2400 Series Loader Service Manual

ENGINE COMPRESSION

A

Checking The tool listed will be needed to do the following procedure: MEL10630 – Engine Compression Kit The engine must be at operating temperature.

Engage the parking brake.

Install steering frame lock. (See Page 1–4.)

Remove the fuel injectors. (See Page 7–11.)

B–12246

Install the correct compression adapter into the cylinder head [A].

B

Connect the compression gauge [B].

The engine must be turning about 300–350 RPM. The compression must be 300–500 PSI (2069–3448 kPa) with no more than 50 PSI (345 kPa) difference between the cylinders.

B–12247

–7–13–

2400 Series Loader Service Manual

COOLANT RECOVERY TANK

A

Removal And Installation Remove the hydraulic control valve. (See Page 2–14 or 2–19.)

Disconnect the hose from the filler neck that goes to the bottom of the recovery tank [A].

PI–05855

B

Remove the bolt from the recovery tank mounting strap [B].

PI–05856

C

Remove the mounting strap [C].

PI–05857

Remove the coolant recovery tank [D].

D

PI–05858

–7–14–

2400 Series Loader Service Manual

RADIATOR AND OIL COOLER

A

Removal And Installation

Do not remove radiator cap when the engine is hot. You can be seriously burned.

W–2070–1285

PI–09406

Remove the radiator cap [A].

B

Remove the plug from the bottom of the radiator and drain the coolant into a container [B].

PI–05370

C

Open the drain plug (Item 1) [C] at the engine block to drain the coolant from the engine.

Installation: Mix the coolant in a separate container.

(See SPECIFICATIONS, Section 8 for correct capacity.)

Protect the cooling system by adding pre–mixed 50% ethylene glycol and 50% water to the system. This mixture will protect the cooling system to –34°F (–36°C).

1

Remove the hydraulic control valve. (See Page 2–14 or 2–19.)

Remove the coolant recovery tank. (See Page 7–14.)

Remove the radiator side screen.

PI–09548

D

Loosen the clamp and remove the radiator hoses from the water pump [D].

PI–05859

–7–15–

2400 Series Loader Service Manual

RADIATOR AND OIL COOLER (Cont’d)

A

Removal And Installation (Cont’d) Loosen the two hose clamps and remove the top radiator hose [A].

PI–05860

B

Loosen the clamp and disconnect the lower radiator hose [B].

At the tee fitting (Item 1) [B] disconnect the tubelines from the bottom of the oil cooler [B].

1

PI–05861

C

Remove the bolts from the fan shroud [C].

PI–05862

Remove the two mounting bolts from the bottom of the radiator and oil cooler assembly [D].

D

PI–05863

–7–16–

2400 Series Loader Service Manual

RADIATOR AND OIL COOLER (Cont’d)

A

Removal And Installation (Cont’d) Lift the radiator and oil cooler assembly up a small amount and off the mounting track [A].

Slide the assembly out the rear access door.

PI–05864

B

Remove the top oil cooler mounting bolts [B].

PI–05865

C

Remove the bottom oil cooler mounting bolts [C].

PI–05866

Remove the oil cooler from the mounting bracket and out of the loader [D].

D

PI–05867

–7–17–

2400 Series Loader Service Manual

RADIATOR AND OIL COOLER (Cont’d)

A

Removal And Installation (Cont’d) Remove the bolts from the mounting bracket for the oil cooler [A].

PI–05868

B

Remove the mounting bracket for the oil cooler from the radiator and remove the mounting bracket from the loader [B].

PI–05869

Remove the radiator from the loader [C].

C

PI–05870

–7–18–

2400 Series Loader Service Manual

RADIATOR FAN

A

Removal And Installation Remove the radiator and oil cooler. (See Page 7–15.)

Remove the shrouding from around the fan [A].

PI–05871

B

Remove the bolts from the fan hub [B].

Installation: Tighten the bolts to 15–18 ft.–lbs. (20–23 Nm) torque.

PI–05872

C

Remove the fan hub [C].

PI–05873

Remove the fan from the engine pulley hub [D].

D

PI–05874

–7–19–

2400 Series Loader Service Manual

ENGINE

A

Removal And Installation Remove the engine hood. (See Page 5–6.)

Remove the battery. (See Page 6–6.)

Drain the fluid from the hydraulic reservoir.

Remove the hydraulic control valve. (See Page 2–14 or 2–19.)

Remove the hydrostatic motor. (See Page 3–3.)

NOTE: The engine and hydrostatic pump are removed as an assembly from the loader.

PI–05875

Remove the radiator and oil cooler. (See Page 7–15.)

B

Disconnect the hose from the port block for the hydraulic reservoir [A].

Disconnect any other hoses or tubelines from the port block that will not be removed with the engine and hydrostatic pump assembly.

Disconnect the control cable from the hydrostatic pump [B].

PI–05876

Disconnect the throttle linkage from the fuel injection pump [C].

C

Disconnect all the fuel lines from the final fuel filter.

PI–05877

D

Disconnect the exhaust pipe from the muffler and exhaust manifold [D].

Remove the exhaust pipe.

PI–05878

–7–20–

2400 Series Loader Service Manual

ENGINE (Cont’d)

A

Removal And Installation (Cont’d) Pull all the control cables out from under the engine to the rear of the engine.

Remove the floor panel in the operator cab. (See Page 5–1.)

Remove the seat and seat mounting frame. (See Page 5–4.)

Disconnect the engine wiring harness.

Disconnect the wire from the power relay [A].

PI–05879

B

Remove the four mounting bolts for the engine [B].

PI–05880

C

Connect a chain hoist to the engine lift hooks [C].

Lift the engine a small amount and slide it forward [D].

Remove the engine and hydrostatic pump assembly from the loader.

ENGINE FLYWHEEL Removal And Installation Remove the flywheel from the crankshaft flange.

PI–05881

Installation: Clean the crankshaft flange of any burrs.

Tighten the bolts to 80 ft.–lbs. (108 Nm) torque.

D

Flywheel Ring Gear The ring gear on the flywheel is an interference fit. Heat the ring gear enough to expand it and hit it with a hammer, evenly, to remove it.

Clean the outer surface of the flywheel to give a smooth fit. Clean the new ring gear and heat it to a temperature of 450–500°F (232–260°C).

Fit the ring gear over the flywheel. Make sure the gear is on its seat correctly.

PI–05882

–7–21–

2400 Series Loader Service Manual

ENGINE MUFFLER

A

Removal And Installation Remove the engine hood. (See Page 5–6.)

Remove the exhaust pipe from the muffler [A].

PI–05883

B

Disconnect the exhaust pipe from the bottom of the muffler [B].

PI–05878

C

Remove the bolts from the top cover. Remove the top cover from the muffler [C].

Remove the four bolts which fasten the muffler to the loader frame.

Remove the plug from the front of the muffler.

PI–05884

Remove the muffler from the loader [D].

D

PI–05885

–7–22–

2400 Series Loader Service Manual

CYLINDER HEAD

A

Removing The Cylinder Head

Maximum Grinding Allowance 0.012” (0,305 mm)

Clean all around the engine block and cylinder head.

Remove the fuel injectors and high pressure fuel lines.

(See Page 7–11.)

Remove the fuel filter and mounting bracket.

0.003” (0,08 mm)

Remove the valve cover.

Remove the nuts from the support brackets of the rocker arms. Remove the rocker arms. Remove the push rods.

0.006” (0,15 mm)

0.006” (0,15 mm)

4.036” (102,5 mm) Minimum After Grinding PI–02633

Loosen and remove the cylinder head bolts.

NOTE: When removing the head, do not use a sharp tool between the head and engine block.

Always put the cylinder head on a flat surface such as wood to prevent damage to the machined surface.

Remove the head from the engine block.

See Page 7–25 for removing and reconditioning the valves.

Cylinder Head Surface Alignment Check the surface of the head with a straight edge [A].

The maximum of 0.012 inch (0,31 mm) can be removed from the surface. After milling the head, install a fuel injector nozzle. The nozzle must not extend more than 0.175 inch (4,45 mm) beyond the surface. Replace the cylinder head if this dimension is over the limit.

DO NOT add washers under injector nozzles to bring them back into specifications.

I–2080–0995

Installing The Cylinder Head

B

Install a new head gasket. Install it dry, no gasket cement is needed.

When the new head gasket is installed, make sure it is positioned correctly over the dowel pins and the markings TOP and FRONT are located correctly [B].

B–03207

–7–23–

2400 Series Loader Service Manual

CYLINDER HEAD (Cont’d)

A

Installing The Cylinder Head (Cont’d)

11

Put oil on the threads of the head bolts.

4

6

13 21

18

Install the head bolts.

Tighten the bolts in the correct sequence [A].

17

Do this in a three step procedure to 100 ft.–lbs. (136 Nm) torque, as follows: Example: First tighten all bolts to 30 ft.–lbs. (41 Nm) torque, then 65 ft.–lbs. (88 Nm) torque and then 100 ft.–lbs. (136 Nm) torque.

19 15

9

1

8

12

2

14

7

5

3

10

20

16

22 B–01472

NOTE: To reduce the risk of cylinder head gasket failure, it is recommended that after a cylinder head has been fitted, the loader be operated at partial load for about 1/2 hour before the cylinder head bolts are tightened again. It is not a good practice just to run the engine without load to make it warm.

B

Install the rubber seal in the counter–bore of the head for the rocker arms [B].

Pipe

Install the rocker arms and tighten the nuts.

Seal

Adjust the valve clearance. (See Page 7–2).

Install the fuel injector and fuel high pressure lines.

Install the fuel filter and bracket.

A–02455

Install the radiator hoses.

Add pre–mixed coolant to the radiator.

–7–24–

2400 Series Loader Service Manual

VALVES

A

Removal Of The Valves Mark the valves so they will be installed in their original position [A].

A–01767

B

Use a valve spring compressor and remove the valve spring locks [B].

Repeat this procedure for each valve.

B–03303

Installing The Valves

C

Make sure the cylinder head is clean.

Put oil on the valve guides and valve stems.

Put each valve in its correct location.

Spring Seat Exhaust Valve

Outer Inner Spring Spring

Spring Cup Locks

Assemble the valve springs and cups [C].

The intake valves are fitted with a rubber seal.

Use the valve spring compressor and install the valve spring locks [B].

Intake Valve

Tap the valve stem with a hammer a small amount to seat the valve stem locks.

Outer Spring

Seal Inner Locks Spring Spring Cup B–03355

Reconditioning The Valve And Valve Seats

D

Use the correct equipment to grind the valve and valve seat.

The angle of the intake and exhaust valves is 45°.

Check the valve head depth in the cylinder after grinding [D].

The correct specifications are as follows: Intake . . . . . . . . . . . . . . . . 0.035–0.045” (0,89–1,14 mm) Exhaust . . . . . . . . . . . . . . 0.042–0.052” (1,07–1,32 mm) A–01653

–7–25–

2400 Series Loader Service Manual

VALVES (Cont’d)

A

Installing Valve Guides Check the valve guides for wear with a dial indicator [A].

If the movement is more than the listed specifications, replace the guide.

Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005” (0,13 mm) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 0.006” (0,15 mm)

B–03215

B

NOTE: Make sure to check the valve stem for wear before replacing the valve guide [B].

INT. 0.0015/0.0035” (0,038/0,089 mm) EXH. 0.0225/0.004” (0,057/0,10 mm)

0.625” (15,88 mm)

0.375/0.376” (9,53/9,55 mm)

INT. 0.3725/0.3735” (9,46/9,49 mm) EXH. 0.375/0.376” (9,53/9,55 mm)

INT. 4.831/4.847” (122,7/123,1 mm) EXH. 4.847/4.863” (123,1/123,5 mm)

PI–02634

C

Remove the guide with a hydraulic press or hand operated tool [C].

Remove any metal burrs from the bore in the head before installing the new valve guides.

B–01887

D

Put oil in the bore and press in the new guide [D].

NOTE: Once the guide is started into the bore, do not stop until the guide is seated.

Press the guide into the head until it is 0.625 inch (15,88 mm) above the cylinder head.

B–01863

–7–26–

2400 Series Loader Service Manual

VALVES (Cont’d)

A

A

Installing The Valve Seats

B

Before replacing the valve seats, install new valve guides.

INTAKE A – 0.283/0.288” (7,19/7,31 mm) B – 2.0165/2.0175” (51,22/51,24 mm) C – Radius 0.015” (0,38 mm) Max.

Using the valve guide bore as a pilot, machine the recess into the cylinder head as the dimensions show in figure [A].

Make sure to make the correct reference to the intake or exhaust valve seats.

C

EXHAUST A – 0.375/0.380” (9,52/9,65 mm) B – 1.678/1.679” (42,62/42,65 mm) C – Radius 0.015” (0,38 mm) Max.

B

Clean the grit from the insert groove.

Use the correct insert tool [B].

A B C D

Press the insert into the head until it is all the way in and is even with the bottom of the groove.

E

NOTE: DO NOT use a hammer to hit the insert for installation.

F G H J K

INTAKE

EXHAUST

0.0625” (1,59 MM) @ 45° 0.750” (19,05 mm) 0.250” (6,35 mm) 3.0” (76,20 mm) 1.582/1.583” (40,18/40,21 mm) 2.009/2.019” (51,03/51,28 mm) 0.03125” (0,79 mm) Rad. 0.0625” (1,59 mm) Rad. 0.0625” (1,59 mm) @ 45° 0.372/0.373” (9,45/9,47 mm)

0.0625” (1,59 mm) @ 45° 0.750” (19,05 mm) 0.312” (7,92 mm) 3.0” (76,20 mm) 1.248/1.249” (31,70/31,72 mm) 1.670/1.680” (42,42/42,67) mm 0.03125” (0,79 mm) Rad. 0.0625” (1,59 mm) Rad. 0.0625” (1,59 mm) @ 45° 0.372/0.373” (9,45/9,47 mm)

F

A

E

B

D

C

G

H J K

B–02627

C

Grind the new insert as the dimensions show in figure [C].

B–02626

0.094 (2,39 mm) 0.099 (2,51 mm)

NOTE: Make sure the valve seat is at an included angle of 90° so the valve head depth below the head surface is within 0.042–0.052 inch (1,07–1,32 mm).

30° 45°

If the cylinder head surface has been machined, do the following: Machine the insert groove.

Machine the back of the insert to remove material to give an even fit. Make sure to chamfer the insert to 0.020–0.030 inch (0,51–0,76 mm) at 45°.

Showing Flare To Be Cut at 30° For Exhaust Valve

D

Checking The Valve Springs The valve springs for the intake and exhaust valves are the same. Check the spring ends for damage and check the specifications [D].

A–02457

15.4 lbs. ± 1.0 lbs.

(17 kg ± 0,45 kg)

1.625” (39,69 mm)

40 lbs. ± 2.0 lbs.

(18,1 kg ± 0,91 kg)

Valve Spring Inner 1.780” (45,21 mm) Valve Spring Outer PI–02635

–7–27–

2400 Series Loader Service Manual

ROCKER ARMS

A

Disassembly

2

Mark the rocker arm and support brackets for correct assembly.

5

Remove the snap rings (Item 1) [A] from each end of the shaft (Item 2) [A].

Inset

4

Remove the rocker (Item 3) [A], bracket (Item 4) [A] and spring (Item 5) [A].

4

1 3

C–02638 A–02448

B

Inspect the rocker arm bushings and shaft for wear [B].

Replace the parts as needed.

0.875/0.8762” (22,23/22,26 mm)

0.0008/0.0035” (0,02/0,09 mm) 0.877/0.875” (22,28/ 22,31 mm) 0.001/0.0035” (0,03/0,09 mm)

0.7505/0.752” (19,06/19,10 mm)

0.7485/0.7495” (19,01/19,04 mm) PI–02636

Assembly

C

When installing new bushings in the rocker arm, make sure the oil holes are in correct alignment [C].

Align Oil Feed Holes

Reverse the order of disassembly and make sure that each set of rocker arm pairs has the correct off–set.

Put oil on all the parts for protection.

A–02352

–7–28–

2400 Series Loader Service Manual

PISTON AND CONNECTING RODS

A

Removal Remove the cylinder head. (See Page 7–23.)

Remove the oil pan and balancer unit. (See Page 7–42.)

Remove the ridge and carbon deposits at the top of the cylinder bore with a ridge reamer.

Make sure the pistons have identification marks [A].

B–03248

B

Rotate the crankshaft until a pair of connecting rods are at bottom dead center. Make sure the cap and rod have identification marks [B].

B–03295

C

Remove the nuts and remove the bearing cap [C].

NOTE: If the bearings are to be used again, they must be identified so they are returned to their original location.

A–02344

D

Use a hammer handle, push the piston and rod out of the block [D].

After the pair has been removed, rotate the engine crankshaft and remove the other pair of pistons.

A–01651

–7–29–

2400 Series Loader Service Manual

PISTON AND CONNECTING RODS (Cont’d)

A

Disassembly

0.0019/0.0039” (0,05/0,10 mm)

0.0928/0.0938” (2,36/2,38 mm) 0.0957/0.096” (2,43/2,44 mm)

Transition Fit

0.0019/0.0039” (0,05/0,10 mm) 0.0928/0.0938” (2,36/2,38 mm) 0.0957/0.0967” (2,43/2,44 mm) 0.0928/0.0938” (2,36/2,38 mm) 0.0019/0.0039” (0,05/0,10 mm) 0.2525/0.2535” (6,41/6,44 mm)

Remove the rings from the piston.

Remove the piston pin.

1.343/1.375” (34,92/34,93 mm)

NOTE: If the piston pin does not come out easily, do not drive it out. Warm the piston in clean oil to a temperature of 120°F (50°C) and push the pin out.

1.37485/1.37505” (34,92/34,93 mm)

0.0025/0.0045” (0,06/0,11 mm)

0.249/0.250” (6,32/6,35 mm) 0.0025/0.0045” (0,06/0,11 mm)

0.2525/0.2535” (6,41/6,44 mm)

Inspection 0.249/0.250” (6,32/6,35 mm)

Clean all the parts in clean solvent.

Check the clearance of the new rings in the piston grooves [A].

PI–02637

B

Check the ring gap in the cylinder bore [B].

B–03334

C

Make sure the specifications are correct [C].

0.016/0.034” (0,41/0,86 mm) 0.012/0.030” (0,30/0,76 mm)

0.030” (0,76 mm)

0.012/0.030” (0,30/0,76 mm)

0.001” (0,025 mm)

0.012/0.030” (0,30/0,76 mm) 0.012/0.030” (0,30/0,76 mm)

PI–02638

Check the piston and pin bushing [D].

D

Replace the bushings with a hydraulic press. Remove all metal burrs from the piston bore before installing the new bushing.

1.535/1.5365” (38,99/39,03 mm)

1.5313/1.5323” (38,90/38,92 mm)

Transition

0.00075/0.0017” (0,02/0,04 mm)

Use the correct size reamer to fit the new bushing to the piston pin.

1.326/1.336” (33,68/33,93 mm) 1.359/1.363” (34,52/34,62 mm) Before Reaming 1.3758/1.3765” (34,95/34,96 mm) After Reaming

PI–02639

–7–30–

2400 Series Loader Service Manual

PISTON AND CONNECTING RODS (Cont’d)

A

Check the connecting rod alignment [A].

5.0” (127 mm)

Installation Install the piston pin by putting the piston in clean oil at a temperature of 120°F (50°C). ±0.010” (±0,254 mm)

Make sure the identification marks are located correctly at the rod and piston.

±0.010” (±0,254 mm)

Install a new snap ring on each side of the piston pin.

PI–02375

B

Install the piston rings using an expanding tool to prevent the ring from breaking [B].

B–01868

C

NOTE: When fitting internally stepped compression rings, make sure that the step is toward the piston crown [C].

Second & Third Segments Piston Crown

Put oil on the rings so they move freely in the piston grooves.

Position the ring gaps un–evenly around the piston.

NOTE: Before the pistons are installed, check the cylinder bores.

Rotate the crankshaft until a pair of crank pins are at bottom dead center.

First Segments

B–08086

D

Using a ring compressor tool, compress the rings on the piston. Make sure the F is to the front of the engine block and install the piston into the block [D].

B–03337

–7–31–

2400 Series Loader Service Manual

PISTON AND CONNECTING RODS (Cont’d)

A

Installation (Cont’d) Put oil on the bearings. Install the bearing cap [A].

B–03208

Tighten the nuts on the connecting rod [B].

Rotate the crankshaft to put the other pair of crank pins at bottom dead center. Repeat the procedure and install the other pair of pistons.

B

CYLINDER LINERS Inspection The cylinder liners are of cast alloy iron and are interference fit to the block.

Check the cylinder bore with an inside micrometer. Check the bore at three positions (top, center & bottom). The checks must be made at parallel and right angles to the center line of the bore, giving six dimensions for each bore.

75 ft.–lbs.

(102 Nm) B–03325

The standard bore is 3.877–3.879 inch (98,48–98,53 mm). When the bore is 0.008 inch (0,2 mm) over standard the liner can be bored to 0.030 inch (0,76 mm) oversize.

If the bore wear is over 0.030 inch (0,76 mm), replace the cylinder liner.

Removal Remove all the parts from the engine. Press the cylinder liners out from the bottom of the engine block.

Installation Clean the bore and remove any metal burrs. Clean the grease from the liner and dry it.

Put LOCTITE about 1.0 inch (25,4 mm) below the upper part of the cylinder block bore.

C

Push the liner in until 0.00 inch ± 0.004 inch (± 0,10 mm) of the liner is above the block face [C].

Shims can be used to give the correct dimensions.

Bore and hone the liners to the correct dimensions.

STANDARD – 3.877–3.879 inch (98,48–98,53 mm) NOTE: When using a boring bar on the top face of the engine block, install a parallel plate between the boring bar and engine face.

B–03249

–7–32–

2400 Series Loader Service Manual

MAIN BEARINGS

A

Removal The crankshaft has five main bearings. The end play is controlled by a thrust washer on both sides of the center main bearing.

Each main bearing cap has identification marks in relation to the engine block [A].

The position of each cap can not be changed from the original location.

Remove the oil pan.

A–01723

Remove the balancer and oil pump assembly. (See Page 7–42.)

B

Remove the bolts from the main bearing caps.

Remove the main bearing cap and remove the bearing from the cap half.

Remove the top half of the bearing by pushing on one side of the bearing half and rotating the crankshaft [B].

B–01865

C

On the center main bearing, remove the cap and thrust washers from each side of the cap [C].

B–03308

Remove the top half of the bearing and thrust washer by pushing on one side of the bearing and rotating the crankshaft [D].

D

B–03289

–7–33–

2400 Series Loader Service Manual

MAIN BEARINGS (Cont’d)

A

Installation Check the crankshaft journals before installing the main bearings. (See Page 7–35.)

Lubricate the new bearings. Install them by putting the end without the tab into the block and rotating the engine crankshaft until the tab is on its seat.

Install the other bearing half in the main bearing cap.

Lubricate the bearing and install it on the engine block.

180 ft.–lbs.

(244 Nm)

Install the bolts and tighten to position the cap, then loosen them.

B–03345

Install the center main bearing and thrust washer.

B

Install the center main bearing into the cap. Install the bolts and tighten to position the cap, then loosen the bolts.

Repeat the procedure until all the main bearings are installed.

Tighten the main bearing cap bolts to the correct torque [A].

Crankshaft End Play The end play can be checked by either a feeler gauge or a dial indication [B] & [C].

The maximum end play is 0.014 inch (0,36 mm). The fitting of oversize thrust washers can be used to correct the end play if it is over specifications.

B–03347

C

B–03291

–7–34–

2400 Series Loader Service Manual

A

PI–02640

CRANKSHAFT Removal Remove the oil pan. Remove the balancer and oil pump assembly. (See Page 7–42.)

Remove the crankshaft pulley, timing case cover, timing gears and timing cover. (See Page 7–37.)

Remove the flywheel.

Remove the rear main seal. (See Page 7–36.)

Remove the connecting rod caps. (See Page 7–29.)

Remove the main bearing caps. (See Page 7–33.)

Lift the crankshaft out of the engine block for inspection.

Checking Use a micrometer, check the crankshaft for the correct dimensions as shown in figure [A].

NOTE: You can grind the crankshaft to 0.010 inch (0,25 mm), 0.020 inch (0,51 mm) and 0.030 inch (0,76 mm) undersize.

(See SPECIFICATIONS Section 8 for the correct dimensions.)

–7–35–

2400 Series Loader Service Manual

CRANKSHAFT (Cont’d)

A

Installation Clean the crankshaft and check that all the oil passages are clean and open. Clean the engine, lubricate and install the upper halves of the main bearings.

NOTE: If you do not install new bearing, always return the old bearings back to their original position.

Put the crankshaft, carefully, into position. Install the main bearing caps. (See Page 7–34.)

Install the rear main oil seal. Install the rear main bridge [A].

A–01658

The rear face of the bridge must be flush with the rear face of the engine block [A].

Lubricate the connecting rod bearings. Install the rod caps. (See Page 7–31.)

Install the balancer and oil pump assembly. (See Page 7–42.) Install the oil pan.

Install the timing case, timing gears, timing case cover and crankshaft pulley. (See Page 7–37.)

Install the flywheel.

REAR MAIN OIL SEAL

B

Removal And Installation The crankshaft is fitted with a lip type oil seal and has a mounting flange with an extended width to provide a seat for the seal. This seal is easily damaged and you must be careful not to damage it. Any visual damage across the lip of the seal will cause leakage.

0.250” (6,4 mm) 0.125” (3,2 mm)

When installing a new seal, check the crankshaft flange, and if it is found to be grooved, the seal must be pressed further into the housing [B]. Lubricate both the seal and the housing when installing the seal.

B–08085

–7–36–

2400 Series Loader Service Manual

TIMING CASE COVER

A

Removal And Installation Remove the alternator and belt. (See Page 6–10.)

Remove the crankshaft pulley bolt and washer. Remove the pulley from the crankshaft.

Remove the bolts and nuts from the cover.

Remove the timing case cover from the engine.

Clean the timing case cover and timing case back plate.

Remove the front seat from the cover by pushing it out through the front of the cover.

B–03230

Put a new seal in position so the rubber seal goes toward the inside of the cover.

B

Press the new seal in from the front until it is seated below the front edge of the cover [A].

0.380/0.390” (9,7/9,9 mm)

Make sure it is seated at the correct specification [B].

Put a new gasket on the cover. Install the cover, be careful not to damage the front seal.

Install the bolts and nuts and finger tighten.

Install the crankshaft pulley to center the front seal on the pulley hub.

B–03194

Tighten the bolts and nuts. Remove the crankshaft pulley and tighten the bolts behind the pulley.

C

Install the crankshaft pulley with the mark on the pulley in alignment with the line on the front face of the crankshaft [C].

Alignment Marks

A–01704

Install the bolt and washer and tighten [D].

D

Install the alternator and belt. (See Page 6–10.)

70 ft.–lbs.

(95 Nm)

B–11423

–7–37–

2400 Series Loader Service Manual

IDLER GEAR AND HUB

A

Removal And Installation Remove the timing case cover. (See Page 7–37.)

1.187/1.188” 1.996/1.998” (30,15/30,17 mm) (50,70/50,75 mm)

0.0023/0.0047” (0,06/0,12 mm)

Remove the nuts from the idler gear plate.

Remove the retainer plate.

Remove the idler gear.

Remove the idler gear hub.

1.998/2.0” (50,75/50,8 mm) 1.192/1.195” (30,28/30,35 mm)

Check the dimensions for the idler gear and hub [A].

Check the gear and hub for wear, cracks and pitting.

Where necessary, replace the idler gear bushing. When the bushing is replaced, it will be necessary to bore, to finish the bushing I.D. to fitted size.

0.004/0.008” (0,10/0,20 mm) PI–02641

B

Make sure the oil passage is clean in the engine and hub.

Install the hub.

Rotate the engine crankshaft so that No. 1 piston is at TDC. Install the idler gear on the hub. Make sure the timing marks are in alignment with the crankshaft, camshaft, fuel pump and idler gear [B].

Install the retainer plate. Install the nuts and tighten to 30 ft.–lbs. (41 Nm) torque.

A–01659

C

Check the idler gear end play, the correct end play is 0.003–0.007 inch (0,076–0,178 mm) [C].

Check the backlash at the teeth of the gears. The backlash must be 0.003 inch (0,076 mm) minimum.

Install the timing case cover. (See Page 7–37.)

A–01661

–7–38–

2400 Series Loader Service Manual

CAMSHAFT GEAR

A

Removal And Installation The tool listed will be needed to do the following procedure: MEL1054 – Puller Remove the timing case cover. (See Page 7–37.)

Remove the bolt, tab washer and retainer washer. Install the puller to remove the gear from the camshaft [A].

Inspect the gear for wear or damage.

A–01692

Remove the idler gear. (See Page 7–38.)

Rotate the engine crankshaft so No. 1 piston is at TDC. Install the camshaft gear. Install the bolts and tighten to 50 ft.–lbs. (68 Nm) torque.

B

Install the idler gear, make sure the timing marks are in alignment. (See Page 7–38.)

FUEL INJECTION PUMP GEAR Removal Remove the timing case cover. (See Page 7–37.)

Remove the idler gear. (See Page 7–38.)

Remove the three bolts and washers from the injection pump gear. Remove the gear.[B].

A–01703

Installation Install the fuel injection pump gear. Make sure the dowel is in alignment with the slot on the injection pump shaft.

Install the bolts and washers and tighten to 30 ft.–lbs. (41 Nm) torque.

Install the idler gear. (See Page 7–38.)

Make sure the timing marks are in alignment.

CRANKSHAFT GEAR Removal The crankshaft gear is an interference fit on the end of the crankshaft. A key is installed between the gear and crankshaft.

–7–39–

2400 Series Loader Service Manual

TIMING CASE

A

Removal And Installation Remove the timing case cover. (See Page 7–37.)

Remove the idler gear. (See Page 7–38.)

Remove the fuel injection pump gear. (See Page 7–39.)

Remove the camshaft gear. (See Page 7–39.)

Remove the bolts and washers from the timing case [A].

Remove the bolts which fasten the case to the oil pan.

Installation: If the timing case is installed without the oil pan, make sure the bottom of the timing case is even with the face of the engine block before tightening the bolts.

CAMSHAFT Removal And Installation Remove the valve cover, rocker arm assembly and push rods.

Remove the timing case cover. (See Page 7–37.)

Remove the idler gear. (See Page 7–38.)

C–01411

Remove the camshaft gear. (See Page 7–39.)

Remove the oil pan. Remove the fuel lift pump.

B

Remove the camshaft thrust washer [B].

A–01649

C

Remove the camshaft from the engine [C].

A–01662

–7–40–

2400 Series Loader Service Manual

CAMSHAFT (Cont’d)

A

Remove the tappets from the engine [A].

Installation: Lubricate the tappets before installation.

Lubricate the camshaft and bearings before installation.

After the rocker arms are installed, make sure to adjust the valve clearance. (See Page 7–2.)

Inspection Check the camshaft and the bearings [B].

Use the correct tools for removal and installation of the camshaft bearings.

B

A–01696

0.0025/0.0045” (0,06/0,11 mm)

1.997/1.998” (50,72/50,75 mm)

1.987/1.988” (50,45/50,50 mm) 0.0025/0.0053” (0,06/0,14 mm)

1.625” 1.211” (41,28 mm) (30,76 mm) 0.0025/0.0053” (0,06/0,14 mm)

1.967/1.968” (49,96/49,99 mm) 0.004/0.016” (0,10/0,41 mm)

0.215/0.218” (5,46/5,54 mm)

1.157” (29,40 mm)

0.300/0.303” (7,62/7,70 mm)

PI–02642

–7–41–

2400 Series Loader Service Manual

BALANCER UNIT AND OIL PUMP

A

Balancer Removal And Installation

Bottom Of Engine Block

Crankshaft Gear

Remove the engine from the loader. (See Page 7–20.)

Drain the oil from the oil pan. Remove the oil pan from the engine block.

Balancer Gear

Installation: Tighten the oil pan bolts to 13 ft.–lbs. (18 Nm) torque.

NOTE: Support the balancer unit, the balancer weight is approximately 55 lbs. (25 kg).

Balancer Weights

Remove the six bolts and washers. Remove the balancer unit.

B–09538

Installation: Tighten the bolts to 40 ft.–lbs. (54 Nm) torque.

Engine Timing To Balancer Unit Put No. 1 piston at TDC (compression stroke). Make sure the locating dowels are in the engine block.

Position the balancer unit with the dowel pins. Engage the idler gear at the crankshaft gear. Look at the balance weight flats and make sure they are level with each other [A].

If this position can not be obtained, the timing is not correct.

When the timing is correct, install the bolts and tighten to the correct torque.

B

Oil Pump Removal And Installation Remove the nut from the drive gear for the balance weights [B].

Installation: Put LOCTITE on the threads and tighten to 70 ft.–lbs. (95 Nm) torque.

B–09563

C

Remove the drive gear for the balance weights [C].

B–09566

–7–42–

2400 Series Loader Service Manual

BALANCER UNIT AND OIL PUMP (Cont’d)

A

Oil Pump Removal And Installation (Cont’d) Remove the drive shaft [A].

NOTE: Be careful not to damage the needle bearings if they are to be used again.

B–09542

B

Remove the bolts from the oil pump body [B].

Installation: Tighten the bolts to 22 ft.–lbs. (30 Nm) torque.

B–09543

C

Remove the oil pump body, outer rotor and inner rotor [C].

Oil Pump Inspection See SPECIFICATIONS, Section 8 for the correct dimensions. Check the parts for wear or damage.

Replace the parts as needed.

B–09544

Oil Pump Relief Valve

D

Use a punch and hammer, remove the pin which holds the relief valve in the balancer frame [D].

B–09545

–7–43–

2400 Series Loader Service Manual

BALANCER UNIT AND OIL PUMP (Cont’d)

A

Oil Pump Relief Valve (Cont’d) Remove the cap, spring and poppet from the balancer frame [A].

Check the parts, replace them as needed.

The relief valve is not adjustable. If it is not to specifications, replace the spring.

B–09540

Balancer Disassembly And Assembly

B

Remove the oil pump assembly and drive shaft.

Remove the bolts from the cover plate [B].

Remove the cover plate.

B–09564

C

Remove the bolts from the oil transfer plate [C].

Assembly: Tighten the bolts to 24 ft.–lbs. (33 Nm) torque.

B–09561

D

NOTE: Before removing the oil transfer plate, note the raised symbols to indicate oil flow for R.H. or L.H. oil filter position [D]. Mark the plate for correct installation.

B–09560

–7–44–

2400 Series Loader Service Manual

BALANCER UNIT AND OIL PUMP (Cont’d)

A

Balancer Disassembly And Assembly (Cont’d) Remove the end cover bolts [A].

Assembly: Tighten the bolts to 40 ft.–lbs. (54 Nm) torque.

B–09562

B

Remove the cover [B].

B–09548

C

Remove the balancer weights [C].

Assembly: When assembling the balancer weights, make sure the weight flats are in alignment with each other [C].

Inspection Clean all parts with solvent. Use air pressure to dry them.

B–09557

Check the front and rear drive shaft needle bearings for wear or damage.

D

Check the balancer weight for damage.

Check the balancer weight bearings for wear or damage.

1.0” (25 mm)

See SPECIFICATIONS, Section 8 for the correct dimensions.

0.925” (23,5 mm) 5.138” (130,5 mm)

NOTE: When needle bearings and bushing bearings are replaced, they must be pressed into position with the correct driver tool [D].

1.152” 1.062” 1.500” (29,26 mm) (27 mm) (38 mm) Drive Shaft Rear Needle Bearing

–7–45–

B–09539

2400 Series Loader Service Manual

BALANCER UNIT AND OIL PUMP (Cont’d)

A

Inspection (Cont’d)

0.108” (2,74 mm)

NOTE: When needle bearings and bushing bearings are replaced, they must be pressed into position with the correct driver tool [A].

0.108” 0.685” (17,4 mm) (2,74 mm)

BUSHINGS 1.248” (31,7 mm) 1.653” (42 mm)

Clean and lubricate the frame bores.

1.120” (28,45 mm) 1.350” (34,29 mm) FRONT NEEDLE BEARING

1.5” (38 mm) 2.0” (50,8 mm)

1.49” (37,85 mm)

B–09539

B

Press in the bushing bearings until they are 0.098–0.108 inch (2,5–2,75 mm) below the machined surface [B].

B–09546

Clean and lubricate the bores in the frame end cover.

C

Press in the bushings until they are 0.108–0.128 inch (2,75–3,25 mm) below the machined surface [C].

B–09541

Clean and lubricate the bores for the needle bearings.

D

Press in the rear needle bearing until the bearing is 5.12–5.16 inch (130–131 mm) from the front of the frame [D].

Press in the front needle bearing until the bearing is 0.098–0.118 inch (2,5–3,0 mm) below the front surface of the frame.

B–09547

–7–46–

2400 Series Loader Service Manual

SPECIFICATIONS Page Number

DECIMAL & MILLIMETER EQUIVALENTS Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14 ENGINE SPECIFICATIONS Balance Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft & Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System & Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft, Main Bearings & Thrust Washer . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Re–grind Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Block & Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

De–Rating For Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Injection Pump & Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intake Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump, Gear & Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston & Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Pin & Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker Arms & Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Case & Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8–10 8–7 8–9 8–7 8–7 8–12 8–6 8–5 8–10 8–11 8–5 8–9 8–9 8–5 8–8 8–6 8–6 8–5 8–11 8–8 8–5 8–5

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–13 LOADER SPECIFICATIONS – 2400 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation & Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8–2 8–2 8–2 8–1 8–2 8–1 8–1 8–2

LOADER SPECIFICATIONS – 2410 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation & Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8–4 8–4 8–4 8–3 8–4 8–3 8–3 8–4

SPECIFICATIONS

U.S. TO METRIC CONVERSION Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–14 STANDARD TORQUE SPECIFICATIONS FOR BOLTS Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–15

–8––1–

2400 Series Loader Service Manual

–8–0–

2400 Series Loader Service Manual

LOADER SPECIFICATIONS – 2400 D

Dimensions are given for loader equipped with standard tires and dirt bucket. Dimensions may vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parenthesis.

LOADER DIMENSIONS

D Where applicable, specifications conform to SAE standards. Specifications are subject to change without notice.

40° 70.0 (1778)

55°

149.4 (3795)

45° 28.0 (711)

94.9 (2410)

123.6 (3139) 97.4 (2474)

32°

12.2 (310) 127.0 (3226)

35° 70.56 (1792)

159.2 (4044)

A – 12 x 16.5 – 57.6 (1463) 31 x 15.5 – 15 – 61.6 (1565) 14 x 17.5 – 62.2 (1580) Solid – 62.5 (1588) B – 12 x 16.5 – 69.9 (1775) 31 x 15.5–15 – 77.1 (1958) 14 x 17.5 – 76.2 (1935) Solid – 70.4 (1788)

MC–01076 MC–01077

OPERATION & PERFORMANCE 1.

Weights Operating Weight (W/Std. Tires) . . . . . . .

Rated Operating Capacity . . . . . . . . . . . .

Tipping Load (SAE Rating) . . . . . . . . . . .

9270 lbs. (4209 kg) 2400 lbs. (1090 kg) 4800 lbs. (2179 kg)

Travel Speed (12 x 16.5 Tires) Work Range . . . . . . . . . . . . . . . . . . . . . . . .

Travel Range . . . . . . . . . . . . . . . . . . . . . . .

5.5 MPH (8,8 km/hr.)

14.5 MPH (23,3 km/hr.)

Controls Steering . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direction . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission . . . . . . . . . . . . . . . . . . . . . . .

Control Valve . . . . . . . . . . . . . . . . . . . . . . .

Engine Speed . . . . . . . . . . . . . . . . . . . . . .

Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Brake (Parking) . . . . . . . . . . . . . . . . . . . . .

2400 MTC

Steering Wheel Single Foot Pedal Two–Speed Range Selector Lever Joystick control lever lift & tilt. Front Auxiliary (Opt.) electrically controlled.

Hand lever throttle; key type starter switch & shut–down Engine–Hydrostatic (Belt drive to pump) Foot Operated Manual Brake

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Governed RPM . . . . . . . . . . . .

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of Cylinders . . . . . . . . . . . . . . . . . . . . .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . .

Displacement . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . .

Lubrication System . . . . . . . . . . . . . . . . . .

Crankcase Ventilation . . . . . . . . . . . . . . . .

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Perkins 4.236 74 HP (55,2 kW) 2200 RPM 194 ft.–lbs. (263 Nm) @ 1350 RPM Four 3.875/5.00(98,4/127) 235.9 cu. in. (3,86 L) Liquid Pressure System W/Filter External Dry replaceable paper cartridge with safety element Compression (Diesel) 800 – 1000 RPM 2290 – 2330 RPM

–8–1–

2400 Series Loader Service Manual

LOADER SPECIFICATIONS – 2400 (Cont’d) 1.

HYDRAULIC SYSTEM Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Capacity . . . . . . . . . . . . . . . . . . . . . . .

Small Stage . . . . . . . . . . . . . . . . . . . . . . . .

Large Stage . . . . . . . . . . . . . . . . . . . . . . . .

Charge Pump . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Cylinders

2400 MTC Engine driven, dual stage gear type Rated @ 2300 RPM @ 1050 PSI (7240 kPa) 7.1 GPm (26,8 L/min.)

17.1 GPM (64,7 L/min.)

2350 PSI (16201 kPa) 10.3 GPM (39 L/min.) @ 2300 Engine RPM Full flow replaceable cartridge type 3 filter located on return flow side

......................

Doubleacting

Bore Diameter Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . .

Steering Cylinder (1) . . . . . . . . . . . . . . . . .

Rod Diameter Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . .

Steering Cylinder (1) . . . . . . . . . . . . . . . . .

Stroke Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . .

Steering Cylinder (1) . . . . . . . . . . . . . . . . . . . . .

Control Valve . . . . . . . . . . . . . . . . . . . . . . . .

3.0 (76) 2.75 (70) 2.75 (70) 1.75 (44) 1.50 (38) 1.25 (32) 25.8 (655) 25.9 (658) 12.5 (318)

Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . .

Three–spool, Series, Open Center W/Float Detent on Lift, W/Electrical Controlled Front Auxiliary Standard SAE tubes, hoses & fittings

Hydraulic Function Time Raise Lift Arms to Maximum Height . . . . .

Lower Lift Arms from Maximum Height . .

Move Bucket to Dump Position . . . . . . . . .

Move Bucket to Retracted Position . . . . .

6.8 Seconds 4.4 Seconds 2.3 Seconds 1.6 Seconds

Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . . .

Final Drive

.................................

Bobcat Fluid (P/N 6563328). If fluid is not available, use 10W–30/10W–40 Class SE Motor Oil for temperatures above 0°F (–18°C) and 5W–30 for temperatures below.

Belt driven, 65 amp. open, integral regulator 12 volt, 1000 cold crank amps. @ 0°F (–18°C) 180 Min. Reserve Capacity 12 volt

Belt driven single Bi–directional, hydrostatic pump driving fully reversing hydrostatic motor. Separate geroler type charge pump.

Axle (Ratio 19.08:1 both front & rear differentials) Gear Box (Ratio 1.68:1)

CAPACITIES Cooling System . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication W/Filter . . . . . . . . . . . .

Hydraulic/Hydrostatic System . . . . . . . . . .

Front Axle Differential . . . . . . . . . . . . . . . . .

Rear Axle Differential . . . . . . . . . . . . . . . . .

Drop Gearcase . . . . . . . . . . . . . . . . . . . . . . .

Wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . .

22 qts (20,8 L) 19 gals. (72 L) 7 qts. (6,6 L) 8 gals. (30 L) 9.0 pts. (4,3 L) 9.0 pts. (4,3 L) 0.5 qts. (0,2 L) 3.6 pts. (1,7 L)

TIRES Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .

Terra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solid Rubber . . . . . . . . . . . . . . . . . . . . . . . . .

12 x 16.5 – 6 Ply Rating, Bar Lug 55 PSI (379 kPa) 14 x 17.5 – 10 Ply Rating, Bar Lug 55 PSI (379 kPa) 31 x 15.5–15 – 8 Ply Rating, Terra Lug 45 PSI (310 kPa) 8.0 x 16

* Revised Aug. 90

–8–2–

2400 Series Loader Service Manual

LOADER SPECIFICATIONS – 2410 D

Dimensions are given for loader equipped with standard tires and dirt bucket. Dimensions may vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parenthesis.

LOADER DIMENSIONS

D Where applicable, specifications conform to SAE standards. Specifications are subject to change without notice.

40° 55°

70.0 (1778)

142.8 (3627) 157.3 (3995)

H 45° 28.1 (714)

95.0 (2418)

123.5 (3137) 61.9 (1573)

98.0 (2489)

31° 33.0 (838)

12.3 (312)

35° 70.6 (1793)

127.0 (3226) 157.9 (4011)

A – 12 x 16.5 – 57.6 (1463) 31 x 15.5 – 15 – 61.6 (1565) 14 x 17.5 – 62.2 (1580) Solid – 62.5 (1588) B – 12 x 16.5 – 69.9 (1775) 31 x 15.5–15 – 77.1 (1958) 14 x 17.5 – 76.2 (1935) Solid – 70.4 (1788)

MC–01076 MC–01077

2410 MTC OPERATION & PERFORMANCE Weights Operating Weight . . . . . . . . . . . . . . . . . . .

Rated Operating Capacity . . . . . . . . . . . .

Tipping Load (SAE Rating) . . . . . . . . . . .

With Opt. Ctws.

9400 lbs (4268 kg) 2400 lbs. (1090 kg) 4800 lbs. (2179 kg)

Travel Speed (12 x 16.5 Tires) Work Range . . . . . . . . . . . . . . . . . . . . . . . .

Travel Range . . . . . . . . . . . . . . . . . . . . . . .

Controls Steering . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direction . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission . . . . . . . . . . . . . . . . . . . . . . .

Control Valve . . . . . . . . . . . . . . . . . . . . . . .

Engine Speed . . . . . . . . . . . . . . . . . . . . . .

Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Brake (Parking) . . . . . . . . . . . . . . . . . . . . .

10,085 lbs. (4579 kg) 3000 lbs. (1362 kg) 6000 lbs. (2724 kg)

0.0 to 5.5 MPH (8,8 km/hr.)

0.0 to 14.5 MPH (23,3 km/hr.)

Steering wheel Single Foot Pedal Two–Speed Range Selector Lever Joystick control lever lift & tilt. Front Auxiliary electrically controlled.

Hand lever throttle; key type starter switch & shut–down Engine–Hydrostatic (Belt drive to pump) Foot Operated Manual Brake

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Governed RPM . . . . . . . . . . . .

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of Cylinders . . . . . . . . . . . . . . . . . . . . .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . .

Displacement . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Ventilation . . . . . . . . . . . . . . . .

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Perkins 4.236 74 HP (55,2 kW) 2200 RPM 194 ft.–lbs. (263 Nm) @ 1350 RPM Four 3.875/5.00(98,4/127) 235.9 cu. in. (3,86 L) Liquid Pressure System W/Filter External Dry replaceable paper cartridge with safety element Compression (Diesel) 800 – 1000 RPM 2290 – 2330 RPM

–8–3–

2400 Series Loader Service Manual

LOADER SPECIFICATIONS – 2410 (Cont’d) 1.

HYDRAULIC SYSTEM Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Capacity . . . . . . . . . . . . . . . . . . . . . . .

Small Stage . . . . . . . . . . . . . . . . . . . . . . . .

Large Stage . . . . . . . . . . . . . . . . . . . . . . . .

Charge Pump . . . . . . . . . . . . . . . . . . . . . . . .

System Relief Setting . . . . . . . . . . . . . . . . .

Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . .

2410 MTC Engine driven, dual stage gear type Rated @ 2200 RPM @ 1200 PSI (8274 kPa) 7.1 GPM (26,8 L/min.)

19.5 GPM (73,8 L/min.)

10.3 GPM (39 L/min.) @ 2300 Engine RPM 2500 PSI (17238 kPa) Full flow replaceable cartridge type 3 filter located on return flow side

Hydraulic Cylinders . . . . . . . . . . . . . . . . .

Doubleacting

Bore Diameter Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . .

Steering Cylinder (1) . . . . . . . . . . . . . . . . .

Rod Diameter Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . .

Steering Cylinder (1) . . . . . . . . . . . . . . . . .

Stroke Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . . .

Steering Cylinder (1) . . . . . . . . . . . . . . . . . . . . .

Control Valve . . . . . . . . . . . . . . . . . . . . . . . .

3.0 (76) 2.75 (70) 2.75 (70) 1.75 (44) 1.50 (38) 1.25 (31) 25.8 (655) 25.9 (658) 12.5 (318)

Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . .

Three–spool, Series, Open Center W/Float Detent on Lift, W/Electrical Controlled Front Auxiliary (Opt.) Standard SAE tubes, hoses & fittings

Hydraulic Function Time Raise Lift Arms to Maximum Height . . . . .

Lower Lift Arms from Maximum Height . .

Move Bucket to Dump Position . . . . . . . . .

Move Bucket to Retracted Position . . . . .

6.0 Seconds 4.4 Seconds 2.3 Seconds 1.6 Seconds

Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . . .

Final Drive

.................................

Bobcat Fluid (P/N 6563328). If fluid is not available use 10W–30/10W–40 Class SE Motor Oil for temperatures above 0°F (–18°C) and 5W–30 for temperatures below.

Belt driven, 65 amp. open, integral regulator 12 volt, 1000 cold crank amps. @ 0°F (–18°C) 180 Min. Reserve Capacity 12 volt

Belt driven single Bi–directional, hydrostatic pump driving fully reversing two–speed hydrostatic motor. Separate geroler type charge pump.

Axle (Ratio 19.08:1 both front & rear differentials) Gear Box (Ratio 1.68:1)

CAPACITIES Cooling System . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication W/Filter . . . . . . . . . . . .

Hydraulic/Hydrostatic System . . . . . . . . . .

Hydraulic/Hydrostatic Reservoir . . . . . . . .

Front Axle Differential . . . . . . . . . . . . . . . . .

Rear Axle Differential . . . . . . . . . . . . . . . . .

Drop Gearcase . . . . . . . . . . . . . . . . . . . . . . .

Wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . .

22 qts (20,8 L) 19 gals. (72 L) 7 qts. (6,6 L) 17.0 gals. (64,4 L) 8 gals. (30 L) 9.0 pts. (4,3 L) 9.0 pts. (4,3 L) 0.5 qts. (0,2 L) 3.6 pts. (1,7 L)

TIRES Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .

Terra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .

Terra . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solid Rubber . . . . . . . . . . . . . . . . . . . . . . . . .

12 x 16.5 – 6 Ply Rating, Bar Lug 55 PSI (379 kPa) 14 x 17.5 – 10 Ply Rating, Bar Lug 55 PSI (379 kPa) 31 x 15.5–15 – 8 Ply Rating, Terra Lug 45 PSI (310 kPa) 38 x 20 x 16.5 – 8 Ply Rating, Terra Lug 25 PSI (172 kPa) 8.0 x 16

–8–4–

2400 Series Loader Service Manual

ENGINE SPECIFICATIONS All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Cylinder Head Cylinder Head Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.875 (505,8) Cylinder Head Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.063 ± 0.015 (103,2 ± 0,38) Grinding Allowance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,30) Minimum Cylinder Head Depth After Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.035 (102,5) Maximum Extension of Nozzle After Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.175 (4,45) Leak Test Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 lbf.–in.2 (2,11 kgf.–cm2) Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve Bore in Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.374/0.376 (9,51/9,54) Valve Guides I.D. of Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.375/0.376 (9,53/9,55) O.D. of Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.626/0.627 (15,9/15,93) Bore in Cylinder Head for Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.625/0.626 (15,88/15,9) Interference Fit of Guide to Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0005/0.0015 (0,013/0,04) Depth of Counter Bore–Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4063 (10,32) Overall Length of Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.438 (61,92) Guide Extension Above Cylinder Head Top Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.625 (15,88)

Exhaust Valve Valve Stem Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.375/0.3728 (9,45/9,47) Clearance Fit of Valve in Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0023/0.004 (0,060/0,10) Valve Head Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.435/1.445 (36,45/36,7) Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve Depth Below Cylinder Head Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.047/0.057 (1,19/1,45) Valve Stem Oversize (Service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,08) 0.015 (0,38) & 0.030 (0,76) Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,30) Overall Length of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.847/4.863 (123,11/123,52) Intake Valve Valve Stem Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.373/0.374 (9,47/9,5) Clearance Fit of Valve in Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0015/0.0035 (0,040/0,090) Valve Head Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.736/1.746 (44,09/44,35) Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve Depth Below Cylinder Head Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035/0.045 (0,89/1,14) Valve Stem Oversize (Service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,08) 0.015 (0,38) & 0.030 (0,76) Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 (0,30) Overall Length of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.831/4.847 (122,71/123,11) Valve Springs Inner Valve Spring Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.563 (39,7) Load @ Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 lbs. ± 1 lbs. (7 kg ± 0,45 kg) Installed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Damper Coils to the Cyl. Head Outer Valve Spring Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.780 (45,2) Load @ Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 lbs ± 2 lbs (18 kg ± 0,91) Installed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Damper Coils to the Cyl. Head Rocker Arms & Tappets Overall Length of Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.969 (75,41) O.D. of Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.747/0.749 (18,97/19,02) Tappet Bore Diameter in Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.750/0.7512 (19,05/19,08 Tappet Clearance in Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0015/0.004 (0,038/0,1)

–8–5–

2400 Series Loader Service Manual

ENGINE SPECIFICATIONS (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Rocker Arms & Tappets (Cont’d) O.D. of Tappet Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.187 (30,16) Overall Length of Rocker Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.796 (426,62) O.D. of Rocker Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7484/0.7496 (19,01/19,04) Interference Fit of Bushing in Rocker Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008/0.0035 (0,02/0,09) Clearance of Bushing on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0012/0.0035 (0,03/0,09) Piston & Piston Rings Piston Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cavity in Crown Piston Height Above Cyl. Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003/0.010 (0,08/0,25) Bore Diameter for Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.374/1.375 (34,92/34,93) Piston Ring Groove Width No. 1, 2 & 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0957/0.0969 (2,43/2,46) No. 4 & 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2524/0.2543 (6,41/6,46) Top Ring (Compression) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chromium Plate–Parallel Face Second & Third Ring (Compression) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internally Stepped Fourth Ring (Scraper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring Loaded Conformable Fifth Ring (Scraper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maxi–groove Ring Width No. 1, 2 & 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0929/0.0937/2,36/2,38) Ring Clearance in Groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002/0.004 (0,05/0,1) Ring Width No. 4 & 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.249/0.250 (6,32/6,35) Ring Clearance in Groove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002/0.004 (0,05/0,1) Ring Gap No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.016/0.034 (0,41/0,86) Ring Gap No. 2 & 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012/0.030 (0,3/0,76) Ring Gap No. 4 & 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012/0.030 (0,3/0,76) Piston Pin & Bushing Piston Pin Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Floating O.D. of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3748/1.375 (34,92/34,93) Length of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.297/3.312 (83,74/84,12) Piston Pin Fit in Piston Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transition Small End Bushing Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel Backed Lead Bronze Lined O.D. of Small End Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.535/1.537 (38,99/39,03) Small End Bushing Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.316/1.336 (33,43/33,93) Small End Bushing I.D. Before Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.359/1.363 (34,52/34,62) After Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3756/1.3764 (34,94/34,96) Clearance Between Bushing & Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00075/0.0017 (0,019/0,043) Cylinder Block & Liners Height of Block Between Top & Bottom Faces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.367/17.375 (441,12/441,33) Parent Bore Diameter for Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0626/4.0638 (103,19/103,22) Main Bearing Parent Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.166/3.167 (80,42/80,44) Camshaft Bore Diameter No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.187/2.189 (55,56/55,59) No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.990/1.992 (50,55/50,59) No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.970/1.972 (50,04/50,08) Cylinder Liner Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry–Interference Fit (Production) Dry–Transition Fit (Pre–Finish Service) O.D. of Production Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.065/4.067 (103,26/103,29) O.D. of Pre–Finish Service Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0626/4.0634 (103,19/103,21) Interference Fit of Production Liner in Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003/0.005 (0,08/0,13) Transition Fit of Pre–Finish Service Liner in Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 0.001 (± 0,03) Finish Bore Diameter of Production Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.877/3.878 (98,48/98,5) Bore Diameter of Pre–Finish Service Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.878/3.879 (98,5/98,52) Overall Length of Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.004/9.016 (228,7/229,0) Height of Top of Liner Above Cylinder Block Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00 ± 0.004 ( ± 0,1)

–8–6–

2400 Series Loader Service Manual

ENGINE SPECIFICATIONS All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Crankshaft, Main Bearings & Thrust Washer Crankshaft Overall Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.01/24.04 (609,85/610,62) Main Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.998/2.999 (76,16/76,18) Main Journal Length No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.453/1.473 (36,91/37,41) No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.545/1,549 (39,24/39,34) No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.738/1.741 (44,15/44,22) Main Journal Fillet Radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.145/0.156 (3,68/3,96) Surface Finish–All Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 micro in. (0,4 microns) Main Bearing Journals Re–Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8–12 Oil Seal Helix Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05/0.08 (1,27/2,03) Oil Seal Helix Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004/0.008 (0,10/0,20) Flange Diameter of Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.247/5.249 (133,27/133,32) Pilot Bearing Recess Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.781 (19,84) Pilot Bearing Recess Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.849/1.8504 (46,98/47,0) Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004/0.015 (0,1/0,38) Thrust Washer Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steel Backed, Aluminum Tin or Lead Bronze Faced Thrust Washer Position in Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Center Main Bearing Thrust Washer Thickness–STD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.089/0.091 (2,26/2,31) Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.096/0.099 (2,44/2,51) Thrust Washer O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.088/4.091 (103,84/103,9) Thrust Washer I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42/3.43 (86,87/87,12) Main Bearing Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre–Finished, Steel Backed, Aluminum Tin Faced Main Bearing Width No. 1, 2, 4 & 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.245/1.255 (31,62/31,88) No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.435/1.445 (36,45/36,7) O.D. of Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.166 (80,41) I.D. of Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.001/3.003 (76,23/76,27) Main Bearing Shell Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0822/0.0826 (2,088/2,098) Main Bearing Running Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002/0.004 (0,05/0,11)

Connecting Rod and Bearings Connecting Rod Bearing Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre–Finished, Steel Backed Aluminum Tin Faced Connecting Rod Bearing Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.245/1.255 (31,62/31,88) O.D. of Rod Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.646 (67,22) I.D. of Rod Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5008/2.502 (63,52/63,55) Rod Bearing Running Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0012/0.003 (0,03/0,08) Rod Bearing Shell Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0723/0.726 (1,836/1,844) Rod Journals Re–Grind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 8–12 Rod Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.499/2.518 (63,47/63,96) Rod Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.589/1.591 (40,35/40,42) Rod Journal Fillet Radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.145/0.156 (3,68/3,96) Connecting Rod Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H Section Locating of Rod to Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serrations Rod Small End Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.531/1.532 (38,9/38,92) Rod Large End Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.646/2.647 (67,21/67,22) Center Line Length from Large End to Small End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.624/8.626 (219,05/219,1) Rod Large End Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.577/1.580 (40,06/40,13) End Float of Rod on Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008/0.0146 (0,22/0,37) Rod Cap Bolt Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 (12,7) Rod Cap Bolt Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U.N.F.

–8–7–

2400 Series Loader Service Manual

ENGINE SPECIFICATIONS (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Camshaft & Thrust Washer Journal Length No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.211 (30,75) No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.625 (41,27) No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.157 (29,40) Journal Diameter No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.996/1.998 (50,71/50,74) No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.987/1.988 (50,46/50,48) No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.967/1.968 (49,95/49,98) Block Camshaft Bore Diameter No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.999/2.001 (50,8/50,83) No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.990/1.992 (50,55/50,6) No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.970/1.972 (50,04/50,09) Journal Running Clearance No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0024/0.0043 (0,06/0,11) No. 2 & 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0024/0.0055 (0,06/0,14) Cam Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.299/0.303 (7,62/7,7) Passage for Rocker Arm Shaft Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Journal Camshaft Thrust Washer Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360° Thrust Washer O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.872/2.874 (72,95/73,0) Block Recess Diameter for Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.875/2.885 (73,03/73,28) Thrust Washer I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.75 (44,45) Thrust Washer Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.215/0.218 (5,47/5,54) Block Recess Depth for Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.187/0.190 (4,75/4,83) Thrust Washer Extended Beyond Block Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.026/0.031 (0,66/0,79) Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004/0.016 (0,1/0,41) Timing Case & Timing Gears Camshaft Gear No. of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Camshaft Gear I.D. of Gear Boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.375/1.376 (34,93/34,96) Camshaft Gear O.D. of Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.374/1.375 (34,9/34,91) Fit of Camshaft Gear on Camshaft Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . –0.0008/ + 0.0012 (–0,02/ + 0,03) Injection Pump Gear No. of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Injection Pump Gear I.D. of Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.749/1.751 (44,45/44,47) Injection Pump Gear Hub Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.748/1.749 (44,4/44,42) Idler Gear No. of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Idler Gear Bore Diameter of Gear Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.999/2.00 (50,79/50,82) Idler Gear O.D. Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.996/1.998 (50,7/50,74) Idler Gear Running Clearance on Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0024/0.0047 (0,06/0,12) Idler Gear Width W/Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.186/1.187 (30,14/30,16) Idler Gear Hub Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.191/1.194 (30,26/30,33) Idler Gear End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004/0.008 (0,1/0,2) Crankshaft Gear No. of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Crankshaft Diameter of Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.875/1.876 (47,63/47,64) All Gears – Timing Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,08) Minimum Oil Pump, Gear & Relief Valve Type of Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotor Type No. of Lobes – Inner Rotor (Concentric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Six Outer Rotor (Concentric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seven Drive Position on Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . By the idler from Crankshaft Gear Clearance of Inner to Outer Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.001/0.003 (0,025/0,076) Inner Rotor End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0015/0.003 (0,038/0,076) Outer Rotor End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006/0.0025 (0,014/0,063) Outer Rotor to Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.011/0.013 (0,28/0,33) Oil Pump Drive Gear No. of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 I.D. of Oil Pump Gear Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.497/0.498 (12,62/12,64) O.D. of Oil Pump Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.499/0.4996 (12,67/12,69) Interference Fit of Gear on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0012/0.0023 (0,03/0,06) Clearance Between Drive & Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003/0.007 (0,08/0,18) Oil Pump Idler Gear No. of Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Oil Pump Idler Gear I.D. of Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.999/1.001 (25,4/25,43)

–8–8–

2400 Series Loader Service Manual

ENGINE SPECIFICATIONS All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Oil Pump, Gear & Relief Valve (Cont’d) Oil Pump Idler Gear O.D. of Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.999/1.0008 (25,4/25,42)) I.D. of Oil Pump Idler Gear Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.875/0.876 (22,23/22,26) O.D. of Idler Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.873/0.874 (22,19/22,2) Oil Pump Idler Gear Running Clearance on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008/0.003 (0,02/0,07) Oil Pump Idler Gear End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002/0.016 (0,05/0,41) Relief Valve Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring Loaded Plunger Relief Valve Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50/60 PSI (345/414 kPa) Length of Relief Valve Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.826 (20,98) O.D. of Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.558/0.559 (14,19/14,21) I.D. of Valve Housing Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.571 (14,5) Clearance of Plunger in Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008/0.012 (0,209/0,314) Spring–Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 (32.51) Spring–Load @ Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.77/8.24 lbf. (35/7N) Oil Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow Oil Filter By–Pass Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opens between 8/17 lbf./in.2 (55/117 kNm2) Torque for Filter Mount Retainer Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ft.lbs. (20 Nm) Cooling System & Water Pump Thermostat Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bellows Thermostat Open Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170/180°F (77/83°C) Fully Open @ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202°F (94°C) Thermostat Valve Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.312/0.469 (7,93/11,91) Water Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal O.D. of Water Pump Shaft for Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.749/0.750 (19,03/19,04) I.D. of Pulley Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.750/0.752 (19,07/19,09) Clearance Fit of Pulley on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0012/0.0024 (0,03/0,06) O.D. of Shaft for Water Pump Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.626/0.627 (15,91/15,92) I.D. of Impeller Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.625/0.626 (15,87/15,89) Interference Fit of Impeller on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0004/0.002 (0,01/0,05) O.D. of Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.094/3.096 (78,59/78,64) Impeller Blade to Body Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012/0.032 (0,3/0,81) Water Pump Seal Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Synthetic Rubber, Carbon Faced Radiator Cap Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 PSI (48 kPa)

Fuel Lift Pump Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In–Line Fuel Lift Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.C. Delco V.P. Series Method of Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eccentric of Camshaft Fuel Injection Pump & Injectors Fuel Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spin–on Canister Element Injection Pump Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.A.V. Injection Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.P.A. Injection Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise Injection Pump Plunger Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.355 (8,5) Timing Letter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C No. 1 Cylinder Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7–9 for Procedure Injector Nozzle Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pintle Injector Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7–12 for correct identification code & working pressure.

–8–9–

2400 Series Loader Service Manual

ENGINE SPECIFICATIONS (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

De–Rating for Altitude The following chart is given as a general guide, which can be used on a percentage basis, where specific figures for an engine rating are not available.

Maximum Fuel Delivery De–Rating Measured at 800 RPM Pump Speed

Altitude

0–2000 ft. (600 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Change 2,000 – 4,000 ft. (1200 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6% 4,000 – 6,000 ft. (1800 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12% 6,000 – 8,000 ft. (2400 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18% 8,000 – 10,000 ft. (3000 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24% 10,000 – 12,000 ft. (3600 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30% Any necessary adjustments for the fuel injection pump must be done by Trained Service Personnel.

Balancer Unit No. of Teeth on Drive Shaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Diameter of Drive Shaft Front Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.124/1.125 (28,55/28,58) Rear Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.936/0.937 (23,78/23,8) Diameter of Oil Pump Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.124/1.125 (28,55/28,58) No. of Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Diameter of Balance Weight Drive Gear Spline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.649/0.651 (16,51/16, 53) Diameter of Bearing Bore (Drive Shaft) Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.374/1.375 (34,89/34,93) Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.799/1.805 (45,72/45,85) O.D. of Bearing (Drive Shaft) Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.375 (34,92) Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.181 (30,0) I.D. of Bearing (Drive Shaft) Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.125 (28,58) Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.937 (23,8) Diameter of Balance Frame & End Frame Bushing Bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.656/1.657 (42,07/42,09) O.D. of Balance Frame & End Frame Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66 (42,16) I.D. of Balance Frame & End Frame Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.501/1.503 (38,13/38,17) Clearance of Balance Weight Shaft in Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002/0.005 (0,06/0,12) Shaft Diameter of Balance Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.498/1.499 (38,05/38,07) Minimum & Maximum Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004/0.012 (0,1/0,3) No. of Teeth on Drive Shaft Balance Weight Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 End Play of Balance Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.007/0.015 (0,18/0,37) End Play of Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006/0.014 (0,17/0,35) No. of Teeth on Idler Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 I.D. of Gear Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.875/1.876 (47,64/47,65) O.D. of Gear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.875 (47,63) I.D. of Gear Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 (38,1) O.D. of Idler Gear Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.499/1.50 (38,09/38,1) Idler Gear Hub Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/16 –20 U.N.F. Idler Gear End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003/0.009 (0,08/0,23) Thrust Washer Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.163/0.169 (4,14/4,29) O.D. of Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.323 (59) I.D. of Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.787 (20)

–8–10–

2400 Series Loader Service Manual

ENGINE SPECIFICATIONS All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Engine Bolt Torques

Ft. Lbs.

Cylinder Head Bolts (1/2”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Connecting Rod Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Connect Rod Nuts (Cap Painted Green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Main Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Idler Gear Hub Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Flywheel Place Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Camshaft Gear Retainer Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Crankshaft Pulley Retaining Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Oil Filter Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Fuel Injector Nozzle Fastening Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 High Pressure Fuel Pipe Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Balancer Retaining Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Thermostat with Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Nm 136 95 102 244 41 108 122 54 407 41 16 20 49 14

Service Wear Limits The following wear limits indicate the condition when it is recommended that the respective item must be serviced or replaced.

Cylinder Head Bow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transverse 0.003 (0,08) Longitudinal 0.006 (0,15) Max. Bore Wear (New Liners Needed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008 (0,2) Crankshaft Main & Big End Journal Wear Out–of–Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,04) Max. Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.014 (0,36) Valve Stem to Bore/Guide Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake 0.005 (0,13) Exhaust 0.006 (0,15) Valve Head Thickness Between Run–out Valve Seat & Face of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.031 (0,79) Rocker Arm Clearance on Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 (0,13) Camshaft Journals – Out–of–Round & Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 (0,05) Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,51) Idler Gear End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25) Valve Head Depth Below Cyl. Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake 0.061 (1,55) Exhaust 0.055 (1,4)

–8–11–

2400 Series Loader Service Manual

ENGINE SPECIFICATIONS (Cont’d) All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

F

C

D

C

R2

R2

B

A

B

A

R2

A

B R1

R2

A

A

B R1

R1

E

C

E

R1

E

R1

E

PI–02598

Crankshaft Re–Grind Data 0.010 (0,25) Undersize

0.020 (0,51) Undersize

0.030 (0,76) Undersize

A

2.988/2.989 (75,90/75,92)

2.978/2.979 (75,64/75,67)

2.968/2.969 (75,39/75,41)

B

2.488/2.490 (63,20/63,25)

2.478/2.480 (62,94/62,99)

2.468/2.469 (62,69/62,71)

C

1.554 (39,47) Maximum

D

1.759 (44,68) Maximum

E

1.596 (40,54) Maximum

F

1.554 (39,47) Maximum

R

0.145/0.156 (3,68/3,96) All Journals

Surface finish of crankpins, journals and fillet radii 16 to 8 micro inches (0,4 to 0,2 microns) C.L.A. Magnetic Crack Detection D.C. Flow – 2.5 Amps.

A.C. Current – 1300 Amps.

Limits of taper and out–of–round for pins and journals: Taper 0.0002 (0,005) Out–of–Round 0.0002 (0,005) Maximum Run–out with the crankshaft mounted on the end main journals.

Independent Readings: Crankshaft Pulley Diameter T.I.R. 0.002 (0,05)

Rear Oil Seal Diameter T.I.R. 0.002 (0,05)

Journals T.I.R. – Run–out must not be opposed.

Number 1 Number 2 Number 3 Mounting 0.003 (0,08) 0.006 (0,15)

–8–12–

Flywheel Flange Diameter T.I.R. 0.002 (0,05)

Number 4 0.003 (0,08)

Number 5 Mounting

2400 Series Loader Service Manual

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS Specifications Use Melroe hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not available, use 10W–30 or 10W–40 SAE Motor Oil.

DO NOT use automatic transmission fluids in this loader or permanent damage to the transmission will result.

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin. This can cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately.

W–2145–0290

Where temperatures below zero are common, loaders must be kept in warm building. Extra warm–up time must be used each time the loader is started during cold temperature conditions. Cold fluid will not flow easily and it makes action of the hydraulic function slower. Loss of fluid flow to the hydrostatic transmission pump (indicated

by TRANS light ON) will cause transmission damage in less than 60 seconds.

When the temperature is below –20°F (–30°C), hydrostatic oil must be warmed before starting.

The hydrostatic system will not get enough oil at low temperatures and will be damaged. Park the machine in an area where the temperature will be above 0°F (–18°C) if possible.

I–2007–1285

–8–13–

2400 Series Loader Service Manual

DECIMAL AND MILLIMETER EQUIVALENTS FRACTIONS 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2

DECIMALS

MM

0.015625 0.03125 0.046875 0.0625 0.078125 0.09375 0.109375 0.1250 0.140625 0.15625 0.171875 0.1875 0.203125 0.21875 0.234375 0.2500 0.265625 0.28125 0.296875 0.3125 0.328125 0.34375 0.359375 0.3750 0.390625 0.40625 0.421875 0.4375 0.453125 0.46875 0.484375 0.5000

0.397 0.794 1.191 1.588 1.984 2.381 2.778 3.175 3.572 3.969 4.366 4.762 5.159 5.556 5.953 6.350 6.747 7.144 7.541 7.938 8.334 8.731 9.128 9.525 9.922 10.319 10.716 11.112 11.509 11.906 12.303 12.700

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

FRACTIONS

DECIMALS 33/64

17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1

1 mm = 0.03937’’

0.515625 0.53125 0.546875 0.5625 0.578125 0.59375 0.609375 0.6250 0.640625 0.65625 0.671875 0.6875 0.703125 0.71875 0.734375 0.7500 0.765625 0.78125 0.796875 0.8125 0.828125 0.84375 0.859375 0.8750 0.890625 0.90625 0.921875 0.9375 0.953125 0.96875 0.984375 1.000

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

MM 13.097 13.494 13.891 14.288 14.684 15.081 15.478 15.875 16.272 16.669 17.066 17.462 17.859 18.256 18.653 19.050 19.447 19.844 20.241 20.638 21.034 21.431 21.828 22.225 22.622 23.019 23.416 23.812 24.209 24.606 25.003 25.400

0.001’’ = 0.0254 mm

U.S. TO METRIC CONVERSION TO CONVERT

INTO

MULTIPLY BY

LINEAR MEASUREMENT

Miles Yards Feet Feet Inches Inches Inches

Kilometers Meters Meters Centimeters Meters Centimeters Millimeters

AREA

Square Miles Square Feet Square Inches Acre

Square Kilometers Square Meters Square Centimeters Hectare

VOLUME

Cubic Yards Cubic Feet Cubic Inches

Cubic Meters Cubic Meters Cubic Centimeters

0.7646 0.02832 16.39

WEIGHT

Tons (Short) Pounds Ounces (Avdp.)

Metric Tons Kilograms Grams

0.9078 0.4536 28.3495

PRESSURE

Pounds/Sq. In.

Kilopascal

6.895

WORK

Foot–Pounds

Newton–Meter

1.356

LIQUID VOLUME

Quarts Gallons

Liters Liters

0.9463 3.785

LIQUID FLOW

Gallons/Minute

Liters/Minute

3.785

TEMPERATURE

Fahrenheit

Celsius

1.609 0.9144 0.3048 30.48 0.0254 2.54 25.4 2.59 0.0929 6.452 0.4047

1.Subtract 32° 2. Multiply by 5/9 –8–14–

2400 Series Loader Service Manual

STANDARD TORQUE SPECIFICATIONS FOR BOLTS The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from Clark that have zinc phosphate coating are specified by the letter H following the part number.

THREAD SIZE INCH LBS. (Nm)

FOOT LBS. (Nm)

SAE GRADE 5

SAE GRADE 8

.250

80–90 (9,0–10,2)

110–120 (12,4–14,0)

.3125

180–200 (20,3–22,6)

215–240 (24,3–27,10

.375

25–28 (34–38)

35–40 (47–54)

.4375

40–45 (54–61)

60–65 (81–88)

.500

65–70 (88–95)

90–100 (122–136)

.5625

90–100 (122–136)

125–140 (170–190)

.625

125–140 (170–190)

175–190 (240–260)

.750

220–245 (300–330)

300–330 (410–450)

.875

330–360 (450–490)

475–525 (645–710)

1.000

475–525 (645–710)

725–800 (985–1085)

1.125

650–720 (880–975)

1050–1175 (1425–1600)

1.250

900–1000 (1200–1360)

1475–1625 (2000–2200)

1.375

1200–1350 (1630–1830)

2000–2200 (2720–2980)

1.500

1500–1650 (2040–2240)

2600–2850 (3530–3870)

1.625

2000–2800 (2720–2980)

3450–3800 (4680–5150)

1.750

2500–2750 (3390–3730)

4300–4800 (5830–6500)

1.875

3150–3500 (4270–4750)

5500–6100 (7450–8300)

2.000

3800–4200 (5150–5700)

6500–7200 (8800–9800)

–8–15–

2400 Series Loader Service Manual

–8–16–

2400 Series Loader Service Manual

2400–1 ®

Revision Number

25 June 1990

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT ARTICULATED LOADER Model

2400 SERIES

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720455 (5–90)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

At the time the above manual was printed, Sheet 4 of 4 (P/N 6720500) was not available. Please insert the enclosed chart after Sheet 3 of 4 (P/N 6720500).

Printed in U.S.A.

2400–2 ®

Revision Number

14 August 1990

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT ARTICULATED LOADER Model

2400 SERIES

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720455 (5–90)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

The attached pages are a revision to the 2400 Series Service Manual (P/N 6720455). Remove and put in the pages as listed below: TAKE OUT

PUT IN

4–13, 4–14

4–13, 4–14 (Revised Aug. 90)

7–11, 7–12

7–11, 7–12 (Revised Aug. 90)

8–1, 8–2

8–1, 8–2 (Revised Aug. 90)

2400–3 ®

Revision Number

29 May 1991

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT ARTICULATED LOADER Model

2400 SERIES

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720455 (5–90)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

The attached pages are a revision to the 2400 Series Service Manual (P/N 6720455). Remove and put in the pages as listed below: TAKE OUT

PUT IN

HYDRAULIC/HYDROSTATIC FLOW CHART FOR MODEL 2410 Chart # 6720493 (Printed May 1990)

HYDRAULIC/HYDROSTATIC FLOW CHART FOR MODEL 2410 Chart # 6720493 (Printed May 1991)

HYDRAULIC/HYDROSTATIC SYSTEM OPERATION Chart # 6720493 (Printed May 1990)

HYDRAULIC/HYDROSTATIC SYSTEM OPERATION Chart # 6720493 (Printed May 1991)

HYDRAULIC/HYDROSTATIC FLOW CHART FOR MODEL 2410 BACKHOE Chart # 6720494 (Printed May 1990)

HYDRAULIC/HYDROSTATIC FLOW CHART FOR MODEL 2410 BACKHOE Chart # 6720494 (Printed May 1991)

HYDRAULIC/HYDROSTATIC SYSTEM OPERATION Chart # 6720494 (Printed May 1990)

HYDRAULIC/HYDROSTATIC SYSTEM OPERATION Chart # 6720494 (Printed May 1991)

HYDRAULIC/HYDROSTATIC FLOW CHART FOR MODEL 2410 THREE–POINT HITCH Chart # 6720495 (Printed May 1990)

HYDRAULIC/HYDROSTATIC FLOW CHART FOR MODEL 2410 THREE–POINT HITCH Chart # 6720495 (Printed May 1991)

HYDRAULIC/HYDROSTATIC SYSTEM OPERATION Chart # 6720495 (Printed May 1990)

HYDRAULIC/HYDROSTATIC SYSTEM OPERATION Chart # 6720495 (Printed May 1991)

2–29, 2–30

2–29 (Revised May 91), 2–30 (Revised May 91)

INSTRUMENT PANEL WIRING DIAGRAM (P/N 6720500) MODEL 2410 MTC (Printed May 1990) 4 of 4 Pages

INSTRUMENT PANEL WIRING DIAGRAM (P/N 6720500) MODEL 2410 MTC (Printed May 1990) 4 of 4 Pages (Revised May 1991)

2400–4 ®

Revision Number

20 July 1992

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT ARTICULATED LOADER Model

2400 SERIES

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720455 (5–90)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

The attached pages are a revision to the 2400 Series Service Manual (P/N 6720455).

Remove and put in the pages as listed below: TAKE OUT

PUT IN

HYDRAULIC/HYDROSTATIC FLOW CHART FOR MODEL 2410 Chart # 6720493 (Printed May 1991)

HYDRAULIC/HYDROSTATIC FLOW CHART FOR MODEL 2410 Chart # 6720493 (Printed May 1991) (Revised July 1992)

HYDRAULIC/HYDROSTATIC FLOW CHART FOR MODEL 2410/BACKHOE Chart # 6720494 (Printed May 1991)

HYDRAULIC/HYDROSTATIC FLOW CHART FOR MODEL 2410/BACKHOE Chart # 6720494 (Printed May 1991) (Revised July 1992)

HYDRAULIC/HYDROSTATIC FLOW CHART FOR MODEL 2410/THREE–POINT HITCH Chart # 6720495 (Printed May 1991)

HYDRAULIC/HYDROSTATIC FLOW CHART FOR MODEL 2410/THREE–POINT HITCH Chart # 6720495 (Printed May 1991) (Revised July 1992)

3–23, 3–24

3–23, 3–24 (Revised July 1992)

DRIVE SYSTEM–TAB PAGE

DRIVE SYSTEM–TAB PAGE (Revised July 1992) 4–47 (Added July 1992)

2400–5 ®

Revision Number

8 February 1994

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT ARTICULATED LOADER Model

2400 SERIES

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720455 (5–90)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

The attached pages are a revision to the 2400 Service Manual (P/N 6720455). Take out and put in the pages as listed below:

TAKE OUT

PUT IN

DRIVE SYSTEM – TAB PAGE

DRIVE SYSTEM – TAB PAGE (Revised Jan. 94) 4–14a thru 4–14g (Added Jan. 94)

2400–6 ®

Revision Number

28 February 1994

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT ARTICULATED LOADER Model

2400 SERIES

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6720455 (5–90)

NOTICE

Insert This Sheet With The Appropriate Manual For Future Reference.

The attached pages are a revision to the 2400 Service Manual (P/N 6720455). Take out and put in the pages as listed below:

TAKE OUT

PUT IN

4–29, 4–30 4–33, 4–34

4–29 (Revised Feb. 94), 4–30 4–33, 4–34 (Revised Feb. 94)