bobcat 630 | 631 | 632 skid steer loader service manual. check electrical charging system. 7. check...

BC-S-630,631+

BBoobbccaattService Manual

630, 631 & 632Bobcat &

Melroe Bobcat

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF BOBCAT OR IT’S SUCCESSORS. BOBCAT AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

Serv

ice

Man

ual

http://www.jensales.com/products/bobcat-skid-steer-loader-service-manual-bc-s-630-631.html

Service Manual


FOREWORD

This manual provides instruction for routine servicing and adjustment of the Bobcat, and detailed overhaul instructions of the drive system, loader hydraulic/hydrostatic system and general main frame components.

Refer to the Owner's Manual for general operating instructions (Starting Procedure, .Daily Checks, Bucket Operation, Minor Maintenance, etc.).

A general inspection of the following items should be made whenever the machine has had service or repair:

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

2. Inspect for any sign of fuel, oil or hydraulic fluid leaks.

3. Lubricate the machine.

4. Check battery condition and cables.·

5. Inspect air cleaner system for damage or leaks. Check element and make replacement, if necessary.

6. Check electrical charging system.

7. Check indicator lamps.

8. Check tires for wear and pressure.

9. Check the Bob·Tach attachment for condition. Inspect the wedges for damage or wear.

10. Inspect safety items fot-condition (Operator Guard. Seat Belt, Safety Treads, Lamps, etc.).

1 1. Make a visual inspection for loose or broken parts or connections.

12. Operate the loader, checking all functions.

Advise the owner if any of the above items are in need of repair.

CONTENTS

ALPHABETICAL INDEX • • • • . . • • . . . . • . . . . . • . • . . • . . • .. 9 DRIVE SYSTEM . • . . • . . . . . . • • • • . . • . . . . • • • . • • . . • . .• 4 ELECTRICAL SYSTEM .•.......•.......•....•.....• 6 ENGINE SERVICE . . . . . . . . • . . . . • . • . . . . • . . . . . • . . . • .• 7 HYDRAULIC SYSTEM. . . . . . . . . . • . . • . . . • . . . . . . . . • . .. 2 HYDROSTATIC SYSTEM. . . • . . . . . . . . . . . • . . . . . • . . • • •• 3 MAIN FRAME .......•.•.•.•••........•....••.... 5 PREVENTIVE MAINTENANCE •..•.............••..... 1 TECHNICAL DATA . . . . . . . . . . • . . . . . . . . • • . . . . . . . . . .. 8

PREVENTIVE MA INTENANCE

HYDRAULIC SYSTEM

HYDROSTATIC SYSTEM

DRIVE SYSTEM

MAIN FRAME

ELECTRICAL SYSTEM

ENGINE SERVICE

TECHNICAL DATA

ALPHABETICAL INDEX

630.631.632 Loader Service Manual


PREVENTIVE MAINTENANCE

80~TACH AND ~VOT ~NS ....... . ENGINE MUFFLER ............... . ENGINE SERVICE (GENERAL) ....... . HYDRAULIC FLUID AND FILTER ..... . INTRODUCTION ............•..... LOADER lUBRICATION .......•..... SERVICE INTERVALS ............. . TIRES ....•.................... TRANSMISSION & DRIVE SYSTEM '"

Paragraph Number

1-8 1-9 1-3 1-4 1-1 1-7 1-2 1-6 1-5

Page Number

1-16 1-17 1-4

1-14 1-1

1-16 1-3

1-15 1-15

PREVENTIVE MAINTENANCE

630. 631. 632 Loader Service Manual


632: Carburetor Adjustment (Fig. 1-23)

The only adjustments to the carburetor are; (1 I idle adjusting needle and (2) throttle idle adjustment.

Idle Adjusting Needle

(1) Turn needle all the way in. DO NOT use force, it will cause damage to the needle.

(2) Turn needle out (counterclockwise) about 1-1/2 turns, then start engine.

(3) If engine does not run smoothly, turn needle out until it does.

Throttle Idle Adjustment

(1) Start the engine.

Fig. 1 -23 Carburetor Adjustment 16321

(2) Hold governor speed change lever against the stop.

(3) Make adjustment to throttle idle screw until engine runs 800 RPM.

1 -3.4b Fuel Shut-Off

The 630 and 632 Bobcat are equipped with a fuel-shut (automatic). The fuel shutoff solenoid is activated when the ignition switch is turned "off" and shuts off the fuel to the carburetor.

Be sure to check the wires to the fuel shut-off solenoid for opens when the engine stops or will not start.

NOTE: On the 630; SIN 12,999 & Below and 632; SIN 12,046 & Below there is a kit available to install the fuel line shut-off on these loaders (See the Parts Catalog for Part Number).

1-3.5 Engine Cooling System

630 and 631 : These engines are cooled with air. Be sure cooling fins on cylinder heads are kept clean.

632: Check coolant level at the coolant recovery tank (Fig. 1 -24). The tank must be 1/3 full when cold. Also, when engine is cold. check to see that radiator is full. Fig. 1-25 Belt Tension Adjustment (6311

-1-10-

Fig. 1-24 Coolant Recovery Tank

C-2299



HYDRAULIC SYSTEM

CONTROL VALVE ............... . HYDRAULIC CIRCUIT •............. HYDRAULIC CYLINDERS ........... . HYDRAULIC PUMP .........•.•.... HYDRAULIC SYSTEM INFORMATION .. HYDRAULIC TROUBLESHOOTING .... . QUICK-COUPLERS ................ .

Paragraph Number

2-4 2-1 2-6 2-5 2-2 2-3 2-7

Page Number

2-9 2-7

2-11 2-11 2-7 2-8

2-17

. HYDRAULIC SYSTEM


HYDROSTATIC SYSTEM

BY-PASS VALVE ................ . HYDROSTATIC CIRCUIT ........... . HYDROSTATIC MOTORS, (630 & 632

SIN 15320 & Below). ............ . HYDROSTATIC MOTOR REPAIR, (630 &

632 SIN 15320 & Below) ......... . HYDROSTATIC MOTOR REPAIR, (631 &

632 SIN 15321 & Above) ......... . HYDROSTATIC PUMP ASSEMBLY ... . HYDROSTATIC TROUBLESHOOTING .. . PUMP ASSEMBLy ............... . REPLENISHING VALVE ............ . STEERING CONTROLS ............ . STEERING LINKAGE ADJUSTMENT ... .

Paragraph Number

3-5 3-1

3-8

3-9

3-10 3-7 3-2 3-6 3-4

3-11 3-3

Page Number

3-18 3-13

3-26

3-30

3-36 3-19 3-13 3-18 3-17 3-41 3-16

HYDROSTATIC SYSTEM



(14) Remove the brake disc.

If the discs can not be removed because of limited space between the sprocket retaining nuts, loosen the four (4) bolts on one hydrostatic motor and move the motor to make space for removing the brake discs.

(15) Use a chain breaker tool to separate both front chains.

(16) Remove the front chains from the motor sprockets.

(17) Disconnect the four (4) high pressure hoses from the pump and motors.

(18) Remove the hoses.

(19) Install plugs in the motor and pump openings.

(20) Remove the case drain hoses from the motors.

(21) Use a lead pencil to draw an outline around the outside perimeter of motors. This will aid as a reference to remove paint from chaincase later.

(22) Remove the four (4) fastening bolts for motors (Fig. 3-21).

(23) Hold motor at an angle and remove rear chains from the motor sprockets (Fig. 3-22).

3-8.2 Installing Hydrostatic Motors

(1) Remove all paint from the motor mounting area as outlined by the lead pencil.

(2) Install the motor with two (2) large openings facing toward the rear.

(3) Put the rear chain over the motor sprocket (Fig. 3-221.

(4) Install bolts, washers and use new locknuts into motor. Hand tighten the nuts.

(5) Install the front drive chains. Use special tool (See Tool Catalog) or pliers to pull chain ends together (Fig. 3-22).

(6) Install a new connector link from the outside of the chain (Fig. 3-23).

(7) Use a vise grip with narrow jaws to press the connector link plate on the connector link pins.

(8) Put a 5/8" thick steel block behind the new connector link. Use a ball peen hammer to peen the two (2) pins on the connector link (Fig. 3-24). (A special tool is also available for installing links (See Tool Catalog)).

(9) Repeat this procedure for both motors.

(10) Install both brake discs over the sprockets on the motors.

NOTE: It may be necessary to temporarily put both brake discs on one motor sprocket to make room for tightening the four motor fastening bolts.

(11) Turn the disc retaining washer so that the lobes on the disc are over the lobes of the retaining washer (Fig. 3-25\.

e ·C·2364

Fig. 3..,...24 Peening Connector Links

-3-27-

C-2373

Remove Motor Mount Bolts

Fig.3-22 Remove.rlhotor

o. Connector link

Fig. 3-23 Install Front Drive Chains

B·3022

Fig. 3-25 Disc Brake Installed



DRIVE SYSTEM

AXLE AND BEARINGS ............ . BRAKE INSTAllATION ............ . FINAL DRIVE ................... .

Paragraph

Number

4-2 4-3 4-1

Page

Number

4-1 4-2 4-1

DRIVE SYSTEM

630, 631, 632 Loader Service Manual


MAIN FRAME

BOB-TACH .................... . BOB-TACH FRAME .............. . LIFT ARMS .................... . MAIN FRAME TO UPRIGHT

FRAME BOLTS . . . . . . . . . . . . . . . . . PIVOT PIN REPLACEMENT OF

THE LIFT ARMS ............... . ROPS REMOVAL & INSTALLATION .. .

Paragraph Number

5-3 5-6 5-5

5-4

5-2 5-1

Page Number

5-2 5-3 5-3

5-3

5-1 5-1

MAIN FRAME



ELECTRICAL SYSTEM

Paragraph Number

ALTERNATOR SERVICE .. ,. .. .. .. ,. .. .. .. .. .. .. 6-4 ELECTRICAL CIRCUIT (631 & 632) .... 6-3 ELECTRICAL GENERAL INFORMATION 6-2 STARTER ....................... 6-5 USING AN EXTRA BATTERY ........ 6-1

Page Number

6-24 6-21 6-19 6-26 6-1

ELECTRICAL SYSTEM

630,631,632 Loader Service Manual


ENGINE SERVICE

DUETZ ENGINE (631) ............ . FORD ENGINE (632) ............. . WISCONSIN (630) ............... .

Paragraph Number

78 7C 7A

Page Number

78-1 7C-1 7A-1

ENGINE SERVICE

.... .. ....

WISCONSIN (630)

DEUTZ (631)" ,

- FORD (632) . ,

630,631.632 Loader Service Manual


ENGINE SERVICE (WISCONSIN ENGINE-630) Paragraph

Number

ACCESSORIES INSTALLATION ...... . ACCESSORIES REMOVAL .......... . AIR HOUSING INSTALLATION ...... . AIR HOUSING REMOVAL .......... . CAMSHAFT INSTALLATION ........ . CAMSHAFT REMOVAL ............ . CAMSHAFT GEAR INSTALLATION ... . CAMSHAFT GEAR REMOVAL ....... . CARBURETOR & MANIFOLD

INSTALLATION " .............. . CARBURETOR & MANIFOLD

REMOVAL. ................... . CARBURETOR SERVICE ... . . . . . . . . . CRANKSHAFT INSTALLATION ..•..•.. CRANKSHAFT REMOVAL .......... . CYLINDER BLOCK INSTALLATION ... . CYLINDER BLOCK REMOVAL ....... . CYLINDER HEAD INSTALLATION .•... CYLINDER HEAD REMOVAL .•.•..... ENGINE IGNITION SYSTEM ......... . ENGINE REMOVAL •............... FLYWHEEL INSTALLATION ....•..... FLYWHEEL REMOVAL ............ . GEAR COVER INSTALLATION ..•..... GEAR COVER REMOVAL .......... . GOVERNOR SERVICE ............. . IDLER GEAR & SHAFT

INSTALLATION ................ . IDLER GEAR & SHAFT

REMOVAL .................... . OIL PAN INSTALLATION .....•..... OIL PAN REMOVAL .............. . OIL PUMP INSTALLATION ......... . OIL PUMP REMOVAL ............. . PISTON RING INSTALLATION ....... . PISTONS & CONNECTING ROO

INSTALLATION . . . . . . . . . . . . . . . . . PISTONS & CONNECTING ROO

REMOVAL .................... . TROUBLESHOOTING .... ' .......... . VALVE T APPE1 INSTALLATION ..... . VALVE TAPPET REMOVAL. ........ . VALVES AND SEAT INSERT

INSTALLATION .. . . . . . . . . . • . . . . . VALVES AND SEAT INSERT

REMOVAL .................... .

7A-37 7A-5

7A-35 7A-7

7A-22 7A-19 7A-31 7A-l1

7A-34

7A-8 7A-3

7A-23 7A-18 7A-24 7A-17 7A-33 7A-9 7A-2 7A-4

7A-36 7A-6

7A-32 7A-l0 7A-38

7A-30

7A-12 7A-29 7A-13 7A-28 7A-14 7A-25

7A-27

7A-15 7A-l

7A-21 7A-20

7A-26

7A-16

Page Number

7A-ll 7A-4

7A-ll 7A-4 7A-7 7A-7

7A-10 7A-4

7A-l1

7A-4 7A-3 7A-7 7A-7 7A-8 7A-6

7A-l0 7A-4 7A-2 7A-3

7A-ll 7A-4

7A-l0 7A-4

7A-ll

7A-l0

7A-5 7A-9 7A-5 7A-9 7A-5 7A-8

7A-8

7A-5 7A-l 7A-7 7A-7

7A-8

7A-6

WISCONSIN (630)




631 ENGINE SERVICE (OEUTZ ENGINE-FL4110)

Paragraph Number

BLOWER FAN ................... 7B-6 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . 7B-12 CYLINDER HEAD & VALVES. . . . . . . . 7B-7 , CYLINDERS, PISTON,

CONNECTING RODS........... . . 7B-8 ENGINE FRONT COVER . . . . . . . . . . . . 7B-10 ENGINE INFORMATION.. . . . . . . . . . . . 7B-4 ENGINE REMOVAL.. . . . . . . . . . . . . . . 7B- 5 FLYWHEEL ................ , . . . . . 7B-1 3 FUEL INJECTION NOZZLES .. ,...... 7B-3 FUEL SYSTEM ...... , , ..... , . , . . . 7B-1 GOVERNOR .... , , . , . , .... , .. , . . . 7B-11 OIL PUMP, FILTER HOUSING

AND RELIEF VALVE, , . . . . . . . . . . . 7B-9 TROUBLESHOOTING . . . . . . . . . . . . . . . 7B-1

Page Number 78-8

78-17 7B-8

7B-12 7B-14 78-7 7B-7

78-19 7B-7 7B-3

7B-16

7B-13 7B-1

631 ENGINE SERVICE (DEUTZ ENGINE-F2L511)

Paragraph Number

BLOWER FAN ........ , .. ,',..... 7B-20 CAMSHAFT ....... , . . . . . . . . . . . .. 7B-26 CAMSHAFT, CYLINDER HEAD

& VALVE ..... , .. , , .. , ... , ... , 7B-21 CYLINDERS, PISTONS,

CONNECTING RODS .... , ... ,.... 7B-22 ENGINE FRONT COVER . , . , .... , , ,. 7B-24 ENGINE INFORMATION .. , . . . . . . . . .. 7B-18 ENGINE MOUNTS ... , .......... , .. 7B-15 ENGINE REMOVAL. , ........ , .... , 78-19 FLYWHEEL, .. , .... , . . . . . . . . . . . .. 7B-27 FUEL INJECTION NOZZLES ......... 7B-17 FUEL SYSTEM ......... , , , . , , . , .. 7B-1 6 GOVERNOR ...... , ............ ,. 7B-25 OIL PUMP, FILTER HOUSING

AND RELIEF VALVE ......... , , .. 7B-23 TROUBLESHOOTING . . . . . . . . . . . . . .. 7B-14

Page Number 78-27 78-38

7B-28

7B-22 7B-34 7B-27 7B-21 7B-27 7B-40 7B-26 7B-21 7B-37

7B-34 7B-20

OEUTZ (631) . "

630,631,632 Loader Service Manual


ENGINE SERVICE (FORD ENGINE-632)

CAMSHAFT AND VALVE LIFTERS ... . CAMSHAFT BEARINGS ............ . CARBURETOR REPAIR ............ . CHECKS AND ADJUSTMENTS ...... . CONNECTING ROD BEARINGS ...... . CRANKSHAFT .................. . CRANKSHAFT REAR OIL SEAL ..... . CYLINDERHEAD . . . . . . . . . . . . . . . . . . ENGINE DIAGNOSIS & TESTING ..... ENGINE FRONT COVER, TIMING

CHAIN & CRANKSHAFT SPROCKETS ENGINE OVERHAUL .............. . ENGINE REMOVAL ............... . FLYWHEEL RING GEAR ........... . FRONT OIL SEAL .........•...... INTAKE MANIFOLD ..........•.... MAIN BEARINGS ................ . OIL PAN ...................... . OIL PUMP, INSPECTION ........... . OIlL PUMP, REMOVAL ......•...... PISTONS AND CONNECTING RODS ... TIMING CHAIN TIGHTENER ..••.•... TROUBLESHOOTING . . . . . . . . • . . . . . . VALVE PUSHROD .........•...... VALVE ROCKER ARM COVER, ROCKER ARM AND/OR SHAFT ..... . VALVE SPRING, RETAINER AND STEM

SEAL (CYLINDER HEAD INSTALLED). VALVE SPRING, RETAINER AND STEM

SEAL (CYLINDER HEAD REMOVED) . WATER PUMP .................. .

Paragrap,", Page Number 7C-18 7C-27

7C-3 7C-2

7C-24 7C-26 7C-22 7C-ll

7C-4

7C-15 7C-5 7C-7

7C-19 7C-16 7C-10 7C-23 7C-20 7C-6

7C-21 7C"";25 7C-17

7C-1 7C-9

7C-8

7C-13

7C-12 7C-14

Number 7C-23 7C-30 7C-9 7C-2

7C-27 7C-29 7C-26 7C-18 7C-9

7C-21 7C-l0 7C-16 7C-25 7C-23 7C-18 7C-26 7C-25 7C-16 7C-26 7C-27 7C-23 7C-l

7C-17

7C-17

7C-20

7C-20 7C-21

FORD (632) .

630, 631,632 Loader Service Manual


TECHNICAL DATA

ENGINE SPECIFICATIONS (630 WISCONSIN) ............. .

ENGINE SPECIFICATIONS (631 OEUTZ) ................. .

ENGINE SPECIFICATIONS (632 FORD) .................. .

TECHNICAL DATA ............... .

Paragraph Number

Page Number

8A-1

88-1

8C-1 80-1

WISCONSIN (630)

OEUTZ (631)

FORD (632)

TECHNICAL DATA

TECHNICAL DATA.

630.631.632 Loader -. Service Manual


ENGINE SPECIFICATIONS, 630 (WISCONSIN)

ENGINE SPECIFICATIONS .......... . LOADER SPECIFICATIONS ......... .

Paragraph Number

SA-1

Page Number

SA-1 SA-3

WISCONSIN (630)



SA -1.4 Crankshaft

Crank Pin Diameter ................... 1.S76 -1.875 (47,625 -47,650) Crank Pin Length. . . . . . . . . . . . . . . . . . . .. 1.130 - 1.135 (28,702 - 28,S29) Crankshaft End Play (Cold) .... . . . . . . . . . . . . .. .002 - .004 (O,051 - 0,102)

SA-l.5 Idler Gear

Idler Gear to Shaft Collar Clearance. . . . . . . . . .. .003 - .004 (0,0762 - 0,1 020)

SA-l.6 Connecting Rod

Connecting Rod to Crank Pin Clearance (Diameter) .0012 - .0033 (0,030 - 0,086) Connecting RodtoCrankPinClearance(SideClearance) .009 - .018 (O,229 - 0.457) Connecting Rod Bushing to Piston Pin Clearance.. .0005 - .0011 (O,013 - 0,028)

SA -1. 7 Piston, Piston Pin, Piston Rings

Piston to Cylinder at Piston Skirt (Wide Skirt) .... .0035 - .0040 (0,089 - 0,1 02) Piston Pin to Piston Clearance .. . . . . . . . . . . .. .0000 - .0008 (0,000 - 0,020) Piston Ring Gap ........................... 010 - .020 (0,254 - 0.508) Piston Ring Side Clearance in Grooves:

Top Ring. . ... . . . . . . . . . . . . . . . . . . . . . .. .002 - .0035 (0,051 - 0,089) 2nd Ring. . . . . . . . . . . . . . . . . . . . . . . . . . .. .001 - .0025 (0,025 - 0,064) 3rd Ring ...... . • . . . . . . . • . . . . . . . . . . .. .001 - .0025 (0,025 - 0,064) Oil Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . .. .0025- .004 (0.064 - 0,101)

SA -1.8 Ignition System

Breaker Point Gap . . . . . . . . . . . . . . . . . . . . . . .. .018 - .022 (0,458 - 0.559) Spark Plug Gap ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .030 (0.762)

8A-l.9 Distributor Advance Characteristics

The distributor has an automatic advance. The automatic advance is 11 -1/20 in the distributor, equal to 230 on the crankshaft. The distributor is fully advanced at 1800 RPM engine speed.

SA-1.10 Starter

The starter is the gear drive type and is 1 2 volt, negative ground.

SA -1 .11 Engine Torque Specifications

Item Cylinder Head Bolts ..................... . Spark Plug ........................... . Manifold Nuts ......................... . Timing Gear Cover . . . . . . . . . . . . . . . . . . . ... . Oil Pan Bolts . . . . . . . . . . . . . . . . . . . . . ..... . Connecting Rod Bolts . . . . . . . . . . . . . . . . .... . Cylinder Block. . . . . . . . . . . . . . . . . . . . . .... . Main Bearing Plate Bolts .................. . Flywheel Nut. . . . . . . . . . . . . . . . . . . . ...... .

Ft.-Lbs. 22 - 24 25 - 30 18 - 23 14 - 18

6-9 22 - 28 40 - 50 25 - 30 40 - 60

-SA-3-

Nm 30 - 33 34 - 41 24 - 31 19 - 24

8 - 12 30 - 38 54 - 68 34 - 41 54 - 81



ENGINE SPECIFICATIONS (631 DEUTZ)

ENGINE SPECIFICATIONS (F2L411 D) .... LOADER SPECIFICATIONS (F2L411 D) ..• ENGINE SPECIFICATIONS (F2L511 ) .•... LOADER SPECIFICATIONS (F2L511) •.•.

Paragraph Number 88-1

88-2

Page Number 88-1 88-4 88-5 88-8

DEUTZ 631



ENGINE SPECIFICATIONS, 632 (FORD)

ENGINE SPECIFICATIONS

LOADER SPECIFICATIONS

Paragraph Page Number Number

8C-1 8C-1 8C-6

FORD (632)

'.:':


DECIMAL & MILLIMETER

EQUIVALENTS

TECHNICAL DATA

HYDRAULIC/HYDROSTATIC TRANSMISSION

FLUID

LOADER TORQUE SPECIFICATIONS

SPECIAL TOOLS

STANDARD TORQUE SPECIFICATIONS

FOR BOLTS ..•..•

U.S. TO METRIC CONVERSION

Paragraph Page

Number Number

80-3

8D-2 80-1 8D-1 80-1 80-3 80-1

80-2 80-3

TECHNICAL DATA


ALPHABETICAL INDEX

ALPHABETICAL INDEX

Paragraph

Number

9-1

Page

Number

9-1

ALPHABETICAL INDEX

630. 631. 632 loader Service Manual


9 ALPHABETICAL INDEX

Subject Page

Air Cleaner System ........................ 1 - 7 Air Housing, installation of (630) ............. 7 A-13 Air Housing, removal of (630) ................ 7 A-6 Alternator Assembly & Installation . . . . . . . . . .... 6 - 26 Alternator Belt, adjustment & replacement ........ 6-23 Alternator Disassembly .................... 6-24 Alternator Output, check ................... 6-24 Alternator Removal ....................... 6-24 Alternator Service . . . . . . . . . . . . . . . . . . . . . ... 6 - 24 Alternator Wiring, check .................... 6-23 Axle Assembly & Installation .................. 4-2 Axles & Bearings .......................... 4-1 Axle & Bep-ring, re.moval . . . . ................. 4 - 1

Battery & Cables, check condition of ............ 6-23 Battery, installing new ..................... 1-14 Battery, using an extra ................. 1 -13, 6-1 Bearings, camshaft (632) .................. 7C-30 Bearings, connecting rods (632) ............. 7C-27 Bearings, main (632) ..................... 7C-26 Bearings, Main & Connecting Rod (632) ........ 7C-15 Blower Fan, F2l4110 (631) ................. 7B-8 Blower Fan, F2l511 0 (631) ................ 7B-27 Bob-Tach ............................... 5-2 Bob-Tach Frame .......................... 5 - 3 Bob-Tach Installation ....................... 5-2 Bob-Tach Pins ............................ 5-2 Bob-Tach & Pivot Pins ................. . ... 1 - 1 6 Bob-Tach Removal ......................... 5-2 Bob-Tach Wedges, checking .................. 5- 2 Brake Installation .......................... 4-2 Breather, crankcase ........................ 1-7 Brush Replacement (Starter) ................. 6-28 By-Pass Valve ........................... 3-18

Camshaft (632) ........................ 7C-14 Camshaft, F2l411 0 (631) ................. 7B-17 Camshaft, f2l511 0 (63TI ................. 7B-38 Camshaft End Play (632) .................. 7C-1 0 Camshaft, installation of (630) . . . . . . . . . . . . ... 7 A - 9 Camshaft Gear, installation of (630) ........... 7A-12 Camshaft, removal of (630) ............ 7A-6, 7A-9 Camshaft Repair (632) .................... 7C-11 Camshaft & Valve lifters (632) .............. 7C-23 Carburetor Adjustment. . . . . . . . . . . . . . . . . . ... 1 - 1 0 Carburetor & Manifold, installation of (630) ...... 7 A-13 Carburetor & Manifold, removal of (630) ......... 7A-6 Carburetor Repair (632) .................... 7C-9 Carburetor Service (630) ................... 7A-5 Carburetor, Throttle & Governor Adjustments (632) .7C-4 Chain Replacement ........................ 4-1 Connecting Rod (632) .................... 7C-14 Connections, 370 Flare ..................... 2-7 Connection, straight thread o-ring .............. 2 - 7 Control Valve ........................ ~ ... 2-9 Control Valve, assembling .................... 2-9 Control Valve, disassembly & inspection of ........ 2-9 Control Valve, removing ..................... 2 - 9 Crankshaft (632) ........... 7C-11, 7C-14, 7C-29 Crankshaft Assembly, F2l41 10 (631) ......... 7B-18 Crankshaft Assembly, F2l5110 (631) ......... 7B-39 Crankshaft Connecting Rod Bearing, to check (632) 7C-11

Subject Page

Crankshaft End Play (632) ................. 7C-1 0 Crankshaft Inspection, F2l411 0 (631) ......... 7B-1 8 Crankshaft Inspection, F2l511 0 (631) ......... 7B- 39 Crankshaft, installation of (630) .............. 7A-9 Crankshaft Journals, reconditioning (632) ....... 7C-1 i Crankshaft, removal of (630) ................ 7 A-9 Crankshaft Removal, F2l411 0 (631) .......... 7B-18 Crankshaft Removal, F2l511 0 (631) .......... 7B- 38 Crankshaft Sprockets (632) ................ 7C- 21 Crankshaft, three bearing (630) ....•.......... 7 A-9 Cylinder Block (632) ............... 7C-13, 7C-15 Cylinder Block, installation of (630) ........... 7 A - 10 Cylinder Block, removal of (630) .............. 7A-8 Cylinder Head (632) ......... 7C-l0, 7C-13,7C-18 Cylinder Head, installation of (630) ........... 7 A-12 Cylinder Head, installation of F2l411 0 (631) .... 7B-11 Cylinder Heads, removal of (630), ............. 7 A-6 Cylinder Head & Valves, F2l411 D (631) ......... 7B-8 Cylinder Head & Valve, F2l511 D (631) ........ 7B- 28 Cylinders, Pistons & Connecting Rods,

F2l411D(631\ ...................... 7B-12 Cylinders, Pistons & Connecting Rods,

F2l5110 (631) ....................... 7B-32

Detent Spool, repair ....................... 2-10 Diode Trio, checking ...................... 6-25 Distributor Maintenance .................... 7 A - 4 Drive Chains . . . . . • . . . . . . . ................ 4-1 Drive, final . . . . . . . . . . . . .................. 4 - 1

Electrical Circuit (631,632) ................. 6-21 Electrical Connector, ROPS .................. 6-22 Electrical General Information . . .............. 6 - 1 9 Electrical System .......................... 6 - 1 Electrical Wiring, check .................... 6-28 Engine Compression, checking (632) ........... 7C-3 Engine Cooling System ..................... 1 - 1 0 Engine Diagnosis & Testing (632) ............. 7C-9 Engine Electrical System .................... 1 - 11 Engine Front Cover, F2l41 1 D (631) ........... 7B-14 Engine Front Cover, F2l511 D (631) ........... 78- 34 Engine Front Cover (632) .................. 7C- 21 Engine Ignition System (630) ................ 7 A-4 Engine Information, F2l411 D (631) ............ 78-7 Engine Information, F2l511 D (631) ........... 78- 27 EngineMounts,F2l411D(631) .............. 7B-2 Engine Mounts, F2l511 D (631) ............. 7B- 21 Engine Muffler, the ....................... 1-17 Engine Oil & Filter ...... . . . . . . . . . . . . . . . .... 1 - 5 Engine Oil Pressure (632) ................... 7C-2 Engine Overhaul (632) .................... 7C-1 0 Engine, removal of (630) ................... 7 A- 5 Engine Removal, F2L411 D (631) .............. 7B-7 Engine Removal, F2L51 10 (631) ............. 7B- 27 Engine, removal of (632) ....•............. 7C-16 Engine Service (General) ..................... 1 -4 Engine Service (630) ...................... 7 A-1 Engine Service, f2L411 D (631 ) ............... 7B-1 Engine Service, F2l511 D (631) .............. 7B- 20 Engine Service Ford Engine (632) .............. 7C-1

Filter Housing, F2l411 0 (631) .............. 7B-14

630,631,632 loader Service Manual


9 ALPHABETICAL INDEX (Cant'd)

Subject Page

Float Adjustment{630} .................... 7 A- 5 Flywheel (632) ......................... 7C-14 Flywheel, F2L411 D (631) ................. 7B-19 Flywheel, F2L511 D (631) ................. 7B-40 Flywheel Face Alignment, check (632) ......... 7C-1 0 Flywheel, installation of (630) ............... 7 A-13 Flywheel, removal of (630) .................. 7A-6 Flywheel Ring Gear (632) .................. 7C-25 Fuel & Control Linkage Adjustment, F2L411 D (631) .7B-3 Fuel Delivery, adjustment of F2L411 D (631) ...... 7B-6 Fuel Delivery, adjustment of F2L511 D (631) ..... 7B-25 Fuel Filter, F2L411 D (631) .................. 7B-4 Fuel Filter, F2L511 D (631) ................. 7B- 22 Fuel Injection Nozzles, F2L411 D ...... ~":- ... :-~~:: . 7B- 7 Fuel Injector Nozzles, F2L511 D (631) .......... 7B-26 Fuel Injection Nozzles, disassembly & repair

F2L411D(631) ........................ 7B-7 Fuel Injection Nozzles, installation of F2L411 D (631) 7B- 7 Fuel Injection Nozzles, removal of F2L411 D (631) .. 7B- 7 !=uellnjection Pump, F2L411 D (631) ........... 7B- 5 Fuel Injection Pump, F2L511 D (631) .......... 7B-23 Fuel Injection Pump, removal of F2L511 D (631) .... 7B- 5 Fuellnjection, removal of F2L511 D (61) ........ 7B- 23 Fuel Injection Pump Service, F2L411 D (631) ...... 7B-5 Fuellnjection Pump Service F2L511 D (631) ..... 7B-23 Fuel Injection Pump, to install F2L411 D (631) ..... 7B- 5 Fuel Injection Pump. to install F2L511 D (631) .... 7B-23 Fuel LiftPump, F2L411D ................... 7B-4 Fuel Lift Pump, F2L511 D .................. 7B-23 Fuel Shut-Off ........................... 1 - 1 0 Fuel System (630, 632) ..................... 1-8 Fuel System, F2L411 D (631) ................ 7B- 3 FueISystem,F2L511D(6311 ............... 7B-21 Fuel System (General) (631) .................. 1-9 Fuel System, venting air from, F2L411 D (631 ) ..... 7B- 3 Fuel System, venting air from. F2L511 D (631) .... 7B- 22

Gear Cover, installation of (630) ............. 7 A-12 Gear Cover, removal of (630) ................ 7 A-6 Governor Adjustment (630) ................. 7 A- 5 Governor, F2L411 D (631) ................. 7B-16 Governor,F2L511D(631) ................. 7B-37 Governor Service (630) ................... 7 A-13

Hydraulic Circuit ......... : ................ 2 - 7 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . .... 2 - 11 Hydraulic Cylinder, removing ................. 2-12 Hydraulic Cylinder, repair ................... 2 - 1 3 Hydraulic Fluid & Filter . . . . . . . . . . . . . . . . . . . . . 1 - 1 4 HydrauliC Pump. . . . . . . . . . . . . . . . . . . . ...... 2 - 1 1 Hydraulic Pump Replacement ................ 2 - 1 1 Hydraulic System Information . . . . . . . . . . . . . . . . . 2 - 7 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1 3 Hydrostatic Motors (630&632S/N 15320&Below) .3-26 Hydrostatic Motor Asseml:>ly (630 & 632

SIN 15320 & Below) .................... 3-32 Hydrostatic Motor Assembly (631 & 632

SIN 15321 & Above ..................... 3-38 Hydrostatic Motor Disassembly (630 & 632

SIN 15321 & Above) .................... 3-36 Hydrostatic Motor Disassembly & Inspection

(630 & 632 SIN 15320 & Below) ............ 3-31

Subject Page

Hydrostatic Motor Inspection (631 & 632 SIN 15321 & Above) .................... 3-38

Hydrostatic Motor, installing (630 & 632 SIN 15320 & Below) .................... 3-27

Hydrostatic Motors, removing the (630 & 632 SIN 15320 & Below) ...................... 3-26 Hydrostatic Motor, repair (630 & 632 SIN 15320 & Below) ...................... 3- 30 Hydrostatic Motor, repair (631 & 632 SIN 15321 & Above) ...................... 3-36 Hydrostatic Motor, start-up procedure .......... 3 - 35 Hydrostatic Pump Assembly, repair . . . . . . . . . . . . 3 - 1 9 Hydrostatic Pump Disassembly . . . . . . . . . . . . . .. 3 - 1 9 Hydrostatic Pump Inspection ................. 3 - 20 Hydrostatic System, to remove air from .......... 3- 29

Idler Gear & Shaft, installation of (630) ......... 7A-12 Idler Gear & Shaft, removal of (630) ............ 7 A-7 Ignition System .......................... 1 - 14 Ignition System (632) ..................... 7C-6 Ignition System Tests (632) ................. 7C- 7 Ignition Timing (632) ...................... 7C-8 Inspecting, 30-hour ........................ 1 - 2 Inspection, pre-delivery ..................... 1 - 2 Intake Manifold (632) .................... 7C-18 Introduction . . . . . . . . . .................... 1 -1

Lift Arms ............................... 5-3 Lift Arms, pivot pin replacment ................ 5 - 1 Lift Cylinder, checking . . . . . . . . . . . . . . . . . . . . . 2 - 11 Lubrication, loader. . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 6

Main Frame To Upright Frame Bolts ............. 5 - 3

Oil Cooler, engine F2L511 D (631) ............ 7B-40 Oil Pan (632) .......................... 7C-25 Oil Pan, installation (6320) ................. 7 A-11 Oil Pan, removal of (630) ................... 7 A- 7 Oil Pump (632) ................... 7C-16, 7C-26 Oil Pump, Filter Housing & Relief Valve

F2L411D(631} ....................... 7B-13 Oil Pump, Filter Housing & Relief Valve

F2L511 D (631) ....................... 7B-34 Oil Pump, installation of (632) ............... 7 A-11 Oil Pump, removal of (630) .................. 7 A- 7 Oil Seal Crankshaft Rear (632) ............... 7C-26 Oil Seal, front (632) ...................... 7C-23

Pistons & Connecting Rods (632) ............. 7C-27 Pistons & Connecting Rods, installation of (630) .. 7 A-1 0 Pistons & Connecting Rods, removal of (630) ..... 7 A- 7 Pistons, Pins & Rings (632) ................. 7C-12 Piston Rings, installation of (630) ............ 7 A - 1 0 Pump Assembly, #1 ....................... 3-24 Pump Assembly, #2 .......... ;" ........ : ... 3-23 Pump Assembly, removal & installation .......... 3 - 1 8 Pumps To Manifold Block, installing . . . . . . . . . . . . 3 - 2 5

Quick-Couplers .......................... 2 -1 7 Quick-Couplers, restriction in the .............. 2 - 1 7

Rectifier, checking . . . . . . . . . . . . . . . . . . . . . . . . 6 - 25

-9-2-630,631,632 Loader

Service Manual


9 ALPHABETICAL INDEX (Cont'd)

Subject Page

Rectifier Module, to check the ................ 6- 21 Regulator, checking ....................... 6-24 Regulator Module, to check the ............... 6- 21 Relief Valve ............................ 2-10 Relief Valve, oil pressure F2L411 0 (631) ....... 7B-14 Relief Valve, oil pressure F2L511 0 (631) ....... 7B-34 Replenishing Valve ....................... 3-17 Replenishing Valves, checking ................ 3-17 ROPS, removal & installation .................. 5-1 Rotor, checking ..............•........... 6-25

Serial Number, engine ...................... 1-1 Serial Number Identification .................. 1 -1 Serial Number, loader ....................•.. 1 -1 Spark Plugs {6301 ......... " ............. 7A-4 Specifications, engine (630) ................. 8A-2 Specifications, engine F2L411 0 (631) ........•. 8B-2 Specifications, engine F2L511 0 (631) .......... 8B-5 Specifications, engine (632) .•.........•..... 8C- 2 Specifications, loader (630) .....•........... 8A-1 Specifications, loader (631) ................. 88-1 Specifications, loader (632) .... , ............ 8C-l Specifications, loader torque .....•........... 80-1 Starter Assembly ....•........•........... 6-28 Starter, disassembly ...................... 6-26 Starter, checking ......................... 6-26 Starter, removing ..............•.....•... 6-26 Stator, (Alternator) checking ...............•. 6-.25 Stator, (Flywheel Altemator) to check the ........ 6-20 Steering Linkage Adjustment . . • • . . . . . . . . . . . . . 3 -16 Steering Controls ....•.............•..... 3-41 Steering Linkages; installing (630 SIN 15300 & Below) (631 SIN 12253 & Below) (632 SIN 15450 & Below) .•....•.•...••.•.. 3-41 Steering Linkages, installing (630 SIN 15301 & Above) (631 SIN 12254 & Above) (632 SIN 1 5451 & Above) .................. 3-43 Symbols ............................... 1 - 1

Tappet (632) .......................... 7C-14 Tilt Cylinder, checking . . . . . . . • . . . . . . . . . • . . . 2 -1 2 Tilt Cylinder Spacer . • . . . . . . . . . . . . . . . . . . . . . 2 - 1 7 Timing Chain (632) .............•........ 7C-21 Timing Chain, tightener (632) ....•.....•.... 7C-23 Timing Procedure (630) ........•.......•... 7 A-4 Tires ••............................... 1-15 Tools, special ........................... 80-1 Tubelines & Hoses ..•.....•...............• 2-7 Transmission & Drive System ...........••... 1-15 Troubleshooting, electrical .•.. . . . . . . . . • . . . . • 6 - 21 Troubleshooting, the flywheel altemator ......... 6-19 Troubleshooting, hydraulic ............•.....• 2-8 Troubleshooting, hydrostatic ................. 3-13 Troubleshooting, Deutz F2L411 0 (631) ......... 7B-1 Troubleshooting, Deutz F2L511 0 (631) ........ 7B-20 Troubleshooting, Ford Engine (632) ............ 7C-1 Troubleshooting, Wisconsin Engine (630) ........ 7A-3

Valves (632) ......... , ................ 7C-ll Valve Clearance (632) ..................... 7C-2 Valve Guides (632) ...................... 7C-1 0 Valve Pushrod (632) ..................... 7C-17

Subject Page

Valve Rocker Arm (632) ................... 7C-17 Valve & Seat Inserts, removal of (630) .......... 7A-8 Valve Seat, grinding (632) ................. 7C-11 Valves & Seat Inserts, installation of (632) ...... 7 A-1 0 Valve Spring (632) ...................... 7C-20 Valve Tappets, installation of (632) ............ 7A-9 Valve Tappets, removal of (632) .............. 7A-9

Water Pump (632) ....................... 7C-21

Yoke, Pintle Bearing, etc., installation ........... 3-21

-9-3-630,631,632 Loader

Service Manual


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