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
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
630.631.632 Loader Service Manual
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
630. 631. 632 Loader Service Manual
(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
630.631.632 Loader Service Manual
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
630.631.632 Loader Service Manual
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)
630.631.632 Loader Service Manual
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)
630.631.632 Loader Service Manual
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
630. 631. 632 Loader Service Manual
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
630. 631. 632 Loader Service Manual
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