Bobcat 600 600D 610 611 Loader Service Manual 6556276 (6–12) – PDF DOWNLOAD

Description

Bobcat 600 600D 610 611 Loader Service Manual 6556276 (6–12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 600 600D 610 611 Loader Service Manual 6556276 (6–12) – PDF DOWNLOAD

Language : English
Pages : 216
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 600 600D 610 611 Loader Service Manual 6556276 (6–12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 5
GENERAL SERVICE 7
SERVICE SCHEDULE 9
TIRES 10
LOADER LUBRICATION 10
CHANGING AND ADDING HYDRAULIC OIL 10
REMOVING WATER FROM HYDRAULIC TANKS 10
BOB–TACH FRAME 11
HYDRAULIC FLUID FILTERCHANGE 11
ENGINE AIR CLEANER 12
OIL TYPE AIR CLEANER 12
HEAVY DUTY AIR CLEANER 12
ENGINE OIL 13
OIL SPECIFICATIONS FOR ENGINES 13
ENGINE OIL FILTER (Wisconsin) 14
ENGINE OIL FILTER (Duetz Diesel) 14
OIL FILTER (Petter) 14
CRANKCASE AIR VENT (Wisconsin) 15
CRANKCASE AIR VENT (Deutz) 15
FUEL SPECIFICATIONS 15
FUEL FILTER 15
EXCESS FUEL LEVER ADJUSTMENT (Deutz Engine) 17
FUEL PUMP (Wisconsin) 17
FUEL ADJUSTMENT (Petter) 18
ENGINE COOLING SYSTEM 18
WATER SCRUBBER MUFFLER (600 Diesel) 18
IGNITION TIMING (Wisconsin Engine) 19
DISTRIBUTOR MAINTENANCE (Wisconsin) 20
SPARK PLUG (Wisconsin) 20
ELECTRICAL SYSTEMS 21
CHECKING REGULATOR AND RECTIFIER 21
STATOR CHECKS 22
ALTERNATOR CHECK 24
REGULATOR CHECK #1 24
REGULATOR CHECK #2 24
REGULATOR CHECK #3 25
TROUBLESHOOTING 31
TROUBLESHOOTING THE DRIVE SYSTEM 33
TROUBLESHOOTING THE HYDRAULIC SYSTEM 37
TROUBLESHOOTING THE ENGINE 43
DRIVE SYSTEM 49
CLUTCH ADJUSTMENT 52
Adjustment Procedure 52
Steering Clutch Adjustment 53
DISASSEMBLY & ASSEMBLY 55
Disassembly 55
Assembly 57
INSTALLING CLUTCH NEEDLE BEARINGS 61
DRIVE BELT INSTALLATION (Split Shaft) 61
REMOVAL OF DRIVEN SHEAVE 63
INSTALLING OF DRIVEN SHEAVE 64
DRIVEN SHEAVE DISASSEMBLY 65
ASSEMBLY OF DRIVEN SHEAVE (TAPERED JACKSHAFT) 65
DISASSEMBLY OF DRIVE SHEAVE (STRAIGHT JACKSHAFT) 66
ASSEMBLY OF DRIVEN SHEAVE (STRAIGHT JACKSHAFT) 66
DRIVEN SHEAVE ALIGNMENT 66
JACKSHAFT BEARING INSTALLATION 67
REMOVAL OF VARIABLE DRIVE SHEAVE WITH ROTO SWIVEL INSIDE (600, 610 Gasoline and Diesel, Serial Number 72319 and Up) 68
ROTO–SWIVEL DISASSEMBLY 69
ROTO–SWIVEL ASSEMBLY 69
ASSEMBLY PROCEDURES FOR 610 VARIABLE SPEED WITH ROTO–SWIVEL INSIDE 69
REMOVAL OF VARIABLE SHEAVE WITH ROTO–SWIVEL OUTSIDE (600 Gasoline, LP and Diesel; Serial Number 67253–72318) 70
REMOVAL OF FRAME SUPPORT VARIABLE SHEAVE (600 Gasoline and LP; serial Number 62796–67252) 70
AXLE REMOVAL (FRONT AXLE) 71
AXLE BEARING AND SEAL INSTALLATION 72
INSTALLATION OF AXLE 73
AXLE SPROCKET REMOVAL & INSTALLATION 74
LOWER JACKSHAFT REMOVAL 75
LOWER JACKSHAFT SPROCKET REPAIR 76
LOWER JACKSHAFT INSTALLATION 76
DRIVE CHAIN ADJUSTMENT 78
BRAKE ASSEMBLY 80
ASSEMBLY OF BRAKE 80
BRAKE ADJUSTMENT 81
HYDRAULIC SYSTEM 83
HYDRAULIC SYSTEM 85
Hydraulic Circuit Operation 85
HYDRAULIC SYSTEM (600 Electric and 600 Diesel W/Petter Engine) (Hydraulic Flow) 86
Hydraulic System (600, 610 Gasoline and LP Gas) (Hydraulic Fluid Flow) 85
HYDRAULIC SYSTEM (600 and 610 Diesel W/Deutz Engine) (Hydraulic Flow) 85
RESTRICTOR FOR TILT HYDRAULIC CIRCUIT (Grapple Operation Only) 86
CHECKING THE CONDITION OF HYDRAULIC SYSTEM 86
RECOMMENDED HYDRAULIC OILFLOW RATE 87
CHECKING CONDITION OF HYDRAULIC PUMP 87
CHECKING THE PRESSURE SETTING OF THE CARTRIDGE RELEASE (In Lift and Auxiliary Control Valve) 88
MASTER RELEASE VALVE ADJUSTMENT 88
CARTRIDGE RELEASE ADJUSTMENT 88
CHECKING VARIABLE SPEED VALVE PRESSURE ADJUSTMENT (Variable Speed Swivel Couplings) 89
Variable Speed Control Valve With Holding Pressure Release Valve 89
CHECKING PRESSURE ADJUSTMENT (Variable Speed Control Valve with no Holding Pressure Valve ) 90
VARIABLE SPEED CLOSING PRESSURE ADJUSTMENT (Variable Speed Control Valve with or with no Holding Release Valve) 90
VARIABLE SPEED HOLDING RELEASE PRESSURE SETTING (600 PSI [4137 kPa] Minimum) 90
DISASSEMBLY OF VARIABLE SPEED CONTROL VALVE (Seal Replacement with Control Valve in the Bobcat) 91
ASSEMBLY OF VARIABLE SPEED CONTROL VALVE, SEAL REPLACEMENT WITH CONTROL VALVE IN THE BOBCAT (With Holding Release Valve) 91
CONTROL VALVE SEAL INSTALLATION 92
INSTALLING VALVE SPOOL SEALS IN THE VARIABLE SPEED CONTROL VALVE 93
HYDRAULIC PUMP SERVICE (Webster Pump) 94
DISASSEMBLY 94
ASSEMBLY OF HYDRAULIC PUMP (Webster Pump) 95
HYDRAULIC PUMP DISASSEMBLY (Cessna Pump) 96
HYDRAULIC PUMP ASSEMBLY (Cessna Pump) 96
HYDRAULIC LIFT OR TILT CYLINDER DISASSEMBLY 97
INSTALLATION OF CYLINDER SEALS 97
HYDRAULIC CYLINDER ASSEMBLY 97
HYDRAULIC PUMP ALIGNMENT (500 ELECTRIC) 98
HYDRAULIC PUMP ALIGNMENT (600 Wisconsin) 99
37° Flare Connections 100
Tubelines and Hoses 100
Installing O–Rings 100
WISCONSIN ENGINE SERVICE 101
RETURN OF NORMAL COMPRESSION 103
GOVERNOR ADJUSTMENT 103
STORAGE OF ENGINE 104
RETURN STORED ENGINE TO SERVICE 104
CARBURETOR ADJUSTMENT 104
CARBURETOR RECONDITIONING 104
TO DISASSEMBLE THROTTLE BODY 104
DISASSEMBLY OF THE FUEL BOWL 105
O ASSEMBLE FUEL BOWL AND INTAKE ASSEMBLY 105
TO ASSEMBLE THROTTLE BODY 106
ASSEMBLY OF FUEL BOWL AND THROTTLE BODY 106
LP CARBURETOR SERVICE 107
CARBURETOR REMOVAL 107
LP CARBURETOR RECONDITIONING 107
DISASSEMBLY PROCEDURE LP CARBURETOR 107
CLEANING AND INSPECTION 108
ASSEMBLE LP CARBURETOR 108
VAPORIZER & PRIMARY REGULATOR SERVICE 110
DISASSEMBLING THE VAPORIZER 110
TO ASSEMBLE THE VAPORIZER 110
ADJUSTMENT OF VAPORIZER 111
LP FUEL FILTER LOCK–OFF 112
FUEL FILTER LOCK–OFF DISASSEMBLY 112
ENGINE RECONDITIONING 113
REMOVAL OF ENGINE 113
REMOVAL OF ACCESSORIES 113
REMOVAL OF FLYWHEEL 113
REMOVAL OF AIR HOUSING 113
REMOVAL OF CARBURETOR AND MANIFOLD 114
REMOVAL OF CYLINDER HEAD 114
REMOVAL OF GEAR COVER 114
REMOVAL OF CAMSHAFT 114
REMOVAL OF IDLER GEARAND SHAFT 114
REMOVAL OF OIL PAN 114
REMOVAL OF OIL PUMP 114
REMOVAL OF PISTONS AND CONNECTING RODS 115
REMOVAL OF VALVES AND SEAT INSERTS 115
REMOVAL OF CYLINDER BLOCK 116
REMOVAL OF CRANKSHAFT 116
REMOVAL OF CAMSHAFT 116
REMOVAL OF VALVE TAPPET 116
ASSEMBLY OF ENGINE AFTER RECONDITIONING INSTALLATION OF VALVE TAPPETS 116
INSTALLATION OF CAMSHAFT 116
INSTALLATION OF CRANKSHAFT 117
INSTALLATION OF VALVES AND SEAT INSERTS 117
INSTALLATION OF CYLINDER BLOCKS 117
INSTALLATION OF PISTON RINGS 117
INSTALLATION OF PISTONS AND CONNECTING RODS 118
INSTALLATION OF OIL PUMP 118
OIL PAN INSTALLATION 118
INSTALLATION OF IDLER GEAR AND SHAFT 119
INSTALLATION OF CAMSHAFT GEAR 119
INSTALLATION OF GEAR COVER 119
INSTALLATION OF CYLINDER HEAD 119
INSTALLATION OF CARBURETOR AND MANIFOLD ASSEMBLY 120
INSTALLATION OF AIR HOUSING 120
INSTALLATION OF FLYWHEEL 120
INSTALLATION OF ACCESSORIES 120
DEUTZ ENGINE SERVICE 121
INSTRUCTIONS FOR TIGHTENING BOLTS AND STUDS 123
CHECK AND ADJUSTMENTS 123
Adjustment of Valve Clearance 123
Compression Check 124
Checking Fuel System 124
Checking Fuel Injection Pump 124
To Find top Dead Center And Start Of Fuel Injection 125
Adjustment Of Start Of Fuel Injection 125
ENGINE RECONDITIONING 126
TO ASSEMBLE THE ENGINE 128
INSPECTION AND REPAIR 139
Checking The Crankshaft 139
Reconditioning Crankshaft 139
Checking Crankcase 139
Checking And Installing Main Bearing 140
Checking And Installing Camshaft And Bearings 141
Checking The Oil Pump 142
Installing A New Gear Starter Ring On Flywheel 142
Checking Front Cover And Repair Of Engine Governor 142
Check and Repair Of The Governor 145
Checking And Replacement Of Connecting Rod Bearings 146
Checking And Replacement Of Piston Pin Bushing 147
Checking Cylinders 147
Checking And Measuring Pistons 147
Repair Of Cylinder Head 148
Repair Of Rocker Arms 151
Repair Of Cooling Air Blower 151
Removing And Installing A Fuel Injection Nozzle 152
GENERAL ENGINE DATA (F2L410) 153
Torque Specifications (Deutz Engine) 153
FITS, CLEARANCES, ADJUSTMENTS – DEUTZ ENGINE 154
Oil System 154
Fuel System 154
Governor, Front Cover and Throttle 154
Cylinder Head and Valves 154
Cylinder and Piston 154
Camshaft, Crankshaft, Bearings 155
SPECIAL TOOLS 155
Mainframe & Hydraulics 155
Deutz Engine Tools 155
PETTER ENGINE SERVICE 157
ENGINE DISASSEMBLY AND REPAIR 159
Removal Of Connecting Rod 160
Removal Of Crankshaft 160
Removal Of Camshaft 161
Removal Of Oil Pump And Governor Assembly 162
Oil Filter 162
Lubricating Oil Pump 164
Installation Of Camshaft 165
Connecting Rod Assembly 166
Installation Of Cylinders And Pistons 166
Piston Assembly 167
Installation Of Cylinder Heads 167
Installation Of Valve Rocker Gear 168
Adjustment Of Valve Rockers 168
Adjustment Of Decompressor 168
Fuel Pump Installation 168
Fuel Filter Assembly 168
Fuel And Oil Filter Assembly 168
Timing The Engine 168
Injector Installation 169
TECHNICAL DATA (Fits, Clearances & Torques) 170
SPECIFICATIONS 171
ENGINE SPECIFICATIONS (WISCONSIN) 173
ENGINE SPECIFICATIONS (Wisconsin) 175
Fuel Specifications 175
Engine Oil 175
Specifications 175
Valve Mechanism 176
Crankshaft 176
Idler Gear 176
Connecting Rod 176
Piston, Piston Pin, Piston Rings 176
Ignition System 176
Distributor Advance Characteristics 176
Starter 176
Engine Torque Specifications 176
600 LOADER (WISCONSIN GAS) 177
OPERATIONAL & PERFORMANCE 177
ENGINE 177
LOADER HYDRAULICS 177
ELECTRICAL 177
DRIVE SYSTEM 177
CAPACITIES 177
COUNTERWEIGHT 177
MACHINE WEIGHT (Less Bucket) 177
610 LOADER (WISCONSIN GAS) 178
OPERATIONAL & PERFORMANCE 178
ENGINE 178
LOADER HYDRAULICS 178
ELECTRICAL 178
DRIVE SYSTEM 178
CAPACITIES 178
COUNTERWEIGHT 178
MACHINE WEIGHT (Less Attachments) 178
ENGINE SPECIFICATIONS (DEUTZ) 179
ENGINE SPECIFICATIONS (Deutz F2L 411) 181
Fuel System 181
Lubrication System 181
overn, Front Cover and Throttle 182
Cylinder Head and Valves 182
Cylinder, Piston and Connecting Rod 182
Camshaft, Crankshaft, Bearings 182
Torque Specifications 183
Special Tools 183
600D LOADER (DEUTZ DIESEL) 184
OPERATIONAL & PERFORMANCE 184
ENGINE 184
LOADER HYDRAULICS 184
ELECTRICAL 184
DRIVE SYSTEM 184
CAPACITIES 184
TIRES 184
COUNTERWEIGHT 184
MACHINE WEIGHT (Less Bucket) 184
611 LOADER (DEUTZ DIESEL) 185
OPERATIONAL & PERFORMANCE 185
ENGINE 185
LOADER HYDRAULICS 185
ELECTRICAL 185
DRIVE SYSTEM 185
CAPACITIES 185
TIRES 185
COUNTERWEIGHT 185
MACHINE WEIGHT (Less Bucket) 185
611D LOADER (BUREAU OF MINES APPROVED) 186
OPERATIONAL & PERFORMANCE 186
ENGINE 186
LOADER HYDRAULICS 186
ELECTRICAL 186
DRIVE SYSTEM 186
CAPACITIES 186
TIRES 186
COUNTERWEIGHT 186
MACHINE WEIGHT (Less Attachments) 186
ENGINE SPECIFICATIONS (PETTER) 187
ENGINE SPECIFICATIONS (Petter) 189
Fuel Specifications 189
Engine Oil 189
Specifications 189
Lubrication System 189
Cylinder Head 190
Valve Mechanism 190
Camshaft 190
Crankshaft 190
Crankshaft Regrinding Diameters 190
Connecting Rod 190
Piston 190
Cylinder Block 190
Torque Specifications 191
600D LOADER (DEUTZ DIESEL) 192
OPERATIONAL & PERFORMANCE 192
ENGINE 192
LOADER HYDRAULICS 192
ELECTRICAL 192
DRIVE SYSTEM 192
CAPACITIES 192
TIRES 192
COUNTERWEIGHT 192
MACHINE WEIGHT (Less Bucket) 192
MOTOR SPECIFICATIONS, (ELECTRIC) 193
600E LOADER (RELIANCE ELECTRIC) 195
OPERATIONAL & PERFORMANCE 195
MOTOR 195
LOADER HYDRAULICS 195
POWER TRAIN 195
CAPACITIES 195
TIRES 195
COUNTERWEIGHT 195
MACHINE WEIGHT (Less Attachment) 195
TECHNICAL DATA 197
LOADER TORQUE SPECIFICATIONS 199
Hydraulic Fluid 199
Special Tools 199
DECIMAL AND MILLIMETER EQUIVALENTS 200
U S TO METRIC CONVERSION 200
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 201
ALPHABETICAL INDEX 205
SERVICE BULLETINS 205
019 207
042 209
SERVICE MANUAL REVISIONS 207
600-002 211
600-003 213
600-004 215

DESCRIPTION:

Bobcat 600 600D 610 611 Loader Service Manual 6556276 (6–12) – PDF DOWNLOAD

FOREWORD:

This manual provides instruction for proper routine servicing and adjustment of the Bobcat, and
detailed overhaul instructions of the power train, loader hydraulic/hydrostatic system and
general mainframe components.
Refer to the Owner’s Manual for general operating instructions (Starting Procedure, Daily
Check, Bucket Operation, Minor Maintenance, etc.).
A general inspection of the following items should be made whenever the machine has
undergone service or repair:
1. Check hydraulic fluid level, engine oil level and fuel supply.
Advise the owner if any of the above items are in need of repair.
2. Inspect for any sign of fuel, oil or hydraulic fluid leaks.
3. Lubricate the machine.
4. Check battery condition, electrolyte level and cables.
5. Inspect air cleaner system for damage or leaks. Check element and make replacement,
if necessary.
6. Check alternator drive belt for condition and tension.
7. Check for loose drive chains by lifting the rear of the machine and turning the rear wheels
by hand.
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 for condition (ROPS Guard, Seat Belt, Safety Treads, Lights, etc.).
11. Make a visual inspection for loose or broken parts or connections.
12. Operate the loader, checking all functions.

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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