Complete repair service manual with Electrical Wiring Diagrams for Bobcat Skid-Steer Loaders 653, S630, with technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Bobcat Skid-Steer Loaders 653, S630 workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6724375 (5-96) - 653 Operation & Maintenance Manual.pdf
6724493 (1-97) - 653 Service Manual.pdf
6724493 (6-12) - 653 Service Manual.pdf
6900444 (8-97) - 653 Operation & Maintenance Manual.pdf
6987159 (10-10) - S630 Skid-Steer Loader Operation & Maintenance Manual.pdf
6987160 (10-10) - S630 Skid-Steer Loader Service Manual.pdf

Total Pages: 2,021 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE CONTENTS
6724375 (5-96) - 653 Operation & Maintenance Manual...1
  OPERATOR SAFETY WARNINGS...3
  CONTENTS...5
    REFERENCE INFORMATION...5
    MELROE COMPANY IS ISO 9001 CERTIFIED...6
    REGULAR MAINTENANCE ITEMS...6
  FOREWORD...7
    SERIEAL NUMBER LOCATIONS...9
    LOADER SERIAL NUMBER...9
    ENGINE SERIAL NUMBER...9
    DELIVERY REPORT...9
    BOBCAT LOADER IDENTIFICATION...10
    OPTION AND ACCESSORIES...11
  SAFETY...13
    SAFETY INSTRUCTIONS...15
      Safety Is The Operator's Responsibility...15
      Before Operating The Bobcat Loader...16
      Safe Operation Needs A Qualified Operator...16
    FIRE PREVENTION...17
    MACHINE SIGNS (DECALS)...18
  OPERATING INSTRUCTIONS...21
    INSTRUMENT PANEL...23
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...24
      Lift Arm By-Pass Control...25
      Traction Lock Override...25
    ENGINE SPEED CONTROL...26
    PARKING BRAKE...26
    STEERING LEVERS...27
    STOPPING THE BOBCAT LOADER...27
    SEAT BAR RESTRAINT SYSTEM...28
    HYDRAULIC CONTROLS...30
      Foot Pedals...30
      Lift Arm Operation...30
      Lift Arm Float Position...30
      Tilt Operation (Bucket)...30
      Bucket Position Valve Operation (Optional)...30
      Auxiliary Hydraulics (Optional)...31
      Auxiliary Hydraulics (Momentary Operation)...32
      Front Auxiliary Control (Optional)...32
      Rear Auxiliary Control (Optional)...32
      Front Auxiliary Hydraulics Continuous Operation (Detent)...32
      Attachment Functions Control...33
    GETTING READY FOR OPERATION...34
    STARTING THE ENGINE...35
      Normal Starting Condition...36
      Cold Temperature Starting Condition...37
      Warming The Hydraulic / Hydrostatic System...37
    STOPPING THE ENGINE...37
    ATTACHMENTS AND BUCKETS...38
      Installation And Removal...39
    OPERATING PROCEDURE...41
      Filling The Bucket...42
      Emptying The Bucket...42
      Digging Into The Ground...43
      Leveling The Ground (Using Lift Arms In Float Positions)...43
      Backfilling...44
    PARKING THE BOBCAT LOADER...44
    TRANSPORTING THE BOBCAT LOADER...45
    TOWING THE LOADER...45
    STOPPING THE BOBCAT LOADER...45
    LIFTING THE  LOADER...46
      Four Point Lift...46
      Single Point Lift...46
  PREVENTIVE MAINTENANCE...47
    MAINTENANCE SAFETY...48
    SERVICE SCHEDULE...49
    LIFT ARM SUPPORT DEVICE...50
      Engaging The Lift Arm Support Device...50
      Disengaging The Lift Arm Support Device...50
    OPERATOR CAB...51
      Raising The Operator Cab...51
      Lowering The Operator Cab...52
      Emergency Exit...52
    SEAT BAR RESTRAINT SYSTEM...53
      Inspecting The Seat Bar...53
      Maintaining The Seat Bar...53
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...54
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)...54
      Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)...54
      Inspecting The Traction Lock (Engine RUNNING)...54
      Inspecting The Lift Arm By-Pass Control...54
      Maintenance...54
      Troubleshooting Chart...55
    REAR DOOR...56
      Adjustment...56
    REAR GRILL...56
    AIR CLEANER SERVICE...57
      Replacing Filter Element...57
    FUEL SYSTEM...58
      Fuel Specifications...58
      Filling The Fuel Tank...58
      Fuel Filter...58
      Removing Air From The Fuel System...59
    ENGINE LUBRICATION SYSTEM...60
      Checking Engine Oil...60
      Replacing Oil And Filter...60
    ENGINE COOLING SYSTEM...62
      Cleaning The Cooling System...62
      Checking The Coolant Level...62
      Removing Coolant From The Cooling System...63
      Proplylene Glycol...63
    ALTERNATOR BELT...64
      Adjusting The Alternator Belt...64
    TIMING BELT...64
    ELECTRICAL SYSTEM...65
      Description...65
      Service The Electrical System...65
      Fuse Location...65
      Using A Booster Battery (Jump Starting)...66
      Removing And Installing The Battery...67
    HYDRAULIC / HYDROSTATIC SYSTEM...68
      Checking And Adding Fluid...68
      Replacing The Hydraulic / Hydrostatic Filter...68
      Replacing Hydraulic Fluid...69
      Hydraulic Reservoir Breather Cap...70
    SPARK ARRESTOR MUFFLER...71
    TIRE MAINTENANCE...72
      Wheel Nuts...72
      Tire Rotation...72
      Tire Mounting...72
    FINAL DRIVE TRANSMISSION (CHAINCASE)...73
      Checking And Adding Oil...73
      Removing Oil From The Chaincase...73
    DRIVE BELT...74
      Adjusting The Drive Belt...74
      Drive Belt Replacement...76
    LUBRICATION OF THE BOBCAT LOADER...77
    PIVOT PINS...78
    BOB-TACH...79
    FAN GEARBOX...79
      Checking And Maintenance...79
  MACHINE SIGN TRANSLATIONS...81
    IMPORTANT - 6560573...83
    WARNING - 6579511...84
    SERVICE SCHEDULE - 6708212...85
    WARNING - 6579510...87
    WARNING - 6579528...88
    DANGER - 6579639...88
    WARNING - 6577754...88
    DANGER - 6579509...88
  SPECIFICATIONS...89
    PERFORMANCE...91
    CONTROLS...91
    ENGINE...92
    HYDRAULIC SYSTEM...92
    ELECTRICAL...92
    DRIVE SYSTEM...92
    CAPACITIES...92
    TIRES...93
    FLOOR PRESSURE...93
    VIBRATION DATA...93
    MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES...94
    ADDITIONAL PUBLICATIONS...97
  WARRANTY...101
6724493 (1-97) - 653 Service Manual...103
  MAINTENANCE SAFETY...105
  ALPHABETICAL INDEX...107
  CONTENTS...109
    FOREWORD...110
    SAFETY INSTRUCTIONS...113
    SERIAL NUMBER LOCATIONS...115
    LOADER SERIAL NUMBER...115
    ENGINE SERIAL NUMBER...115
    DELIVERY REPORT...115
    BOBCAT LOADER IDENTIFICATION...116
  PREVENTIVE MAINTENANCE...117
    SERVICE SCHEDULE...119
    LIFTING AND BLOCKING THE LOADER...120
      Procedure...120
    TRANSPORTING THE LOADER...121
      Procedure...121
    TOWING THE LOADER...121
      Procedure...121
    STOPPING THE BOBCAT LOADER...121
    LIFTING THE LOADER...122
      Four Point Lift...122
      Single Point Lift...122
    LIFT ARM SUPPORT DEVICE...123
      Engaging The Lift Arm Support Device...123
      Disengaging The Lift Arm Support Device...123
    OPERATOR CAB...124
      Description...124
      Raising The Operator Cab...124
      Lowering The Operator Cab...125
      Raising The Operator Cab (Hand Controls)...126
      Lowering The Operator Cab (Hand Controls)...127
      Emergency Exit...128
    SEAT BAR RESTRAINT SYSTEM...129
      Description (Foot Controls)...129
      Seat Bar Inspection (Foot Controls)...129
      Seat Bar Maintenance (Foot Controls)...129
      Description (Hand Controls)...130
      Seat Bar Inspection (Hand Controls)...130
      Seat Bar Maintenance (Hand Controls)...130
    AIR CLEANER SERVICE...131
      Replacing Filter Element...131
    FUEL SYSTEM...132
      Fuel Specifications...132
      Filling The Fuel Tank...132
      Fuel Filter...132
      Removing Air From The Fuel System...133
    ENGINE LUBRICATION SYSTEM...134
      Checking Engne Oil...134
      Replacing Oil And Filter...134
    ENGINE COOLING SYSTEM...136
      Cleaning The Cooling System...136
      Checking The Coolant Level...136
      Removing Coolant From The Cooling System...137
      Proplylene Glycol...137
    ALTERNATOR BELT...138
      Adjusting The Alternator Belt...138
    BOB-TACH...138
    FAN GEARBOX...138
      Checking And Maintaining...138
    ELECTRICAL SYSTEM...139
      Using A Booster Battery (Jump Starting)...139
    HYDRAULIC / HYDROSTATIC SYSTEM...140
      Replacing Hydraulic Fluid...140
      Hydraulic Reservoir Breather Cap...141
    SPARK ARRESTOR MUFFLER...142
      Cleaning Procedure...142
    TIRE MAINTENANCE...143
      Wheel Nuts...143
      Tire Rotation...143
      Tire Mounting...143
    FINAL DRIVE TRANSMISSION (CHAINCASE)...144
      Checking And Adding Oil...144
      Removing Oil From The Chaincase...144
    DRIVE BELT...145
      Adjusting The Drive Belt (Equipped With Fixed Drive Idler)...145
      Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler...147
      Drive Belt Replacement...149
    LUBRICATION OF THE BOBCAT LOADER...150
      Procedure...150
    PIVOT PINS...151
    REMOTE START SWITCH...152
      Procedure...152
  HYDRAULIC SYSTEM...155
    TROUBLESHOOTING...157
    HYDRAULIC SYSTEM INFORMATION...158
      Flare Connections...158
      O-Ring Face Seal Connection...158
      Staright Thread O-Ring Fitting...158
      Tubelines And Hoses...158
    LIFT CYLINDER(S)...159
      Checking The Lift Cylinder(s) For Internal Leakage...159
      Removal And Installation...159
    TILT CYLINDER...160
      Checking The Tilt Cylinder For Internal Leakage...160
      Removal And Installation...160
      Rod End Seal Replacement...161
    HYDRAULIC CYLINDER IDENTIFICATION...162
      Lift Cylinder Components...162
      Tilt Cylinder Components...163
    HYDRAULIC CYLINDERS...164
      Disassembly...164
      Assembly...166
    HYDRAULIC CONTROL VALVE...172
      Removal And Installation...172
      Checking The Main Relief Valve...175
      Main Relief Valve Adjustment...176
      Main Relief Valve Removal And Installation...176
      Identification Chart...177
      Disassembly And Assembly...178
      Load Check Valve...178
      Main Relief Valve...179
      Port Relief Valve...179
      Anti-Cavitation valve...180
      Rubber Boot...181
      Lift Spool Detent...182
      Tilt Centering Spring...186
      Auxiliary Spool...187
      Auxiliary Electric Solenoid...188
      Inspection...189
      Identification & Installation Of Spool Seal...190
    HYDRAULIC PUMP...191
      Removal And Installation...191
      Checking The Output Of The Hydraulic Pump...193
      Disassembly And Assembly...195
      Inspection...197
      Identification...197
    HYDRAULIC FILTER HOUSING...198
      Removal And Installation...198
    HYDRAULIC FLUID RESERVOIR...199
      Removal And Installation...199
    CONTROL PEDALS...200
      Removal And Installation...200
      Pedal Adjustment...200
    PEDAL INTERLOCK LINKAGE...201
      Removal And Installation...201
      Adjustment...202
  HYDROSTATIC SYSTEM...203
    TROUBLESHOOTING...205
    HYDROSTATIC SYSTEM INFORMATION...206
      Replenishing Valve Function...206
    CONTROL PANEL...207
      Removal And Installation...207
      Steering Shaft Removal And Installation...208
      Steering Shaft Disassembly And Assembly...208
      Steering Lever Removal And Installation...209
      Rubber Boot Replacement...209
    STEERING LINKAGE...210
      Removal And Installation...210
      Steering Linkage Adjustment...212
      Steering Neutral Adjustment...214
    HYDROSTATIC DRIVE MOTOR...216
      Removal And Installation...216
      Identification...217
      Disassembly And Assembly...218
      Inspection...222
    HYDROSTATIC PUMP...223
      Removal And Installation...223
      Identification...226
      Disassembly And Assembly...228
      Inspection...236
      Swashplate Pre-Load...238
    DRIVE BELT HOUSING...239
      Removal And Installation...239
    SPRING LOADED DRIVE IDLER...241
      Identification...241
      Disassembly...242
      Assembly...246
    DRIVE BELT TENSIONER PULLEY...251
      Removal And Installation...251
      Disassembly...252
      Assembly...254
      Checking Pulley End Play...258
    OIL COOLER...258
      Removal And Installation...258
  DRIVE SYSTEM...259
    PARKING BRAKE...261
      Removal And Installation...261
      Disassembly And Assembly...261
    PARKING BRAKE DISC...262
      Removal And Installation...262
    CHAINCASE FLUID...263
      Removing Oil From The Chaincase...263
    CHAINCASE COVERS...264
      Center Chaincase Cover Removal And Installation...264
      Front Chaincase Cover Removal And Installation...265
      Rear Chaincase Cover Removal And Installation...265
    MOTOR CARRIER...266
      Shaft Seal Replacement...266
      Removal And Installation...268
      Disassembly...269
      Assembly...270
    AXLE SEAL...273
      Removal And Installation...273
    AXLE, SPROCKET AND BEARINGS...275
      Removal And Installation...275
    DRIVE CHAIN...279
      Removal...279
  MAIN FRAME...281
    SEAT BAR...283
      Removal And Installation...283
      Assembly...285
      Compressing The Gas Cylinder...286
    OPERATOR CAB GAS CYLINDER...287
      Removal And Installation...287
      Disassembly And Assembly...287
    OPERATOR CAB...288
      Removal And Installation...288
    OPERATOR SEAT...291
      Removal And Installation...291
    BOB-TACH...292
      Removal And Installation...292
      Bob-Tach Lever And Wedge...294
      Bob-Tach Stops...295
    LIFT ARMS...296
      Removal And Installation...296
    REAR GRILL...300
      Removal And Installation...300
    FUEL TANK...301
      Removal And Installation...301
      Fuel Level Sender...302
    REAR DOOR...303
      Removal And Installation...303
      Hood Removal And Installation...304
      Bumper Removal And Installation...304
      Door Latch Removal And Installation...304
      Door Latch And Catch Adjustment...305
  ELECTRICAL SYSTEM...307
    ELECTRICAL SCHEMATICS...309
    TROUBLESHOOTING...331
    ELECTRICAL SYSTEM INFORMATION...332
      Description...332
      Fuse Location...332
    BATTERY...333
      Removal And Installation...333
      Servicing The Battery...334
      Using A Booster Battery (Jump Starting)...335
    ALTERNATOR...336
      Alternator Output Test...336
      Rectifier (Diode) Test...336
      Alternator Regulator Test...337
      Removal And Installation...338
      Adjusting The Alternator Belt...338
      Disassembly And Inspection...339
      Stator Continuity Test...339
      Stator Ground Test...339
      Rotor Continuity Test...340
      Rotor Ground Test...340
      Rectifier Continuity (Diode) Test...340
      Assembly...341
    STARTER...342
      Removal And Installation...342
      Disassembly And Assembly...343
      External Pinion...347
      Inspection And Repair...348
      Magnetic Switch Test...351
      No Load Test...351
      Parts Identification...352
    STANDARD INSTRUMENT PANEL...353
      Removal And Installation...353
    FRONT LIGHTS...354
      Removal And Installation...354
    RELAY SWITCHES...354
      Location...354
      Glow Plug Preheat Relay...354
  ENGINE SERVICE...355
    TROUBLESHOOTING...357
    ENGINE SPEED CONTROL...358
      Removal And Installation...358
      Disassembly...358
    RADIATOR...359
      Removal And Installation...359
    ENGINE MUFFLER...360
      Removal And Installation...360
    BLOWER HOUSING/FAN GEARBOX...361
      Removal And Installation...361
      Tension Pulley Removal And Installation...364
      Blower Fan Disassembly And Assembly...365
    FAN GEARBOX...367
      Disassembly...367
      Assembly...372
      Checking Backlash...377
      Identification...380
    AIR CLEANER...381
      Removal And Installation...381
    ENGINE...382
      Removal And Installation...382
      Engine Mount Replacement...387
    FLYWHEEL...388
      Removal And Installation...388
      Flywheel Ring Gear...388
    INJECTION PUMP TIMING...389
      Checking Procedure...389
      Adjusting Injection Pump Timing...390
    TIMING BELT...391
      Removal...391
      Installation...393
    FUEL INJECTION PUMP...394
      Removal...394
      Installation...395
    FUEL INJECTOR NOZZLE...396
      Removal And Installation...396
      Checking The Injector Nozzle...397
    CYLINDER LOCATION AND COMPRESSION...397
      Data...397
    GLOW PLUGS...398
      Removal And Installation...398
      Checking The Glow Plugs...398
    CYLINDER HEAD...399
      Removing The Cylinder Head...399
      Disassembly Of The Cylinder Head...401
      Servicing The Cylinder Head...402
      Checking The Valves...403
      Checking Valve Springs...403
      Checking The Valve Guides...404
      Checking The Valve Seats...404
      Checking The Combustion Chamber...405
      Reassejmbly Of The Cylinder Head...406
      Installing The Cylinder Head...408
    ENGINE BLOCK...411
      Disassembly Of The Engine...411
      Assembly Of The Engine...413
    PISTONS AND CONNECTING RODS...417
      Disassembly And Assembly...417
      Checking The Piston...417
    CRANKSHAFT AND BEARINGS...418
      Checking The Crankshaft...418
    CRANKSHAFT PULLEY...419
      Removal And Installation...419
    PEUGEOT ENGINE TOOL KIT MEL1474...420
    ENGINE TORQUE...422
  SYSTEM ANALYSIS...423
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...425
      Inspecting The BICS™ Controller ...425
      Inspecting The Deactivation Of The Auxiliary Hydraulics System...425
      Inspecting The Seat And Seat Bar Sensors...425
      Inspecting The Traction Lock...425
      Inspecting The Lift Arm By-Pass Control...425
      Maintenance...425
      Troubleshooting Chart...426
      Troubleshooting Guide...427
        BICS CONTROLLER...427
        TRACTION LOCK...428
        SEAT SENSOR...429
        SEAT BAR SENSOR...430
        LIFT LOCK BY-PASS VALVE...431
    BICS™ SYSTEM CONTROLLER...432
      Removal And Installation...432
      Controller Test...433
    SEAT BAR SENSOR...434
      Removal And Installation...434
      Seat Bar Sensor Test...435
    SEAT SENSOR...436
      Removal And Installation...436
      Seat Sensor Test...437
    TRACTION LOCK...438
      Removal And Installation...438
    LIFT LOCK BY-PASS VALVE...439
      Removal And Installation...439
      Disassembly And Assembly...440
    TILT LOCK VALVE...441
      Removal And Installation...441
      Disassembly And Assembly...443
  SPECIFICATIONS...445
    SKID STEER LOADER SPECIFICATIONS...447
      Performance...447
      Controls...447
      Engine...448
      Hydraulic System...448
      Electrical...448
      Drive System...448
      Capacities...448
      Tires...449
      Floor Pressure...449
    ENGINE SPECIFICATIONS...450
      Fuel Injection Nozzles...450
      Fuel Injection Pump...450
      Cylinder Head...450
      Valves...450
      Valve Springs...451
      Valve Guides...451
      Combustion Chamber...451
      Cylinders...451
      Piston Rings...451
      Pistons...451
      Connecting Rod...452
      Crankshaft...452
    TORQUE SPECIFICATIONS...453
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...455
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...456
    DECIMAL AND MILLIMETER EQUIVALENTS...457
    U.S. TO METRIC CONVERSION...457
6724493 (6-12) - 653 Service Manual...459
  MAINTENANCE SAFETY...461
  ALPHABETICAL INDEX...463
  CONTENTS...465
    FOREWORD...466
    SAFETY INSTRUCTIONS...469
    SERIAL NUMBER LOCATIONS...471
    LOADER SERIAL NUMBER...471
    ENGINE SERIAL NUMBER...471
    DELIVERY REPORT...471
    BOBCAT LOADER IDENTIFICATION...472
  PREVENTIVE MAINTENANCE...473
    SERVICE SCHEDULE...475
    LIFTING AND BLOCKING THE LOADER...476
      Procedure...476
    TRANSPORTING THE LOADER...477
      Procedure...477
    TOWING THE LOADER...477
      Procedure...477
    STOPPING THE BOBCAT LOADER...477
    LIFTING THE LOADER...478
      Four Point Lift...478
      Single Point Lift...478
    LIFT ARM SUPPORT DEVICE...479
      Engaging The Lift Arm Support Device...479
      Disengaging The Lift Arm Support Device...479
    OPERATOR CAB...480
      Description...480
      Raising The Operator Cab...480
      Lowering The Operator Cab...481
      Raising The Operator Cab (Hand Controls)...482
      Lowering The Operator Cab (Hand Controls)...483
      Emergency Exit...484
    SEAT BAR RESTRAINT SYSTEM...485
      Description (Foot Controls)...485
      Seat Bar Inspection (Foot Controls)...485
      Seat Bar Maintenance (Foot Controls)...485
      Description (Hand Controls)...486
      Seat Bar Inspection (Hand Controls)...486
      Seat Bar Maintenance (Hand Controls)...486
    AIR CLEANER SERVICE...487
      Replacing Filter Element...487
    FUEL SYSTEM...488
      Fuel Specifications...488
      Filling The Fuel Tank...488
      Fuel Filter...488
      Removing Air From The Fuel System...489
    ENGINE LUBRICATION SYSTEM...490
      Checking Engne Oil...490
      Replacing Oil And Filter...490
    ENGINE COOLING SYSTEM...492
      Cleaning The Cooling System...492
      Checking The Coolant Level...492
      Removing Coolant From The Cooling System...493
      Proplylene Glycol...493
    ALTERNATOR BELT...494
      Adjusting The Alternator Belt...494
    BOB-TACH...494
    FAN GEARBOX...494
      Checking And Maintaining...494
    ELECTRICAL SYSTEM...495
      Using A Booster Battery (Jump Starting)...495
    HYDRAULIC / HYDROSTATIC SYSTEM...496
      Replacing Hydraulic Fluid...496
      Hydraulic Reservoir Breather Cap...497
    SPARK ARRESTOR MUFFLER...498
      Cleaning Procedure...498
    TIRE MAINTENANCE...499
      Wheel Nuts...499
      Tire Rotation...499
      Tire Mounting...499
    FINAL DRIVE TRANSMISSION (CHAINCASE)...500
      Checking And Adding Oil...500
      Removing Oil From The Chaincase...500
    DRIVE BELT...501
      Adjusting The Drive Belt (Equipped With Fixed Drive Idler)...501
      Adjusting The Drive Belt Equipped With The Spring Loaded Drive Idler...503
      Drive Belt Replacement...505
    LUBRICATION OF THE BOBCAT LOADER...506
      Procedure...506
    PIVOT PINS...507
    REMOTE START SWITCH...508
      Procedure...508
  HYDRAULIC SYSTEM...511
    TROUBLESHOOTING...513
    HYDRAULIC SYSTEM INFORMATION...514
      Flare Connections...514
      O-Ring Face Seal Connection...514
      Staright Thread O-Ring Fitting...514
      Tubelines And Hoses...514
    LIFT CYLINDER(S)...515
      Checking The Lift Cylinder(s) For Internal Leakage...515
      Removal And Installation...515
    TILT CYLINDER...516
      Checking The Tilt Cylinder For Internal Leakage...516
      Removal And Installation...516
      Rod End Seal Replacement...517
    HYDRAULIC CYLINDER IDENTIFICATION...518
      Lift Cylinder Components...518
      Tilt Cylinder Components...519
    HYDRAULIC CYLINDERS...520
      Disassembly...520
      Assembly...522
    HYDRAULIC CONTROL VALVE...528
      Removal And Installation...528
      Checking The Main Relief Valve...531
      Main Relief Valve Adjustment...532
      Main Relief Valve Removal And Installation...532
      Identification Chart...533
      Disassembly And Assembly...534
      Load Check Valve...534
      Main Relief Valve...535
      Port Relief Valve...535
      Anti-Cavitation valve...536
      Rubber Boot...537
      Lift Spool Detent...538
      Tilt Centering Spring...542
      Auxiliary Spool...543
      Auxiliary Electric Solenoid...544
      Inspection...545
      Identification & Installation Of Spool Seal...546
    HYDRAULIC PUMP...547
      Removal And Installation...547
      Checking The Output Of The Hydraulic Pump...549
      Disassembly And Assembly...551
      Inspection...553
      Identification...553
    HYDRAULIC FILTER HOUSING...554
      Removal And Installation...554
    HYDRAULIC FLUID RESERVOIR...555
      Removal And Installation...555
    CONTROL PEDALS...556
      Removal And Installation...556
      Pedal Adjustment...556
    PEDAL INTERLOCK LINKAGE...557
      Removal And Installation...557
      Adjustment...558
  HYDROSTATIC SYSTEM...559
    TROUBLESHOOTING...561
    HYDROSTATIC SYSTEM INFORMATION...562
      Replenishing Valve Function...562
    CONTROL PANEL...563
      Removal And Installation...563
      Steering Shaft Removal And Installation...564
      Steering Shaft Disassembly And Assembly...564
      Steering Lever Removal And Installation...565
      Rubber Boot Replacement...565
    STEERING LINKAGE...566
      Removal And Installation...566
      Steering Linkage Adjustment...568
      Steering Neutral Adjustment...570
    HYDROSTATIC DRIVE MOTOR...572
      Removal And Installation...572
      Identification...573
      Disassembly And Assembly...574
      Inspection...578
    HYDROSTATIC PUMP...579
      Removal And Installation...579
      Identification...582
      Disassembly And Assembly...584
      Inspection...592
      Swashplate Pre-Load...594
    DRIVE BELT HOUSING...595
      Removal And Installation...595
    SPRING LOADED DRIVE IDLER...597
      Identification...597
      Disassembly...598
      Assembly...602
    DRIVE BELT TENSIONER PULLEY...607
      Removal And Installation...607
      Disassembly...608
      Assembly...610
      Checking Pulley End Play...614
    OIL COOLER...614
      Removal And Installation...614
  DRIVE SYSTEM...615
    PARKING BRAKE...617
      Removal And Installation...617
      Disassembly And Assembly...617
    PARKING BRAKE DISC...618
      Removal And Installation...618
    CHAINCASE FLUID...619
      Removing Oil From The Chaincase...619
    CHAINCASE COVERS...620
      Center Chaincase Cover Removal And Installation...620
      Front Chaincase Cover Removal And Installation...621
      Rear Chaincase Cover Removal And Installation...621
    MOTOR CARRIER...622
      Shaft Seal Replacement...622
      Removal And Installation...624
      Disassembly...625
      Assembly...626
    AXLE SEAL...629
      Removal And Installation...629
    AXLE, SPROCKET AND BEARINGS...631
      Removal And Installation...631
    DRIVE CHAIN...635
      Removal...635
  MAIN FRAME...637
    SEAT BAR...639
      Removal And Installation...639
      Assembly...641
      Compressing The Gas Cylinder...642
    OPERATOR CAB GAS CYLINDER...643
      Removal And Installation...643
      Disassembly And Assembly...643
    OPERATOR CAB...644
      Removal And Installation...644
    OPERATOR SEAT...647
      Removal And Installation...647
    BOB-TACH...648
      Removal And Installation...648
      Bob-Tach Lever And Wedge...650
      Bob-Tach Stops...651
    LIFT ARMS...652
      Removal And Installation...652
    REAR GRILL...656
      Removal And Installation...656
    FUEL TANK...657
      Removal And Installation...657
      Fuel Level Sender...658
    REAR DOOR...659
      Removal And Installation...659
      Hood Removal And Installation...660
      Bumper Removal And Installation...660
      Door Latch Removal And Installation...660
      Door Latch And Catch Adjustment...661
  ELECTRICAL SYSTEM...663
    ELECTRICAL SCHEMATICS...665
    TROUBLESHOOTING...687
    ELECTRICAL SYSTEM INFORMATION...688
      Description...688
      Fuse Location...688
    BATTERY...689
      Removal And Installation...689
      Servicing The Battery...690
      Using A Booster Battery (Jump Starting)...691
    ALTERNATOR...692
      Alternator Output Test...692
      Rectifier (Diode) Test...692
      Alternator Regulator Test...693
      Removal And Installation...694
      Adjusting The Alternator Belt...694
      Disassembly And Inspection...695
      Stator Continuity Test...695
      Stator Ground Test...695
      Rotor Continuity Test...696
      Rotor Ground Test...696
      Rectifier Continuity (Diode) Test...696
      Assembly...697
    STARTER...698
      Removal And Installation...698
      Disassembly And Assembly...699
      External Pinion...703
      Inspection And Repair...704
      Magnetic Switch Test...707
      No Load Test...707
      Parts Identification...708
    STANDARD INSTRUMENT PANEL...709
      Removal And Installation...709
    FRONT LIGHTS...710
      Removal And Installation...710
    RELAY SWITCHES...710
      Location...710
      Glow Plug Preheat Relay...710
  ENGINE SERVICE...711
    TROUBLESHOOTING...713
    ENGINE SPEED CONTROL...714
      Removal And Installation...714
      Disassembly...714
    RADIATOR...715
      Removal And Installation...715
    ENGINE MUFFLER...716
      Removal And Installation...716
    BLOWER HOUSING/FAN GEARBOX...717
      Removal And Installation...717
      Tension Pulley Removal And Installation...720
      Blower Fan Disassembly And Assembly...721
    FAN GEARBOX...723
      Disassembly...723
      Assembly...728
      Checking Backlash...733
      Identification...736
    AIR CLEANER...737
      Removal And Installation...737
    ENGINE...738
      Removal And Installation...738
      Engine Mount Replacement...743
    FLYWHEEL...744
      Removal And Installation...744
      Flywheel Ring Gear...744
    INJECTION PUMP TIMING...745
      Checking Procedure...745
      Adjusting Injection Pump Timing...746
    TIMING BELT...747
      Removal...747
      Installation...749
    FUEL INJECTION PUMP...750
      Removal...750
      Installation...751
    FUEL INJECTOR NOZZLE...752
      Removal And Installation...752
      Checking The Injector Nozzle...753
    CYLINDER LOCATION AND COMPRESSION...753
      Data...753
    GLOW PLUGS...754
      Removal And Installation...754
      Checking The Glow Plugs...754
    CYLINDER HEAD...755
      Removing The Cylinder Head...755
      Disassembly Of The Cylinder Head...757
      Servicing The Cylinder Head...758
      Checking The Valves...759
      Checking Valve Springs...759
      Checking The Valve Guides...760
      Checking The Valve Seats...760
      Checking The Combustion Chamber...761
      Reassejmbly Of The Cylinder Head...762
      Installing The Cylinder Head...764
    ENGINE BLOCK...767
      Disassembly Of The Engine...767
      Assembly Of The Engine...769
    PISTONS AND CONNECTING RODS...773
      Disassembly And Assembly...773
      Checking The Piston...773
    CRANKSHAFT AND BEARINGS...774
      Checking The Crankshaft...774
    CRANKSHAFT PULLEY...775
      Removal And Installation...775
    PEUGEOT ENGINE TOOL KIT MEL1474...776
    ENGINE TORQUE...778
  SYSTEM ANALYSIS...779
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...781
      Inspecting The BICS™ Controller ...781
      Inspecting The Deactivation Of The Auxiliary Hydraulics System...781
      Inspecting The Seat And Seat Bar Sensors...781
      Inspecting The Traction Lock...781
      Inspecting The Lift Arm By-Pass Control...781
      Maintenance...781
      Troubleshooting Chart...782
      Troubleshooting Guide...783
        BICS CONTROLLER...783
        TRACTION LOCK...784
        SEAT SENSOR...785
        SEAT BAR SENSOR...786
        LIFT LOCK BY-PASS VALVE...787
    BICS™ SYSTEM CONTROLLER...788
      Removal And Installation...788
      Controller Test...789
    SEAT BAR SENSOR...790
      Removal And Installation...790
      Seat Bar Sensor Test...791
    SEAT SENSOR...792
      Removal And Installation...792
      Seat Sensor Test...793
    TRACTION LOCK...794
      Removal And Installation...794
    LIFT LOCK BY-PASS VALVE...795
      Removal And Installation...795
      Disassembly And Assembly...796
    TILT LOCK VALVE...797
      Removal And Installation...797
      Disassembly And Assembly...799
  SPECIFICATIONS...801
    SKID STEER LOADER SPECIFICATIONS...803
      Performance...803
      Controls...803
      Engine...804
      Hydraulic System...804
      Electrical...804
      Drive System...804
      Capacities...804
      Tires...805
      Floor Pressure...805
    ENGINE SPECIFICATIONS...806
      Fuel Injection Nozzles...806
      Fuel Injection Pump...806
      Cylinder Head...806
      Valves...806
      Valve Springs...807
      Valve Guides...807
      Combustion Chamber...807
      Cylinders...807
      Piston Rings...807
      Pistons...807
      Connecting Rod...808
      Crankshaft...808
    TORQUE SPECIFICATIONS...809
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...811
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...812
    DECIMAL AND MILLIMETER EQUIVALENTS...813
    U.S. TO METRIC CONVERSION...813
  SMR...815
    653-1...815
6900444 (8-97) - 653 Operation & Maintenance Manual...817
  OPERATOR SAFETY WARNINGS...819
  CONTENTS...821
    REFERENCE INFORMATION...821
    MELROE COMPANY IS ISO 9001 CERTIFIED...822
    REGULAR MAINTENANCE ITEMS...822
  FOREWORD...823
    SERIAL NUMBER LOCATIONS...825
    LOADER SERIAL NUMBER...825
    ENGINE SERIAL NUMBER...825
    DELIVERY REPORT...825
    BOBCAT LOADER IDENTIFICATION...826
    OPTIONS AND ACCESSORIES...827
  SAFETY...829
    SAFETY INSTRUCTIONS...831
      SAFETY IS THE OPERATOR’S RESPONSIBILITY...831
      BEFORE OPERATING THE BOBCAT LOADER...832
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR*...832
    FIRE PREVENTION...833
    MACHINE SIGNS (DECALS)...834
  OPERATING INSTRUCTIONS...837
    INSTRUMENT PANEL...839
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...840
      Lift Arm By–Pass Control...841
      Traction Lock Override...841
      Auxiliary Hydraulic System (Later Model Loaders)...841
    ENGINE SPEED CONTROL...842
    PARKING BRAKE...842
    STEERING LEVERS...843
    STOPPING THE BOBCAT LOADER...843
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)...844
    SEAT BAR RESTRAINT SYSTEM (HAND CONTROLS)...846
    HYDRAULIC CONTROLS...847
      Foot Pedals...847
        Lift Arm Operation...847
        Lift Arm Float Position...847
        Tilt Operation (Bucket)...847
        Bucket Position Valve Operation (If Equipped)...847
      Hand Controls...848
        Lift Arm Operation...848
        Lift Arm Float Position...848
        Tilt Operation (Bucket)...848
        Bucket Position Valve Operation (If Equipped)...848
      Auxiliary Hydraulics (If Equipped)...849
      Quick Couplers (Flush Face)...849
      Auxiliary Hydraulics Switch...850
      FRONT Auxiliary Hydraulics Operation (RIGHT Steering Lever)...850
      FRONT Auxiliary Hydraulics Continuous Operation(RIGHT Steering Lever)...850
      REAR Auxiliary Hydraulics Operation (LEFT Steering Lever)...850
      Attachment Functions Control...851
      Relieving Hydraulic Pressure...851
    DAILY INSPECTION...852
      Daily Inspection And Maintenance:...852
    GETTING READY FOR OPERATION...853
    STARTING THE ENGINE...854
      Normal Starting...855
      Cold Temperature Starting...856
      Warming The Hydraulic/Hydrostatic System...856
    STOPPING THE ENGINE...856
    ATTACHMENTS AND BUCKETS...857
      Installing...858
      Removing...859
    OPERATING PROCEDURES...860
    OPERATING PROCEDURES (FOOT PEDALS) ...861
      Filling The Bucket...861
      Emptying The Bucket...861
      Digging Into The Ground...862
      Leveling The Ground (Using Lift Arms In FloatPosition)...862
      Backfilling...863
    PARKING THE BOBCAT LOADER...863
    OPERATING PROCEDURES (HAND CONTROLS)...864
      Filling The Bucket...864
      Emptying The Bucket...864
      Digging Into The Ground...865
      Leveling The Ground (Using Lift Arms In Float Position)...865
      Backfilling...866
    PARKING THE BOBCAT LOADER...866
    TRANSPORTING THE BOBCAT LOADER...867
    TOWING THE LOADER...867
    STOPPING THE BOBCAT LOADER...867
    LIFTING THE LOADER...868
      Four Point Lift...868
      Single Point Lift...868
  PREVENTIVE MAINTENANCE...869
    MAINTENANCE SAFETY...871
    SERVICE SCHEDULE...873
    OPERATOR CAB...874
      Raising The Operator Cab...874
      Lowering The Operator Cab...875
      Emergency Exit...876
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)...877
      Inspecting The Seat Bar...877
      Maintaining The Seat Bar...877
    SEAT BAR RESTRAINT SYSTEM (HAND CONTROLS)...878
      Inspecting The Seat Bar...878
      Maintaining The Seat Bar...878
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...879
      Inspecting the BICS™ Controller (Engine STOPPED– Key ON)...879
      Inspecting the Seat and Seat Bar Sensors (Engine RUNNING)...879
      Inspecting the Traction Lock (Engine RUNNING)...879
      Inspecting the Lift Arm By–Pass Control...879
      Maintenance...880
    PIVOT PINS...881
    TIRE MAINTENANCE...881
      Wheel Nuts...881
      Tire Rotation...881
      Tire Mounting...881
    LIFT ARM SUPPORT DEVICE...882
      Engaging The Lift Arm Support Device...882
      Disengaging The Lift Arm Support Device...883
    BOB–TACH...883
    REAR DOOR...884
      Latch Adjustment...884
    REAR GRILL...885
    AIR CLEANER SERVICE...886
      Condition Indicator...886
      Replacing Filter Element...886
    FUEL SYSTEM...887
      Fuel Specifications...887
      Filling the Fuel Tank...887
      Fuel Filter...887
      Removing Air From the Fuel System...888
    ENGINE LUBRICATION SYSTEM...889
      Checking Engine Oil...889
      Oil Chart...889
      Replacing Oil And Filter...889
    ENGINE COOLING SYSTEM...891
      Cleaning The Cooling System...891
      Checking The Coolant Level...891
      Replacing The Coolant...892
    ALTERNATOR BELT...893
      Adjusting The Alternator Belt...893
    TIMING BELT (Engine)...893
    DRIVE BELT...894
      Adjusting The Drive Belt...894
      Drive Belt Replacement...896
    ELECTRICAL SYSTEM...897
      Description...897
      Cleaning Battery Terminals...897
      Fuse Location...897
      Using A Booster Battery (Jump Starting)...898
      Removing And Installing The Battery...899
    FAN GEARBOX...900
      Checking and Maintaining...900
    FINAL DRIVE TRANSMISSION (CHAINCASE)...900
      Checking And Adding Oil...900
      Removing Oil From The Chaincase...900
    HYDRAULIC/HYDROSTATIC SYSTEM...901
      Checking And Adding Fluid...901
      Replacing Hydraulic/Hydrostatic Filter...901
      Replacing Hydraulic Fluid...902
      Hydraulic Reservoir Breather Cap...903
    SPARK ARRESTOR MUFFLER...904
    LUBRICATION OF THE BOBCAT LOADER...905
  SYSTEMS ANALYSIS...907
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...909
      Troubleshooting Chart...909
  MACHINE SIGN TRANSLATIONS...911
    IMPORTANT - 6560573...913
    WARNING - 6579511...914
    SERVICE SCHEDULE - 6708212...915
    WARNING - 6579510...917
    WARNING - 6703725...918
    WARNING - 6579528...919
    DANGER - 6579638...919
    WARNING - 6577754...919
    DANGER - 6579509...919
  SPECIFICATIONS...921
    LOADER SPECIFICATIONS...923
    PERFORMANCE...923
    CONTROLS...923
    ENGINE...923
    HYDRAULIC SYSTEM...924
    ELECTRICAL...924
    DRIVE SYSTEM...924
    CAPACITIES...924
    TIRES...924
    FLOOR PRESSURE...924
    MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES...925
    ADDITIONAL PUBLICATIONS...928
  WARRANTY...929
6987159 (10-10) - S630 Skid-Steer Loader Operation & Maintenance Manual...931
  OPERATOR SAFETY WARNINGS...933
  CONTENTS...935
  FOREWORD...937
    BOBCAT COMPANY IS IS0 9001 CERTIFIED...939
    REGULAR MAINTENANCE ITEMS...939
    SERIAL NUMBER LOCATIONS...940
      Loader Serial Number...940
      Engine Serial Number...940
    DELIVERY REPORT...940
    LOADER IDENTIFICATION...941
    FEATURES, ACCESSORIES AND ATTACHMENTS...942
      Standard Items...942
      Options And Accessories...942
      Buckets Available...943
      Attachments...943
      High-Flow Attachments...943
      Special Applications Kit...944
      Special Applications Kit Inspection And Maintenance...944
  SAFETY & TRAINING RESOURCES...945
    SAFETY INSTRUCTIONS...947
      Before Operation...947
      Safe Operation Is The Operator’s Responsibility...948
      Safe Operation Needs A Qualified Operator...948
      Avoid Silica Dust...949
    FIRE PREVENTION...949
      Maintenance...949
      Operation...949
      Electrical...949
      Hydraulic System...950
      Fueling...950
      Starting...950
      Spark Arrestor Exhaust System...950
      Welding And Grinding...950
      Fire Extinguishers...950
    PUBLICATIONS AND TRAINING RESOURCES...951
    MACHINE SIGNS (DECALS)...952
      No-Text Safety Signs...955
  OPERATING INSTRUCTIONS...957
    INSTRUMENT PANEL IDENTIFICATION...961
      Overview...961
      Left Panel...962
      Display Screen...964
      Right Panel (Standard Key Panel)...965
      Right Panel (Keyless Start Panel)...966
      Right Panel (Deluxe Instrumentation Panel)...967
      Left Switch Panel...969
      Right Switch Panel...969
      Left Side Lower Panel...970
      Right Side Lower Panel...970
      Radio...971
    CONTROL IDENTIFICATION...973
      Standard Controls...973
      Advanced Control System (ACS)...974
      Selectable Joystick Controls (SJC)...975
    OPERATOR CAB...976
      Description...976
      Cab Light...976
      Door Operation...976
      Front Wiper...977
      Side Windows...977
    SEAT BAR RESTRAINT SYSTEM...978
      Operation...978
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...979
      Operation...979
    LIFT ARM BYPASS CONTROL...980
      Operation...980
    PARKING BRAKE...980
      Operation...980
    TRACTION LOCK OVERRIDE...981
      Operation...981
    ENGINE SPEED CONTROL...981
      Operation...981
    EMERGENCY EXIT...982
      External Access...982
      Rear Window...982
      Front Door...982
    BACK-UP ALARM SYSTEM...984
      Description...984
      Operation...984
    DRIVING AND STEERING THE LOADER...985
      Available Control Configurations...985
      Operation (Standard And ACS)...985
      Operation (SJC) In ‘ISO’ Control Pattern...986
      Operation (SJC) In ‘H’ Control Pattern...987
    STOPPING THE LOADER...987
      Using The Control Levers Or Joysticks...987
    TWO-SPEED CONTROL...988
      Description...988
      Operation (Standard And ACS) (If Equipped)...988
      Operation (SJC) (If Equipped)...988
    SPEED MANAGEMENT...989
      Operation...989
      Changing The Factory Default Setting...990
    DRIVE RESPONSE...991
      Description...991
      Operation...991
    STEERING DRIFT COMPENSATION...993
      Description...993
      Operation...993
    HYDRAULIC CONTROLS...995
      Description...995
      Standard Controls (Also ACS In FOOT Pedal Mode)...995
      Advanced Control System (ACS) In HAND Control Mode...996
      Selectable Joystick Controls (SJC) In ‘ISO’ Control Pattern...996
      Selectable Joystick Controls (SJC) In ‘H’ Control Pattern...997
      Hydraulic Bucket Positioning...997
      FRONT Auxiliary Hydraulics Operation...998
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)...999
      FRONT Auxiliary Hydraulics Operation (REVERSE CONTINUOUS FLOW)...999
      REAR Auxiliary Hydraulics Operation...1000
      High-Flow Hydraulics Operation...1001
      Quick Couplers...1001
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)...1002
    ATTACHMENT CONTROL DEVICE (ACD)...1003
      Description...1003
    DAILY INSPECTION...1004
      Daily Inspection And Maintenance...1004
    PRE-STARTING PROCEDURE...1006
      Entering The Loader...1006
      Operation & Maintenance Manual And Operator’s Handbook Locations...1006
      Seat Adjustment...1007
      Joystick Position Adjustment...1008
      Seat Belt Adjustment...1009
      Seat Bar...1009
    STARTING THE ENGINE...1010
      Standard Key Panel...1010
      Keyless Start Panel...1012
      Deluxe Instrumentation Panel...1014
      Cold Temperature Starting...1016
      Warming The Hydraulic / Hydrostatic System...1016
    MONITORING THE DISPLAY PANELS...1017
      Left Panel...1017
      Warning And Shutdown...1017
    STOPPING THE ENGINE AND LEAVING THE LOADER...1018
      Procedure...1018
    COUNTERWEIGHTS...1019
      Description...1019
      Effect On The Loader And Loader Operation...1019
      When To Consider Using Counterweights...1019
      When To Consider Removing Counterweights...1019
      Accessories That Affect Machine Weight...1019
    ATTACHMENTS...1020
      Choosing The Correct Bucket...1020
      Pallet Fork...1020
      Installing And Removing The Attachment (Hand Lever Bob-Tach)...1021
      Installing And Removing The Attachment (Power Bob-Tach)...1023
    OPERATING PROCEDURE...1028
      Inspect The Work Area...1028
      Basic Operating Instructions...1028
      Driving On Public Roads...1028
      Operating With A Full Bucket...1029
      Operating With An Empty Bucket...1029
      Filling And Emptying The Bucket (Foot Pedals)...1030
      Leveling The Ground Using Float (Foot Pedals)...1031
      Digging And Filling A Hole (Foot Pedals)...1031
      Filling And Emptying The Bucket (ACS - Handles, SJC - ‘H’ Pattern)...1032
      Leveling The Ground Using Float (ACS - Handles, SJC - ‘H’ Pattern)...1033
      Digging And Filling A Hole (ACS - Handles, SJC - ‘H’ Pattern)...1034
      Filling And Emptying The Bucket (SJC - ‘ISO’ Pattern)...1035
      Leveling The Ground Using Float (SJC - ‘ISO’ Pattern)...1036
      Digging And Filling A Hole (SJC - ‘ISO’ Pattern)...1037
    TOWING THE LOADER...1038
      Procedure...1038
    LIFTING THE LOADER...1038
      Single-Point Lift...1038
      Four-Point Lift...1039
    TRANSPORTING THE LOADER ON A TRAILER...1040
      Loading And Unloading...1040
      Fastening...1040
  PREVENTIVE MAINTENANCE...1041
    MAINTENANCE SAFETY...1045
    SERVICE SCHEDULE...1047
      Chart...1047
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...1048
      Inspecting The BICS (Engine STOPPED - Key ON)...1048
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...1048
      Inspecting The Seat Bar Sensor (Engine RUNNING)...1048
      Inspecting The Traction Lock (Engine RUNNING)...1048
      Inspecting The Lift Arm Bypass Control...1048
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)...1048
    SEAT BAR RESTRAINT SYSTEM...1049
      Description...1049
      Inspecting...1049
      Maintaining...1049
    SEAT BELT...1050
      Inspection And Maintenance...1050
    LIFT ARM SUPPORT DEVICE...1051
      Installing...1051
      Removing...1052
    BACK-UP ALARM SYSTEM...1053
      Description...1053
      Inspecting...1053
      Adjusting Switch Position...1054
    OPERATOR CAB...1055
      Description...1055
      Raising...1055
      Lowering...1056
      Cab Door Sensor...1057
    REAR DOOR (TAILGATE)...1058
      Opening And Closing...1058
      Adjusting...1058
    REAR GRILL...1059
      Removing...1059
      Installing...1059
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)...1060
      Cleaning And Maintenance...1060
      Filters...1060
      Evaporator / Heater Coil...1061
      Condenser...1062
      Air Conditioning Lubrication...1062
      Troubleshooting...1062
    AIR CLEANER SERVICE...1062
      Replacing Filter Elements...1062
    FUEL SYSTEM...1064
      Fuel Specifications...1064
      Biodiesel Blend Fuel...1064
      Filling The Fuel Tank...1065
      Fuel Filter...1066
      Removing Air From The Fuel System...1066
    ENGINE LUBRICATION SYSTEM...1067
      Checking And Adding Engine Oil...1067
      Engine Oil Chart...1067
      Removing And Replacing Oil And Filter...1068
    ENGINE COOLING SYSTEM...1069
      Maintenance Platform...1069
      Cleaning...1069
      Checking Level...1071
      Removing And Replacing Coolant...1071
    ELECTRICAL SYSTEM...1072
      Description...1072
      Fuse And Relay Location / Identification...1072
      Battery Maintenance...1075
      Using A Booster Battery (Jump Starting)...1076
      Removing And Installing Battery...1077
    HYDRAULIC / HYDROSTATIC SYSTEM...1078
      Checking And Adding Fluid...1078
      Hydraulic / Hydrostatic Fluid Chart...1078
      Removing And Replacing Hydraulic Fluid...1079
      Removing And Replacing Hydraulic / Hydrostatic Filter...1081
      Removing And Replacing Hydraulic Charge Filter...1083
      Breather Cap...1084
    SPARK ARRESTER MUFFLER...1085
      Cleaning Procedure...1085
    TIRE MAINTENANCE...1086
      Wheel Nuts...1086
      Rotating...1086
      Mounting...1086
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1087
      Checking And Adding Oil...1087
      Removing And Replacing Oil...1087
    ALTERNATOR BELT...1088
      Belt Adjustment...1088
      Belt Replacement...1088
    AIR CONDITIONING BELT...1089
      Belt Adjustment...1089
      Belt Replacement...1089
    DRIVE BELT...1090
      Belt Adjustment...1090
      Stop Adjustment...1090
      Belt Replacement...1090
    LUBRICATING THE LOADER...1092
      Lubrication Locations...1092
    PIVOT PINS...1094
      Inspection And Maintenance...1094
    BOB-TACH (HAND LEVER)...1095
      Inspection And Maintenance...1095
    BOB-TACH (POWER)...1096
      Inspection And Maintenance...1096
    LOADER STORAGE AND RETURN TO SERVICE...1097
      Storage...1097
      Return To Service...1097
  SYSTEM SETUP & ANALYSIS...1099
    DIAGNOSTIC SERVICE CODES...1101
      Viewing Service Codes...1101
      Service Codes List...1102
    CONTROL PANEL SETUP...1107
      Right Panel Setup (Deluxe Instrumentation Panel)...1107
    PASSWORD SETUP (KEYLESS START PANEL)...1109
      Password Description...1109
      Changing The Owner Password...1109
      Password Lockout Feature...1109
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...1110
      Password Description...1110
      Changing The Owner Password...1110
      Changing The User Passwords...1111
      Password Lockout Feature...1111
    MAINTENANCE CLOCK...1112
      Description...1112
      Setup...1112
      Reset...1112
  MACHINE SIGN TRANSLATIONS...1113
    MACHINE SIGN TRANSLATIONS...1115
      Service Schedule (7167998)...1115
      Warning (7167993)...1118
      Warning (7169291)...1118
      Danger (7167989)...1118
      Danger (7167990)...1118
      Danger (7167988)...1119
      Warning (7168114)...1119
      Warning (7167994)...1120
      Warning (7168140)...1121
      Warning (7168142)...1121
      Warning (7168138)...1122
      Warning (7167996)...1123
      Warning (7184346)...1124
      Danger (7170355)...1124
      Warning (6737189)...1125
      Lift Arm Support Device (6706558)...1126
      Warning (7168024)...1127
      Warning (7142141)...1128
      Warning (7168019)...1129
  SPECIFICATIONS...1131
    (S630) LOADER SPECIFICATIONS...1133
      Machine Dimensions...1133
      Performance...1134
      Engine...1134
      Drive System...1135
      Controls...1135
      Hydraulic System...1136
      Electrical System...1137
      Capacities...1137
      Tires...1137
  WARRANTY...1139
    WARRANTY...1141
  ALPHABETICAL INDEX...1143
6987160 (10-10) - S630 Skid-Steer Loader Service Manual...1145
  MAINTENANCE SAFETY...1147
  CONTENTS...1149
  FOREWORD...1151
    FOREWORD...1153
    SAFETY INSTRUCTIONS...1156
    FIRE PREVENTION...1158
      Maintenance...1158
      Operation...1158
      Electrical...1158
      Hydraulic System...1158
      Fueling...1158
      Starting...1158
      Spark Arrestor Exhaust System...1158
      Welding And Grinding...1159
      Fire Extinguishers...1159
    SERIAL NUMBER LOCATIONS...1160
      Loader Serial Number...1160
      Engine Serial Number...1160
    DELIVERY REPORT...1161
    LOADER IDENTIFICATION...1162
  SAFETY & MAINTENANCE...1163
    LIFTING AND BLOCKING THE LOADER...1167
      Procedure...1167
    LIFT ARM SUPPORT DEVICE...1169
      Installing...1169
      Removing...1170
    OPERATOR CAB...1171
      Description...1171
      Raising...1172
      Lowering...1173
      Cab Door Sensor...1174
      Special Applications Kit...1174
      Special Applications Kit Inspection And Maintenance...1174
    TRANSPORTING LOADER ON A TRAILER...1175
      Loading And Unloading...1175
      Fastening...1175
    TOWING THE LOADER...1177
      Procedure...1177
    REMOTE START TOOL KIT-MEL1563...1179
      Remote Start Tool - MEL1563...1179
      Service Tool Harness Control - MEL1565...1180
      Service Tool Harness Communicator - MEL1566...1181
      Remote Start Procedure...1181
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031...1185
      Description...1185
      Remote Start Tool (Service Tool) - 7003030...1186
      Loader Service Tool Harness - 6689747...1187
      Computer Service Tool Harness - 6689746...1188
      Remote Start Procedure...1189
    SERVICE SCHEDULE...1193
      Chart...1193
    AIR CLEANER SERVICE...1195
      Replacing Filter Elements...1195
    ENGINE COOLING SYSTEM...1197
      Maintenance Platform...1197
      Cleaning...1197
      Checking Level...1199
      Removing And Replacing Coolant...1199
    FUEL SYSTEM...1201
      Fuel Specifications...1201
      Biodiesel Blend Fuel...1201
      Filling The Fuel Tank...1202
      Fuel Filter...1203
      Removing Air From The Fuel System...1203
    ENGINE LUBRICATION SYSTEM...1205
      Checking And Adding Engine Oil...1205
      Engine Oil Chart...1205
      Removing And Replacing Oil And Filter...1206
    HYDRAULIC / HYDROSTATIC SYSTEM...1207
      Checking And Adding Fluid...1207
      Hydraulic / Hydrostatic Fluid Chart...1207
      Removing And Replacing Hydraulic Fluid...1208
      Removing And Replacing Hydraulic / Hydrostatic Filter...1210
      Removing And Replacing Hydraulic Charge Filter...1212
      Breather Cap...1213
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1215
      Checking And Adding Oil...1215
      Removing And Replacing Oil...1215
    BOB-TACH (HAND LEVER)...1217
      Inspection And Maintenance...1217
    BOB-TACH (POWER)...1219
      Inspection And Maintenance...1219
    LUBRICATING THE LOADER...1221
      Lubrication Locations...1221
    TIRE MAINTENANCE...1223
      Wheel Nuts...1223
      Rotating...1223
      Mounting...1223
    SPARK ARRESTOR MUFFLER...1225
      Cleaning Procedure...1225
    PIVOT PINS...1227
      Inspection And Maintenance...1227
    LOADER STORAGE AND RETURN TO SERVICE...1229
      Storage...1229
      Return To Service...1229
    STOPPING THE ENGINE AND LEAVING THE LOADER...1231
      Procedure...1231
    EMERGENCY EXIT...1233
      External Access...1233
      Rear Window...1233
      Front Door...1233
    SEAT BELT...1235
      Inspection And Maintenance...1235
  HYDRAULIC SYSTEM...1237
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1241
    HYDRAULIC SYSTEM INFORMATION...1249
      Glossary Of Hydraulic / Hydrostatic Symbols...1249
      Troubleshooting...1253
    CYLINDER (LIFT)...1255
      Testing...1255
      Removal And Installation...1256
      Parts Identification...1258
      Disassembly...1259
      Assembly...1261
    CYLINDER (TILT)...1263
      Testing...1263
      Removal And Installation...1264
      Base End Pivot Pin Removal And Installation...1266
      Parts Identification...1267
      Disassembly...1268
      Assembly...1270
    CYLINDER (BOB-TACH)...1273
      Testing...1273
      Removal And Installation...1274
      Parts Identification...1275
      Disassembly...1276
      Assembly...1277
    MAIN RELIEF VALVE...1281
      Description...1281
      Testing...1282
      Adjusting...1284
      Removal And Installation...1285
    HYDRAULIC CONTROL VALVE (STANDARD)...1287
      Description...1287
      Removal And Installation...1288
      Mount Bracket Removal And Installation...1291
      Identification Chart...1292
      Lift Load Check Valve Removal And Installation...1293
      Load Check Valve Removal And Installation (Tilt & Auxiliary)...1294
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...1295
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...1295
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...1296
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)...1296
      Port Relief Valve Removal And Installation...1297
      Plug Removal And Installation...1298
      Rubber Boot Removal And Installation...1299
      End Cap Block Removal And Installation...1300
      Lift Spool And Detent Removal And Installation...1301
      Tilt Spool Removal And Installation...1311
      Auxiliary Spool Removal And Installation...1313
      Auxiliary Solenoid Removal And Installation...1315
      Solenoid Removal And Installation...1316
      Lock Valve Removal And Installation...1317
      Lift Arm Bypass Orifice Removal And Installation...1319
      Main Relief Valve Removal And Installation...1319
      Check Valve Removal And Installation...1320
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)...1321
      Description...1321
      Removal And Installation...1321
      Actuator Removal And Installation (In Loader)...1325
      Actuator Removal And Installation (Out Of Loader)...1327
      Identification Chart...1330
      Mount Bracket Removal And Installation...1331
      Lift Load Check Valve Removal And Installation...1331
      Load Check Valve Removal And Installation (Tilt & Auxiliary)...1332
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...1333
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...1333
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...1334
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)...1334
      Port Relief Valve Removal And Installation...1335
      Plug Removal And Installation...1336
      End Cap Block Removal And Installation...1337
      Lift Spool Removal And Installation...1337
      Tilt Spool Removal And Installation...1342
      Auxiliary Spool Removal And Installation...1344
      Auxiliary Solenoid Removal And Installation...1346
      Solenoid Removal And Installation...1347
      Lock Valve Removal And Installation...1348
      Lift Arm Bypass Orifice Removal And Installation...1349
      Main Relief Valve Removal And Installation...1349
      Check Valve Removal And Installation...1350
    LIFT ARM BYPASS CONTROL VALVE...1351
      Description...1351
      Testing...1351
      Removal And Installation...1352
      Bracket Removal And Installation...1353
      Disassembly And Assembly...1353
    HYDRAULIC PUMP...1355
      Description...1355
      Pump Test At Quick Couplers...1355
      Direct Pump Test (Standard Section)...1356
      Direct Pump Test (Charge Section)...1358
      Removal And Installation...1360
      Hydraulic Pump Startup...1361
      Parts Identification...1362
      Disassembly And Assembly...1363
    HYDRAULIC PUMP (HIGH FLOW)...1365
      Description...1365
      Pump Test At Quick Couplers...1365
      Direct Pump Test (Standard Section)...1366
      Direct Pump Test (Charge Section)...1367
      Direct Pump Test (High Flow Section)...1369
      High Flow Relief Valve Adjustment...1371
      High Flow Relief Valve Removal And Installation...1372
      Solenoid Removal And Installation...1373
      Removal And Installation...1374
      Hydraulic Pump Startup...1375
      Parts Identification...1376
      Disassembly And Assembly...1377
    HYDRAULIC / HYDROSTATIC FILTERS...1379
      Description...1379
      Housing Removal And Installation...1379
    HYDRAULIC FLUID RESERVOIR...1381
      Description...1381
      Removal And Installation...1381
      Hydraulic Fluid Screen...1382
    OIL COOLER...1383
      Description...1383
      Removal And Installation...1383
    BUCKET POSITION VALVE...1385
      Description...1385
      Solenoid Removal And Installation...1385
      Solenoid Testing...1386
      Removal And Installation...1386
      Disassembly And Assembly...1388
    REAR AUXILIARY DIVERTER VALVE...1389
      Description...1389
      Solenoid Testing...1389
      Removal And Installation...1390
      Disassembly And Assembly...1391
    BOB-TACH (POWER) BLOCK...1397
      Description...1397
      Removal And Installation...1397
      Disassembly And Assembly...1399
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...1403
      Description...1403
      Removal And Installation...1403
      Disassembly And Assembly...1403
  HYDROSTATIC SYSTEM...1405
    HYDROSTATIC SYSTEM INFORMATION...1407
      Troubleshooting...1407
      Description...1408
    HYDROSTATIC DRIVE MOTOR...1409
      Description...1409
      Removal And Installation...1410
      Parts Identification...1412
      Disassembly And Assembly...1413
    HYDROSTATIC DRIVE MOTOR (TWO-SPEED)...1417
      Description...1417
      Removal And Installation...1417
      Parts Identification...1420
      Disassembly...1421
      Assembly...1427
    HYDROSTATIC MOTOR CARRIER...1433
      Description...1433
      Removal And Installation...1434
      Parts Identification...1435
      Disassembly...1436
      Assembly...1437
    HYDROSTATIC MOTOR CARRIER (SJC)...1439
      Description...1439
      Removal And Installation...1440
      Parts Identification...1441
      Disassembly...1442
      Assembly...1444
    CHARGE PRESSURE...1447
      Description...1447
      Testing...1447
      Sender Removal And Installation...1449
      Adjusting...1450
    HYDROSTATIC PUMP...1453
      Description...1453
      Removal And Installation...1454
      Hydrostatic Pump Startup...1455
      Replenishing / High Pressure Relief Valve Removal And Installation...1456
      Parts Identification (Left Half)...1457
      Parts Identification (Right Half)...1458
      Disassembly...1459
      Assembly...1466
    HYDROSTATIC PUMP (SJC)...1473
      Description...1473
      Hydraulic Controller Removal And Installation...1474
      Removal And Installation...1476
      Hydrostatic Pump Start Up...1477
      Parts Identification...1478
      High Pressure Relief And Bypass Valve...1479
      Charge Relief Valve...1480
      Disassembly And Assembly...1481
      Mechanical Neutral Adjustment...1494
      Hydraulic Controller Neutral Adjustment...1497
    DRIVE BELT...1501
      Belt Adjustment...1501
      Belt Replacement...1501
      Stop Adjustment...1503
      Tensioner Pulley Removal And Installation...1504
      Tensioner Pulley Disassembly And Assembly...1504
    TWO-SPEED / BRAKE VALVE...1507
      Description...1507
      Valve Block Removal And Installation...1508
      Valve Block Disassembly And Assembly...1510
    DRAIN MANIFOLD...1513
      Description...1513
      Drain Manifold Removal And Installation...1513
  DRIVE SYSTEM...1515
    BRAKE (SINGLE SPEED)...1517
      Description...1517
      Disc Removal And Installation...1517
    BRAKE (TWO-SPEED)...1519
      Description...1519
    DRIVE COMPONENTS...1521
      Description...1521
      Axle Seal Removal And Installation...1522
      Axle, Sprocket And Bearings Removal And Installation...1524
      Chain Removal And Installation...1529
    CHAINCASE...1531
      Description...1531
      Front Cover Removal And Installation...1531
      Center Cover Removal And Installation...1532
      Rear Cover Removal And Installation...1533
  MAINFRAME...1535
    SEAT BAR...1539
      Description...1539
      Removal And Installation...1539
      Disassembly And Assembly...1540
      Compression Spring Disassembly And Assembly...1541
    OPERATOR CAB...1543
      Gas Spring Removal And Installation...1543
      Gas Spring Bracket Disassembly And Assembly...1544
      Removal And Installation...1544
    OPERATOR SEAT...1547
      Removal And Installation...1547
      Seat Belt Removal And Installation (Retractable)...1547
      Seat Belt And Bracket Removal And Installation (Standard)...1548
      Seat Belt Bracket Removal And Installation...1548
    OPERATOR SEAT (SUSPENSION)...1549
      Removal And Installation...1549
      Slide Rail Removal And Installation...1549
      Seat Belt Removal And Installation...1550
      Lower Cushion Removal...1550
      Lower Cushion Installation...1551
      Back Cushion Removal And Installation...1551
      Shock Removal And Installation...1552
      3-Point Seat Belt Removal And Installation...1552
    BOB-TACH (HAND LEVER)...1555
      Description...1555
      Removal And Installation...1555
      Lever And Wedge Disassembly And Assembly...1557
      Pivot Pin Bushing And Seal Removal And Installation...1559
    BOB-TACH (POWER)...1561
      Description...1561
      Removal And Installation...1561
      Lever And Wedge Disassembly And Assembly...1564
      Pivot Pin Bushing And Seal Removal And Installation...1565
    LIFT ARMS...1567
      Removal And Installation...1567
    REAR GRILLE...1569
      Removal And Installation...1569
    REAR DOOR (TAILGATE)...1571
      Removal And Installation...1571
      Striker Removal And Installation...1572
      Striker Disassembly And Assembly...1572
      Striker (Adjusting)...1572
      Latch Removal And Installation...1573
    FUEL TANK...1575
      Removal And Installation...1575
      Fuel Level Sender Removal And Installation...1577
      Fuel Fill Screen Removal And Installation...1577
    CONTROL PEDALS AND LINKAGES...1579
      Description...1579
      Pedal Removal And Installation...1579
      Linkage Removal And Installation...1580
      Pedal (Adjusting)...1581
      Floor Pan Removal And Installation...1582
    CONTROL PEDALS AND LINKAGES (ACS)...1583
      Description...1583
      Pedal Removal And Installation...1583
      Linkage Removal And Installation...1584
      Pedal (Adjusting)...1584
      Floor Pan Removal And Installation...1585
    CONTROL PANEL...1587
      Description...1587
      Removal And Installation...1588
      Disassembly And Assembly...1589
      Linkage Removal And Installation...1591
      Pintle Arm Disassembly And Assembly...1595
      Linkage Neutral (Adjusting)...1596
      Linkage Travel (Adjusting)...1600
      Shock Removal And Installation...1604
    CONTROL PANEL (SJC)...1605
      Description...1605
      Removal And Installation...1605
    CONTROL HANDLE / LEVER...1607
      Description...1607
      Lever Removal And Installation...1607
      Boot Removal And Installation...1608
    CONTROL HANDLE / LEVER (ACS)...1609
      Description...1609
      Handle Sensor Removal And Installation...1609
      Handle Removal And Installation...1612
      Handle Disassembly And Assembly...1613
      Lever Removal And Installation...1613
      Boot Removal And Installation...1614
    CONTROL HANDLE / LEVER (SJC)...1615
      Description...1615
      Joystick Testing...1615
      Joystick Removal And Installation...1616
    ACCESS PANEL (INSIDE)...1617
      Removal And Installation (Left)...1617
      Removal And Installation (Right)...1617
    ACCESS PANEL (INSIDE) (SJC)...1619
      Removal And Installation (Left)...1619
      Removal And Installation (Right)...1619
    WINDOW (REAR)...1621
      Removal And Installation...1621
      Disassembly And Assembly...1621
    WINDOW (TOP)...1623
      Removal And Installation...1623
    WINDOW (SIDE)...1625
      Removal And Installation...1625
    CAB DOOR...1627
      Description...1627
      Removal And Installation...1627
      Disassembly And Assembly...1628
      Aligning...1629
      Adjusting...1630
      Checking Operation...1630
    ARMREST...1631
      Description...1631
      Removal And Installation...1632
      Disassembly And Assembly...1633
    LEFT SIDE LOWER PANEL...1635
      Removal And Installation...1635
      Disassembly And Assembly...1637
    RIGHT SIDE LOWER PANEL...1639
      Removal And Installation...1639
      Disassembly And Assembly...1640
    HEADLINER...1643
      Removal And Installation...1643
  ELECTRICAL SYSTEM & ANALYSIS...1645
    ELECTRICAL SCHEMATICS...1649
    ELECTRICAL SYSTEM INFORMATION...1677
      Glossary Of Electrical Symbols...1677
      Standard Cab Harness Connectors...1680
      Deluxe Cab Harness Connectors...1681
      Mainframe Harness Connectors...1682
      Description...1683
      Troubleshooting...1684
      Fuse And Relay Location / Identification...1685
      Solenoid Testing...1688
    BATTERY...1689
      Removal And Installation...1689
      Servicing...1690
      Using A Booster Battery (Jump Starting)...1691
    ALTERNATOR...1693
      Belt Adjustment...1693
      Belt Replacement...1693
      Charging System Inspection...1694
      Alternator Voltage Testing...1695
      Low Voltage Testing...1695
      High Voltage Testing...1696
      Removal And Installation...1697
      Parts Identification...1698
    STARTER...1699
      Testing...1699
      Removal And Installation...1699
      Parts Identification...1700
    INSTRUMENT PANELS...1701
      Left Panel...1701
      Display Screen...1703
      Right Panel (Standard Key Panel)...1704
      Right Panel (Keyless Start Panel)...1705
      Right Panel (Deluxe Instrumentation Panel)...1706
      Left Switch Panel...1708
      Right Switch Panel...1708
      Left Panel Removal And Installation...1709
      Right Panel (Standard Key Panel) Removal And Installation...1709
      Right Panel (Keyless Start Panel) Removal And Installation...1710
      Right Panel (Deluxe Instrumentation Panel) Removal And Installation...1710
      Key Switch Disassembly And Assembly...1711
      Alarm Disassembly And Assembly...1711
      Left Switch Panel Removal And Installation...1712
      Right Switch Panel Removal And Installation...1712
    LIGHTS...1713
      Front Removal And Installation...1713
      Rear Removal And Installation...1714
      Cab Light Removal And Installation...1714
    BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)...1715
      Description...1715
      Connector Identification...1716
      Removal And Installation...1722
    BOBCAT CONTROLLER (ACS)...1723
      Description...1723
      Connector And Wire Identification...1724
      Removal And Installation...1725
    BOBCAT CONTROLLER (SJC) (DRIVE)...1727
      Description...1727
      Connector Identification...1728
      Removal And Installation...1730
    SPEED SENSORS (SJC)...1731
      Description...1731
      Testing...1731
      Removal And Installation...1733
    DIAGNOSTIC SERVICE CODES...1735
      Viewing Service Codes...1735
      Service Codes List...1736
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)...1741
      Description...1741
      Inspecting The BICS (Engine STOPPED - Key ON)...1742
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)...1742
      Inspecting The Seat Bar Sensor (Engine RUNNING)...1742
      Inspecting The Traction Lock (Engine RUNNING)...1742
      Inspecting The Lift Arm Bypass Control...1742
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)...1742
      Troubleshooting...1743
    SEAT BAR SENSOR...1745
      Description...1745
      Troubleshooting...1745
      Testing...1746
      Removal And Installation...1747
      Bobcat Interlock Control System (BICS) Circuit Test...1748
    TRACTION LOCK...1751
      Description...1751
      Troubleshooting...1752
      Inspecting...1753
    CONTROL SYSTEM (ACS)...1755
      Description...1755
      Troubleshooting...1756
      Handle Sensor Connector Disassembly And Assembly...1757
      Switch Handle Removal...1758
      Switch Handle Installation...1760
      Actuator Connector Disassembly And Assembly...1763
      Handle Lock Solenoid Removal And Installation...1764
      Handle Lock Solenoid Disassembly And Assembly...1764
      Foot Sensor Removal And Installation...1765
      Foot Sensor Disassembly And Assembly...1766
      Foot Sensor Lock Solenoid Removal And Installation...1766
    ELECTRICAL / HYDRAULIC CONTROLS...1767
      Identification Chart...1767
      Description...1768
      Identification Chart ACD Group 0...1769
      Identification Chart ACD Group 1...1770
      Identification Chart ACD Group 2...1771
      Identification Chart ACD Group 3...1772
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)...1773
      Identification Chart...1773
      Description...1774
      Identification Chart ACD Group 0...1775
      Identification Chart ACD Group 1...1776
      Identification Chart ACD Group 2...1777
      Identification Chart ACD Group 3...1778
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)...1779
      Identification Chart...1779
      Description...1780
      Identification Chart ACD Group 0...1781
      Identification Chart ACD Group 1...1782
      Identification Chart ACD Group 2...1783
      Identification Chart ACD Group 3...1784
    SERVICE PC (LAPTOP COMPUTER)...1785
      Connecting Remote Start Tool...1785
      Connecting Remote Start Tool (Service Tool)...1785
    CALIBRATION...1787
      Description...1787
      Actuator Testing...1787
      Lift And Tilt Calibration (SJC)...1790
      Hydrostatic Pump Calibration (SJC)...1792
      Lift And Tilt Calibration (ACS)...1797
    STEERING DRIFT COMPENSATION...1799
      Description...1799
      Operation...1799
    FLYWHEEL RPM SENSOR...1801
      Description...1801
      Adjustment...1802
    CONTROL PANEL SETUP...1803
      Right Panel Setup (Deluxe Instrumentation Panel)...1803
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...1805
      Password Description...1805
      Changing The Owner Password...1805
      Changing The User Passwords...1806
      Password Lockout Feature...1806
    PASSWORD SETUP (KEYLESS START PANEL)...1807
      Password Description...1807
      Changing The Owner Password...1807
      Password Lockout Feature...1807
    MAINTENANCE CLOCK...1809
      Description...1809
      Setup...1810
      Reset...1813
    BACK-UP ALARM SYSTEM...1815
      Description...1815
      Inspecting...1815
      Adjusting Switch Position...1816
      Troubleshooting (Standard And ACS)...1817
      Troubleshooting (Joystick)...1818
      Alarm Removal And Installation...1819
      Switch Removal And Installation...1819
    FRONT HORN...1821
      Removal And Installation...1821
  ENGINE SERVICE...1823
    ENGINE INFORMATION...1827
      Description...1827
      Specifications...1828
      Torque Values...1831
      Troubleshooting...1831
      Engine Removal And Installation...1833
      Engine Mount Replacement...1840
      Compression - Checking...1841
    ENGINE SPEED CONTROL...1843
      Removal And Installation...1843
      Disassembly And Assembly...1843
      Cable Removal And Installation...1844
    ENGINE SPEED CONTROL (SJC) S/N A3NU11889 AND BELOW & S/N A3NU11024 AND BELOW...1845
      Removal And Installation...1845
      Disassembly And Assembly...1846
    ENGINE SPEED CONTROL (SJC) S/N A3NT11900 AND ABOVE & S/N A3NU11025 AND ABOVE...1849
      Removal And Installation...1849
      Disassembly And Assembly...1850
    MUFFLER...1853
      Removal And Installation...1853
    AIR CLEANER...1855
      Housing Removal And Installation...1855
      Housing Bracket Removal And Installation...1856
    ENGINE COOLING SYSTEM...1857
      Radiator Removal And Installation...1857
      Hydraulic Fan Description...1859
      Hydraulic Fan Disassembly And Assembly...1860
      Lower Fan Duct Removal And Installation...1861
      Blower Housing Removal And Installation...1861
      Hydraulic Fan Motor Assembly Removal And Installation...1862
      Fan Removal And Installation...1862
      Hydraulic Fan Motor Removal And Installation...1863
      Water Pump Removal And Installation...1864
      Water Pump Disassembly And Assembly...1864
      Thermostat Housing Removal And Installation...1865
      Thermostat - Checking...1866
    LUBRICATION SYSTEM...1867
      Oil Pan Removal And Installation...1867
      Oil Pump Removal And Installation...1867
      Relief Valve - Testing...1868
      Oil Pump Inspection...1868
      Oil Filter Cooler Removal And Installation...1869
      Engine Oil Pressure - Testing...1870
    FUEL SYSTEM...1871
      Fuel Shutoff Solenoid - Checking...1871
      Fuel Shutoff Solenoid Removal And Installation...1871
      Fuel Injection Pump - Checking...1872
      Fuel Injection Pump Assembly, Removal And Installation...1873
      Governor Housing Disassembly And Assembly...1876
      Governor Disassembly And Assembly...1878
      Fuel Camshaft Removal And Installation...1880
      Fuel Injection Pump Removal And Installation...1882
      Fuel Injection Pump - Timing...1884
      Fuel Injector Removal And Installation...1885
      Fuel Injector Nozzle Pressure - Checking...1887
      Nozzle Spray Condition...1888
      Valve Seat Tightness...1888
    CYLINDER HEAD...1889
      Glow Plugs - Testing...1889
      Glow Plugs Removal And Installation...1889
      Valve Clearance Adjustment...1890
      Valve Timing - Checking...1891
      Cylinder Head Removal And Installation...1892
      Cylinder Head Disassembly And Assembly...1895
      Cylinder Head - Servicing...1895
      Cylinder Head Top Clearance...1896
      Valve Guide - Checking...1896
      Valve Guide Removal And Installation...1897
      Reconditioning The Valve And Valve Seat...1897
      Valve Spring...1899
      Valve Tappets...1900
      Rocker Arm And Shaft - Checking...1901
      Bridge Arm And Bridge Arm Shaft - Checking...1901
      Bridge Arm Shaft - Removal And Installation...1902
      Push Rod Alignment - Checking...1903
    CRANKSHAFT AND PISTONS...1905
      Piston And Connecting Rod Removal And Installation...1905
      Piston And Connecting Rod - Servicing...1906
      Cylinder Bore - Checking...1909
      Connecting Rod Alignment...1910
      Crankshaft Gear Removal And Installation...1910
      Crankshaft And Bearings Removal And Installation...1911
      Crankshaft And Bearings - Servicing...1913
    CAMSHAFT AND TIMING GEARS...1917
      Timing Gearcase Cover Removal...1917
      Timing Gearcase Cover Installation...1918
      Timing Gears Backlash - Checking...1921
      Idler Gear And Camshaft Removal And Installation...1921
      Camshaft - Servicing...1922
      Idler Gear And Shaft - Servicing...1923
    TURBOCHARGER...1925
      Description...1925
      Testing...1925
      Removal And Installation...1926
    FLYWHEEL AND HOUSING...1929
      Flywheel Removal And Installation...1929
      Ring Gear Removal And Installation...1931
      Housing Removal And Installation...1931
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM...1933
      Description...1933
      Testing...1934
      Removal And Installation...1937
      Disassembly And Assembly...1938
  HEATING, VENTILATION, AIR CONDITIONING...1939
    AIR CONDITIONING SYSTEM FLOW...1942
      Description...1942
      Chart...1943
      Components...1944
      Safety Equipment...1947
    REGULAR MAINTENANCE...1949
      Filters...1949
      Compressor Drive Belt Adjustment...1950
      Compressor Drive Belt Replacement...1950
      Condenser...1950
      Air Conditioning Lubrication...1950
      Air Conditioning Service Chart...1951
      Evaporator / Heater Coil...1952
    TROUBLESHOOTING...1953
      Blower Motor Does Not Operate...1953
      Blower Motor Operates Normally, But Air Flow Is Insufficient...1953
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...1953
      The Compressor Does Not Operate At All, Or Operates Improperly...1953
      Gauge Pressure Related Troubleshooting...1954
      Troubleshooting Tree...1956
      Temperature / Pressure Chart...1960
      Poor A/C Performance...1962
      HVAC Repair And Leaks...1963
      Electrical System...1964
      Engine Coolant Bypassing The Heater Valve...1970
      Heater Valve Not Opening Or Closing...1971
    SYSTEM CHARGING AND RECLAMATION...1973
      Refrigerant Identification...1973
      Reclamation And Charging With Recovery / Charging Unit...1974
    COMPRESSOR...1977
      Removal And Installation...1977
      Oil...1978
      Oil Check...1979
    CONDENSER...1981
      Removal And Installation...1981
    RECEIVER / DRIER...1983
      Receiver / Drier Removal And Installation...1983
      Pressure Relief Valve Removal And Installation...1984
      Pressure Switch Removal And Installation...1985
      Schraeder Valve Removal And Installation...1986
    EVAPORATOR / HEATER UNIT...1987
      Removal And Installation...1987
    THERMOSTAT...1989
      Description...1989
      Removal And Installation...1990
    EXPANSION VALVE...1991
      Removal And Installation...1991
    EVAPORATOR COIL...1993
      Removal And Installation...1993
    HEATER COIL...1995
      Removal And Installation...1995
    BLOWER FAN...1997
      Removal And Installation...1997
      Disassembly And Assembly...1997
    HEATER VALVE...2001
      Removal And Installation...2001
  SPECIFICATIONS...2003
    (S630) LOADER SPECIFICATIONS...2005
      Machine Dimensions...2005
      Performance...2006
      Engine...2006
      Drive System...2006
      Controls...2007
      Hydraulic System...2007
      Electrical System...2008
      Capacities...2008
      Tires...2008
    TORQUE SPECIFICATIONS FOR BOLTS...2009
      Torque For General SAE Bolts...2009
      Torque For General Metric Bolts...2010
    HYDRAULIC CONNECTION SPECIFICATIONS...2011
      Straight Thread O-ring Fitting...2011
      Flare Fitting...2012
      Tubelines And Hoses...2012
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...2013
      Specifications...2013
    CONVERSIONS...2015
      Decimal And Millimeter Equivalent Chart...2015
      U.S. To Metric Conversion Chart...2015
  ALPHABETICAL INDEX...2017
  SERVICE MANUAL REVISION...2021
    Revision No: S630 - 1...2021
    Revision No: S630 - 2...2023
    Revision No: S630 - 3...2025
    Revision No: S630 - 4...2027
    Revision No: S630 - 5...2029
    Revision No: S630 - 6...2031
    Revision No: S630 - 7...2033

Bobcat Skid-Steer Loaders 653, S630 Repair Service Manual + Operation & Maintenance Manual